The document discusses the advantages and applications of liquid-liquid extraction (LLE) as a separation method, particularly when distillation is not feasible. It highlights challenges engineers face in adopting LLE technology and presents KMPS as a leader in LLE solutions, detailing their extensive experience and services in optimizing extraction processes. Several case studies demonstrate successful LLE implementations across various industries, showcasing KMPS's ability to design and supply effective extraction systems.

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Solving Separation
Problems using Liquid-
Liquid Extraction (LLE)
KMPS Whitepaper Series

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Why use Liquid-Liquid Extraction (LLE)?
Distillation may be the chemical process industries workhorse for separating
the components of a liquid mixture. However, extraction comes to the
forefront when separations are either difficult or impossible to economically
handle by ordinary distillation. Some key examples are:
 Removal of high boiling organics from
dilute aqueous streams such as waste
water or fermentation broths.
 Recovery of non-volatile components
which are typically inorganic
chemicals.
 Extraction of water soluble
components from immiscible organic
streams.
 Separation of multi-component
mixtures, often utilizing fractional
extraction technique.
R1
R2
R3
R4
E1
E2
E3
E4
M1
M2
M3
M4
B
A C
F

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Hierarchy of Separation Methods

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Industries Using LLE
Chemical •Washing of acids/bases, polar compounds from organics
Biochemical Processing • Recovery of carboxylic acid from fermentation broths
Effluent Treatment • Recovery of phenol, DMF, DMAC
Pharmaceuticals • Recovery of active materials from fermentation broths
Polymer Processing • Recovery of caprolactam for nylon manufacture
• Separation of catalyst from reaction products
Petroleum • Lube oil quality improvement
• Separation of aromatics/aliphatics (BTX)
Food •Separation of essential oils (flavors and fragrances)
Metals • Copper production
• Recovery of rare earth elements
Inorganic Chemicals • Purification of phosphoric acid
Nuclear • Purification of uranium

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The Challenge of LLE
Most process engineers and scientists have very little education or training in utilizing
LLE technology. Therefore, often this technology is not even considered for a
separation problem. Even when LLE is recognized as a viable technology, there is still
the issue of knowing how to develop an optimal LLE solution and further, how to take
this solution to design and implementation of the production process. Some of the
key questions to be asked:
 How do I select an appropriate solvent for
an LLE process?
 What preliminary data can be developed
on the lab scale for determining
feasibility?
 What type of equipment is commercially
available for LLE and how do I determine
which type is best for my application?
 What are the steps for developing an
optimal LLE process?
 Can I design commercial scale equipment
with a high level of confidence?
KMPS maintains a pilot
plant dedicated to
extraction R & D and
applications testing

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The KMPS Solution
KMPS is a world leader in LLE technology. We call upon 50+ years of experience in
the design and supply of optimal LLE processes. In our pilot plant alone we have
studied more than 200 different LLE processes. We have supplied more than 300
commercial extraction columns and systems. At KMPS we can help you to answer all
of the questions shown above by offering the following:
 A broad level of experience and large database in
LLE processes and equipment.
 Laboratory and pilot plant testing in our Andrew E.
Karr Technology Center. We can supply pilot
columns for on-site testing, in particular when
chemical shipment is an issue.
 We can design and supply many different
extraction devices including KARR®, SCHEIBEL®,
RDC and packed columns as well as mixer-settlers.
We select the best equipment for each process -
not the other way around.
 Our engineers will evaluate multiple separation
techniques for every separation process and
provide our clients with the most cost effective
solutions.

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Recent LLE Success Stories
A biotech company was looking to
develop a process for the recovery of
carboxylic acids from fermentation
broth. Initial testing with an RDC
extraction column (rotating internals)
was unsuccessful due to emulsification.
KMPS has proven that the reciprocating
action in the KARR® Column is often the
only acceptable method to handle these
types of systems. After performing pilot
plant tests, we were able to design a
supply an optimal extraction system
including the KARR® Column and two
downstream distillation columns. The
system was delivered as a modular
system, started up under our direction
and has been successfully operating for
several years.

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Recent LLE Success Stories
A large petrochemical company
was looking to recover organic
acids from a wastewater steam
using a solvent that was produced
by this company. After generating
liquid-liquid equilibrium data to
demonstrate the feasibility of the
process, a pilot plant test program
was performed. The results from
the testing provided the design
criteria for the LLE column and a
distillation column. A complete
modular system was provided by
KMPS which has been successfully
operating since 2013.

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Recent LLE Success Stories
A company specializing in inorganic
chemicals was looking to expand the
capacity of an existing metal
extraction process that used
continuous mixer-settlers. Feed
solution and solvent from the plant
were shipped to our pilot plant
where we tested and optimized the
process in a SCHEIBEL® Column
(rotating turbine agitators). A
production column was designed
and supplied with a process
performance guarantee. This
column has been successfully
operating for the past 5 years,
providing higher capacity and
improved recovery.

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Recent LLE Success Stories
A chemical company in Asia was
looking to recovery a high
concentration of organic acid from
an aqueous reaction mixture.
However, the process involved an
unfavorable density gradient.
KMPS successfully tested the
application in a SCHEIBEL®
Column where the baffle
arrangement minimizes the
tendency towards back-mixing
and efficiency loss during scale up.
A large production column was
supplied and started up
successfully under supervision by
KMPS.

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Solving Separation Problems using
Liquid-Liquid Extraction (LLE)