Scaling up continuous ultrasound-assisted extractor for plant extracts by using spinach leaves as a test material

The ultrasound-assisted extraction (UAE) process of chlorophylls (a, b) and carotenoids in aqueous ethanol solutions from spinach leaves was upscaled from a batch laboratory reactor to a continuous modular flow-cell of pilot scale. The extraction in the laboratory scale was organized in a loop reactor, where pulp was circulated between a stirred vessel and the ultrasound reactor. The pilot scale extraction was made in a novel continuous tubular flow-cell reactor. The analysis of the experimental data proved that the ultrasound application provided a better extraction yield. In the laboratory scale, the application of ultrasound (24 kHz and 2500 W/L) showed the 2.6-fold higher maximum extraction yield compared to non-sonicated conventional solvent extraction. In the pilot scale, the effect was less significant (1.9-fold), due to smaller ultrasound power density (25 kHz and 1500 W/L). The scale-up of the UAE was based on equal extraction yield at both scales. The scale-up revealed that 2.5-fold higher volume-specific ultrasound power is required in the pilot scale to reach the yield obtained in the laboratory scale reactor.