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Pilot Scale Solvent Extraction Equipment Guide: Selection, Design and Applications

2026-06-01
Brief Introduction
Pilot-scale solvent extraction equipment plays a critical role in bridging laboratory research and industrial production. Before investing in a full-scale solvent extraction plant, researchers and engineers use pilot systems to verify process parameters, optimize extraction efficiency, and evaluate equipment performance under realistic operating conditions.
This guide explains the key types of pilot-scale solvent extraction equipment, their applications, and the factors to consider when selecting a suitable system.

What Is Pilot Scale Solvent Extraction?
Pilot-scale solvent extraction is an intermediate testing stage between laboratory experiments and commercial production. It allows operators to evaluate extraction performance using larger processing volumes while maintaining flexibility for process modifications.
Typical pilot systems process volumes ranging from several liters per hour to several hundred liters per hour depending on project requirements.

Common Types of Pilot Extraction Equipment

I. Mixer Settler Systems
Mixer settlers are among the most widely used pilot-scale solvent extraction devices. They consist of a mixing chamber where two liquid phases contact each other and a settling chamber where phase separation occurs.
I-1 Advantages include:
  • Simple structure: The mixer settler generally consists of a cell body, an interface adjustment tube, a motor reducer, a stirring shaft, a stirring paddle, a speed regulator, a movable platform, etc. The structure is relatively simple;
  • Stable operation and strong adaptability: Because the mixer settler has a large volume and a large amount of liquid, it can adapt to a certain range of material and liquid fluctuations. After adjusting the balance, the operation is relatively stable and the adaptability is strong;
  • Reliable scale-up: Single-stage extraction rate and other design parameters are still relatively reliable after scale up.
I-2 Typical applications:
  • Rare earth separation
  • Copper solvent extraction
  • Nickel and cobalt recovery
  • Lithium extraction
  • Chemical purification
  • Rare and precious metals extraction 
I-3 Common Selection of Lab&Pilot Mixer settler
Model                           Mixer volume (ml)    Settler volume (ml) Mixing flux      (L/h)      Motor Power(W) Diameter of Inlet/outlet (mm) Single Dimension (L*W*H,mm)
MCG-300 300 900~1200 1~5 20 Ø10 325*80*100
MCG-500 500 1500~2000 3~10 20 Ø12 434*96*116
MCG-1000 1000 3000~4000 5~20 20 Ø12 580*116*149
MCG-2000 2000 6000~8000 10~40 60 Ø16 715*145*176
MCG-5000 5000 15000~20000 20~100 90 DN15 936*194*240
MCG-10000 10000 30000~40000 40~200 120 DN20 1380*250*300



II. Centrifugal Extractors
The centrifugal extractor is a new, fast and efficient liquid-liquid extraction and separation system. It has higher separation efficiency than traditional extraction equipment such as mixer settler and extraction towers, and is more conducive to continuous production.
The centrifugal extractor uses a motor to drive the drum to rotate at high speed. The two liquids to be mixed and separated complete the mixing and mass transfer under the action of the shear force generated by the stirring paddle, and then are quickly separated under the action of the centrifugal force generated by the high-speed rotation of the drum.

II-1 Advantages include:
  • Simple and stable structure: Top-suspended structure, no bottom bearing, no risk of leakage;
  • High extraction efficiency: Independent mixing chamber, the agitator can be replaced according to the mixing system requirements;
  • Energy saving: Non-annular gap mixing structure, the drum itself does not participate in mixing, low energy consumption and effectively avoids emulsification caused by overmixing;
  • Corrosion resistant: Materials can be stainless steel or non-metallic composite materials;
  • Good sealing performance: Multi-stage shaft seal design, magnetic drive structure is also optional.ce: multi-channel shaft seal design, optional magnetic transmission structure.
II-2 Typical applications:
(1) Fine Chemicals: Two-phase separation, acid washing, alkali washing, and water washing after synthesis reactions.
(2) Hydrometallurgy: Rare earth extraction and separation, copper-cobalt-nickel extraction and separation, vanadium extraction, zirconium-hafnium extraction, rubidium-cesium extraction and separation, etc.
(3) New Energy Industry: Lithium extraction from salt lake brine, lithium extraction from lithium ore leaching solutions, and recovery of lithium from other lithium-containing solutions; extraction and recovery of nickel, cobalt, and manganese from ternary batteries.
(4) Phosphorus Chemicals: Phosphoric acid extraction (can produce electronic-grade phosphoric acid); waste phosphoric acid recovery.
(5) Fermentation Industry: Extraction of lactic acid, succinic acid, and citric acid from fermentation broth; extraction and separation of penicillin, gibberellin, and erythromycin from fermentation broth.
(6) Environmental Protection Industry: Recovery of valuable metals from electroplating sludge; extraction and separation of phenols from phenol-containing wastewater; refining of waste lubricating oil; treatment of organic wastewater such as DMF and DMAC wastewater.
(7)Plant Extraction: Extraction of effective plant components.

II-3 Common Section Of  Lab&Pilot Centrifugaglg Extractor


 
Model LC-36 LC-50 LC-60 LC-80 LC-100
Drum diameter（mm） 36 50 60 80 100
Applicable rotary speed
（r/min）		 2500～3500 2072～2840 2072～2840 2072～2840 2072～2840
Mixing flux（L/h） 1-30 1-50 1-70 1-80 1-100
Motor power（kw） 0.18 0.18 0.37 0.37 0.75
Unit weight（kg） ～20 ～30 ～35 ～45 ～50
Two-phase gravity difference(g/ml) 0.03～3
Max.viscosity（cp） ＜3000
Two-phase flow ratio 1/30～30/1 1/30～30/1 1/30～30/1 1/30～30/1 1/30～30/1
Inlet and outlet pipe diameter（mm） DN15 DN20 DN20 DN20 DN25
Inter-stage pipe diameter
（mm）		 D15 DN20 DN20 DN20 DN25
Discharge valve M16*2 PTFE M16*2 PTFE M16*2 PTFE M16*2 PTFE M16*2 PTFE
Connection type Quick connector
Dimension（mm） 400×350×800 400×370×900 400×370×1000 450×400×1150 500×450×1250
Power supply 220V  50HZ 220V  50HZ 220V  50HZ 220V  50HZ 220V  50HZ


III. Extraction Column
An extraction column is a continuous liquid-liquid extraction device used to transfer target components between two immiscible liquid phases. Compared with mixer settlers, extraction columns provide continuous operation, higher throughput, and a smaller installation footprint, making them suitable for pilot plants and industrial-scale solvent extraction processes.

Extraction columns are widely used inLubricant refining; Extraction of vitamins, glycosides, and alkaloids; Vanillin extraction; Organic acid extraction; Extraction of phenols from phenol-containing wastewater; Extraction of copper, rare earth elements, nickel, cobalt etc.

Working Principle
In an extraction column, the aqueous phase and organic phase flow counter-currently through the column. During contact, mass transfer occurs between the two liquid phases, allowing the desired components to be selectively extracted.
Various internal structures such as packing, sieve plates, or rotating elements increase the contact area between phases and improve extraction efficiency.
The separated phases are discharged continuously from opposite ends of the column, enabling stable and continuous operation.

Key Features
  • Continuous liquid-liquid extraction process
  • High mass transfer efficiency
  • Compact design and reduced floor space
  • Lower solvent inventory compared with mixer settlers
  • Suitable for large-scale industrial production
  • Flexible design for different extraction systems
  • Customizable materials and dimensions
Available Types

1.Packed Extraction Column
Uses structured or random packing to increase interfacial area and improve mass transfer performance.

Common Selection of packed extration column
Model TCS-25 TCS-50 TCS-70 TCS-90 TCS-100 TCS-150
Column ID(mm) 25 50 70 90 100 150
Column height(mm) 500 1000 1500 1600 1800 2000

2.Turbo Extraction Column
A turbo extraction column is a mechanically stirred extraction device equipped with a perforated plate. The widely used Kuhni column is a typical example of a turbo extraction column.

Common Selection of turbo extration column
Model TCT-50 TCT-70 TCT-90 TCT-100 TCT-150
Column ID(mm) 50 70 90 100 150
Column height(mm) 1000 1500 1600 1800 2000

3.Rotating Disc Contactor (RDC)
Uses rotating discs to generate intensive mixing while maintaining continuous operation.

​​​​​​​Common Selection of rotating extration column
Model RDC-50 RDC-100 RDC-150 RDC-200 RDC-300 RDC-500
Column ID(mm) 50 100 150 200 300 500
Column height(mm) 500 700 1500 1800 2000 3000

Key Factors When Selecting Pilot Equipment

1. Process Throughput
Determine the expected feed capacity and future scale-up requirements

2. Number of Extraction Stages
Many solvent extraction processes require multiple extraction, scrubbing, and stripping stages. Modular equipment designs allow flexible stage configuration.

3. Construction Materials
Common materials include:
PP (Polypropylene)
PPH
PVC
PVDF
SS 304
SS316L
Material selection depends on chemical compatibility and operating conditions.

4. Solvent and Chemical Compatibility
Evaluate resistance to acids, alkalis, organic solvents, and oxidizing agents before selecting equipment materials.

Pilot Plant Applications
✅ Rare Earth Extraction
Pilot mixer settler systems are extensively used for separating lanthanum, cerium, neodymium, praseodymium, and other rare earth elements.
✅ Battery Metal Recycling
Solvent extraction is increasingly applied for recovering lithium, nickel, cobalt, and manganese from spent lithium-ion batteries.
✅ Copper Solvent Extraction
Pilot extraction plants help optimize copper purification before commercial SX-EW implementation.
✅ Hydrometallurgical Research
Universities, research institutes, and mining companies frequently use pilot extraction equipment to develop new separation technologies.

Benefits of Pilot Testing
Pilot testing provides:
Process validation
Equipment performance evaluation
Scale-up data generation
Risk reduction before commercial investment
Optimization of reagent consumption

Conclusion
Selecting the right pilot-scale solvent extraction equipment is essential for successful process development and industrial scale-up. Whether using mixer settlers or centrifugal extractors, pilot testing helps improve process efficiency, reduce technical risks, and generate valuable operational data before full-scale implementation.
For customized pilot solvent extraction systems, equipment selection should be based on process chemistry, throughput requirements, and future production objectives.

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