Energy Conservation and Production Efficiency Enhancement in Herbal Medicine Extraction: Self-Adaptive...

Background: Accurately detecting the onset of saturated boiling in herbal medicine extraction processes is critical for improving production efficiency and reducing energy consumption. However, the traditional monitoring methods based on temperature suffer from time delays. To address the challenge, acoustic emission (AE) signals were used in this study owing to its sensitivity to bubble behavior. Methods: An AE signal acquisition system was constructed for herbal extraction monitoring. Characteristics of AE signals at different boiling stages were analyzed in pure water systems with and without herbs. The performance of AE-based and temperature-based recognition of boiling stages was compared. To enhance applicability in different herb extraction systems, multivariate statistical analysis was adopted to compress spectral-frequency information into Hotelling's T² and SPE statistics. For real-time monitoring, a self-adaptive decision-making boiling judgment method (BoilStart) was proposed. To evaluate the robustness, the performance of BoilStart under different conditions was investigated, including extraction system mass and heating medium temperature. Furthermore, BoilStart was applied to a lab-scale extraction process of Dabuyin Wan, which is a practical formulation, to assess its performance in energy conservation and efficiency improvement. Results: AE signal in the 75-100 kHz frequency band could reflect the boiling states of herbal medicine extraction. It was more sensitive to the onset of saturated boiling than the temperature signal. Compared with SPE, Hotelling's T² was identified as the optimal indicator with higher accuracy. BoilStart could adaptively monitor saturated boiling across diverse herbal systems. The absolute error of BoilStart's boiling determination ranged from 1.5 min to 2.0 min. The increasing-temperature time was reduced by about 22-36%. For the extraction process of Dabuyin Wan, after adopting BoilStart, the increasing-temperature time was reduced by about 29%, and the corresponding energy consumption was lowered by about 26%. Conclusions: The first AE-based method for precise boiling state detection in herbal extraction was established. BoilStart's model-free adaptability met industrial demands for multi-herb compatibility. This offered a practical solution to shorten ineffective heating phases and reduce energy consumption.