Abstract Process intensification of liquid–liquid extraction columns using reactive extraction systems and population balance modelling approaches are discussed. As a means of process intensification, bulk organic solvents could be replaced by chemically reactive organic phases in order to enhance the extraction efficiency and selectivity. Moreover, extraction of speciality materials could be achieved by using either ionic liquids or solvent phases containing a controlled quantity of surfactants. For deep insight and hence better performance of liquid–liquid extraction columns, population balance modelling approaches can be utilized for process intensification, since the model parameter estimation is possible in small lab-scale devices instead of pilot plant experiments as it is state of the art. A significantly reduced time-to-market period and savings in costs will result. A further improvement can be achieved when the population balance model is coupled to computational fluid dynamics (CFD) where detailed flow fields and turbulent energy dissipation could be obtained. This will foster high-precision engineering, especially with large-scale industrial units.