MATERIAL SEPARATION DEVICES, SYSTEMS AND RELATED METHODS

Abstract

Embodiments described herein relate to retorts for separating materials or substances (e.g., based on volatility thereof) and forming a base or waste material (e.g., basic sediment and water, inorganic materials, char, organic waste materials, and other solids) and a target material (e.g., shale oil or other oils), contained in feed-stock.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/011,479 filed on 12 Jun. 2014, the disclosure of which is incorporated herein in its entirety by this reference.

BACKGROUND

Material separation devices and systems, such as retorts, may be used to separate, remove, or extract one or more materials from a feedstock material. Typically, material separation devices and systems heat feedstock, thereby changing phase of at least a portion of the feedstock from solid to gas, liquid, semi-liquid, or combinations thereof, separated such target material from the remaining material (e.g., solid material) of the feedstock.

Manufacturers and users of the material separation devices and systems continue to seek improved material separation devices and systems, to improve efficiency, cost, speed of operation, etc., for such devices and systems.

SUMMARY

Embodiments disclosed herein relate to retorts for separating materials or substances (e.g., based on volatility thereof) and forming a base or a waste material (e.g., basic sediment and water, inorganic materials, char, organic waste materials, and other solids) and a target material (e.g., shale oil or other oils), contained in feedstock. The retort may have a generally horizontal orientation or configuration and may include a conveyor that may advance the feedstock from one end toward an opposite end of the containment chamber of the retort. Accordingly, in some embodiments, the feedstock may be heated inside the containment chamber as the feedstock advances from one end to another end thereof. Moreover, as the feedstock is heated, at least a portion of the feedstock (e.g., a target material) may change phase and/or viscosity and may separate from remaining waste material. The term “target material” as used herein, includes material in the feedstock that has decreased viscosity during and/or after processing of the feedstock, such as by heating (e.g., heavy oils separating from dirt and/or rock during heating). The “target material” also includes materials that change phase or physical state (e.g., solid-to-liquid, liquid-to-gas, etc.) during and/or after processing. It should be also appreciated that in some instances, both the phase and viscosity of the “target material” may have changed during processing.

Embodiments include a retort for separating a target material from waste material in feedstock. The retort includes a containment chamber and a heating unit positioned and configured to heat the containment chamber. The retort further includes a conveyor at least partially located within the containment chamber. The conveyor includes one or more openings sized and configured to allow the target material to pass therethrough. The retort also includes a collector assembly configured to receive the target material that passes through the conveyor.

At least one embodiment includes a retort for separating one or more target materials from waste material in feedstock. The retort includes a housing and a containment chamber positioned inside the housing. The containment chamber is sealed. The retort also includes a conveyor assembly positioned inside the containment chamber and between a first location and a second location therein. The conveyor assembly includes a plurality of segments pivotally connected together and forming a loop having a carrying surface configured to carry the feedstock. Each of the plurality of segments includes a plurality of openings sized and configured to allow at least some of the one or more target materials to pass therethrough, the plurality of segments being sized and configured to retain the waste material. The retort also includes a drive mechanism connected to the conveyor and configured to advance the plurality of the segments from the first location to the second location in the containment chamber, and a capture slide positioned within the loop of the conveyor. The capture slide includes one or more surfaces sloping away from the carrying surface and positioned to receive the at least one target material passing through the plurality of openings in the segments. The retort also includes an outlet positioned and configured to receive the at least one target material from the capture slide.

An embodiment includes a method of separating a target material from waste material in feedstock. The method includes advancing the feedstock inside a containment chamber, and heating the feedstock inside the containment chamber during advancement of the feedstock, thereby separating the feedstock into the target material and waste material. The method also includes collecting the target material.

Features from any of the disclosed embodiments may be used in combination with one another, without limitation. In addition, other features and advantages of the present disclosure will become apparent to those of ordinary skill in the art through consideration of the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. Understanding that these drawings depict only typical embodiments and are not therefore to be considered to be limiting of its scope, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 is a perspective view of a retort for separating target materials from to waste material in feedstock, according to an embodiment;

FIG. 2 is a perspective view of the second end of the retort of FIG. 1, according to an embodiment;

FIG. 3 is a perspective view of the first end of the retort of FIG. 1, according to an embodiment;

FIG. 4 is a perspective view of a hopper of the retort of FIG. 1, according to an embodiment;

FIG. 5 is a schematic side view of a retort, according to an embodiment;

FIG. 6 is a schematic front view of the retort of FIG. 5;

FIG. 7 is a perspective view of the first end of the retort of FIG. 1, including the conveyor in the containment chamber, according to an embodiment;

FIG. 8 is a perspective view a portion of a conveyor of a retort according to an embodiment;

FIG. 9 is a perspective view of another portion of a conveyor of a retort, according to an embodiment;

FIG. 10 is a perspective view an axle assembly of a retort, according to an embodiment;

FIG. 11 is a perspective view of a capture slide and a support structure of a retort, according to an embodiment;

FIG. 12 is a flow chart of a method of separating target material from waste material in feedstock, according to an embodiment.

DETAILED DESCRIPTION

Embodiments described herein relate to retorts for separating materials or substances (e.g., based on volatility thereof) and forming a base or waste material (e.g., basic sediment and water, inorganic materials, char, organic waste materials, and other solids) and a target material (e.g., shale oil or other oils), contained in feedstock. The retort may have a generally horizontal orientation or configuration and may include a conveyor that may advance the feedstock from one end toward an opposite end of the containment chamber of the retort. Accordingly, in some embodiments, the feedstock may be heated inside the containment chamber as the feedstock advances from one end to to another end thereof. Moreover, as the feedstock is heated, at least a portion of the feedstock (e.g., a target material) may change phase and/or viscosity and may separate from remaining waste material. The term “target material” as used herein, includes material in the feedstock that has decreased viscosity during and/or after processing of the feedstock, such as by heating (e.g., heavy oils separating from dirt and/or rock during heating). The “target material” also includes materials that change phase or physical state (e.g., solid-to-liquid, liquid-to-gas, etc.) during and/or after processing. It should be also appreciated that in some instances, both the phase and viscosity of the “target material” may have changed during processing.

Generally, feedstock may change from one embodiment to another. Likewise, the target material may vary from one embodiment to the next and may depend, among other things, on the feedstock and on the environment inside the containment chamber of the retort (e.g., temperature, pressure, etc.). In some embodiments, the target material includes one or more hydrocarbon bearing materials (e.g., oils, including shale oil) bound in and/or on, and which may be separated from waste materials under elevated temperatures and/or pressures as described herein. It should be appreciated that, in some instances, the waste material may be further processed and/or used in one or more applications. Alternatively, in some embodiments, at least a portion of the waste material may be discarded and/or disposed (e.g., the waste material may be deposited in a landfill).

The retort may substantially continuously process feedstock and may produce target material (e.g., oil) by substantially continuously heating and advancing the feedstock from a first end to an opposite second end. In some instances, the feedstock may be deposited onto the conveyor at the first end of containment chamber of the retort. As noted above, inside the containment chamber of the retort, the feedstock may be subjected to elevated temperatures and/or pressures as the feedstock continuously moves on the conveyor toward the second end. Under elevated temperatures and/or pressures, the target material (e.g., hydrocarbon containing material and/or fluids such as oil) may separate from waste material (e.g., rock, sands, or soil) in the feedstock.

The target material falls or flows into a collection system or assembly having one or more directing members therein (e.g., slides or funnels), while the waste material may remain on the conveyor and travel to the second end of the retort. In some embodiments, the waste material may exit the retort at or near the second end at a waste outlet. The target material may exit the retort at another outlet (e.g., target material outlet). In some embodiments, the outflow of the target material may be controlled by a valve.

FIGS. 1-4 show a retort 100 according to at least one embodiment. FIG. 1 is a perspective view of the retort 100. The retort 100 includes a feedstock feed mechanism (e.g., an airlock feeder, a hopper, etc.) attached to a housing 102. The feedstock feed mechanism may include a hopper 106 coupled to an airlock feeder 110. FIG. 2 is a perspective view of the retort 100 from a second end 120b. The feedstock may be fed into a containment chamber 122 within the housing 102 at or proximate to a first end 120a of the retort 100. FIG. 3 is a perspective view of a portion of the retort 100 including the first end 120a. The airlock feeder 110 and hopper 106 may be operably coupled to the retort 100, such as at the first end 120a. The housing 102 of the retort 100 may be positioned on and/or secured to a base 104. For example, the base 104 may stabilize the retort 100 during operation and/or may facilitate transportation thereof. The base may also support the hopper 106 such as by one or more vertically extending support members.

FIG. 4 is a perspective view of the hopper 106 having feedstock 108 therein. In some embodiments, the feedstock 108 may be fed into the hopper 106. The hopper 106 may be operably connected to the airlock feeder 110 in a manner that allows or facilitates transfer of the feedstock 108 into the airlock feeder 110, such a slide configured to provide a gravity feed of feedstock to the airlock feeder 110. The airlock feeder 110 may deposit the feedstock 108 onto the conveyor in the containment chamber 122 of the retort 100. In some instances, as described below in more detail, the containment chamber 122 may be located inside the housing 102, which may at least partially insulate the containment chamber 122 from external environment. Hence, in at least one embodiment, the housing 102 has one or more insulated walls positioned and configured to at least partially insulate the containment chamber 122. As described above, the waste material may be advanced inside the containment chamber 122 of the retort 100 and may exit at a second end 120b (FIGS. 2 and 5). At the second end 120b, for example, the waste material may be removed from the retort through an airlock feeder 112 (FIG. 2). Flow of the target material out of the retort 100 may be controlled by a first outlet valve 114 (FIG. 3).

Generally, components or elements of the retort 100 may be operably coupled to a controller 116, which may control operation thereof. For example, the controller 116 may control one or more of the following: temperature inside the containment chamber 122 of the retort 100; advancement of the feedstock 108 through containment chamber 122 (e.g., speed of advancement); outflow of the target material; outflow of waste; inflow of the target material; among others.

In some embodiments, the controller 116 is operably coupled to the components of the retort 100, such as the temperature gauges, the pressure gauge, the burner control box, the heating element (e.g., burner box), the fuel valve, the purge fan, any valve described herein, the generator, a conveyor belt motor, one or both airlock feeders, or any other component described herein. The controller 116 may operate (e.g., activate, deactivate, or otherwise regulate) the individual components of the retort 100 from one location. The controller 116 may include a main power supply switch, an on/off switch for every component operably coupled to the control panel, read-outs for temperature and pressure gauges, and an emergency stop button configured to terminate operation of all components and/or controls of the retort 100. Additionally or alternatively, the controller 116 may include controls for adjusting the conveyor speed, feedstock feed rate, temperature in the housing and/or in the containment chamber 122. The controller 116 also may adjust the pressure in the containment chamber or housing, such as by controlling the purge fan and/or one or more valves.

FIG. 5 is a schematic side view of the retort 100. FIG. 6 is a schematic front view of the retort 100 taken from the second end 120b. FIGS. 5 and 6 are discussed in conjunction below. As shown in FIG. 5, the retort 100 includes the first end 120a and the second, opposite end 120b. The hopper (described above) may be connected to the airlock feeder 110 which may transfer the feedstock from the hopper into a containment chamber 122. In an embodiment, at least a portion of the containment chamber 122 may be positioned inside of the housing 102. Alternatively, the entire containment chamber may be positioned completely inside the housing 102.

Generally, as described below in more detail, the containment chamber 122 may be configured to be heated by one or more heating units. Furthermore, the containment chamber 122 may be configured to be sealed in a manner that facilitates maintaining a predetermined temperature and/or pressure therein (e.g., the containment chamber 122 may be airtight). In some examples, the heating units may radiantly heat the containment chamber 122. It should be appreciated, however, that in additional or alternative embodiments, the containment chamber 122 may be conductively and/or convectively heated, such as by one or more of induction (e.g., induction heating elements), convection (e.g., circulating heated gas), conduction (e.g., directly heating one or more portions of the containment chamber 122 with a heating element in contact therewith), radiant heat, microwaves, or combinations of any of the foregoing.

The airlock feeder 110 may prevent or impede ambient air from entering into the containment chamber 122 while transferring the feedstock into the containment chamber 122. As such, in some instances, the airlock feeder 110 may facilitate maintaining a predetermined temperature and/or pressure inside the containment chamber 122. In at least one embodiment, the feedstock slides from the airlock feeder 110 through a feed chute 124 and onto a conveyor 126, which may be at least partially located in the containment chamber 122. In some embodiments, the airlock feeder 110 may include a heating element therein to at least partially preheat the feedstock prior to feeding the feedstock into the containment chamber 122.

In some embodiments, the containment chamber 122 is at least partially isolated from the housing 102, such as physically or thermally isolated (e.g., at least a portion of the containment chamber 122 may be spaced apart from the wall(s) of the housing 102). The containment chamber 122 may have one or more walls, which may form an approximately tubular shape (e.g., cylindrical, rectangular, or combinations thereof). Additionally, the containment chamber 122 may include one or more end caps (e.g., doors) that may close or at least partially seal otherwise open ends of the (tube) containment chamber 122. In some embodiments, the end caps of the containment chamber 122 may be configured to open in a manner that provides access to the containment chamber 122 and/or may be removable. For example, in some embodiments, the end caps of the containment chamber may be configured as ports or doors (e.g., hinged doors secured to the housing 102). In some instances, the interior space of the containment chamber 122 may be substantially sealed (e.g., sealed from the interior of the housing) such that gases or fluids may not freely pass from the interior space of the containment chamber 122 to the interior space of the housing (e.g., the space between the housing 102 and the containment chamber 122) or to the external environment.

In some embodiments, the conveyor 126 is disposed at least partially within the containment chamber 122 and extends along a length of the containment chamber 122 from a first location, such as the first end 120a toward a second location, such as the second end 120b. Generally, the conveyor 126 may be substantially continuous, such as looped. Hence, the conveyor 126 may continuously advance feedstock from the first end 120a toward the second end 120b of the containment chamber 122. In one or more to embodiments, the overall length of the conveyor 126 may be selected to optimize separation of target material from the stock for the distance travelled, heat applied, and/or belt feed rate used. For instance, the conveyor 126 (e.g., looped or unlooped) may be about 2 feet long or more, such as about 5 feet to about 15 feet, about 7 feet to about 12 feet, about 8 feet to about 10 feet, or about 9 feet. It should be appreciated that the conveyor 126 may be longer than 15 feet or shorter than 2 feet. In some embodiments, the width of the conveyor may be configured to accommodate more or less material thereon. For example, the conveyor 126 may be about 10 inches wide or more, such as about 10 inches wide to about 3 feet wide, about 1 foot wide to about 2 feet wide, about 18 inches wide, or about 16 inches wide or more. In some embodiments, more than one conveyor 126 may be disposed in the containment chamber, such as in series or in parallel.

As described above, the target material may separate from the feedstock and may be removed from the retort 100. The conveyor 126 may be configured to facilitate flow of the target material out of the feedstock. For example, the surface of the conveyor 126 may include one or more perforations or holes (e.g., formed by a mesh or screen) which may allow the target material to pass therethrough. In other words, the target material may flow out of the feedstock and through the openings in the surface of the conveyor 126. Furthermore, in some embodiments, while allowing the target material to pass through the openings, the conveyor 126 may retain the waste material. As described above, the waste material that may be retained on the conveyor 126 may be transported toward and into the waste outlet and subsequently out of the retort such that the returning portion (e.g., bottom of the loop) of the conveyor 126 is substantially free of waste material.

In an embodiment, the conveyor 126 is mounted on and/or advanced by two or more axle assemblies 130 positioned at least near the first and second ends 120a and 120b. The axle assemblies 130 may be positioned on a shaft extending through the walls of the containment chamber 122 and housing 102. The conveyor 126 includes an upper (e.g., advancing) portion above the axle assemblies 130 and a lower (e.g., returning) portion below the axle assemblies 130. The conveyor 126 may be positioned around and/or may pass through a capture slide 134, such that the capture slide 134 is positioned between the upper and lower surface of the conveyor 126.

For example, the axle assemblies 130 may include a shaft 132 that may be to rotatably connected to the containment chamber 122 and/or to the housing 102. In an embodiment, a motor may be operably connected to at least one of the axle assemblies 130 such that the motor may rotate one or more of the axle assemblies 130. Furthermore, rotation of the axle assemblies 130 may produce corresponding continuous advancement of the conveyor 126.

The motor may be configured to supply any suitable feed rate (e.g., rate that the conveyor moves feedstock). As such, in some embodiments, the retort 100 may control the amount of time for moving feedstock from one end of the containment chamber 122 to another end thereof. A feed rate may be selected based on the time needed to substantially completely separate the waste material from the target material in a feedstock, such as one foot per minute or more. In some embodiments, the feed rate may be lower than 1 foot per minute. In some embodiments, the axle assemblies 130 may be pneumatically or hydraulically driven using fluid pressure supplied though bearing valves fluidly coupled to each axle assembly 130.

While in some embodiments the conveyor 126 may carry and/or support the feedstock as well as advance the feedstock within the containment chamber 122, in additional or alternative embodiments, a conveyor may push or force the feedstock along the length of the containment chamber 122. For example, the feedstock may be placed on a stationary surface at or near the first end of the containment chamber 122 and may be advanced toward the second end of the containment chamber 122 on the stationary surface by one or more members mount on a conveyor, which is mounted proximate to the stationary surface (e.g., above or around or on a side of the stationary surface). In an embodiment, as the conveyor advances inside the containment chamber 122, the conveyor members (e.g., segments or paddles) may pass over and/or through the feedstock on the stationary surface, thereby advancing (e.g., sweeping, pushing, forcing, etc.) the feedstock toward the second end 120b.

The stationary surface may be include a tray, plate, or sheet of suitable material (e.g., steel, refractory metals, aluminum, alloys including any of the same, etc.). Also, in an example, the stationary surface may have one or more perforations therein that may allow the target material to pass therethrough (e.g., after processing). For example, the perforations may form or define a mesh or a screen. In some instances, the stationary surface may be supported by a support frame (e.g., metal cross-members). As the material is heated in the internal chamber, the target material may fall and/or flow through the perforations in the stationary surface onto a collector assembly (e.g., the capture slide 134 and funnel 136) mounted below the stationary surface.

The capture slide 134 may extend along at least a portion of the length of the conveyor 126 and may be configured to collect and/or direct the target material to a collection location when the target material flows through the conveyor 126. In some embodiments, the capture slide 134 may have opposing sides that slope downward and away from the top surface of the conveyor 126. For example, the capture slide 134 may have an inverted generally V cross-sectional shape. Moreover, in some instances, the opposing sides of the capture slide 134 may extend past the outside edges (e.g., the width) of the conveyor 126, such that the target material moving or flowing downward on the capture slide 134 is directed around the lower portion of the conveyor 126. Suitable configurations for the capture slide 134 may include constantly angled sides slanting downward from a substantially central point (e.g., the lateral center of the conveyor), sides with outwardly extending arcuate slopes, one or more troughs at the bottom of the capture slide 134, or combinations of any of the foregoing.

In some embodiments, the capture slide 134 may direct material into a funnel 136, which may be positioned below the capture slide 134. The capture slide 134 may direct the target material outward past the lateral extent of the conveyor 126 and toward and/or into the funnel 136. In some examples, the funnel 136 may extend along at least a portion of the length of the capture slide 134 and/or conveyor 126 (e.g., a trough along at least a portion of the conveyor or capture slide). In some embodiments, one or more of the capture slide 134 or the funnel 136 may extend along at least 50% of the length of the conveyor 126, such as along about 50% to about 100%, about 60% to about 90%, about 75% to about 95%, about 80%, or about 90% of the length of the conveyor. In some embodiments, one or more of the capture slide 134 or the funnel 136 may extend less than 50% of the length of the conveyor or more than 100% of the length of the conveyor. In some embodiments, the capture slide 134 and the funnel 136 may extend substantially the same length or different lengths. For example, in an embodiment, the funnel 136 may extend a shorter length than the capture slide 134 and the capture slide 134 may be configured to direct the target material onto the length of the funnel 136, such as by having sloping portions at the ends thereof converging toward the funnel 136. In an embodiment, the funnel 136 may have a longer length than the capture slide 134. As shown in FIG. 6, one or more sides of the funnel 136 may extend laterally past the maximum width of the capture slide 134 and the conveyor belt 126. The funnel 136 may have a cross-sectional shape generally converging downward (e.g., a generally conical or V-shaped portion) for collection of the target material at the bottom of the funnel 136. The funnel 136 may direct or collect the target material as the target material flows or falls from the capture slide 134 and down to a collection location of the funnel 136, such as at an end or midpoint of the funnel 136.

Moreover, the funnel 136 may further direct the target material toward an outlet 138 of the retort 100. For example, the funnel 136 may be positioned at a slight incline, ascending from a lower portion at the outlet 138 to a higher portion opposite thereto, such that the funnel tilts toward the outlet 138. As mentioned above, the valve 114 may regulate the flow of the target material out of the outlet 138. In other words, the valve 114 may be in fluid communication with the funnel 136, such that the target material may flow from the funnel 136 toward the outlet 138. In at least one embodiment, the conveyor 126, capture slide 134, and the funnel 136 may be configured and oriented in a manner that facilitates flow or movement of the target material away from the feedstock under the forces of gravity and without any additional forces applied thereon. Additionally or alternatively, as described herein, the retort 100 may supply downward stream of fluid or media (e.g., liquid, gas, semi-liquid, etc.) that may aid and/or induce the flow of target material away from the feedstock.

In some embodiments, the retort 100 includes one or more heating units, such as heating units 140 (FIG. 5) to heat the containment chamber 122. The heating units 140 may be located in or near the bottom of the housing 102. In some instances, the heating units 140 may include a fuel burner, an electric heating element, an induction coil, a radiator, or other suitable heating element(s). In an embodiment, the heating units 140 may include or may operably couple to a heating unit controller that may control operation of the heating elements. For example, the heating unit controller may control the power or fuel supplied to the heating element(s) and/or duration of operation thereof. In an embodiment, the heating unit controller may be on one or more of the heating units, or may be remote therefrom, such as located in the controller 116 (FIG.1). In any event, the heating units 140 may heat the containment chamber 122, the conveyor 126, the feedstock located in the containment chamber 122, and combinations thereof.

As described above, the heating units 140 may include a burner (e.g., a gas burner). Generally, a flammable fuel may be supplied through to the burner from a fuel line. In some embodiments, the flammable fuel may include natural gas (e.g., methane), butane, propane, hydrogen, diesel fuel, gasoline, or any other suitable fuel. For example, in some embodiments, the flammable fuel may include the target material harvested from the retort 100. In some embodiments, a fuel valve may regulate the follow of the fuel to the burner (e.g., the fuel valve may regulate the amount fuel that flows to the burner). The fuel valve may be manually and/or automatically operated.

The temperature of the containment chamber 122 may be monitored by one or more temperature gauges 142. The temperature gauges 142 may be mounted on the housing 102 and may extend into the containment chamber 122. Additionally or alternatively, the retort 100 includes a pressure gauge 144 inside the containment chamber 122, which may monitor pressure inside the containment chamber 122. In an embodiment, the heating unit controller may be operably coupled to the temperature gauges 142 and may be configured to automatically adjust the operation of the heating units (e.g., fuel supply) based on the temperature measurements provided by the temperature gauges 142.

In an embodiment, the containment chamber 122 may include one or more valves 146 that may control pressure inside the containment chamber 122. For instance, fluid may be supplied into the containment chamber 122 via operation of the one or more valves 146 (i.e., by opening, closing, or otherwise adjusting the valves 146). In some embodiments, the fluid may be a gas such as ambient or heated oxygen, nitrogen, argon, or other suitable gas; a liquid or semi-liquid, such as target material; a solvent; or another liquid configured to wash or aid in separation of the target material out of the feedstock.

One or more valves 146 may direct the flow of the fluid over at least a portion of the conveyor 126 and/or over at least a portion of the containment chamber 122. For example, one or more valves 146 may be configured to supply heated fluid (e.g., gas) onto a portion of the conveyor 126 proximate to an end thereof, such that the axle including a bearing therein is kept substantially free of feedstock, such as waste and/or target materials. The one or more valves 146 may be configured to supply fluid to a portion of the conveyor intermediate to the ends thereof and in a downward direction to aid in separation of target material from waste material as the feedstock advances through the containment chamber 122. The containment chamber 122 may also be operably coupled to a purge fan to control or adjust the temperature, pressure, gas contents, or combination thereof inside the containment chamber 122. The heated gas may be vented from the interior of the housing 102 using at least one of the one or more valves 146 or an exhaust 148 in the housing. In an embodiment, heated gas in the housing may be vented through the exhaust 148 to the hopper and may preheat the feedstock therein (FIG. 3).

In some embodiments, one or more of the valves 146 may be located at the top of the housing 102. It should be appreciated, however, that any of the one or more valves 146 may be located at any suitable and/or accessible location. For instance, the one or more valves 146 may be placed on a side of the housing 102.

In some embodiments, heated gas may be forced into the internal portions of the housing by a blower motor operably coupled to the heating unit controller 150 and the heating element 152, and may by supplied into the containment chamber 122 and over the feedstock therein through perforated piping. Heated gas in the interior of the housing 102 and/or the containment chamber may be controlled by the one or more valves 146.

As noted above, as the feedstock is advanced through the containment chamber 122, the feedstock may be exposed to elevated temperatures. For example, temperature inside the containment chamber 122 may be in one or more of the following ranges: between about 100° F. and 170° F.; 120° F. and about 400° F.; about 200° F. and about 300° F.; 300° F. and about 600° F.; about 400° F. and about 700° F.; or between about 450° F. and 750° F. In some instances, temperature inside the containment chamber 122 may be about 100° F. or more, such as about 150° F., about 200° F., about 350° F., about 500° F., greater than 750° F., or less than 100° F.

As the feedstock is advanced through the containment chamber 122, the feedstock may be exposed to elevated pressures. For example, pressure inside the containment chamber 122 may be in one or more of the following ranges: between about 15 psi and about 100 psi; between about 50 psi and about 500 psi; between about 400 psi and about 1000 psi; between about 800 psi and about 2000 psi; between about 1500 psi and about 4000 psi; and between about 3500 psi and about 10,000 psi. In some instances, pressure inside the containment chamber 122 may be greater than 10,000 psi or less than 15 psi (e.g., the containment chamber 122 may have at least a partial vacuum). Generally, any suitable medium may be used to increase the pressure inside the containment chamber 122, and the specific medium may vary from one embodiment to the next. In some examples, air may be introduced into the containment chamber 122 to increase the internal pressure thereof. Alternatively, a noble or inert gas, such as Argon may be introduced into the containment chamber 122 to raise the internal pressure thereof. For instance, the Argon may limit or prevent oxidation of the feedstock, target material, waste, or combinations thereof during processing.

As described above, when the feedstock is exposed to elevated temperature and/or pressure, the target material may separate from the feedstock and remaining material may form the waste material. In some embodiments, the retort 100 may include a waste removal mechanism. The waste removal mechanism may include a chute 156, a waste airlock feeder, and a means of cleaning the conveyor as explained in more detail below. At the second end of the conveyor belt, the waste material may fall off the end of the conveyor 126 and into a waste chute 156, which may direct the waste to a second, waste airlock feeder 112. In some examples, the retort 100 may include a scraper or waste removal mechanism (e.g., a brush) that may push and/or scrape the waste from the conveyor 126 and toward and/or into the chute 156. For instance, the retort 100 may include a wire brush that may rotate relative to the conveyor 126 (e.g., approximately in an opposite direction relative to the direction of travel of the surface of the conveyor 126) and may contact or scrub the surface of the conveyor 126. In any event, in at least one embodiment, the waste removal mechanism may at least partially clean the conveyor 126, which may prevent or reduce clogging of the openings therein.

The waste airlock feeder 112 may discharge the waste material out of the retort 100. For instance, the waste airlock feeder 112 may discharge the waste material into a waste bin or container. Moreover, the retort 100 may include a valve that may control or regulate the discharge of the waste material from the waste airlock feeder 112. Additionally or alternatively, the waste airlock feeder 112 may be configured to prevent or impede ambient air from entering into the housing 102 and/or into the containment chamber, thereby aiding in maintaining a predetermined temperature and/or pressure therein. In some embodiments, the target material may be discharged at a first end of the retort 100, while the waste material may be discharge at a second, opposite end of the retort 100.

FIG. 7 shows the first end 120a of the retort 100 according to an embodiment. In an embodiment, the containment chamber 122 may include one or more walls (e.g., four or more walls) the form the exterior and interior of the containment chamber 122. In some instances, one or more of the walls may have an arcuate cross sectional shape, as shown in FIG. 7. As described above, the containment chamber 122 may have an end cap at one or more ends that may seal the interior space of the containment chamber 122. The end caps may be mounted on hinges and/or otherwise attached to the walls of the containment chamber 122. Moreover, the end cap may be sealed or locked by any suitable mechanisms, such as bolts or other fasteners, one or more latches, one or more clamps, one or more spring loaded screws, etc. The containment chamber 122 may be configured to seal and hold a pressure or temperature.

The containment chamber 122 and/or the walls thereof may include thermally conductive material to allow conduction of heat from the heating units. In one or more embodiments, the containment chamber 122 may include channels running throughout the walls wherein a fluid (e.g., heated liquid or gas) may be circulated to regulate the temperature of the containment chamber 122.

As described above, in some embodiments, the containment chamber 122 includes the conveyor 126 therein. For instance, the conveyor 126 may include multiple segments 158 that may pivotally connected ad/or linked together to collectively form a loop that has top and bottom surfaces (e.g., the top or carrying surface may carry the feedstock inside and/or along the containment chamber 122). In some examples, the segments 158 of the conveyor 126 may include a mesh surface or one or more layers of mesh materials that may allow the target material to pass through the openings formed by the mesh.

The segment 158 may include any material suitable to withstand the elevated pressures and temperatures inside the containment chamber 122. It should be appreciated that the mesh may have any number of suitable patterns of openings, which may vary from one embodiment to another. Likewise, shapes of the openings may vary from one embodiment to the next. In embodiments, size of the openings in the wire mesh or sieve size may vary. For example, the sieve size of the mesh may be in one or more of the following ranges: about 650 mesh or holes/inch² (“mesh”) to about 400 mesh; about 500 mesh to about 300 mesh; about 400 mesh to about 100 mesh; about 200 mesh to about 50 mesh; about 100 mesh to about 10 mesh; or about 50 mesh to about 2 mesh. In some embodiments, the sieve size may be more than about 2 mesh or less than about 1000 mesh. Suitable mesh materials may include metals and metal alloys (e.g., steel, stainless steel, aluminum, refractory metals, or alloys of any of the foregoing).

Generally, the conveyor 126 may be a rigid, semi-flexible, or a flexible belt or sequence of interconnected segments that may together form a continuous loop. Generally, in some embodiments, the segments 158 may be connected together. For example, as shown in FIG. 8, adjacent segments 158 may be pivotably connected together in a manner that allows pivoting of adjacent segments 158 relative to one another. Such relative pivoting may facilitate movement and/or looping of the conveyor 126 in a continuous loop (as described above), such as around one or more axles.

Each segment 158 may define a discrete length of a portion of the conveyor 126. In some embodiments, the segments 158 may include supports 160, which provide rigidity for the segment 158 in a manner that facilitates supporting feedstock thereof. The length and/or width of the segments 158 may be selected to provide the greatest continuous surface while still being able to curve or wrap around the axle assembly (described below in more detail). In some instances, the size of each of the segments 158 and attached support pieces 160 may be selected to minimize or maximize the pivot angle between adjacent segments 158 and attached support pieces 160.

In some embodiments, a second layer of mesh or perforated material may be attached to the segment 158 over a first layer of mesh, at least partially defining segment 158. The second layer of mesh material may include larger or smaller holes or sieve size than the first layer of mesh material. In one or more embodiments, the second layer of mesh material may overlap a portion of one or more of the adjacent segments, such that the collective surface of the conveyor 126 has overlaps between at least some of the adjacent segments therein. The first and second layers of mesh material may be attached to the segment using fasteners, welding, epoxy, tension fit, or combinations thereof. For example, the second layer of mesh may be secured to one or more segments 158 by bolting a support to one end of the first layer of mesh in a manner such that one end of the second layer of mesh is sandwiched between the first layer of mesh and the support.

The conveyor 126 may be advanced by any number of suitable mechanisms. As shown in FIG. 9, the conveyor 126 may include one or more chains 162 that may be engaged with one or more corresponding sprockets, which may rotate and thereby advance the conveyor 126. For example, one of the chains 162 may extend lengthwise along a first side of the conveyor 126 and one of the chains 162 may extend lengthwise along a second side of the conveyor 126. In some embodiments, the chains 162 may include one or more portions that may be affixed to the segments 158 and may pivot together therewith.

The supports 160 may extend widthwise across the conveyor 126. As noted above, the chains 162 may be on opposing sides of the supports 160. Also, each of the chains 162 may be joined to form a ring or continuous loop that may be continuously advanced by the sprocket(s). Generally, the chains 162 may have metal links therein suitable for interfacing with the sprocket or chain ring (i.e., similar to a bicycle chain) to drive and/or align the conveyor 126. It should be appreciated that the conveyor 126 may be advanced by one or more belts and/or one or more corresponding pulleys, a direct drive, or a similar mechanism.

The plurality of supports 160 may be rigid or flexible. Suitable materials for the supports 160 may include metals and metal alloys, such as steels (e.g., stainless steel) or heat resistant alloys. Each of the supports 160 may form a discrete portion or section of the conveyor 126 or may be integrated with one or more other elements or components. For example, the supports 160 may be integrated with and/or may form the surface of the conveyor 126.

As discussed above, in some embodiments, the conveyor may sweep or push feedstock along a stationary surface. The segments 158 may include the supports 160 that may be configured to sweep, scrape, or otherwise advance the feedstock along the stationary surface. For instance, the support 160 may be configured as and/or may include a scraper, paddle, sweeping member, or a similar advancement member. The advancement members may contact and advance the feedstock on the stationary surface as the conveyor 126 rotates and/or advances in the confinement chamber. The advancing members may include metal, rubber, plastics, combinations thereof, or any suitable material that may be configured to withstand operating temperatures inside the confinement chamber.

As described above, in some embodiments, the conveyor 126 may loop around one more axle assemblies, which may secure and/or advance the conveyor 126 in the containment chamber. FIG. 10 shows axle assemblies 130 according to one or more embodiments. At least one of the axle assemblies 130 may include at least one chain ring or sprocket 164 that may engage the chain of the conveyor (described above). Accordingly, in some embodiments, the rotation of the sprocket(s) 164 (together with one or more of the axle assemblies 130) may produce a corresponding advancement of the conveyor 126 in the containment chamber. In some embodiments, the rotation of the sprocket 164 may be substantially continuous (e.g., at a fixed speed). In some embodiments, the rotation of the sprocket 164 may be non-continuous such as having dwell periods (e.g., durations of time where the conveyor is stationary such as to allow heat saturation or drainage of the target material from the feedstock) or variable speeds depending on the amount (e.g., thickness) of the feedstock thereon.

In some embodiments, at least one of the axle assemblies 130 may include at least one belt segment ring 166. The belt segment ring 166 may serve to support one or more central sections of the conveyor 126. The diameter of the sprocket 164 and/or segment ring 166 may be selected to provide a suitable spacing between the top and bottom surfaces of the conveyor, when the conveyor is looped around the axle assemblies 130. For instance, the spacing may be suitable or sufficient for locating the capture slid and or the funnel within the loop of the conveyor (described above).

One or more of the axle assemblies 130 may include a shaft 132 that may secure the sprocket(s) 164 and the segment ring(s) 166. For example, the sprocket(s) 164 and/or the segment ring(s) 166 may be approximately concentric with the shaft 132. Hence, rotation of the shaft 132 may produce a corresponding rotation of the sprocket(s) 164 and segment ring(s) 166, and vice versa.

As described above, the conveyor may pass through and/or around a capture slide 134 (e.g., the capture slide 134 may be positioned inside the loop of the conveyor). FIG. 11 shows the capture slide 134 according to at least one embodiment. In an embodiment, the support frame 168 may be connected and/or secured to the containment chamber and/or to the housing of the retort. In some instances, the capture slide 134 may be attached to or supported by a support frame 168. Additionally or alternatively, the conveyor may lie on and/or slide along the support frame 168. Hence, in at least one embodiment, the support frame 168 may support at least a portion of the conveyor, thereby facilitating transfer or advancement of the feedstock within the containment chamber. The support frame 168 may be mounted on top of the capture slide 134 and/or on the walls of the containment chamber, such that the conveyor belt support frame 168 extends horizontally across at least a portion of the length and width of the capture slide 134.

For example, the support frame 168 may include three or more lengthwise support members and eight or more widthwise support members horizontally mounted to the top of the capture slide 134, such as by support struts. In some embodiments, the support frame 168 may include more or fewer than three lengthwise support members, such as two, four, or five or more lengthwise support members. In some embodiments, the support frame 168 may include more or fewer than eight widthwise support members, such as two, four, ten, twelve, or twenty or more widthwise support members. The number and position of the support members in a support frame 168 may be selected based on any number of factors including at least the length and/or width of the conveyor 126, the amount of feedstock on the conveyor, or the type of feedstock being fed into the conveyor. The support frame 168 may be constructed of metals or metal alloys such as steels, steel alloys or other suitable heat resistant structural materials. In an embodiment, the support frame 168 may extend along the length of the containment chamber. In some instances, the support frame 168 may connect and/or support one or more of the axle assemblies.

As described above, the capture slide 134 may have a generally V-shaped cross-section (e.g., the capture slide 134 may be oriented relative to the conveyor such that the apex of the V-shaped cross-section of the capture slide 134 may be positioned closer to the carrying surface of the conveyor than the ends of the legs of the V-shape defining the cross-sectional shape of the capture slide 134). For example, the surfaces of the capture slide 134 may generally slope away from the top or carrying surface conveyor, such that the target material passing through the openings in the segments of the conveyor may move or slide along the surfaces of the capture slide 134 and away from the conveyor.

Moreover, the V-shaped cross-section of the capture slide 134 may form or define an opening 170 that may accept a portion of the conveyor. In other words, the conveyor may loop about the capture slide 134 in a manner that a portion of the loop of the conveyor passes through the opening 170 and loops about the capture slide 134. Moreover, the capture slide 134 may be attached to or integrated with the chute 156 that may transfer the waste to the waste airlock feeder, as described above. In particular, the waste may fall off the conveyor into the chute 156 and may further slide or fall into the waste airlock feeder that may be connected to the chute 156.

As described above, in some embodiments, the conveyor may advance feedstock over a stationary surface that may include on or defined by a sheet or a plate (e.g., a perforated sheet of metal). Moreover, the perforated sheet may be supported by a frame. For example, the perforated sheet may be at least partially supported by the support frame 168. In some embodiments, the stationary surface may generally slope or slant towards the outlet valve.

In at least one embodiment, the conveyor and/or the stationary surface may include one or more barriers (FIG. 8), which may prevent or impede the feedstock from moving laterally relative to the movement of the conveyor. In other words, the barriers may prevent or impede the feedstock from falling off the stationary surface (or conveyor) during advancement thereof. For instance, the plate defining the stationary surface may include side barriers that may extend upward (e.g., approximately perpendicular) relative to the stationary surface in a manner that forms barriers that may prevent the feedstock from crosswise movement off the stationary surface. In any event, in some embodiments, the barriers may facilitate advancement of the feedstock along the length of the containment chamber, while limiting or preventing movement of the feedstock off the stationary surface.

The above-described devices and systems also may be embodied in one or more methods. FIG. 12 is a flow diagram of a method 200 of operating a retort for separating a target material from a feedstock. The method 200 may include an act 210 of supplying a feed mechanism with feedstock. In an embodiment, supplying a feed mechanism with feedstock includes loading a hopper with feedstock material. In an embodiment, supplying a feed mechanism with feedstock includes activating the feed mechanism (e.g., the feedstock airlock feeder) to feed the feedstock into the retort.

The method 200 may include an act 220 of advancing the feedstock with a conveyor. In an embodiment, advancing the feedstock with a conveyor may include placing the feedstock on a conveyor inside the containment chamber of a retort, such as by depositing the feedstock on the conveyor via the feedstock airlock feeder. In an embodiment, advancing the feedstock with a conveyor may include activating the conveyor with the feedstock thereon, such that that the conveyor advances the feedstock along the length of the containment chamber. In an embodiment, advancing the feedstock with a conveyor may include advancing the feedstock on a stationary surface with one or more advancement members mounted to a conveyor, substantially as disclosed herein.

The method 200 may include the act 230 of heating the feedstock sufficient to separate at least a portion of the target material therefrom (e.g., cause the target material to at least partially melt and fall therefrom). In an embodiment, heating the feedstock may include heating the containment chamber to a temperature sufficient to cause at least partial separation of the target material from the waste material in the feedstock. Heating the feedstock and/or containment chamber may include using any of the heating mechanisms disclosed herein to heat the containment chamber. In an embodiment, heating the feedstock and/or containment chamber may include heating the feedstock inside the containment chamber during advancement of the feedstock, thereby causing at least a portion of the feedstock to change phase and separate therefrom as the target material. In some embodiments, the method 200 may also include the act of pressurizing the containment chamber to a suitable pressure.

In some embodiments, the method 200 further includes the act of activating the waste airlock feeder to remove waste material from the retort. The method 200 may include the act 240 of collecting the target material. In some embodiments, collecting the target material may include opening the target material collection valve to collect the target material that has separated from the feedstock and passed through the openings in the conveyor. The method 200 may include the act of removing the waste material (e.g., to non-target material separated from the feedstock) from the retort, which may include feeding the waste material into a waste airlock feeder leading to a waste container. The method 200 may further include adjusting one or more operating parameters such as conveyor feed rate, temperature, or pressure, based on the type of feedstock used, the amount or efficiency of collection of the target material per unit volume of feedstock, among others.

In at least one embodiment, a method of operating a retort to separate target material from a feedstock may include, first, engaging a waste airlock feeder (i.e., airlock feeder 112). In an embodiment, the retort and/or the controller thereof may include a safety lock that prevents operation of the retort until the waste airlock feeder is activated. Second, the method may include activating the conveyor. Third, the method may include activating the purge fan at the top of the retort. Fourth, the method may include opening the air valves (e.g., purge relief and/or fluid valves), optionally determining the operating temperature and pressure, and adjusting the air valves in response thereto.

Fifth, the method may include activating the heating unit(s). In some embodiments, the pressure in the containment chamber may be raised to a predetermined level (e.g., to a pressure in one or more ranges described above) before the controller activated the heating unit. Furthermore, in some instances, if pressure inside the containment chamber rises above a predetermined threshold, the controller may direct automatic release of the pressure from the containment chamber, such as through a valve (e.g., an electrically or hydraulically actuated valve, such as solenoid valve, servo actuated valve, etc.). In an embodiment, the heating unit may include a light or other indicator for indicating that the heating unit has been activated and/or is operational. The method also may include activating the feedstock airlock feeder (e.g., feeder 110), after temperature and pressure inside the containment chamber is at suitable and/or predetermined level. While the acts described above are presented in a specific order, one or more of the above acts may be performed simultaneously or in a different order than described.

While various aspects and embodiments have been disclosed herein, other aspects and embodiments are contemplated. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting.

Claims

1. A retort for separating a target material from waste material in feedstock, the retort comprising:

a containment chamber;

a heating unit positioned and configured to heat the containment chamber;

a conveyor at least partially located within the containment chamber, the conveyor including one or more openings sized and configured to allow the target material to pass therethrough; and

a collector assembly configured to receive the target material that passes through the conveyor.

2. The retort of claim 1, wherein the collector assembly includes:

a capture slide disposed below at least a portion of the conveyor; and

a funnel disposed below the capture slide.

3. The retort of claim 2, wherein the capture slide slopes away from a surface of the conveyor that carries the feedstock.

4. The retort of any of claims 1-3, wherein at least a portion of one or more of the containment chamber, the conveyor, and the collector assembly are disposed within a housing.

5. The retort of any of claims 1-4, wherein the containment chamber is substantially sealed.

6. The retort of any of claims 1-5, further comprising a feedstock feed mechanism configured to feed feedstock onto the conveyor.

7. The retort of claim 6, wherein the feedstock feed mechanism includes:

an airlock feeder operably coupled to the containment chamber, the airlock feeder being positioned and configured to deposit feedstock on a first end of the conveyor; and

a hopper operably coupled to the airlock feeder, the hopper being configured to feed feedstock into the airlock feeder.

8. The retort of any of claims 1-7, further comprising a waste removal mechanism configured to remove the waste material separated out of the feedstock from the retort.

9. The retort of claim 8, wherein the waste removal mechanism includes:

a waste chute positioned adjacent to and below a second end of the conveyor;

a waste airlock feeder operably coupled to the waste chute and configured to discharge waste therethrough to an external environment.

10. The retort of any of claims 1-9, wherein the conveyor includes a plurality of segments pivotally connected together and forming a loop, wherein each of the plurality of interconnected segments includes:

one or more support pieces; and

a mesh material positioned on the one or more support pieces, the mesh material configured to allow passage of the target material therethrough and retention of the waste material.

11. The retort of claim 10, wherein the conveyor includes a chain operably coupled to one or more of the plurality of segments, and wherein the chain is operably coupled to one or more axles configured to control advancement of the conveyor.

12. A retort for separating one or more target materials from waste material in feedstock, the retort comprising:

a housing;

a containment chamber positioned inside the housing, the containment chamber being sealed;

a conveyor assembly positioned inside the containment chamber and between a first location and a second location therein, the conveyor assembly including a plurality of segments pivotally connected together and forming a loop having a carrying surface configured to carry the feedstock, each of the plurality of segments including a plurality of openings sized and configured to allow at least some of the one or more target materials to pass therethrough, the plurality of segments being sized and configured to retain the waste material; and

a drive mechanism connected to the conveyor and configured to advance the plurality of the segments from the first location to the second location in the containment chamber;

a capture slide positioned within the loop of the conveyor, the capture slide including one or more surfaces sloping away from the carrying surface and positioned to receive the at least one target material passing through the plurality of openings in the segments; and

an outlet positioned and configured to receive the at least one target material from the capture slide.

13. The retort of claim 12, further comprising a feedstock feed mechanism including:

an airlock feeder operably coupled to the containment chamber, the airlock feeder being positioned and configured to deposit feedstock on a first end of the conveyor; and

a hopper operably coupled to the airlock feeder, the hopper configured to feed feedstock into the airlock feeder.

14. The retort of any of claims 12-13, further comprising a waste removal mechanism, including a waste chute positioned adjacent to and below a second end of the conveyor, and a waste airlock feeder operably coupled to the waste chute and configured to discharge waste therethrough to the external environment.

15. The retort of claim 12, further comprising a funnel disposed below the capture slide and extending laterally past a maximum extent of the capture slide, the funnel having sloping surfaces configured to converge the one or more target materials at a collection point.

16. The retort of claim 12, wherein the drive mechanism includes:

at least one chain operably coupled to one or more of the plurality of segments; and

at least two axles supporting the conveyor, each of the at least two axles including a shaft and sprockets secured at opposing ends of the shaft, the sprockets being configured to engage the at least one chain.

17. A method of separating a target material from waste material in feedstock, the method comprising;

advancing the feedstock inside a containment chamber;

heating the feedstock inside the containment chamber during advancement of the feedstock, thereby separating the feedstock into the target material and waste material; and

collecting the target material.

18. The method of claim 17, wherein heating the feedstock inside the containment chamber during advancement of the feedstock, includes:

heating the feedstock on a conveyor inside of the containment chamber; and

causing the target material to fall through one or more openings on the conveyor and leaving the waste material on the conveyor.

19. The method of any of claims 17-18, further comprising depositing the feedstock on a conveyor extending through the containment chamber.

20. The method of claim 19, wherein depositing the feedstock on a conveyor extending through the containment chamber includes feeding the feedstock into an airlock feeder positioned and configured to deposit the feedstock on the conveyor.