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.

What is claimed is: 
     
         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.