Non-aqueous extraction and separation of bitumen from oil sands ore with rotating elements

Abstract

Rotating elements receivable within an extractor trough of an extractor configured for non-aqueous extraction of bitumen from oil sands are described. The rotating element can include a shaft operatively couplable to a motor, and projections extending outwardly from the shaft and being removably secured thereto. The rotating element can also include a shaft mounting structure couplable to a shaft, comprising a shaft receiving hub configured for receiving the shaft therein. The rotation of the rotating element can provide digestion and extraction of bitumen from the oil sands while advancing solids in a downstream direction within the extractor trough, as solvent diluted bitumen flows in an upstream direction toward a liquid outlet. Methods for servicing a rotating element and for manufacturing a non-aqueous extraction (NAE) extractor are also provided.

1 - 23 . (canceled) 
     
     
         24 . A rotating element receivable within an extractor trough of an extractor configured for non-aqueous extraction of bitumen from oil sands, the rotating element comprising:
 a shaft operatively couplable to a motor configured for driving a rotation of the shaft; and   projections extending outwardly from the shaft and being removably secured thereto;   wherein the rotation of the rotating element provides digestion and extraction of bitumen from the oil sands while advancing solids in a downstream direction within the extractor trough, as solvent diluted bitumen accumulates in an upper region of the extractor trough and flows in an upstream direction toward a liquid outlet.   
     
     
         25 . The rotating element of  claim 24 , wherein the shaft has an edgeless cross-section and comprises elongated slots extending in circumferential arcs around the shaft, and a corresponding one of the projections is provided along a corresponding one of the elongated slots for being removably secured to the shaft. 
     
     
         26 . The rotating element of  claim 25 , wherein a first set of two elongated slots is provided in a spaced-apart relationship around a first circumferential arc of the shaft, a second set of two elongated slots is provided in a spaced-apart relationship around a second circumferential arc of the shaft, the first and second sets of the elongated slots being longitudinally spaced-apart from one another. 
     
     
         27 . The rotating element of  claim 26 , wherein a first subcomponent of two projections is provided along the first set of two elongated slots and a second subcomponent of two projections is provided along the second set of two elongated slots, each one of the projections of the first and second subcomponents of projections extending in a given quadrant defined around the shaft. 
     
     
         28 . The rotating element of  claim 26 , wherein a first subcomponent of two projections is provided along the first set of two elongated slots and a second subcomponent of two projections is provided along the second set of two elongated slots, each one of the projections of the first and second subcomponents of projections extending at an angle between about 45° and about 90° relative to each other. 
     
     
         29 . The rotating element of  claim 25 , further comprising a mounting assembly for removably securing the corresponding one of the projections to the shaft. 
     
     
         30 . The rotating element of  claim 29 , wherein the mounting assembly is displaceable along the corresponding one of the elongated slots to provide the projections in an offset configuration around the shaft. 
     
     
         31 . The rotating element of  claim 29 , wherein the mounting assembly is configured to rotate about a transverse axis of the shaft to modify a positioning of the corresponding one of the projections. 
     
     
         32 . The rotating element of  claim 29 , wherein the mounting assembly is configured such that the corresponding one of the projections is oriented at an angle relative to a transverse plane extending perpendicularly to a longitudinal axis of the shaft. 
     
     
         33 . The rotating element of  claim 29 , wherein the mounting assembly is configured such that the corresponding one of the projections is oriented parallel relative to a transverse plane extending perpendicularly to a longitudinal axis of the shaft. 
     
     
         34 . The rotating element of  claim 29 , wherein the mounting assembly comprises a bracket. 
     
     
         35 . The rotating element of  claim 29 , wherein the corresponding one of the projections and the mounting assembly are integral with each other. 
     
     
         36 . The rotating element of  claim 27 , wherein the projections are removably secured to the shaft via a mounting assembly, and the mounting assembly comprises a single mechanical fastener extending across the shaft to secure two opposite projections of the first subcomponent of two projections or of the second subcomponent of two projections together. 
     
     
         37 . The rotating element of  claim 24 , wherein adjacent ones of the projections are provided in an offset configuration. 
     
     
         38 . The rotating element of  claim 24 , wherein a first subcomponent of two projections is provided longitudinally adjacent to a second subcomponent of two projections, each one of the projections of the first and second subcomponents of projections extending in a given quadrant defined around the shaft. 
     
     
         39 . The rotating element of  claim 24 , wherein a first subcomponent of two projections is provided longitudinally adjacent to a second subcomponent of two projections, each one of the projections of the first and second subcomponents of projections extending at an angle between about 45° and about 90° relative to each other. 
     
     
         40 . The rotating element of  claim 24 , wherein the shaft has a polygonal profile or an edgeless profile. 
     
     
         41 . The rotating element of  claim 40 , wherein the projections of a first subcomponent of projections are provided offset from the projections of a second subcomponent of projections relative to a longitudinal axis of the shaft, the first subcomponent being provided longitudinally adjacent to the second subcomponent. 
     
     
         42 . The rotating element of  claim 37 , further comprising a mounting assembly for removably securing a corresponding one of the projections to the shaft. 
     
     
         43 . The rotating element of  claim 42 , wherein the corresponding one of the projections and the mounting assembly are integral with each other.