US-20260125329-A1 - EXTRACTION APPARATUS

US20260125329A1US 20260125329 A1US20260125329 A1US 20260125329A1US-20260125329-A1

Abstract

In some aspects, the device includes a hopper for receiving compost, with a wide open upper end and a narrow closed lower end. A metering auger is mounted on a first portion of a shaft within the hopper's lower end, and an extraction auger is mounted on a second portion of the same shaft within an adjacent extraction chamber. The extraction chamber includes a tube screen assembly in fluid communication with the hopper and water spray nozzles that direct water onto compost conveyed from the hopper. As the shaft rotates, water washes beneficial materials from the compost, which are collected in a catch basin positioned below the extraction chamber. A drive assembly powers the shaft rotation. In certain embodiments, the apparatus is configured for continuous operation in irrigation pivot systems and can be calibrated based on standardized relationships among water flow rate, auger speed, and compost input weight.

Inventors

Seth Conrad Swinger
Nathanael Robert Clement

Assignees

CHURCH STEWARDSHIP INC.

Dates

Publication Date: 20260507
Application Date: 20251106

Claims (20)

1 . An apparatus for extracting materials from compost, comprising: a hopper for receiving compost, the hopper having a wide open upper end and a narrow closed lower end; a metering auger mounted on a first part of a shaft within the narrow closed lower end of the hopper; an extraction auger mounted on a second part of the shaft; an extraction chamber positioned adjacent to the hopper, the extraction chamber having a tube screen assembly in open communication with the hopper and enclosing the extraction auger, the extraction chamber having water discharge spray nozzles for directing water onto compost being conveyed by the metering auger from the hopper into the extracting chamber by rotation of the shaft, the water directed onto the compost washing materials from the compost as the extraction auger rotates the compost received from the hopper; a catch basin positioned below the extraction chamber to catch the materials washed from the compost; and a drive assembly causing the rotation of the shaft.
2 . The apparatus of claim 1 , wherein the shaft has an inner hollow portion along a length of the extraction auger, wherein the water discharge spray nozzles are mounted on the extraction auger, and wherein the water is supplied to the water discharge spray nozzles through the inner hollow portion of the shaft.
3 . The apparatus of claim 2 , wherein the water is supplied to the water discharge spray nozzles through the inner hollow portion of the shaft via a swivel union connected to an end of the shaft proximal to the extraction auger.
4 . The apparatus of claim 1 , further comprising a lid positioned over the extraction chamber.
5 . The apparatus of claim 1 , wherein a portion of the shaft proximal to the extraction auger is mounted to an elongated outer wall of the catch assembly via a centering mount assembly.
6 . The apparatus of claim 5 , wherein the centering mount assembly has a first position in which the shaft is held in a fixed position two rotatable arms and a second position in which the two rotatable arms rotate to release the shaft.
7 . The apparatus of claim 6 , wherein the tube screen assembly is removable when the centering mount assembly is in the second position.
8 . The apparatus of claim 1 . wherein the hopper has perforated tubes along an upper portion of the wide open upper end for introducing water along an adjacent inner surface of the hopper to reduce static friction of the compost in the hopper.
9 . The apparatus of claim 1 . wherein the hopper has perforated tubes along two opposing upper edges of the wide open upper end for introducing water along an adjacent inner surface of the hopper to reduce static friction of the compost in the hopper.
10 . The apparatus of claim 1 , wherein the metering auger has helical portions of a first diameter, and wherein the extraction auger has helical portions of a second diameter, the second diameter larger than the first diameter.
11 . The apparatus of claim 1 , wherein the metering auger has helical portions of a first pitch, and wherein the extraction auger has helical portions of a second pitch, the second pitch larger than the first pitch.
12 . The apparatus of claim 1 , wherein the extraction chamber has an aperture adjacent to an end of the shaft proximal to the extraction auger for discharging compost after passing through the extraction chamber.
13 . The apparatus of claim 1 , wherein the shaft is inclined, with an end of the shaft proximal to the extraction auger positioned higher than an end of the shaft proximal to the metering auger.
14 . The apparatus of claim 1 , wherein the drive assembly comprises a hand crank coupled to an end of the shaft proximal to the metering auger.
15 . The apparatus of claim 1 , wherein the drive assembly comprises a motor coupled to an end of the shaft proximal to the metering auger.
16 . The apparatus of claim 15 , wherein the drive assembly includes a spring clutch mechanism coupled between the motor and the end of the shaft proximal to the metering auger; and wherein the spring clutch mechanism is configured to decouple the motor from the shaft when excessive torque is present on the shaft.
17 . A method of operating an extraction apparatus, comprising: a) introducing compost into a hopper of the extraction apparatus; b) rotating an auger shaft extending through the hopper and through an adjacent extraction chamber of the extraction apparatus to transport the compost from the hopper into and through the extraction chamber, the compost being maintained within a mesh screen surrounding the auger shaft as the compost passes through the extraction chamber; and c) supplying water to spray nozzles positioned within the extraction chamber, the spray nozzles directing the water towards the compost being transported through the extraction chamber so that the compost is rinsed with the water as the compost is conveyed through the extract chamber, thereby producing a liquid extract passing through the mesh screen surrounding the auger shaft and into a catch basin.
18 . The method of claim 17 , further comprising collecting the liquid extract in the catch basin and delivering liquid extract to an irrigation system or a storage system.
19 . A method of calibrating an extraction apparatus, comprising: a) loading a predetermined input weight of compost into a hopper of the extraction apparatus; b) providing water to spray nozzles of the extraction apparatus at a fixed pressure value; c) rotating an auger shaft extending through the hopper and through an adjacent extraction chamber of the extraction apparatus at a fixed rotational speed to convey the compost from the hopper into and through the extraction chamber, the compost being maintained within a first mesh screen surrounding the auger shaft as the compost passes through the extraction chamber, the first mesh screen having a first predetermined mesh size; d) recording an amount of run time required to empty the hopper of the predetermined weight of compost; e) determining a flow rate of the provided water; and f) calculating an extract dilution ratio according to: Extract Dilution Ratio=Flow Rate×Run Time÷Input Weight.
20 . The method of claim 19 , further comprising adjusting the fixed rotational speed of the auger shaft to provide a desired value for the extract dilution ratio.

Description

CROSS-REFERENCE This application claims the benefit of U.S. Provisional Patent Application No. 63/717,557, filed Nov. 7, 2024, under 35 U.S.C. 119(e) which application is incorporated by reference herein in its entirety. FIELD The present invention relates generally to extraction systems, and more particularly to an apparatus and associated methods for extracting biological materials and nutrients from compost or similar organic materials for use in soil amendment and microbial regeneration applications. BACKGROUND Extraction is a process of selectively separating solid materials and transferring substances of interest into a liquid solution. Such processes are used in various applications, including the recovery of biology and nutrients from organic material for use as soil-building amendments that regenerate microbial ecosystems within soil profiles or on plant surfaces. While extraction can be performed on a small scale using limited tools, specialized equipment is required to scale the process efficiently. Recent advances in microbial testing have revealed the complexity of microbiological communities within extracted liquids, emphasizing the importance of equipment capable of producing consistent, validated, and clean extracts. Existing extraction equipment suffers from several drawbacks, including: inconsistent extraction quality and inefficient operation; limited cleanability, promoting the formation of biofilms that create anaerobic conditions conducive to pathogen growth; and difficult verification and maintenance procedures that lead to downtime and variability in extract quality. Batch-style extraction systems, which typically use air and water agitation in large tanks, suffer from inefficiency, extended downtime, and poor cleanability. The introduction of air can also prematurely stimulate microbial reproduction, depleting dissolved oxygen and reducing the effective shelf life of the extract. Continuous-flow extraction systems offer some improvement but often rely on multiple augers and power sources to handle material transport and extraction separately. Such systems are mechanically complex, costly, and prone to bridging and compaction within the hopper. Inaccessible nozzles and fixed covers further limit cleanability and visibility. Accordingly, there exists a need for a simple, continuous extraction apparatus that is efficient, modular, easy to clean, and capable of producing consistent high-quality extracts. In certain application, particularly agricultural irrigation systems such as center-pivot irrigation, a need exists for extraction equipment optimized for continuous operation in remote or semi-automated environments. Extractors installed near irrigation pivots must have larger hoppers, reinforced construction, and robust operation since they may be checked only periodically. Integrating the present design into such systems provides an automated, field-deployable source of biological extract directly into irrigation lines. SUMMARY The present disclosure provides an extraction apparatus that integrates both metering and extraction functions into a single auger-driven assembly. The apparatus includes a hopper for receiving compost, a single shaft extending through the hopper and into an extraction chamber, and a screened enclosure housing spray nozzles along a hollow portion of the shaft. As the shaft rotates, the metering auger portion conveys compost from the hopper into the extraction chamber, where the extraction auger portion agitates the compost while spray nozzles direct water against it through the surrounding screen. Biological material and nutrients are rinsed from the compost to form a liquid extract that passes through the screen and into a catch basin, while excess solid material is discharged downstream. The invention improves upon prior systems by reducing mechanical complexity, enhancing cleanability, enabling tool-free screen replacement, and providing visibility into the extraction chamber. A single power input controls both metering and extraction, simplifying operation and maintenance while reducing cost. In some embodiments, the extractor is configured for integration with irrigation pivot systems, enabling continuous extraction during irrigation. Such embodiments employ a larger-capacity hopper, weather-sealed enclosures, and durable drive systems capable of sustained operation with minimal operator intervention. BRIEF DESCRIPTION OF THE DRAWINGS The following detailed description, given by way of example and not intended to limit the present disclosure solely thereto, will best be understood in conjunction with the accompanying drawings in which: FIG. 1 is a schematic side view of the extraction apparatus of the present disclosure illustrating the single-shaft metering and extraction auger configuration; FIG. 2A is a partial side view of the extraction apparatus showing the transparent removable lid and cutaway catch basin, and FIG. 2B is a side view of a cylindrica