A method comprising: feeding a feed composition comprising inert solids, liquid hydrocarbons and liquid water to a thermal extraction unit comprising an external casing defining an internal thermal extraction chamber in which first and second intermeshing screws (18A, 18B) rotate at the same speed, the screws each comprising a shaft (146, 148) and a plurality of screw elements (142, 144), the screw elements on the first screw configured to be in close tolerance to adjacent screw elements on the second screw such that frictional heat is generated when the feed composition passes between the screw elements on the first screw and the screw elements on the second screw, and all screw elements in close tolerance with inside surfaces of the casing, and wherein portions of the casing, shafts and screw elements define a tortuous flow path in which the feed composition and a substantially vaporous composition evolved therefrom flow, wherein at least a portion of the tortuous flow path is non-linear, the substantially vaporous composition comprising co-mingled hydrocarbon vapors, water vapor, and fine particles of the inert solids; and reducing pressure while increasing temperature in the thermal extraction chamber as the plurality of intermeshing screw elements push the feed composition toward a discharge end of the thermal extraction chamber at a first velocity, while rotating the screws at a speed sufficient, in combination with geometry of the screws and casing, to create turbulent vacuum thermal conditions in the thermal extraction chamber sufficient to physically transform some or all of the feed composition into the substantially vaporous composition, and forming a heated, substantially dry, depleted feed composition comprising non-fine particles of the inert solids, the substantially vaporous composition traversing the tortuous flow path with a second velocity at least 1.5 times the first velocity. feeding a feed composition comprising inert solids, liquid hydrocarbons and liquid water to a thermal extraction unit comprising an external casing defining an internal thermal extraction chamber in which first and second intermeshing screws (18A, 18B) rotate at the same speed, the screws each comprising a shaft (146, 148) and a plurality of screw elements (142, 144), the screw elements on the first screw configured to be in close tolerance to adjacent screw elements on the second screw such that frictional heat is generated when the feed composition passes between the screw elements on the first screw and the screw elements on the second screw, and all screw elements in close tolerance with inside surfaces of the casing, and wherein portions of the casing, shafts and screw elements define a tortuous flow path in which the feed composition and a substantially vaporous composition evolved therefrom flow, wherein at least a portion of the tortuous flow path is non-linear, the substantially vaporous composition comprising co-mingled hydrocarbon vapors, water vapor, and fine particles of the inert solids; and reducing pressure while increasing temperature in the thermal extraction chamber as the plurality of intermeshing screw elements push the feed composition toward a discharge end of the thermal extraction chamber at a first velocity, while rotating the screws at a speed sufficient, in combination with geometry of the screws and casing, to create turbulent vacuum thermal conditions in the thermal extraction chamber sufficient to physically transform some or all of the feed composition into the substantially vaporous composition, and forming a heated, substantially dry, depleted feed composition comprising non-fine particles of the inert solids, the substantially vaporous composition traversing the tortuous flow path with a second velocity at least 1.5 times the first velocity.