Waste Oil and Sludge Treatment and Recycling by ... Oil and Sludge Treatment and Recycling by Manufacturing UNEPUNEP--IETC IETC のワークショップ Osaka, April 16Osaka, April

Waste Oil and Sludge Treatment and Waste Oil and Sludge Treatment and Recycling by Manufacturing Recycling by Manufacturing

UNEPUNEP--IETCIETCのワークショップのワークショップのワークショップのワークショップのワークショップのワークショップのワークショップのワークショップ

Osaka, April 16Osaka, April 16--18, 201218, 2012

2012/4/12 0

Recycling by Manufacturing Recycling by Manufacturing Alternative Fuel for Cement IndustryAlternative Fuel for Cement Industry

REMATEC CorporationREMATEC CorporationYASUNORI TANAKA, MITSUYUKI NISHIHARA*, MASATOSHI TA NAKAYASUNORI TANAKA, MITSUYUKI NISHIHARA*, MASATOSHI TA NAKA

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012

Today’s Introduction Contents

1. RF Technology (Reclaimed Fuel)2. SCW Technology (Subcritical water)3. Illegal dumping waste treatment and

Copyrights 2012 REMATEC Corporation All rights reserved. 11

3. Illegal dumping waste treatment and management

4. Reconstruction support activities in TOHOKU area (Great East Japan Earthquake and Tsunami Disaster Area)


1. RF Technology(RF is Reclaimed Fuel for


(RF is Reclaimed Fuel forcement industry)

2

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012RF Technology ～～～～Industrial Waste Recycle ～～～～

Current &Traditional treatment MethodsIndustrial wastes

IncinerationLand filling

Petroleum oil industry

Power industry

RFRF＝＝＝＝＝＝＝＝RReclaimed eclaimed FFueluelWaste oilSludgeDust

Oil mud


Power industry

Petrochemical company

Iron and steel company

Incineration and land filling are usually chosen for treating these hazardous wastes. Our company has been using RF technology to convert these wastes into a recycled fuel for over 30 years. This recycled fuel is mainly used and highly welcomed in cement factories.

Cement FactoriesRF Manufacturing plants

Oil mudSolventSewage

3

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012RF Manufacturing Diagram Flow

Waste oil50～60％

Liquid waste

Original Mixing Technology of our Company

Heat ValueConditioning

WastewaterOil sludgeWaste oil

Vibration Screen

Primary mixer Line mixer Vibration sieve RF（（（（Product ））））


Liquid waste30～40％

Solid waste0～20％

SludgeAshWaste clay

Second mixer Product Storage Tank

Transport to Cement factories

By our original technology and manufacturing process,waste oil, wastewater and solid waste are mixed and usedas fuel in cement factories.

4


Properties of RF ～～～～Reclaimed Fuel ～～～～

RF’s Properties ⇒⇒⇒⇒ Original technology of REMATEC CORPORATION

Patent No.3039644

A compound possessing reversible thixotropic

property used as an auxiliary fuel for cement pyroprocess

RF is a material in emulsion state with thixotropy property,its flow behavior such as elasticity and viscosity and theirrelationship with temperature are theoretically stu died inrheology field.

■ A material with Thixotropy property ■Thixotropy is seen in many


■ A material with Thixotropy propertyA thixotropy material has high viscosity

at a steady-state, and has low viscosity when

introduced to a step change in shear rate or by

a mechanical stress.

Using RF technology, we mix various wastes together and endow them with thixotropy property

which displays the natures of preventing oil separating from water or solid separating from liquid

while at a steady-state, but when introduced to a step change in shear rate or by a mechanical stress,

for example shaking, its viscosity will be decreased and will flow fluently. This feature makes RF

easy transportation by pump and pipes.

■Thixotropy is seen in many materials and fluids.

Tomato-sauceMayonnaiseTooth pastePaints

5

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012Static microstructure of RF

1. RF bulk2. Continuous fluid phases3. Larger dispersion drops (oils and/or aqueous fluids)4. Smaller dispersion drops (oils and/or aqueous fluids)5. Solid components to be possible raw material of cement5A. Solid components containing possible cement

raw materials (~3mm size)6. Other solid particles7. Accessory substance (bonding medium)7A, 8, 9. Microstructures


7A, 8, 9. Microstructures

RF is a compound with some specific viscosity

characteristics and is comprised of oil and other

liquid components, and solid components

containing possible cement materials.

With this structure no phase change occurs, for example,

oil separating from liquid, or solid separating from aqueous fluids.

6

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012RF’s viscosity and shear rate

RF, with low viscosity on

initial movement, can be

transported by normal pipe

work and can be used in

spray combustion, without

any separation of oils and

solids (sands, muds, rusts

etc.) from aqueous fluids.

Vis

cosi

ty (

cp)


As shear rate is increased, viscosity of RF will decrease, that results in higher-

mobility or flowability of RF and enables easily pipe transportation and spray

combustion in cement kiln.

Shear rate (sec-1)

Vertical axis is viscosity of RF.

Horizontal axis stands for shear

rate of RF product.

7


RF’s Application Example ～～～～Effectively used by Cement Factories ～～～～

This flow shows the main manufacture process in cement factory. RF is supplied from the middle part of pre-heater and end part of rotary kiln. By manufact uring RF, industry waste are recycled as fuel and raw material of cement. Final treatment is not needed.

Effective utilizationin cement factories

Final treatment for Waste

Supply Flow Reuse and Recycle


Osaka RF Factory(Production capacity 200ton/day) ⇒ RF ProductKyusyu RF Factory(Production capacity 192ton/day) ⇒ RF Product

8

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012RF system’s Contribution to Society

Society

IndustriesAutomobile,

iron and steel, machinery,

food, electronics,

chemicals,

medicals, rubber, etc...

CementFactories

RF

Wastes

Information of waste

Proposal

Solution

Rematec’s pledges to society

• Promote industrial waste treatment

and recycling by utilizing appropriate

and effective technologies.

• Take active steps to help build a sustainable

society.

• Actively engage in promoting independent efforts

for preventing global warming.

• Promoting practices for preventing environmental


Wastes

Lower carbon emission

Rematec is admitted as eco first company by Japanesegovernment. Promoting Industrial waste treatment andrecycling and increasing RF manufacture amountannually are Rematec’s commitment to government.

This is a cascade type cycle for waste recycle by utilizing RF technology.

2010 2009 2008 2007 2006 2005 2004 2003 2002

RF production amount (t) 108,809 93,470 95,536 95,497 90,184 89,440 93,759 95,601 90,061

Recycle ratio (%) 97.1% 97.3％％％％ 97.2% 97.4% 98.1％％％％ 98.2％％％％ 98.7％％％％ 97.9％％％％ 97.4％％％％

Conversion to Coal (t) 74,485 65,277 66,075 66,020 62,138 62,238 65,478 66,315 62,633

Reduction amount of CO2

generation (t････CO2)187,702 180,086 182,287 182,136 171,427 171,702 180,642 182,950 172,793

• Promoting practices for preventing environmental

pollutions and taking actions positively.

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012Characters of RF Technology

• Our company’s original technology ⇒A wide range of wastes can be treated and recycled

• Wide range of waste, such as waste oil, waste acid/alkali, sludge or ash can be used as feeding materials of RF.

POINT 1POINT 1

• No emission of waste gas and discharge of wastewater. ⇒

POINT 2POINT 2


• No emission of waste gas and discharge of wastewater. ⇒ No secondary pollution.

• RF manufacture is a composition adjustment process by mixing various of wastes. • Since there is no need to burn waste in treatment process, no waste gas is emitted. • There is also no wastewater generated since almost 100% of the wastes is recycled. • It’s an earth-friend recycling system.

• A RF product ⇒ Sold as auxiliary fuel. Final disposal is not needed • RF is sold to cement factories to be used as alternative fuel to fossil fuels and the final

incineration ash become a part of raw material of cement.• Final disposal and management are not needed.

POINT 3POINT 3

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012Our Achievements in Plant Design & Construction

2008. O Factory at A

Major Cement Manufacturer

Range of Activities

Our experience runs from RF manufacture to plant designand construction and overseastechnology transfer. Applications include: construction of our Osaka factoryin 1983, Kyusyu factory in 1988,technology transfer to Taiwan in1993 and to Korea in 1996 and theseveral plants’ constructions at the Japan’s major cement industry.


1993. Kaohsiung Taiwan

1996. Ulsan Korea

1983. Our company’s Osaka Factory

1988. Our company’s Kyushu Factory

at the Japan’s major cement industry.


A Case Introduction for Business Expansion in Thailand

2010 October Attended exhibition in Thailand （EntechPolutec) and arranged a meeting with a major cement company in Thailand.

2010 November23th-24th

Went to Thailand visiting the major Cement and Waste Recycle company and carried out feasibility study. Cooperative consultation was conducted between two companies.

2010 December 15th

Major Cement & Recycle Company of Thailand came Osaka and visited our factory in Kishiwada city.

2011 March 8th

Went to Thailand to make a discussion with Major Cement Company on the possibility of business expansion and synergy effect on total cement


Through reciprocal visits and information exchange,

the technology transfer.

Through reciprocal visits and information exchange,

business relationship building is going on for fulfilling

the technology transfer.

8th the possibility of business expansion and synergy effect on total cement industry causing by RF technology introduction.

12


2. Introduction of SCW Technology


Technology

13

(Subcritical water technology)

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012Subcritical Water’s Properties

High

hydrolysis

High

solubility

0

20

40

60

80

-25

-20

-15

-10

誘電

率[-

]

log(

Kw)[

(mol

/kg)

2 ]

ε

Kw

Temperature dependence of water’s dielectric

constant and ion product at 25MPa

Point 1

Point 2


100℃

1atm

liquid1.0gcm-3

Sub-critical water

300℃

84.8atm

Super-critical water

Above 374℃

Above 218atm.

gas0.0006gcm-3

0.05 g cm-3

0.71 g cm-3

0.315 g cm-3 OH-H+

H+OH-

OH-H+

H+OH-

OH-H+

OH- H+

OH-H+

hydrolysis

capability

Ordinary state Sub-critical water state

With a low ion product and low OH concentration, organic matter can notbe decomposed.

High concentration of OH ion

at sub-critical state lead to the

decomposition of organic substance

200 400 600 8000

-25

Temp.[Ｋ]

Subcritical water is below the water’s critical point. In this area, it has high solubility and hydrolysis capability.

Subcritical

water reactionNitric AcidWaste

pickling

Pretreatment

Process

Post-treatment

Process

Liquid (Nitric Acid)

Precipitate

（（（（Metal oxide））））

Application 1 Treatment Flow for Nitric Acid Recovery from Waste Pickling

•Impurity removal

Iron and steel industries use large amount of acid for surface treatment, and large volume of waste

pickle acid liquid is being discharged , they are usually treated by neutralization and land filling. We

use subcritical water reaction to treat and recycle nitric acid from pickling. Recovered nitric acid is

returned to iron and steel factories.

New recycle technology of REMATEC New application of chemical reaction

0

200

400

600

800

1000

1200

1400

Virgin Nitric Acid Recovered AcidK

g-C

O2/ton N

itric A

cid

（（（（Metal oxide））））

Ferric

Oxide

•Impurity removal

•Concentration control•Hydrolysis of Ferric nitrate

•Generation of Free HNO3

•Solid-liquid separation

15

41414141％％％％ reduction reduction reduction reduction

ratioratioratioratio

Environmental conservation type technologyN2O, a by-product in virgin nitric acid manufacturing process (a greenhouse gas with about 300 times more powerful than CO2 ).→Through the use of recycled nitric acid from waste pickling, we can get 41% CO2 reduction ratio for per ton’s nitric acid compared with using virgin nitric acid.


Food wastesSewage

Traditional methane methane fermentation processfermentation process

Subcritical water

Using SubSub-- critical watercritical water＊Retention time 7-10days＊Reaction Vessel to 1/4＊Half side area→ Low-cost

＊Long retentiontime(25-35 days)

＊Large vessel

high cost

Conventional type reactor

Reaction conditions(Temp: 130-180℃℃℃℃)

Solubilization and Acid formation(hydrolases, lipases, Acidogenesis,…) Methane fermentation(Methanogenesis)

Application 2 High speed methane fermentation system


Fermentation Reactor

Subcritical water

Low molecularsubstances

Food wastesSewage

CH4 production

We use subcritical water treatment as a pretreatmen t process for methane fermentation. Long time solubilization and acid formation in tradition al type reactor can be shortened after the introduction of subcritical water treatment. Compa ct treatment system can be easily settled and as easily adopted as distributed energy supply syst ems in cities or countries.

＊Half side area→ Low-cost＊Minimum utilities

(Temp: 130-180℃℃℃℃)(Pressure: below 5MPa)

A part of methane gas used as energy

16

Energy supplier

ElectronicPowersupply


3. Illegal dumping waste treatment and management


treatment and management

17


Using superheated steam technology for fire extinction in an illegal waste dumping sit e

A project for recovering an illegal waste dumping site

There were several fire burning spots in the dumping waste

It was too difficult to extinguish the fires only by water inject

�Stream has higher diffusivity than water.�Air is substituted by stream injected from the bottom of burning waste layer and fire extinguished fire by suffocation function. �24 hours continuous operation were conducted for about 3 weeks.�Results were confirmed through monitoring of temperature and oxygen concentration data.

【【【【Back ground 】】】】【【【【Fire extinction by superheated steam】】】】


Fire extinction were conducted based on the

analysis results.

Fire extinction were conducted based on the stream diffusion model and thermo-fluid analysis results.

the fires only by water inject

We proposed the treatment plan of using the superheated stream

technique

Support Request

Horizontal boring injector

length 56-84m

Depth 25～～～～35m

Injected stream volume

1.5t/h(MAX)

e-19

A-0

A-1A-7 A-6A-8 A-4A-5 A-2A-3

→Air richStream rich ←

Waterinject

Stream inject


□Illegal dumping in Aomori and Iwate PrefectureIllegal dumping waste amount: reached to 1,100,000ｍ3

Types of waste: a wide variety of waste including combustion residue,waste oil, sludge, waste food,etc.

Illegal dumping vendors: over 12,000

□ Role of Rematec CorporationWe proposed the treatment plan to Iwate Pref.Illegal dumping waste were managed and recycled.

Recovering Illegal dumping site andrecycling waste in Iwate and Aomori Prefectures


□Current situation280,000ton of waste in Iwate and 750,000 tons of waste in Aomori were clearly removed now.

These waste were sorted and treated in the following ways.

・Solid waste (sludge)・Liquid waste⇒ 230,000ton of wastes were treated in Ofunato factory of

Taiheiyou Cement Corporation (81.2% of total quantity)・Waste plastics, sludge, waste metals, sludge containing high salt concentration⇒Dowa Eco-system Co.,Cleaning Centre of Kamaishi city,

Iwate North Clean Co., etc.

19Source: HP of Iwate Pref.

Recycle and reuse


4. Reconstruction Activities in TOHOKU area


Disaster waste by Tsunami 75,6000 ton in Ofunato city1,016,000 ton in Rikuzen -Takada city(Data Source: HP of Ministry of the Environment of Japan )


2011.03 .20

This p hoto was taken one week after the Tsunami, the day we went to inspect this area. It records the damaged houses ,disaster debris, and other great amount wastes.


UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012Disaster related waste by Tsunami

75,6000 ton in Ofunato city and 1,016,000 ton in Rikuzen-Takada city



Treatment Flow for Disaster Waste

Disasterwaste

Sorting Crushing Washing(Salt removal process)

Recycling(Energy and raw material for cement manufacture) Waste water treatment

Treated water

Due to the strict effluent discharge standards in Ofunado city, water treatment process was designed and conducted for meeting these standards.

Effluent


Photo is our treating site in Ofunato city .


Dynamic state analysis for washing fluid in salt removal equipment

Fluent analysis for washing fluid was conducted for getting an optimum washing parameters. 3D analysis for flow line and t he dynamic state analysis for washing fluid in salt removal equipmen t are illustrated here.The important point is salt concentration diff erence between wood chips and washing water.

Water [ｍｍｍｍ/s]


This figure shows the mass fraction of water and air in washing equipment.

This fig. shows the cross section distribution of fluid speed while rotating at 30rpm. Vector represents flow direction .

Air


Coagulant development for effectively treating colored wastewater from wood washing


A coagulant for effectively removing colored subst ances eluted from wood washing process was developed and applied in t he treatment facility. Photos illustrate the colored washing s olution and decoloration effect of this coagulant.

Colored washing solution(COD contents, lignin,etc. )

Treated water


Conveyors Scrubber

Disaster wasteare transported to scrubber by conveyors


Wood chips after salt removing and dewatering

Water treatmentprocess

26


Copyrights 2012 REMATEC Corporation All rights reserved. 27Disaster waste（Before salt removing）

Raw material for cement use（After salt removing）

UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012Business Expansion ImaginationBusiness Expansion Imagination

TechnologyDeveloping

Total Solution forTotal Solution forWaste RecycleWaste Recycle

Business Expansion in AsiaBusiness Expansion in Asia

Other Countriesin Asia

（3 countries)

Developing Developing Recycling technologyRecycling technology

New Technology

Waste Recycling

New Technology

for Industrial

Waste Recycling


Other FactoriesIn Thailand

（3 factories）

Expanding RF Expanding RF Manufacturing StrongholdsManufacturing Strongholds

RFRFRFRF

REMATEC

Strongholds Spreading

（3 countries)

Major Cement Factories

In Thailand

Companies (Thailand)

28


Overseas Countries

Technology Transfer Process

ODA

CDM

Host countries

Government

Japan

Government


Rematec Corporation

Local company

Local company

Information

Collection

Tech. Association

Local company

Discussion

29

Thank you for listening!!Thank you for listening!!

We would like to provide technical assistances to developing countries for promoting wastes recycling technologies’ widely application.

Copyrights 2012 REMATEC Corporation All rights reserved.リマテック株式会社

REMATEC CORPORATION

technologies’ widely application.

Through the application of ODA or CDM projects in y our government, it is possible to fulfill technology tr ansfer between countries and companies.

For the further discussion, please contact us by fo llowing email address or company’s [email protected]://www.rematec.co.jp/

Documents

Waste Oil and Sludge Treatment and Recycling by ... Oil and Sludge Treatment and Recycling by Manufacturing UNEPUNEP--IETC IETC のワークショップ Osaka, April 16Osaka, April