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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)
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
1. RF Technology(RF is Reclaimed Fuel for
Copyrights 2012 REMATEC Corporation All rights reserved. 2
(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
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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
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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 ))))
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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.
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UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
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
Copyrights 2012 REMATEC Corporation All rights reserved. 5
■ 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
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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.
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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)
Copyrights 2012 REMATEC Corporation All rights reserved. 7
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.
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UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
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
Copyrights 2012 REMATEC Corporation All rights reserved. 8
Osaka RF Factory(Production capacity 200ton/day) ⇒ RF ProductKyusyu RF Factory(Production capacity 192ton/day) ⇒ RF Product
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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
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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
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• 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.
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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.
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
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
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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.
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UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
2. Introduction of SCW Technology
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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
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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
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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.
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
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
Copyrights 2012 REMATEC Corporation All rights reserved. 16
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
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
3. Illegal dumping waste treatment and management
Copyrights 2012 REMATEC Corporation All rights reserved. 17
treatment and management
17
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
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】】】】
Copyrights 2012 REMATEC Corporation All rights reserved. 1818
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
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
□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
Copyrights 2012 REMATEC Corporation All rights reserved. 19
□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
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
4. Reconstruction Activities in TOHOKU area
Copyrights 2012 REMATEC Corporation All rights reserved. 2020
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 )
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
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.
Copyrights 2012 REMATEC Corporation All rights reserved. 2121
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
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UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
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
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Photo is our treating site in Ofunato city .
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
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]
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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
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
Coagulant development for effectively treating colored wastewater from wood washing
Copyrights 2012 REMATEC Corporation All rights reserved. 2525
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
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
Conveyors Scrubber
Disaster wasteare transported to scrubber by conveyors
Copyrights 2012 REMATEC Corporation All rights reserved. 26
Wood chips after salt removing and dewatering
Water treatmentprocess
26
UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
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
Copyrights 2012 REMATEC Corporation All rights reserved. 2828
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)
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UNEPUNEP--IETCIETCApril 16April 16--18, 201218, 2012
Overseas Countries
Technology Transfer Process
ODA
CDM
Host countries
Government
Japan
Government
Copyrights 2012 REMATEC Corporation All rights reserved. 29
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/