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On-site Regeneration System of Activated Carbon Filtration Unit

On-site Regeneration System of Activated Carbon Filtration Unit

JTOP Co.,Ltd.

Activated Carbon Filtration Supported by the Regenerative Function for Successive and Efficient Treatment of Wastewater

JTOP Co.,Ltd. has developed an activated carbon filtration system equipped with the automatic      
regeneration device. During the operation, it intermittently regenerates the filtration material (activated carbon) by the injection of superheated steam (400-450℃, about for 4 hours), without taking out the filtration material from inside the tank.

Even if the filtration material is not replaced, wastewater treatment (refractory organic matter treatment, COD treatment, decolorization treatment, etc.) and exhaust gas treatment can be steadily performed without deteriorating operation efficiency.
As this system is a ‘packaged’, other commercial activated carbon cannot be applied for the regeneration.

                                       Fig. 1 Activated carbon filtration unit with regeneration device

Our technology is to repeat activated carbon regeneration on-site without exchanging the activated carbon. We have applied this technique to water or gas clarification devices.

Major features and advantages

Organic substances adsorbed to activated carbon are pyrolyzed, evaporated and removed by superheated steam at about 400℃ or more. Thus, activated carbon is regenerated automatically without taking out from the inside of the equipment.
Because this technology derives from activation and regeneration by low-temperature steam injection, weight reduction and performance degradation of the activated carbon are almost zero after regeneration. This technology results in weight reduction by less than 0.1% and performance degradation by less than 1%. On the other hand, conventional methods normally have weight reduction by more than 30% and performance degradation by more than 20%. Therefore, it can be said both are almost ZERO.
Having developed highly efficient activated carbon regeneration and low running cost system, our equipment is recommended to be application for wastewater purification and deodorizing processing of exhaust gas.

(1) Activated carbon can be automatically regenerated without exchange, so no cost is required for purchasing activated carbon, waste disposal and manpower removing the waste.

(2) JTOP system is very compact (less than 1/10 space comparing with conventional), so it can be loaded on a light lorry (truck) namely mobile, and installation work is easy.

(3) Wastewater treatment (refractory organic matter treatment, COD treatment, decolorization treatment, etc.) and exhaust gas treatment can be performed without replacing activated carbon.

(4) In the case of organic wastewater treatment, no sludge is produced.

(5) As of June 2019, there are devices that have been operating for over 10 years (more than 3000 times of activated carbon regeneration).

Technology Data

Possible applications

JTOP Co., Ltd. is a manufacturer of on-site regenerating activated carbon devices that do not require replacement of activated carbon.
There is a possibility that the dyed drainage can be treated to be colorless and transparent. The treated water can be reused as washing water in the manufacturing process. (Drainage recycling technology, system that does not discharge drainage into the river)
Our company has already sold and delivered as a wastewater recycling equipment product that purifies and processes dyed wastewater discharged from textile factories to colorless and odorless water, through the JICA project in Indonesia. We have experience of SDGs business there.
Verification Survey Summary Report (Indonesia)


Competitive advantage

Comparison with the conventional method
The conventional method picks up used activated carbon from a tank and it is regenerated by using a kiln furnace which causes more than 30% weight reduction and 20% performance degradation, reflecting costs of activated carbon for replacement, waste transportation and waste treatment.
By contrast, our automatic reproduction technology is able to regenerate saturated activated carbon by superheated steam without taking out the active carbon from the equipment.

JTOP method is less than 0.1% weight reduction, less than 1% performance degradation. It is not necessary expense and waste logistics cost, also new activated carbon purchase cost.
This system is superior in its easier maintenance of performance.
In the conventional method, if it is necessary to replace the activated carbon four times a year with a 10m3 activated carbon, the cost for one year is about 10 million JPY, but in the case of JTOP on-site regeneration activated carbon system, the regeneration cost can be annually less than 200,000 JPY.
Compared to the conventional method, the running cost is about less than 1/50.

                     Fig 2. Comparison of activated carbon filtration between conventional method and JTOP method

Performance

JTOP Co.,Ltd. has installed the active carbon filtration devices with the regeneration system to wastewater treatment plants, for various applications (see Fig. 3 and 4).

                    Fig. 3 Filtration and heat decomposition of phenylenediamine in wastewater in a chemical factory

                              Fig. 4 Treatment for persistent organic pollutant (1,4-dioxane) in a chemical factory

In addition, filtration performance (adsorption rate) of the activated carbon does not change throughout of the 10 times cycle (see table 1), as well as physical and chemical properties (see table 2).

                         Table 1. Filtration cycle test (regeneration between cycles) of activated carbon for the filtration
                                     of wastewater which include highly concentrated organics (lab-scale experiment)

                          Table 2. Properties of fresh and regenerated activated carbon (lab-scale experiment)

Technical maturity / Past record of introduction

1) Domestic sales of machines: 79
Application: wastewater treatment in a manufacturer of automobile parts, Chemical plant, warm bath facility

2) Overseas sales of machines: 9
・China 4
・Taiwan 2
・Indonesia 2
・Bangladesh 1
Application: wastewater treatment in a textile mill (Indonesia, Bangladesh), Chemical plant (China, Taiwan)

From now on, we are examining and promoting the same drainage recycling business as Indonesia through the JICA project in Bangladesh. In March 2019, we visited two local fiber manufacturers in Bangladesh, confirming that there was a large need for wastewater treatment from local companies.

We also visited the Ministry of the Environment (MOE), the Dhaka Water Supply & Sewerage Authority (DWASA), the Bangladesh University of Eng and Tech (BUET), a local water treatment engineering company, etc. with local JICA staff. We confirmed the magnitude of needs for local development issues and drainage measures.

Information on patent related to this technology

Patent Technology NO.4242440
Patent Technology NO.4275721
Patent Technology NO.4335292
Patent Technology NO.5142398
Patent Technology NO.5357961
Patent Technology NO.5497325
Patent Technology NO.6395963

(All are patented  in Japan)

Company Data

Name JTOP Co.,Ltd.
Address 4-5-44 Migata-cho, Izumi-city, Osaka, 594-0042, JAPAN
Capital JPY 80 million JPY (as of March 31, 2019)
Contact person

Mr. Jiichi NAKAKI
nakaki@jtops.com
+81-725-51-3860

Number of employees 14 (as of March 31, 2019)
Date of company foundation 14th December 2009
The type of business Manufacturing and sales of equipment for environmental protection, environmental consulting

                Corporate website: http://www.jtops.com/en/

International operation         

Number of employees for international operation 

4

Overseas
offices

City, Country Name of Company (if applicable)
N/A N/A

 


Modality of business transaction

Export of product
At the time of entry, we would like to export and sell products directly from Japan via a Japanese company without a local staff.

Partnership
For the time being, we would like to export and sell our products directly from Japan (in cooperation with local Japanese companies), eventually export major parts etc. to local partner companies and consign product assembly as well as product sales locally to local partner companies. (commission of production and sale)

Direct investment
In cooperation with a local engineering company, we would like to establish a system where products can be locally manufactured, assembled and sold.
※Vital elements are supplied from Japan.

Licensing of patent
We would like to enter into a license agreement with a local partner company.

Attachments

Schematic illustration of the technology


                            Fig. 5 The entire process of activated carbon filtration and regeneration in JTOP method

Contact Person(s)

Mr. Jiichi NAKAKIE-mail: nakaki@jtops.com

*Please mention that you saw UNIDO's website when making the first contact with the company.

Registered Category

  • Environmental Technologies : Pollution Prevention and Control