Treatment and Recycling System for Industrial Waste and Medical Waste to Form a Sustainable Society
In order to promote a recycling society as an intermediate waste treatment company, we have a crushing and sorting facility, an incinerator / drying facility, a solid fuel RPF facility, a copper nugget manufacturing machine, and a fluorescent lamp tube recycling plant to improve the recycling rate. We are providing a one-stop service for waste treatment by actively recycling high-mix, small-lot waste.
Fig. 1 Waste Treatment Flowchart
We undertake all sorts of the industrial waste generated from the manufacturing industry and offices, the medical waste generated from hospitals, and the construction waste generated from construction sites. When mixed waste brought to our company, those that can be used as raw materials for RPF are roughly sorted, separated into individual product, then it is crushed using a crusher and further sorted by hand.
On the other hand, since it is difficult to manually sort chlorine-containing waste plastics, they are sorted by a special optical sorter, and chlorine-free waste plastics are extracted to the maximum extent and reused as RPF raw materials. RPF is an alternative to coal and is supplied as boiler fuel for steel and paper mills. Regarding the quality standard of RPF, we provide it in a state where it meets the quality standard of JIS Z7311: 2010 "Solid fuel (RPF) such as paper and plastic derived from waste" which is the standard of RPF industry association in Japan. Other recycled products are supplied in a state that meets the specifications and demand of the recycling company.
Wood chips are crushed on a line dedicated to wood, and are reused as paper chips and fuel chips by screening and cutting them into appropriate size. Hazardous waste and infectious waste are incinerated for detoxification and thermal recycling. The recycling rate of cinders is improved by using it as a material for concrete. The incinerator is effective not only in detoxifying the waste but also in reducing the amount of waste, which contributes to prolonging the remaining life of the final disposal site. The processing flow is shown in Fig. 1.
In this way, we have achieved a high recycling rate by taking the time to separate the collected waste.
Major Features and Advantages
- Detoxification and capacity reduction by proper treatment will be promoted, which will lead to the conservation of the surrounding environment. Furthermore, the volume of waste will be reduced by careful sorting, which will lead to a reduction in the load on the final disposal site.
- By recycling waste, the local recycling rate will improve. It secures a recycling rate of about 80% every year in Japan, which is a relatively high level nationwide. In particular, in the wood-only line, after making chips, they are recycled as paper chips and fuel chips, and the recycling rate is 100%. In addition, the fluorescent tube recycling plant also crushes glass and supplies it as a recycling raw material, with a recycling rate of 99.9%.
In developing countries, it is generally considered that not only general waste but also infectious waste and industrial waste containing harmful substances will be discharged due to population growth and industrial development.
On the other hand, there are medical institutions that use autoclaves to sterilize infectious waste, but only a small number of them are used, and when a machine breaks down, it is thrown away as it is at a landfill site.
In addition, since the mainstream method for treating hazardous waste in these countries is open-dumping, there is a high possibility that it will affect the surrounding environment.
We have been implementing and sustainably operating treatment facilities according to the type and nature of the waste for many years in Japan, and by detoxifying and reducing the volume of waste, we can contribute to the waste treatment issues in emerging countries.
The advantages of our technology include the followings.
1) Superiority in incinerator / drying process
As for the accompanying dryer, by utilizing the heat of hot water passed through the jacket portion of the incinerator, it enables to add waste liquid and sludge and apply negative pressure to evaporate the water. The sludge after drying is mixed with lime after pH adjustment and recycled as a roadbed improver. It contributes not only to proper incineration of hazardous waste but also to promotion of recycling.
2) Superiority in crushing / sorting / RPF manufacturing process
In the sorting process, many competitors in the industry use the conventional process which is to operate only by the wind power sorting machine. However, we achieve higher efficiency for recycling by combining the wind sorting and optical sorting system. We strive to recycle resources that do not contain chlorine, and reuse them as raw materials for RPF.
In addition, instead of the usual 2-axis or 3-axis crushing equipment, we use 4-axis crushing equipment for waste that is difficult to crush, such as long shapes and flexible container bags, so that more waste would be appropriate for recycling.
We use analyzers to manage the operation to maintain high quality and meet the standards. The analysis is conducted once every three minutes.
The unique one-stop waste management system can handle hazardous waste including medical and other sorts of waste (such as metal, wood chips, waste plastics, rubble, glass ceramic waste, etc.) by combining various waste treatment technologies. This is the greatest feature of our technology.
In other words, the company’s greatest strength is the proper use of treatment facilities according to the type and nature of the target waste, and the construction of an operation system for its sustainable maintenance, and it accounts for more than 80% of the collected waste to be recyclable.
Technical maturity / Past record of introduction
In Japan, we meet a wide range of needs from customers throughout 5 Tokai prefectures, the Kinki Chugoku region, and Aichi prefecture, where our business is based. The annual amount of waste received exceeds 50,000 tons. Among which, approximately 40,000 tons (80% of the total) are recycled, and the rest is incinerated.
In addition, this operating technology was adopted as a private-sector cooperation scheme of the Japan International Cooperation Agency (JICA) (project name: “Dissemination / demonstration project for treatment and management improvement of hazardous waste including medical waste in Vientian City”) In particular, regarding the proper treatment of medical waste, disseminate the effectiveness of the waste management system by Kayama Kogyo Co., Ltd. to local counterparts (Vientiane Prefecture Administration Bureau) and local organizations such as the Ministry of Industry and Commerce, the Ministry of Environment and Natural Resources, and the Ministry of Health. Has a track record of carrying out activities. The details can be found in the “Attachments” in the bottom of this page.
Information on patent related to this technology
|Name||Kayama Kogyo Co.,Ltd.|
15-5 Minamiichiban-cho, Atsuta-ku, Nagoya, Aichi 456-0055 Japan
|Capital||50 million JPY (as of July 2021)|
|Contact person||Mr. Shinichi Tabata
Affiliation: General Manager of Planning Department
Corporate website: https://www.kayama-k.co.jp/english
|Number of employees||148 including seconded and part-time workers (as of April 2021)|
|Date of company foundation||November 11, 1961|
|The type of business||
【Waste intermediate treatment industry】
|Number of employees for international operation
||6 (including 2 expatriates)|
||City, Country||Name of Company
|Vientiane, Lao People’s Democratic Republic||Lao kayama Sole Co.,Ltd|
Modality of business transaction
Equipment such as incinerators and crushing and sorting machines will be procured from Japan, but we assume that the collection, transportation and intermediate processing operations will be operated locally.
Equipment such as incinerators and crushing and sorting machines will be procured from Japan, but for local collection and transportation, it is assumed that we will operate local companies and intermediate processing operations. Alternatively, it is envisioned that a joint venture will be established and operated with a local company.
Schematic illustration of the technology
【JICA Pre-Project Report in 2016 (only in Japanese)】
JICA Project【Installation Ceremony】
*Please mention that you saw UNIDO's website when making the first contact with the company.
- Environmental Technologies : Waste treatment and management / Circular Economy (3R)