Drying for upcycling of barley tea lees that cannot be dried by others / Test cases / Barley tea lees drying, Upcycling drying

Summary

1. problems with barley tea lees and the importance of drying
If left unattended, barley tea lees after barley tea production can become rancid due to microorganisms, producing foul odors and pathogens.
Conventional dryers become clogged with carbohydrates contained in barley tea lees, which is especially noticeable in low-temperature drying.

2. KENKI DRYER solution
Our unique, world-patented technology allows any type of barley tea lees to be dried and discharged at low temperatures without clogging.
Indirect steam drying method suppresses compositional changes of dried materials, making it ideal for upcycling.
Low temperature drying reduces fuel costs, parts wear and maintenance costs.
Continuous operation is possible, easy operation control and unmanned operation 24 hours a day.

3. Examples of Barley Tea Lees Utilization
Upcycling of dried barley tea lees into fertilizers, composts, fertilizers, beauty and health products, etc.
Biochar and bio-coke are used as raw materials for reductants and deoxidizers in the steel and foundry industries.

4. Other advantages of KENKI DRYER
Reduction of environmental impact through reduction of waste volume, industrial waste costs, and transportation costs.
Zero CO2 emissions achieved by not using fossil fuels and installing electric boilers.
Capable of drying sticky and adhesive materials that cannot be dried anywhere else.

5. KENKI DRYER Patents
KENKI DRYER’s unique technology has been patented in a total of 11 patents (2 in Japan and 9 in 7 foreign countries).

6. target fields
High moisture content organic waste dryers, sludge dryers, slurry dryers, methane fermentation digested liquid dryers, waste recycling dryers

7. patented countries
Japan, Taiwan, U.S.A., France, Germany, U.K., Switzerland, Canada

Conclusion
The KENKI DRYER is an innovative drying system that solves the problems of wheat tea lees drying and promotes upcycling. It also contributes to reducing environmental impact and can be utilized in various fields.

There are various types of barley tea, for example, six-row barley, two-row barley, and pigeon pea have been commonly used in the past.
The KENKI DRYER uses steam as the heat source for low temperature indirect drying, so there is little change in the composition of the dried material after drying, and it can be fully utilized as a recycled or upcycled product. The dried materials can be recycled and upcycled.

If barley tea lees are left in a high moisture state, the activity of microorganisms (especially bacteria and molds) in the lees will cause them to spoil. These microorganisms use the moisture and nutrients in the barley lees to reproduce, producing gases and odors, and the growth of the microorganisms causes spoilage and the development of foul odors and pathogens. Drying is an effective way to solve these problems.

However, due to the sugars contained in barley wort, the barley wort in a barley wort dryer sticks to the inside of the dryer during drying, clogging it and preventing it from being discharged. With KENKI DRYER’s unique world-patented technology, any type of barley tea lees can be dried at low temperatures without clogging the dryer, and the lees can be discharged smoothly after drying.

The barley tea market has grown rapidly in recent years due to the renewed interest in barley tea as a result of increased health awareness. Barley tea contains no caffeine and has no diuretic properties. In addition, barley tea contains polyphenols, which are effective in preventing lifestyle-related diseases.
The barley tea is popular in all seasons except summer. However, it is not as popular as it is in the summer. For example, according to a 2019 survey, 88% of respondents said they drink barley tea in the summer, while about half of respondents said they drink barley tea in the winter.

Wood is currently in short supply in Japan. The use of dried beverage lees such as barley tea lees as fuel instead of wood, or the use of dried beverage lees as biochar or bio-coke by carbonization, is attracting much attention. For example, bio-coke can be used as a reductant or deoxidizer to replace coke in the steel and foundry industries.
Biochar and bio-coke are carbonized materials made from biological resources that are effective in revitalizing organisms and improving the environment. We can provide carbonization services using our Biogreen pyrolysis equipment, which does not use fossil fuels and does not emit CO2, a greenhouse gas, from the equipment.

KENKI DRYER, with 11 patents in 8 countries, is an indirect steam dryer, but it is a completely unique product that is different in structure from other similar indirect steam dryers. The KENKI DEYER uses steam as a heat source, but its high drying heat efficiency means that less steam is used. The use of excess steam is not costly in terms of fuel, and the dryer does not emit carbon dioxide during drying, allowing for decarbonized drying. Alternatively, by installing an electric boiler, no greenhouse gases or CO2 emissions are generated during drying.
The KENKI DRYER is a continuous dryer, not a batch dryer that stores and dries materials to be dried. Therefore, operation is simple and unmanned operation is possible 24 hours a day.

Drying barley tea lees reduces their weight, which in turn reduces the amount of waste materials produced, which in turn reduces the cost of industrial waste, which is rising due to the recent trucking problem in 2024.

KENKI DRYER can dry sticky and adhesive materials that others cannot dry. KENKI DRYER is a breakthrough drying device with a total of 11 patents (2 in Japan and 9 in 7 overseas countries). Please consider KENKI DRYER for your high moisture organic waste dryer, sludge dryer, slurry dryer, methane fermentation digestate dryer, and waste upcycling or recycling dryer.

KENKI DRYER has been granted 11 patents in 8 countries (Japan, Taiwan, USA, France, Germany, UK, Switzerland, Canada).

Drying barley tea lees can be beneficial for several reasons:

Preservation and Shelf Life:
Drying removes moisture, which helps in preventing microbial growth, mold, and spoilage, thereby extending the shelf life of the barley tea lees.

Storage Efficiency:
Drying reduces the volume and weight of the lees, making storage and transportation more efficient and cost-effective.

Nutrient Concentration:
The drying process concentrates the nutrients, making the dried barley tea lees a more potent source of fiber, vitamins, and minerals when used in various applications.

Versatility in Usage:
Dried barley tea lees can be ground into a powder and used as a supplement in foods, beverages, animal feed, or even as a natural fertilizer. This versatility is enhanced by the ease of handling and incorporation of dried materials.

Waste Reduction:
By drying and repurposing barley tea lees, waste is minimized, contributing to more sustainable production practices and potentially providing additional revenue streams.

Improved Flavor and Aroma:
The drying process can enhance the flavor and aroma of barley tea lees, making them more desirable as an ingredient in culinary applications.

Convenience:
Dried barley tea lees are easier to use in various recipes and applications without the need for immediate processing, adding convenience for both manufacturers and consumers.
By drying barley tea lees, these benefits can be realized, adding value to what might otherwise be considered a waste product.

Source：ChatGPT

Drying barley tea lees, which are the leftover residues from brewing barley tea, presents several difficulties similar to those encountered with barley lees. Here are the key challenges:

High Moisture Content: Barley tea lees typically retain a significant amount of water after brewing, which makes the drying process energy-intensive and time-consuming.

Composition and Structure: Barley tea lees consist of fibrous material, proteins, and residual starches. These components can bind water strongly, making it difficult to remove the moisture through conventional drying methods.

Heat Sensitivity: The organic compounds in barley tea lees can be sensitive to high temperatures. Excessive heat can cause degradation of nutrients and flavor compounds, reducing the quality of the dried product.

Sticky and Clumpy Nature: When wet, barley tea lees can be sticky and prone to clumping. This can cause issues in mechanical drying equipment, as the material may adhere to surfaces and create blockages.

Uniform Drying: Achieving uniform drying can be challenging due to the uneven distribution of moisture within the lees. Some parts may dry faster than others, leading to inconsistent quality.

Energy Consumption and Cost: Effective drying of barley tea lees requires considerable energy input, which can be costly. Balancing energy efficiency with product quality is essential but difficult to achieve.

Retention of Nutritional and Sensory Qualities: The goal of drying barley tea lees is often to retain as much of the nutritional and sensory qualities as possible. This requires careful control of drying conditions to avoid loss of valuable compounds.

To mitigate these challenges, specialized drying techniques such as freeze-drying, vacuum drying, or low-temperature air drying might be used. These methods aim to reduce moisture content while preserving the quality and nutritional value of the barley tea lees.

Source：ChatGPT

• Material to be dry: Barley tea lees that cannot be dried by others
• Purpose of drying: Upcycling, Reducing industrial waste cost and amount
• Moisture content: 64.3％W.B. before drying, 5.7％W.B. after drying
• Requirements for dryer: To prevent clogging inside the dryer caused by the stickiness and adhesiveness. Automated continuous operation with no operator attended.
  Machine cost can be recovered in short term.
• Test result: OK

Waste drying

Competitive comparison

Compost is a mixture of ingredients used as plant fertilizer and to improve soil’s physical, chemical, and biological properties. It is commonly prepared by decomposing plant and food waste, recycling organic materials, and manure. The resulting mixture is rich in plant nutrients and beneficial organisms, such as bacteria, protozoa, nematodes, and fungi. Compost improves soil fertility in gardens, landscaping, horticulture, urban agriculture, and organic farming, reducing dependency on commercial chemical fertilizers. The benefits of compost include providing nutrients to crops as fertilizer, acting as a soil conditioner, increasing the humus or humic acid contents of the soil, and introducing beneficial microbes that help to suppress pathogens in the soil and reduce soil-borne diseases.

Source：Wiki Compost

A fertilizer (American English) or fertiliser (British English) is any material of natural or synthetic origin that is applied to soil or to plant tissues to supply plant nutrients. Fertilizers may be distinct from liming materials or other non-nutrient soil amendments. Many sources of fertilizer exist, both natural and industrially produced. For most modern agricultural practices, fertilization focuses on three main macro nutrients: nitrogen (N), phosphorus (P), and potassium (K) with occasional addition of supplements like rock flour for micronutrients. Farmers apply these fertilizers in a variety of ways: through dry or pelletized or liquid application processes, using large agricultural equipment or hand-tool methods.

Source：Wiki Fertilizer

The three primary elements of fertilizer, essential for plant growth and commonly referred to as macronutrients in the context of plant nutrition, are:

Nitrogen (N):
Function: Promotes leaf and stem growth, as it is a crucial component of chlorophyll, the compound that plants use in photosynthesis to convert sunlight into energy. Nitrogen is also a key part of amino acids, the building blocks of proteins.
Deficiency Symptoms: Yellowing of leaves (chlorosis), stunted growth, and poor yield.

Phosphorus (P):
Function: Essential for energy transfer and storage in plants, as it is a component of ATP (adenosine triphosphate). Phosphorus also plays a vital role in root development, flowering, and seed production.
Deficiency Symptoms: Dark green or purplish leaves, delayed maturity, and poor root development.

Potassium (K):
Function: Regulates various metabolic activities in plants, including photosynthesis, protein synthesis, and water regulation. Potassium is also important for improving disease resistance and overall plant health.
Deficiency Symptoms: Leaf edges may turn yellow or brown (scorching), weak stems, and reduced resistance to drought and diseases.
Fertilizers are often labeled with an N-P-K ratio, which indicates the relative proportions of these three essential nutrients. For example, a fertilizer labeled as 10-20-10 contains 10% nitrogen, 20% phosphorus, and 10% potassium.

Source：ChatGPT

The shortage of lumber in Japan as of 2024 can be attributed to several factors:

1. Increased Demand: The global demand for lumber has surged due to a post-pandemic construction boom. As economies recover, the need for housing, infrastructure, and renovations has significantly increased, putting pressure on lumber supplies.

2. Supply Chain Disruptions: Ongoing disruptions in global supply chains, including transportation delays, port congestions, and logistical challenges, have made it difficult to import lumber into Japan efficiently.

3. Reduced Domestic Production: Japan’s domestic lumber production has been declining due to factors such as aging forestry workers, a lack of investment in modern forestry practices, and environmental regulations that limit logging activities.

4. Natural Disasters: Japan is prone to natural disasters such as earthquakes, typhoons, and floods, which can disrupt lumber production and supply chains, further exacerbating shortages.

5. Environmental Regulations: Stricter environmental regulations and sustainability practices have led to reduced logging activities in Japan and other countries, limiting the availability of lumber.

6. Geopolitical Tensions: Trade tensions and geopolitical issues with major lumber-producing countries can impact the availability and cost of imported lumber. Restrictions or tariffs on lumber exports from key suppliers can lead to shortages.

7. Economic Factors: Fluctuations in currency exchange rates, inflation, and the overall economic climate can affect the affordability and accessibility of imported lumber.

8. COVID-19 Impact: The lingering effects of the COVID-19 pandemic, including labor shortages and health-related restrictions, continue to impact production and transportation sectors globally, affecting lumber supply.

9. Forest Management Issues: Poor forest management practices and insufficient reforestation efforts in Japan have led to a depletion of local timber resources, contributing to the shortage.

These factors combined create a challenging environment for ensuring a steady supply of lumber in Japan, impacting various sectors that rely on this essential resource.

Source：ChatGPT

Biochar is a form of charcoal that is produced by heating organic material (biomass) such as wood, crop residues, or manure in a controlled environment with little or no oxygen through a process called pyrolysis. Here are some key aspects of biochar:

1. Production Process: Biochar is created through pyrolysis, which involves heating biomass in the absence of oxygen. This process thermally decomposes the organic material, producing a stable, carbon-rich product.

2. Soil Amendment: One of the primary uses of biochar is as a soil amendment. When added to soil, it can enhance soil fertility, improve water retention, increase microbial activity, and reduce the need for chemical fertilizers.

3. Carbon Sequestration: Biochar is highly stable and can remain in the soil for hundreds to thousands of years, effectively sequestering carbon and reducing greenhouse gas emissions. This makes it a valuable tool in mitigating climate change.

4. Environmental Benefits: Biochar can help reduce soil erosion, improve soil structure, and increase agricultural productivity. It also has the potential to filter and remove contaminants from soil and water, contributing to environmental remediation.

5. Energy Production: The pyrolysis process that produces biochar also generates syngas (a mixture of hydrogen, carbon monoxide, and other gases) and bio-oil, which can be used as renewable energy sources.

6. Waste Management: By converting agricultural and forestry residues, animal manure, and other organic waste into biochar, it provides a sustainable method of managing waste materials.

7. Livestock and Composting: Biochar can be used in animal husbandry to improve feed efficiency and reduce methane emissions from livestock. It is also used in composting to enhance the composting process and reduce odors.

8. Water Purification: Due to its porous structure and high surface area, biochar can be used as a filtration medium to remove pollutants from water, including heavy metals, organic contaminants, and nutrients.

Overall, biochar represents a versatile and sustainable solution with multiple applications in agriculture, environmental management, and energy production, contributing to both soil health and climate change mitigation.

Source：ChatGPT

Bio-coke is an eco-friendly fuel source produced from biomass, which are organic materials like plants and animals. Unlike traditional coke, which is derived from coal, bio-coke is made from renewable resources and offers a more sustainable alternative.

Here’s a breakdown of bio-coke:

• Raw Materials: Bio-coke can be created from various forms of biomass, including:

  • Waste materials like used tea leaves, coffee grounds, fruit peels, and sawdust
  • Energy crops specifically grown for bio-fuel purposes

• Production Process: Biomass goes through a process called pyrolysis, which involves heating the material in the absence of oxygen. This process removes moisture and volatile compounds, leaving behind a solid carbonaceous material – bio-coke.

• Applications: Bio-coke is primarily used as a substitute for coal coke in industrial processes, particularly steelmaking. Steelmaking traditionally relies on coal coke as a source of carbon and heat. Bio-coke offers a more sustainable alternative by reducing dependence on fossil fuels and potentially lowering greenhouse gas emissions.

Benefits of Bio-Coke:

• Renewable Source: Bio-coke is derived from renewable biomass, unlike coal coke which is a finite resource.
• Reduced Emissions: Bio-coke production can potentially lower greenhouse gas emissions compared to traditional coke production.
• Waste Management: Bio-coke can utilize waste materials like used coffee grounds and sawdust, promoting waste management and diverting them from landfills.

Challenges of Bio-Coke:

• Production Scale: Bio-coke production is still under development, and large-scale production facilities are not yet widespread.
• Properties: Bio-coke may have slightly different properties compared to coal coke, potentially requiring adjustments in industrial processes.
• Cost: Currently, bio-coke production can be more expensive than traditional coke production.

Overall, bio-coke is a promising development in the pursuit of more sustainable industrial practices. As research and development progress, bio-coke has the potential to become a more viable and widely used alternative to coal coke.

Source：Gemini

Both biochar and bio-coke are products derived from organic materials, but they have some key differences:

Processing Temperature:

• Biochar: Produced at lower temperatures (typically around 300-700°C) through a process called pyrolysis. Limited oxygen is present during pyrolysis.
• Bio-coke: Produced at higher temperatures (around 700-1000°C) in an almost complete absence of oxygen. This higher temperature process is more similar to coal coking.

End Product:

• Biochar: A porous and lightweight material with a high surface area. It’s rich in carbon but can also retain some nutrients from the original biomass.
• Bio-coke: Denser and has a higher carbon content compared to biochar. It shares some similarities with traditional coke in terms of physical properties.

Applications:

• Biochar: Primarily used for soil amendment. Its porous structure helps retain water and nutrients, improving soil health. It can also be used for filtration, as a source of renewable energy, and for capturing pollutants.
• Bio-coke: Intended as a sustainable substitute for coal coke in industrial processes, particularly steelmaking. It provides carbon and heat, similar to coal coke, but with potentially lower greenhouse gas emissions.

Here’s a table summarizing the key differences:

Feature	Biochar	Bio-coke
Processing Temperature	Lower (300-700°C)	Higher (700-1000°C)
Oxygen Presence	Limited	Almost absent
End Product	Porous, lightweight	Dense, high carbon
Applications	Soil amendment, filtration	Industrial fuel (steel)

Source：Gemini

Uses of Biochar from Beverage Lees

1. Soil Amendment:
   • Improving Soil Fertility: Biochar enhances soil fertility by increasing nutrient retention and improving soil structure.
   • Water Retention: Its porous structure helps retain moisture in the soil, reducing the need for frequent watering.
   • Microbial Activity: Biochar provides a habitat for beneficial soil microorganisms, enhancing soil health and plant growth.
2. Environmental Applications:
   • Carbon Sequestration: Biochar is stable and can sequester carbon for hundreds to thousands of years, helping mitigate climate change.
   • Pollution Remediation: Biochar can adsorb heavy metals and organic pollutants, making it useful for soil and water remediation efforts.
3. Agricultural Uses:
   • Compost Enhancer: Adding biochar to compost can improve the composting process and enhance the nutrient content of the final product.
   • Animal Bedding: Biochar can be used as animal bedding to reduce odors and improve waste management.
4. Industrial Applications:
   • Filtration: Due to its high surface area and adsorptive properties, biochar can be used in water filtration systems.
   • Energy Production: The by-products of the pyrolysis process, such as syngas and bio-oil, can be used as renewable energy sources.
5. Horticulture:
   • Gardening: Biochar can be mixed with potting soil to improve plant growth and reduce the frequency of watering and fertilizing.
   • Greenhouse Media: It can be used as a growing medium in greenhouses, enhancing plant health and productivity.

Source：ChatGPT

Using biochar as a coke substitute in metallurgical processes, particularly in iron and steel production, is an emerging concept aimed at reducing the environmental impact of traditional coke usage. Here’s a detailed look at the potential of biochar as a coke substitute:

Background on Coke in Metallurgy

1. Role of Coke: Coke is used as both a fuel and a reducing agent in blast furnaces. It provides the high temperatures necessary for melting iron ore and the carbon required to reduce iron oxides to metallic iron.
2. Environmental Concerns: The production and use of coke result in significant carbon dioxide (CO₂) emissions and other pollutants.

Biochar as a Coke Substitute

1. Production of Biochar: Biochar is produced through the pyrolysis of organic materials (biomass) in a low-oxygen environment. Common feedstocks include agricultural residues, wood chips, and other organic waste.
2. Properties: Biochar is rich in carbon, highly porous, and has a high surface area. These properties make it potentially useful in metallurgical processes.

Advantages of Using Biochar

1. Reduced Emissions: Biochar is considered carbon-neutral or even carbon-negative, as it can sequester carbon that would otherwise be released into the atmosphere.
2. Renewable Resource: Unlike coke, which is derived from coal, biochar comes from renewable biomass sources, making it more sustainable.
3. Waste Utilization: Producing biochar from agricultural and forestry waste materials adds value to these by-products and reduces waste.

Challenges

1. Consistency and Quality: The properties of biochar can vary depending on the feedstock and production conditions, which may affect its performance as a coke substitute.
2. Economic Feasibility: Producing biochar at the scale needed for industrial metallurgy can be expensive, and the economic viability needs to be assessed.
3. Technical Compatibility: Existing blast furnaces and metallurgical processes are optimized for coke. Adapting them to use biochar may require significant modifications.

Research and Development

1. Optimizing Production: Research is ongoing to optimize the production of biochar for metallurgical use, focusing on achieving the desired carbon content and physical properties.
2. Pilot Projects: Pilot projects and studies are being conducted to test the feasibility of using biochar in industrial settings, such as in steel mills.
3. Lifecycle Analysis: Comprehensive lifecycle analyses are being performed to evaluate the environmental and economic impacts of substituting coke with biochar.

Potential Applications

1. Iron and Steel Production: Biochar can be used as a reducing agent and fuel in blast furnaces and electric arc furnaces, potentially reducing the carbon footprint of steel production.
2. Non-Ferrous Metallurgy: Biochar could be used in the production of non-ferrous metals, where reducing agents are required.
3. Other High-Temperature Processes: Biochar can be employed in various industrial processes that require high temperatures and reducing environments.

Conclusion

Using biochar as a coke substitute in metallurgical processes offers promising environmental benefits, particularly in reducing greenhouse gas emissions and utilizing renewable resources. However, several challenges need to be addressed, including ensuring consistent quality, economic feasibility, and compatibility with existing industrial processes. Continued research and development, along with pilot projects, will be crucial in determining the practicality and scalability of biochar as a coke substitute in the metallurgy industry.

Source：ChatGPT

One of the International Patented Technology that KENKI DRYER has is a self-cleaning structure called Steam Heated Twin Screw technology (SHTS technology). No matter how materials are sticky, adhesive and viscous is, they can be dried without clogging inside of the dryer because of this unique structure that no other products has.
For example, even materials stuck to the blades of one screw, blades of the other screw in the dryer’s body forcibly peels the materials off as they rotate. Since the blades rotate by peeling the material off each other, any sticky, adhesive and viscous material does not adhere to the blade, and the blades continue rotating, peeling, agitating and heating material without stopping while they carries material further. Also, since surface of blades are always renewed and kept clean, heat near the blades is not blocked and it is conducted directly into the materials.

Self-cleaning screw

KENKI DRYER has three main characteristics. They are 1) Any materials can be dried as expected including sticky, adhesive and viscous materials and raw material slurry that no other company can deal with, 2) dried material can by recycled or utilized as raw materials because of its low-temperature drying method, and 3) there is no need to assign operator since its continuous operating system makes 24 hours unattended operation possible.

Products

The unique and original drying mechanism of KENKI DRYER is also International Patented Technology. Because 4 drying mechanisms which are crashing drying, agitation drying, circulation drying and indirect drying work simultaneously and add heat to material being dried repeatedly and continuously, inner part of the material is dried thoroughly and quality of discharged material after drying is stable. This series of drying mechanisms prevents agglomeration which causes insufficient drying from feeding process of the material into the dryer until discharging process after drying completed. Various ingenuities to conduct heat surely into inner part of the materials are exercised and stable heating and drying are proceeded continuously.

Methods

Even KENKI DRYER uses only saturated steam as its heat source, it is outstanding in safety and hygiene point of view with its unique drying mechanism based on combined use of conductive heat transfer method and heated air method. Since steam is a stable heat source, quality of discharged material after drying is also stable and equable. Maximum allowed steam pressure is 0.7Mpa and adjustment of steam pressure, adjustment of drying temperature in other words, can be easily done. Saturated steam is commonly used in many factories so that it can be said as a familiar and handy heat source. In comparison with drying methods using burner or hot blasts, saturated steam method is an indirect drying applying heat exchange via pipes that steam is passing through, therefore, it hardly burns the materials and is outstanding in safety and hygiene point of view.

Heat source, Steam