Low-temperature drying for upcycling of difficult-to-dry organic waste / Test cases / Organic waste drying, Upcycling drying

SUMMARY

1. Introduction

Upcycling and recycling of organic waste from factory production processes is becoming increasingly important and in demand from the perspective of environmental protection and decarbonization.

2. features of KENKI DRYER

• Low-temperature drying minimizes compositional changes, making it ideal for upcycling
  • Heat source is indirect drying using steam from a boiler, enabling drying at low temperatures
  • Compositional changes of organic waste are minimized, enabling effective use as fertilizer, compost, soil conditioner, feed, etc.
  • Bioplastics can also be produced from organic waste of vegetable origin
  • Zero-emission drying reduces environmental impact
• Dries any kind of sticky or adhesive materials using a unique, world-patented mechanism
  • Smooth drying of organic waste with high water content, which is prone to clogging in other dryers
  • The world’s only revolutionary drying equipment with 11 patented technologies from 8 countries
• Utilization of organic waste after drying
  • Can be used as fuel, Biochar, or Biocoke
    • Attention as an environmentally friendly alternative to fossil fuels
    • Use as a substitute for coke in the steel and foundry industries, as a soil conditioner, and as activated carbon
  • Carbonization is possible without fossil fuels with the pyrolysis equipment Biogreen
• Energy-saving design to reduce running costs
  • Indirect steam drying for high drying heat efficiency and low steam consumption
  • No fuel cost by using steam currently in use or surplus steam
  • Drying with zero CO2 emissions is also possible by installing an electric boiler.
• Low maintenance cost
  • No trouble after start of operation and less wear and tear on parts
  • Low rotation speed of the blades in the dryer’s main body minimizes wear and tear on parts, making maintenance easy
• Continuous operation allows 24-hour operation
  • Continuous drying system, rather than a batch system in which materials to be dried are stored and dried
  • Easy operation control and unmanned operation 24 hours a day

3.Effects of KENKI DRYER

• Reduction of waste volume and industrial waste costs
  • Reduce weight and volume of waste by drying organic waste
  • Copes with the rising cost of industrial waste due to the 2024 truck problem
• Reduction of CO2 emissions
  • Reduce the number of trucks due to reduced waste volume
  • Biogreen carbonization without fossil fuels
  • Drying without CO2 emissions by installing electric boilers

4. summary

KENKI DRYER is a revolutionary, environmentally friendly drying system that can dry highly adhesive and sticky organic waste.

The upcycling and recycling of organic waste from factory production is becoming increasingly important in terms of environmental protection and decarbonization.
KENKI DRYER uses steam from a boiler as a heat source for indirect low-temperature drying. Since organic waste is dried at low temperatures, there is little change in its composition and it can be effectively used as an upcycling process, enabling zero-emission drying.

When organic waste is left in a high moisture state, decomposition is caused by the activity of microorganisms (especially bacteria and molds) contained in the organic waste. These microorganisms use the moisture and nutrients in the organic waste to reproduce, producing gases and odors in the process, and the growth of the microorganisms causes decomposition and the development of odors and pathogens. Drying is an effective solution to these problems.
However, many organic wastes are difficult to dry due to their strong adhesiveness, and some other types of dryers may clog the dryer while drying organic wastes, preventing them from being discharged. KENKI DRYER’s unique world-patented mechanism allows it to dry even highly adhesive and sticky organic waste with high water content smoothly without clogging the dryer.

The dried organic waste can be used as fertilizer, compost, soil conditioner or feed for livestock such as cows and pigs, and bioplastics can be produced from plant-based organic waste as an alternative to petroleum-based plastics.

Wood is currently in short supply in Japan. The use of dried organic waste as a fuel instead of wood, or the use of dried organic waste 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.
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 organic waste reduces its weight, which in turn reduces the amount of waste, which in turn reduces the cost of industrial waste, which is rising due to the recent trucking problem in 2024, and also reduces carbon dioxide emissions by reducing the number of trucks transporting waste.

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).

Organic waste is any material that comes from plants or animals and can decompose naturally. This means that it can be broken down by microorganisms, such as bacteria and fungi, into simpler organic matter. Organic waste is a major component of municipal solid waste, and it can be a valuable resource if it is composted or recycled.

Here are some examples of organic waste:

• Food scraps, such as fruit peels, vegetable trimmings, and coffee grounds
• Yard trimmings, such as leaves, grass clippings, and branches
• Manure from animals
• Paper products, such as cardboard and newspapers
• Wood scraps

Organic waste can be composted to create a nutrient-rich soil amendment that can be used to improve plant growth. It can also be anaerobically digested to produce biogas, which can be used as a renewable energy source.

Source：Gemini

There are three main reasons for drying organic waste

1. Prevention of decomposition

If organic waste is left in a high moisture state, it can decompose due to microbial growth, causing foul odors and pathogens. Drying is an effective way to solve these problems.

Drying reduces the water activity of organic waste. Water activity is an indicator of the amount of water available to microorganisms, and generally speaking, microbial growth is inhibited when water activity falls below 0.6.

Specifically, the following effects can be expected

・Inhibition of microbial growth: Decreased water activity inhibits the growth of microorganisms such as bacteria and molds that cause spoilage.
・Decrease in enzyme activity: Many enzymes are activated in water, but drying inhibits their activity and slows the decomposition of organic matter.
・Inhibition of chemical reactions: Many of the chemical reactions involved in decomposition require water, and drying inhibits these reactions.

2. volume and weight reduction

Drying organic waste can significantly reduce its volume and weight.

For example, the moisture content of food waste is approximately 60-80%, but drying can reduce the moisture content to less than 10%. This means a reduction of approximately one sixth in volume and one quarter in weight.

This helps to reduce the cost of waste disposal and improve the efficiency of transportation and storage.

3. resource recovery

Dried organic waste can be used for several purposes

Fuel: The dried material itself can be used as fuel or converted to biogas for use as fuel.
Fertilizer: The dried organic waste can be composted or used as a soil amendment.
Feed: Can be used as livestock feed.
Other: Can be used as a raw material for paper, fiber, plastics, etc.

Thus, drying organic waste offers a variety of benefits, including reduced environmental impact, cost savings, and resource recovery.

Source：Gemini

• Material to be dry: Difficult-to-dry Organic waste
• Purpose of drying: Upcycling, Reducing industrial waste cost and amount
• Moisture content: 56.7％W.B. before drying, 3.2％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

A fuel is any material that can be made to react with other substances so that it releases energy as thermal energy or to be used for work. The concept was originally applied solely to those materials capable of releasing chemical energy but has since also been applied to other sources of heat energy, such as nuclear energy (via nuclear fission and nuclear fusion).
The heat energy released by reactions of fuels can be converted into mechanical energy via a heat engine. Other times, the heat itself is valued for warmth, cooking, or industrial processes, as well as the illumination that accompanies combustion. Fuels are also used in the cells of organisms in a process known as cellular respiration, where organic molecules are oxidized to release usable energy. Hydrocarbons and related organic molecules are by far the most common source of fuel used by humans, but other substances, including radioactive metals, are also utilized.
Fuels are contrasted with other substances or devices storing potential energy, such as those that directly release electrical energy (such as batteries and capacitors) or mechanical energy (such as flywheels, springs, compressed air, or water in a reservoir).

Source：Wiki Fuel

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

Bioplastics are a type of plastic derived from renewable biological sources, such as vegetable fats and oils, corn starch, straw, woodchips, sawdust, and recycled food waste. Unlike conventional plastics, which are made from petroleum-based raw materials, bioplastics are made from biomass. There are several types of bioplastics, each with different properties and applications.

Types of Bioplastics

1. Bio-based plastics: Made partially or wholly from biological sources. Examples include:

   • Polylactic Acid (PLA): Derived from corn starch or sugarcane, used in packaging, disposable cutlery, and medical implants.
   • Polyhydroxyalkanoates (PHA): Produced by bacterial fermentation of sugars or lipids, used in medical devices and packaging.

2. Biodegradable plastics: These can be broken down by microorganisms into water, carbon dioxide, and biomass under certain conditions.

   • Starch Blends: Composed of starch mixed with other biodegradable polymers.
   • Polybutylene Succinate (PBS): Biodegradable plastic made from succinic acid and 1,4-butanediol.

3. Compostable plastics: These biodegrade under composting conditions within a specific timeframe.

   • Polylactic Acid (PLA): When used in compostable products, it can break down in industrial composting facilities.

Advantages of Bioplastics

• Reduced Carbon Footprint: Production often generates fewer greenhouse gas emissions compared to conventional plastics.
• Biodegradability: Some bioplastics can decompose in natural environments, reducing litter and pollution.
• Renewable Resources: Made from plant-based materials, which can be sustainably grown and harvested.

Challenges and Considerations

• Cost: Often more expensive to produce than conventional plastics.
• Performance: May not always match the durability and versatility of petroleum-based plastics.
• Recycling and Composting Infrastructure: Limited facilities available for processing bioplastics.
• Environmental Impact: Not all bioplastics are biodegradable, and improper disposal can still contribute to pollution.

Bioplastics are part of a broader effort to create more sustainable materials and reduce reliance on fossil fuels. However, their development and adoption involve balancing environmental benefits with practical and economic considerations.

Source：ChatGPT

Bioplastics are a type of plastic derived from renewable biological sources, such as vegetable fats and oils, corn starch, straw, woodchips, sawdust, and recycled food waste. Unlike conventional plastics, which are made from petroleum-based raw materials, bioplastics are made from biomass. There are several types of bioplastics, each with different properties and applications.

Biodegradable plastic is a type of plastic that can be broken down by living organisms, typically microbes, into simpler substances like water, carbon dioxide, and biomass. It’s one kind of bioplastic, but the terms aren’t exactly interchangeable.

Here’s the key difference:

• Bioplastic: This refers to the origin of the plastic. It’s made from renewable sources like plants or microorganisms (bio-based). Not all bioplastics are biodegradable.
• Biodegradable Plastic: This describes the end-of-life of the plastic. It can be broken down by living things under certain conditions (e.g., composting facilities).

So, all biodegradable plastics are bioplastics, but not all bioplastics are biodegradable.

Here are some additional details about biodegradable plastics:

• Materials: They can be derived from various renewable sources like corn starch, cellulose, or even be made with the help of microorganisms.
• Benefits: Biodegradable plastics offer an advantage over traditional plastics by decomposing in a reasonable timeframe, potentially reducing plastic pollution in landfills.
• Considerations: Biodegradable plastics often require specific conditions for breakdown, such as industrial composting facilities. Improper disposal might not lead to biodegradation and could still cause environmental issues.

Overall, biodegradable plastics are a promising development for reducing plastic waste, but it’s important to understand their proper use and limitations.

Source：Gemini

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

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