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NTN TECHNICAL REVIEW No.742006 New Product Honing Sludge and Electro Furnace Dust Briquetter Shouzo GOTOH Kanji NAKAMURA Being an ISO14001-certified company, NTN is responsible for helping establish recycling technology to contribute to our recyclingoriented society. At first NTN started recycling grinding sludge with a grinding sludge briquetting machine, achieving Zero-emission with cost reduction. In 2002 NTN has established UNITOP, an environmental venture business based on briquetting technology. Horning sludge and electro furnace dust were picked up as the next targets. After testing, practical machines for horning sludge and electro furnace dust were developed. These machines will contribute to environmental load reduction. 1. Introduction In 1998, the NTN Iwata Works became the first member of the NTN Group to acquire ISO 14001 certification. At that point, among NTN’s waste, grinding sludge was the type that accounted for the largest environmental impact. In 1998, all of NTN produced approximately 8,000 tons of grinding sludge that was disposed of by industrial waste disposal agents. As a part of our efforts to acquire ISO 14001 certification, we began a commitment to recycling technologies with the aim of both recycling grinding sludge and reducing industrial waste disposal costs. Through the use of a solid-liquid separation technique for grinding sludge. We successfully established the recycling system that is illustrated schematically in Fig. 1. In 2000, we developed a grinding sludge recycling machine capable of commercial operation and began a full-scale grinding sludge recycling operation. Three years later, we succeeded in recycling nearly all the grinding sludge produced by the entire NTN Group. Consequently, we achieved “zero emissions” of waste, mitigating environmental impacts, which is the main objective of ISO 14001, as well as cost reduction by eliminating industrial waste disposal expenses. To further promote our waste reduction efforts, in 2002, we founded UNI TOP, an environmental venture company that boasts a unique grinding sludge briquetting technique. We have also succeeded in meeting the needs of our customers for technical assistance in their solidliquid separation and solidifying efforts. We are now committed to the commercialization of a briquetter for honing sludge and electric-arc-furnace dust. Grinding sludge Classification Separation and collection Solid-liquid separation immediately after sludge generation Reduce Volume reduction Grinding sludge briquetter Reuse Recycling Plant Coolant Briquette Higher-level cycle Recycle Reused Prevention of spontaneous combustion Fig. 1 3R recycling for grinding sludge Steel mill Quality assurance Equipment Development Dept. Production Engineering R&D Center -74-
Honing Sludge and Electro Furnace Dust Briquetter 2. Honing Sludge Briquetters In 2004, NTN received a request from an automaker that wished for us to develop a briquetter that could solidify the sludge that results from the honing work on engine cylinder bores. We first attempted to meet this request with our grinding sludge briquetting technique. Regrettably, the sludge started to leak through the mechanical gaps between the die and the pressurizing shaft when pressurizing was begun. We investigated the cause of difficulty in solid-liquid separation and solidification, learning that the unique shape of the swarf (shavings) from the honing process is the cause. A microscopic photograph of honing swarf is shown in Fig. 2, while a microscopic photograph of grinding swarf is provided in Fig. 3. Through comparison of the two photos, it is apparent that grinding shavings are curled and can easily become entangled with each other, while honing shavings are rolled and cannot easily become entangled. To realize solid-liquid separation and solidification of honing sludge, the authors first tested a method, as shown in Fig. 4, in which the mechanical gaps are blocked with pieces of filter paper that allow only the coolant to drain away while retaining the honing swarf in the honing sludge briquetting system. As a result, the authors verified that honing sludge could undergo solid-liquid separation and solidification through the use of this system. Encouraged by this finding, the authors fabricated the prototype honing sludge briquetting system shown in Fig. 5. In the fall of 2005, this system was commissioned at a customer automaker’s site and allowed to run continuously on a trial basis. The automaker was satisfied with the basic functions of this system. Fig. 6 illustrates the prototype machine schematically, and Fig. 7 shows the honing sludge used in the authors’ test. Fig. 8 is a view of a briquette obtained from the authors’ test, and Fig. 9 illustrates a view of the filtered and recovered coolant. For reference, a photographic view of the coolant in process is shown in Fig. 10. From a comparison of Fig. 9 and Fig. 10, the readers can see that the coolant is cleaned by filtration through solid-liquid separation and solidification using paper filters. The authors’ newly developed honing sludge briquetter has the following advantages: 1) Reliable solid-liquid separation and solidification: Labor time saving through stable operation Paper filters Fig. 4 Test method of horning sludge briquetting Fig. 2 Magnified horning swarf Machine dimensions Width :1,265mm Depth : 596mm Height :1,560mm Fig. 3 Magnified grinding swarf Fig. 5 Test machine for horning sludge briquetting -75-
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