For community development

Recycling Plant

Waste-Glass Recycling Plant

Waste glass is not just waste, but a new resource. Supersol is an artificial light porous foamed material that is made by crushing, milling, baking and foaming waste glass. The Waste-Glass Recycling Plant is a plant for recycling waste glass produced in the local community into Supersol.

You just need to place waste glass bottles into the hopper. The Waste-Glass Recycling Plant automatically crushes them and performs milling, sorting and baking to produce Supersol.

Outline

The Waste-Glass Recycling Plant is a set of machines to produce Supersol, a pumice-like light porous foamed material, from waste glass produced in the local community as 99% of its basic materials.

The Waste-Glass Recycling Plant consists of 9 machine units, a bottle supply hopper, a bottle conveyor, a crusher, a cullet mill, powder conveyors, a powder sifter, a mixing machine, a baking machine and a Supersol sizer; and automatic control panels. The bottle supply hopper can hold about 4.5 m3 of waste glass, which is crushed into cullet of less than 6 mm in size by the crusher. The cullet is then milled into glass powder with a median grain diameter of 35 µm by the cullet mill. The glass powder is sent to the powder sifter, which removes foreign objects and powder grains that are not of a specified size. The mixing machine mixes glass powder and add-in materials, and continuously sends the resulting powder mixture to the baking machine. There the powder mixture is preheated, softened, baked and foamed in the temperature range of 700 ~ 920 degrees centigrade. The layer of glass powder mixture having an initial thickness of 15 mm is converted into a light porous slab having a thickness of about 60 mm. More than 70% of these machines have originally been developed by Trim.

Most conventional glass recycling machines crushes glass only into cullet. The resulting cullet is used for making glass again if it is transparent or brown, and other cullet is mixed in secondary concrete products, asphalt paving and blocks. The cullet, however, is low-value-added products, and its use in business is limited. On the other hand, Supersol, produced by the Waste-Glass Recycling Plant, has a wide range of application, such as a light embanking material in civil engineering, a culture medium or an inorganic soil amendment in horticulture and agriculture, a purification material in water purification and an insulator in architecture. It is now used in various areas for various purposes.

Production Stages and Machine Units

The Waste-Glass Recycling Plant map

Bottle Supply Hopper

Bottle Supply Hopper

The bottle supply hopper can hold about 4.5 m3 (3.5 t) of waste glass bottles, and the vivratory feeder attached to the hopper bottom supplies glass bottles stably to the conveyor.


* This movie is in Japanese.

Crusher

Crusher

Crushing glass bottles

Waste glass bottles carried in by the conveyor are crushed in a single process into cullet less than 6 mm in size (the specified grain size of the crusher) by a compact crusher having a diameter of 1,600 mm.

Glass bottles are compressed and crushed by rollers, which is based on the mechanism of the mill. To improve the wear resistance of the machine, special steel is used for the inner parts, and removable couplings are used for the inner structure. As a result, our crusher has better wear resistance and durability than ordinary glass crushers. (Patented)


* This movie is in Japanese.

Cullet Mill

Cullet Mill

Milling cullet into powder

Glass cullet of less than 6 mm in size produced by the glass crusher is further milled to produce galss powder. Our cullet mill is a tube mill modified for glass cullet. Its inlet can easily take in glass pieces of different sizes and shapes, and its outlet discharges glass powder in the order of smaller specific gravities. The produced glass powder is separated from paper, such as bottle labels, by a rotary sieve within the two-layer hopper. The cullet mill contains many alumina balls, which collide with each other to mill cullet. The machine requires no maintenance for about 2 years. The full-automatic operation of the cullet mill synchronized with the glass crusher enables a continuous production of glass powder, and has achieved a stable glass powder production of the specified grain size and a higher production efficiency (more than 97%).


* This movie is in Japanese.

Powder Sifter

Powder Sifter

Sorting glass powder

Glass powder produced by the cullet mill is sorted according to grain sizes, and powder of the specified grain size is taken out.

Connection with a powder conveyor allows the continuous sorting of powder. In addition, because of its closed system, no powder is released into the surrounding environment.


* This movie is in Japanese.

Powder Conveyors

Powder Conveyors

Powder conveyors transfer glass powder from the cullet mill, the powder sifter, and the mixing machine.

These are spinflow conveyors based on the principle of whirlpools. They allow full-automatic, stable powder transfer, while powder transfer was considered difficult before. Furthermore, since they do not use air flow, the generation of static electricity is low, and no dust is released into the work environment.

Mixing Machine

Mixing Machine

Mixing powder with add-in materials

Glass powder sorted out by the powder sifter and two types of foaming materials are automatically measured and mixed. These materials. which are different in quantity, specific gavity and shape, are thus uniformly mixed.

The mixing machine is of sequential batch type and can produce 350 kg of powder mixture in a batch process. In addition, the whole process of feeding, measuring and adding the two types of foaming materials is fully automated, allowing the stable production of glass powder mixture in uniform quality.


* This movie is in Japanese.

Baking Machine

Baking Machine

Baking powder mixture

Powder mixture produced by the mixing machine is baked to make a light porous foamed material, or Supersol. The baking machine consists of a baking section and an annealing section, each of which has a light, insulating and fireproof sructure. The machine also has a wire-mesh belt conveyor to allow continuous baking.

Furthermore, the baking machine is equipped with 16 burners to carry out the processes of preheating, softening, baking and foaming.


* This movie is in Japanese.

Supersol Sizer

Supersol Sizer

Sizing Supersol pieces

Produced Supersol blocks are broken and sorted into specified sizes.

The breaker has breaking blades whose shape and material have been specifically designed for Supersol production, allowing efficient breaking and sorting.