Country/Region:GLOBAL | Overseas

Separation of Hazardous Substances/Materials and Thermal Recycling

With conventional materials recycling that focus mainly on metals such as iron, landfilling was involved for used products that were collected.
In aiming for "zero-landfill" without any limitations, in 1998, Fuji Xerox obtained the cooperation of recycling companies (13 companies) throughout Japan that possess the latest technologies to disassemble 100 copy machines weighing approximately 18 tons that were used and collected, to separate them into individual parts, and disassemble them into materials. A demonstrative test for "zero-landfill" where collected used products were completely made into resources was implemented.
Based on this demonstration, it was confirmed that zero landfill could be realized, by separating each of the used copy machines parts into a maximum of 44 categories, and by processing each of these through the latest recycling process.
Starting in February 1999, this process was put into practice at our Ebina Facility, focusing on the parts that were disassembled in the recycling line but could not be reused, and the process from disassembly and separation to recycling was systemized as a management system.
In addition, "Ecoland," which researches and demonstrates efficiency of disassembly and separation operations was built at the Ebina Facility.
Fuji Xerox started disassembly and separation of used machines collected from the Tokyo metropolitan area within the company.
On top of all this, in order to expand the "zero-landfill" system to a national level, we created a network with recycling companies (23 companies throughout Japan) that possess a level of technology that is the same as that for the demonstrative test.
As a result, a system for realizing "zero-landfill" (excluding process losses) for used products collected from customers was completed nationally in August 2000.

Processing System for 100% Recycling

Disassembly of Product Parts: *Iron parts(Frame)→Crushing→Dissolution→Iron/Aluminum/Copper/Gold/Tin/Silver/Lead. *Composite parts made of iron/nonferrous metals(Printed-wiring board, motor)→Crushing→Sorting→Melting→Purification→Iron/Aluminum/Copper/Gold/Tin/Silver/Lead *External plastic parts(Cover/Tray)→Crushing→Cleaning→Kneading→Re-pellet→Cover/tray *Other plastic parts(Housing/ducts)→Crushing→Reducing agent for blast furnaces *Parts mainly using rubber(DADF/Belt)→Crushing→Removal of foreign substances→Pulverization→Fuel for cement manufacturing *Parts mainly using glass(Lens/Platen glass)→Crushing→Removal of foreign substances→Cleaning→Cullet→Glass *CRU toner(CRU)→Melting/Solidification→Crushing→Reducing agent for blast furnaces *CRU toner(Drum)→Compression→Dissolution→Aluminum→Drum *CRU toner(Toner)→Kneading→Auxiliary fuel for cement furnaces *Packaging materials(Styrofoam)→Crushing→Removal of foreign substances→Dissolution→Re-pellet→P8 pellets *Packaging materials(Pallet)→Crushing→Removal of foreign substances→Chips for plywood *Hazardous parts(Lamp1)→Crushing→G cullet→Glass *Hazardous parts(Lamp2)→Crushing→G cullet→Vacuum heating→Purification→Mercury *Hazardous parts(Batteries)→Crushing→Melting→Purification→Cadmium

Structure for Zero-landfill

Collection of materials87.0%/Usage of slag2.1%/Usage of heat(Heating catalyst/Thermo fusion)10.9%/Process losses0.03%

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