Fossil oil, especially heavy oil contains approximately 1% of large particle carbon material (sludge) including remained catalyst used at the time of refinery. When end users use heavy oil, they remove the sludge and put into incineration disposal as waste fluid because the sludge has harmful effects to diesel engine system. In another words, the users are burdened 1% of fuel loss, useless CO2 discharge and more, cost for the fuel disposal. We have realized to reuse the sludge as fuel by utilizing our Nanotechnology.

We provide solution to recycle sludge by productization of the technology. The business is to manufacture and sell the system to recycle sludge mainly in heavy oil (Fuel Oil C, HFO, etc.) to be reused as a fuel.


Sludge is generated when relatively macromolecular carbon sort of material in oil clumps and is grain-shaped due to change in temperature or mixture of different oil. Sludge is so much flame-retardant that it not only remains unburned inside of the engine causing grime, but is emitted into air as exhausted gas including PM and smoke, having a negative impact on the human body. Further, it is wasting of fuel. Sludge is broadly divided into the following two types;


  1. 1. Formation of small particle size sludge

Generally heavy oil is used after heating due to the high viscosity.
We take the large ships as an example, Main Tank: 60 degrees Celsius, Service Tank: 90 degrees Celsius, at the time of engine injection: 130~150 degrees Celsius. Therefore as previously described, sludge is generated and the particle diameter comes up to approximately a few μm at maximum.


  1. 2. Formation of large particle size sludge

FCC catalyst (silica, alumina) is used in the purified process of the oil. FCC catalyst will never get mixed with oil products of high volatility such as gasoline, kerosene, light oil, fuel oil A, etc. due to purification by distillation, however in case of heavy oil, which is contaminated with FCC catalyst of 10μm or less, these small particle size of sludge attach and wrap around FCC catalyst to forming large size (up to 10 several μm) sludge.


Hence sludge has been processed in large vessels and at diesel power plants, which is all only intended for small particle size sludge with following techniques specifically.

◉Sludge dispersant: To input approx. 0.1% to disperse small particle size sludge.
◉ Homogenizer: Mechanically unwrap small particle size sludge.

Our sludge processing is a technique to crush FCC catalyst itself to process small & large particle size sludge together

Takehiko Matsumura


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