Superheated Steam Technology

What Is Superheated Steam (SHS)?

Superheated steam (SHS) is a state of water vapor produced by heating water vapor beyond its saturation temperature (approximately 100°C); it is a colorless, transparent gas composed of water vapor (H₂O). Generally, during the process of heating water to turn it into steam, once the steam reaches the saturated state, applying additional heat transforms it into superheated steam. Superheated steam has high energy density and thermal efficiency and is used in many industrial processes and power plants.

Properties of Superheated Steam (SHS)

① Rapid heating is possible through combined heat transfer

Superheated steam (SHS) contains four times as much thermal energy (per unit volume) as hot air and can heat materials through a combination of convection, radiation, and condensation.

② Create an ultra-low-oxygen atmosphere inside the furnace (under process conditions)

In a superheated steam atmosphere, an ultra-low-oxygen environment similar to that of an inert gas can be achieved, enabling oxidation suppression, thermal decomposition, and carbonization.

Fields and Applications of Superheated Steam (SHS) Technology

Automotive Sector

• Cleaning and Degreasing of Machining Chips from Aluminum Alloys (AC, ADC, etc.)
• Cleaning and Degreasing of Aluminum Alloy Briquettes (AC, ADC, etc.)
• Cleaning and Degreasing of Irregularly Shaped Materials, Sheets, and Parts

Metal Materials Sector

• Cleaning and Degreasing of Machining Chips from Various Metals
  (Copper alloys, iron-based alloys, stainless steel, and specialty metals: Inconel, etc.)
• Waste and Recycled Materials (UBC, shredded materials, mixed metals, etc.)
• Cleaning and Degreasing of Irregularly Shaped Materials, Sheets, and Parts

Environmental Sector

• Recovery of Valuable Metals (e.g., Waste Circuit Boards, etc.)
• Thermal Decomposition Treatment of Organic Materials (Carbon-Based, Plastic-Based, and Other Organic Materials)
• Carbonization Treatment (Food Waste, Contaminated Soil, etc.)

Chemical Powders Sector

• Drying and Firing Processes
• Revitalization Treatment
• Organic Matter Removal Treatment

Features of Superheated Steam (SHS) Systems

Can be processed without ignition (safe and stable operation)

Thanks to the properties of superheated steam (SHS), which creates an ultra-low-oxygen treatment atmosphere, stable heat treatment is achieved without causing combustion inside the furnace.

Improving the Quality of Processed Materials (Increasing Added Value)

By performing the process in a superheated steam atmosphere—which has the same effect as an inert gas—we aim to improve product quality by suppressing oxidation of the treated material.
(Improved yield and safe dissolution during metal dissolution through oxidation suppression and reduction of residual carbon content)

Heat Recovery System (Energy-Saving Benefits)

We maximize the use of the energy from the processed material and the waste heat generated, implement heat recycling within the equipment system, and strive to reduce operating costs (through energy conservation).
(Use as a heat source for heating equipment and for steam generation using a waste heat boiler)

System Patterns

We will propose the optimal solution based on your needs and processing conditions.

[SH-ELS Type] Electric Heater Heating System—External-Heat Rotary Kiln

1) System Overview

The use of electric heaters enables easy operation and precise temperature control, and this model is capable of processing materials at high temperatures (up to 800°C).

2) Basic Specifications

• Processing temperature: 300–800°C (ambient temperature) *Selected based on the desired temperature.
• Atmosphere: Superheated steam
• Heat source: Electricity

[SH-ELB Type] Electric Heater Heating System: External-Heat Rotary Kiln + Waste Heat Boiler System

1) System Overview

The use of electric heaters enables easy operation and precise temperature control, and this model is capable of processing materials at high temperatures (up to 800°C). Additionally, the use of a waste heat boiler improves energy efficiency in steam generation.

2) Basic Specifications

• Processing temperature: 300–800°C (ambient temperature) *Selected based on the desired temperature.
• Atmosphere: Superheated steam
• Heat source: Electricity
• Energy-Efficient Equipment: Waste Heat Boiler

[SH-HRS Type] Waste Heat Utilization System: External-Heat Rotary Kiln

1) System Overview

An energy-efficient model that maximizes the thermal recycling of the energy (calorific value) in the waste being processed. By designing an optimal exhaust gas system tailored to the waste’s calorific value and utilizing the recovered heat, it dramatically reduces the unit processing cost.

2) Basic Specifications

• Processing temperature: 300–500°C (ambient temperature) *Selected based on the desired temperature.
• Atmosphere: Superheated steam
• Heat source: Waste heat (exhaust gas from the heat booster)

[SH-HRB Type] Waste Heat Utilization System: External-Heat Rotary Kiln + Waste Heat Boiler System

1) System Overview

An energy-efficient model that maximizes the thermal recycling of the energy (calorific value) in the waste material. By designing an optimal exhaust gas system tailored to the waste’s calorific value and utilizing the waste heat, it dramatically reduces the unit processing cost. Additionally, the use of a waste heat boiler improves energy efficiency in steam generation.

2) Basic Specifications

• Processing temperature: 300–500°C (ambient temperature) *Selected based on the desired temperature.
• Atmosphere: Superheated steam
• Heat source: Waste heat (exhaust gas from the heat booster)
• Energy-Efficient Equipment: Waste Heat Boiler

Field Testing (Performance Verification)

We can conduct validation tests for equipment installation based on your heat treatment needs, whether for research and development purposes (such as product improvement or the development of next-generation powders) or to evaluate the feasibility of implementing a rotary kiln system.

Flow of the Pilot Test

• Meeting
  We will discuss the purpose of the test and your requirements during the meeting.
• Test Plan Development
  Based on the results of our meeting, we will develop a test plan that meets the client's needs.
• Incorporation into Equipment Specifications
  We will conduct the test in the presence of the customer. We can also accommodate batch testing.
• Test Administration
  We will organize the data—such as temperature conditions and processing times—and evaluate how the results compared to the plan.
• Summary of Results Evaluation Data
  We will incorporate the test results into the equipment specifications and submit a proposal for those specifications.

Validation Tests and Trials

Rotary Kiln Demonstration Unit (Electric Heater Type: ELS Model)

1) System Overview

This is a continuous rotary kiln that uses an external heating system with electric heaters as its heat source, allowing for easy temperature control.

2) Specifications

• Retort effective dimensions: φ400 × 1300L
• Retort material: SUS310S
• Heat source: Electric heater
• Atmosphere: Superheated steam
• Control Temperature: 300–700°C (MAX)

Small-Scale Batch-Type Rotary Kiln Demonstration Unit (Electric Heater Type: ELS Model)

1) System Overview

This is a small-scale batch-type rotary kiln that allows for easy temperature control using electric heaters and facilitates performance evaluation of small-lot samples through batch processing.

2) Specifications

• Retort effective dimensions: φ400 × 600L
• Retort material: SUS310S
• Heat source: Electric heater
• Atmosphere: Superheated steam, N2, Ar, etc.
• Control Temperature: 300–800°C (MAX)

Mesh Belt Oven Demonstration Unit (Hot Air Circulation Type: HRS Model)

1) System Overview

A hot-air circulation mesh belt oven system. It enables performance testing and evaluation of irregularly shaped materials and components that cannot be processed in a rotary kiln.

2) Specifications

• Effective dimensions inside the furnace: W500 × H70 × 800L
• Mesh Material: SUS304
• Heat source: Waste heat (hot air circulation)
• Atmosphere: Superheated steam
• Control Temperature: 300–550°C (MAX)

Batch Box Furnace

1) System Overview

Box-Type Device (Batch-Type) for Simple Testing

2) Specifications

• Box Feeding Tray Dimensions: 140 × H100; Holds 2 items
• Heat source: Electric heater
• Atmosphere: Superheated steam, N2, Ar, etc.
• Control Temperature: 300–600°C (MAX)

Patented Technology

Special Patent No. 4199758, “Apparatus for Degreasing and Recycling Mixtures and Mixed Waste”
Japanese Patent No. 4134150 “Apparatus and Method for Degreasing Magnesium Alloys and Mixtures Containing Magnesium Alloys”