Sun Metalon and Komatsu Launch Joint Research on Innovative Recycling Process for Iron-based Polishing Sludge

SUN METALON, a deep-tech startup driving decarbonization in the metal industry, has partnered with Komatsu Ltd. to launch a groundbreaking joint research project. The collaboration aims to establish a low-cost, low-CO2 emission, and safe method to regenerate high-purity metal resources from polishing sludge, a byproduct produced in large quantities during metal processing. As part of this initiative, SUN METALON's experimental equipment has been installed at Komatsu's factory to verify its practical applicability.

This joint research tackles a significant challenge in the manufacturing of seal rings, critical components in Komatsu's construction equipment. These high-chromium cast iron rings play a crucial role in preventing lubricant leakage and protecting against debris infiltration in construction equipment undercarriages. The production process generates substantial amounts of polishing sludge – a difficult-to-handle mixture of fine metal particles, oil, and water. Komatsu alone produces about 150 tons of this sludge annually, which has traditionally posed recycling challenges due to handling difficulties and safety concerns during melting processes. SUN METALON's innovative approach leverages its patented metal heating technology to efficiently extract impurities from metal waste. The partners have already successfully completed initial evaluations of this heat treatment process on polishing sludge. Looking ahead, they plan to refine and scale up the recycling process, conduct extensive practical trials, and explore applications across various industries. This endeavor not only promises significant resource conservation and waste treatment cost reductions but also aligns with broader decarbonization efforts in metal processing.

Kazuhiko Nishioka, Co-Founder & CEO of SUN METALON, expressed enthusiasm about the project: "Our collaboration with Komatsu addresses a long-standing industry challenge. By enabling the recycling of polishing sludge into valuable iron resources, we're paving the way for a more circular and sustainable manufacturing ecosystem. This technology has the potential to revolutionize resource utilization and significantly reduce carbon emissions across the entire manufacturing sector."

A Komatsu representative from the Production Engineering Department at the Himi Plant added: "SUN METALON's recycling process offers a promising solution to a problem we've long grappled with. Our initial evaluations of the cast iron recycling technology have been very encouraging. We anticipate this innovation will not only enhance our environmental performance and safety standards but also deliver substantial economic benefits by reclaiming valuable alloy materials.”