Process Flow
Equipment / System Architecture
RDF/SRF production is designed around the accepted waste stream and the receiving fuel specification; output quality cannot be assumed from mixed waste alone.
An RDF or SRF production facility prepares defined non-hazardous waste into a controlled fuel fraction through receipt, sorting, removal of unsuitable materials, size reduction, metal separation, screening, optional drying and dispatch. The process route is determined by incoming waste composition, moisture, chlorine and ash constraints, target particle size and off-taker specification.
Typical applications
- Pre-processing of commercial and industrial non-hazardous waste
- Fuel preparation for cement-kiln or approved industrial-energy users
- Sorting and size reduction for defined residual-waste streams
- Regional alternative-fuel preparation facilities with controlled dispatch
Main equipment and system architecture
- Enclosed reception and controlled feed systems
- Manual and mechanical sorting selected for the agreed waste stream
- Primary and secondary shredders sized to feed characteristics
- Screens, magnets and eddy-current separators where appropriate
- Air separation or optional drying only when justified by material and offtake
- Dust, odor, fire and storage-control systems
Capacity and design basis
Capacity is based on the accepted waste categories, calorific-value target where required, moisture, contamination, reject fraction, storage residence time, off-taker logistics and operating schedule. Fuel-quality outcomes remain subject to laboratory and receiving-specification confirmation.
Utilities and infrastructure
- Electrical supply for shredders, separation, extraction and handling
- Dust and odor control appropriate to waste characteristics
- Fire detection, suppression interfaces and emergency access
- Drainage/leachate handling based on enclosed receipt and waste condition
- Truck circulation, covered storage and dispatch infrastructure
Customer engineering inputs
- Approved incoming waste list and prohibited-material criteria
- Composition, moisture, chlorine/ash data where available and sampling plan
- Required fuel specification, particle size and off-taker acceptance criteria
- Waste permits, site boundaries, storage limits and local environmental conditions
- Transport plan and contingencies for rejects and non-conforming materials
CAPEX and OPEX drivers
CAPEX is driven by reception building, sorting scope, shredding stages, separation equipment, extraction/odor/fire controls, storage and dispatch. OPEX is driven by electricity, shredder wear, labor, residue handling, maintenance, sampling, compliance monitoring and transport.
Safety, environmental and compliance considerations
The design must address fire and self-heating risk, dust, odor, moving machinery, batteries or prohibited materials, vehicle movement, controlled storage, drainage and permit conditions for the actual waste stream.
Outputs and acceptance basis
Acceptance is based on safe operation, agreed incoming-waste controls, defined size and separation checks, sampling/quality procedures, documented rejects handling, commissioning trials and the off-taker’s confirmed acceptance basis.
Related project evidence
No verified completed RDF/SRF production project is currently published on this website. This page therefore does not state a project output or fuel-quality claim; published references are listed in Projects & Cases.
Frequently asked questions
What is the difference between RDF and SRF?
The terms are used differently by market and regulation. The applicable output specification, sampling method and off-taker acceptance criteria must be agreed for the specific project.
What waste streams are suitable?
Suitability depends on the approved incoming-waste list, composition, moisture, contaminants, local permits and the receiving fuel specification.
Is drying always required?
No. Drying is considered only when incoming material condition and target fuel requirements justify the energy and capital cost.
How are metals removed?
Magnetic and, where appropriate, eddy-current separation can be positioned around shredding and screening stages based on the defined material mix.
How is fuel quality controlled?
The system uses agreed sampling, classification, process-control and dispatch records. Any calorific, chlorine or ash criteria are project-specific.
Can an RDF line accept municipal waste?
Only the permitted and defined fraction should be accepted. The facility must have a documented receiving and sorting basis for the actual waste stream.
What are the main fire controls?
Controls can include receiving inspection, storage limits, temperature or detection systems, separation, suppression interfaces, housekeeping and emergency access appropriate to the site.
What happens to rejects?
Reject handling and routing are defined in the project basis and must comply with local permit, safety and downstream-disposal requirements.
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Provide feedstock samples or composition data, expected volume, site constraints, permits and intended recovered-material offtake. Open technical items remain marked TBC until confirmed.
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