_2726.webp)
This February, Alfa Therm Limited commissioned a complete RDF Dust Removal Line at Siddeshwari Industries Pvt. Ltd., Muzaffarnagar. Now, more than six months later, the plant has been running smoothly, delivering consistent results and transforming waste into high-quality Refuse-Derived Fuel (RDF) day after day.
Project Overview
This comprehensive RDF Dust Removal Line has been thoughtfully engineered to deliver high efficiency and reliability. The system comprises
- Apron Feeder: Robustly introduces raw waste into the processing line.
- Feed Conveyor: Steadily transfers materials toward the trommel.
- Trommel: Effectively screens materials, separating into undersize and oversize fractions.
- Undersize Conveyor: Channels finer particles for downstream processing.
- Oversize Conveyor: Redirects larger, non-conforming material for further shredding.
- C&D Conveyor: Routes construction and demolition materials efficiently.
- Air Density Separator: Utilizes air flow to segregate dust and lighter contaminants from combustible fractions.
- Primary Shredder: Model UHT 20/300 – Initiates size reduction, preparing materials for finer shredding.
- Secondary Shredder: Model UHT 20/300 – Further processes material into uniform RDF granules suitable for energy generation or fuel preparation.
This sequence ensures comprehensive separation, shredding, and purification—delivering high-calorific, clean RDF in line with Alfa Therm’s commitment to sustainable waste-to-energy solutions.
Enhanced Workflow & Operational Advantages
- Reliable Material Feed:
The Apron Feeder ensures the steady introduction of mixed waste into the system with durability and consistency, minimizing throughput fluctuations. - Efficient Size Separation:
The Trommel, coupled with dedicated conveyors for each fraction, ensures that each material stream (undersize vs. oversize) is accurately routed. This minimizes blockages and improves downstream processing. - Effective Dust and Lightweight Removal:
The Air Density Separator plays a pivotal role in extracting light contaminants—such as dust fragments—ensuring that only clean biomass proceeds to shredder units. This step significantly improves RDF quality while safeguarding operator health and machine integrity. - Dual-Stage Shredding Precision:
Employing both Primary and Secondary Shredders (UHT 20/300), which are the twin-shaft shredders, the system achieves uniform, manageable RDF granules. The two-stage approach provides optimal size control and helps extend the operational life of the machinery. - Seamless Integration & Scalability:
Designed as an integrated system, the line operates with synchrony from feed to final output. Its modular setup allows for tailored capacity scaling when future throughput demands increase.
How the Waste Moves Through the Line
The process begins with the Apron Feeder, which ensures steady, controlled feeding of mixed waste into the system. Unlike conventional loading methods, this feeder regulates the speed and guarantees continuous loading, preventing sudden surges or gaps in material flow. From here, the waste passes onto the Feed Conveyor, which gently carries it forward for processing.
The first major transformation happens in the Trommel—a rotating screening drum. As the waste tumbles inside, it is separated based on size. Fine material and dust fall through the perforations, reducing impurities early on, while oversized pieces continue moving. The dust and fine particles are directed out via a dedicated Dust Removal Conveyor, ensuring the line remains clean and the final RDF has a higher calorific value.
Next, the oversized fraction moves along the Oversize Conveyor toward the Air Density Separator with Hood. Here, lightweight and combustible fractions are carefully separated from heavier, unwanted materials. This step is critical for isolating the RDF fraction—the part of the waste stream that will eventually serve as an alternative fuel. Meanwhile, construction and demolition debris, which cannot be processed further, is diverted away on the C&D Conveyor.
The usable waste then enters the shredding phase. It is first carried by the Infeed Conveyor into the Primary Shredder (UHT 20/300), which breaks down bulky pieces into smaller, manageable chunks. These are transferred through connecting conveyors and fed into the Secondary Shredder (UHT 20/300), where the waste is finely shredded into uniform particles.
Finally, the refined material travels along the Final Output Conveyor. What began as mixed and dusty municipal waste now emerges as clean, consistent RDF—ready to replace fossil fuels in industrial applications.
Proven Benefits for Siddeshwari Industries
Since February, Siddeshwari Industries has seen several tangible benefits:
- Consistent RDF Production: The line produces uniform, dust-free RDF that meets the strict requirements of cement kilns and other industrial users.
- Reduced Waste to Landfill: Large volumes of municipal and industrial waste are now being processed into valuable fuel instead of ending up in dumpsites.
- Improved Efficiency: With automated feeding, screening, separating, and shredding, the system minimizes downtime and reduces manual intervention.
- Sustainability Gains: By replacing traditional fossil fuels with RDF, the plant contributes directly to lowering emissions and supporting circular economy goals.
Visual Layout Insight
About Alfa Therm Limited
With over three decades of expertise, Alfa Therm Limited continues to lead India’s waste-to-energy revolution—designing and delivering cutting-edge RDF, MRF, composting, incineration, and pollution control systems. The successful implementation at Siddeshwari Industries underscores our commitment to driving sustainable industrial transformation and enhancing energy recovery across sectors.
Looking Ahead
With half a year of successful operation already behind it, the RDF Dust Removal Line at Siddeshwari Industries stands as a showcase of Alfa Therm Limited’s engineering expertise and commitment to sustainable waste-to-energy solutions.
The plant is not just an installation—it’s a working model of how waste can be continuously converted into a resource, day after day, with minimal disruption and maximum efficiency.
At Alfa Therm, we are proud to see this line running reliably since February, and we look forward to supporting Siddeshwari Industries in their ongoing journey toward cleaner energy and responsible waste management.
Contact Alfa Therm for tailored waste processing solutions:
Corporate Office: Udyog Vihar, Gurgaon, Haryana
Manufacturing Plant: Kundli, Sonipat, Haryana
Reach out via fill the form, and our team will contact you in 24 hours.
Frequently Asked Questions (FAQs)
Unlike traditional systems, this line integrates advanced separation and shredding technologies that focus on producing cleaner, higher-calorific RDF. Its design minimizes dust and impurities, ensuring better combustion efficiency for industrial users.
RDF provides a sustainable alternative to coal and other fossil fuels. By using waste-derived fuel, industries reduce greenhouse gas emissions, conserve natural resources, and prevent large amounts of waste from ending up in landfills.
Cement manufacturing, paper mills, and power generation plants are among the biggest users of RDF. These sectors require consistent, high-energy fuel sources, making RDF an ideal fit for their operations.
Yes, RDF production reduces dependence on expensive fossil fuels, cuts waste disposal costs, and provides a steady, affordable energy source. Many industries also benefit from government incentives for adopting alternative fuels.
With rapid urbanization and growing waste volumes, RDF technology offers a scalable solution for waste management and renewable energy. As more industries shift toward sustainability, RDF will play a central role in meeting energy needs while addressing environmental challenges.
