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Waste Shredding and Secondary Fuel Production for Waste-to-Energy
The shredding of materials such as commercial waste, industrial waste, post-consumer waste, paper and plastics is a central component of modern waste recycling. Companies benefit from the efficient processing of these materials by recovering raw materials and significantly reducing the amount of waste. This leads to a sustainable circular economy and cost optimization in waste management.
Waste Shredding and Secondary Fuel Production for Waste-to-Energy Waste Shredding and Secondary Fuel Production for Waste-to-Energy Waste Shredding and Secondary Fuel Production for Waste-to-Energy
WEIMA offers high-performance shredders both as a stand-alone solution and as part of a multi-stage waste processing plant. With systems for pre- and post-shredding, continuous material processing can be guaranteed, which can be flexibly adapted to different requirements, for example for the production of refuse-derived fuels (RDF).
Learn more about waste processing and production of refuse derived fuel (RDF) and solid recovered fuel (SRF)
Shredder for pre-shredding and secondary shredding of waste
Shredding industrial & commercial waste with WEIMA
WEIMA’s shredding solutions enable the conversion of commercial and post-consumer waste into refuse-derived fuel (RDF) through advanced RDF shredders. These materials are not only recycled but also used to generate energy, replacing fossil fuels. In cement production in particular, RDF shredding makes a significant contribution to reducing the reliance on fossil fuels. This process helps to lower environmental pollution while providing economic benefits.
Post-consumer plastic after shredding with a WEIMA shredder at Stiphout Plastics
Customer applications: Waste shredding with WEIMA
Practical examples of successful waste processing with WEIMA shredders.
RDF shredding with WEIMA: Efficient fuel processing
The RDF shredding of waste to produce refuse-derived fuels (RDF) is a key component of modern recycling processes. Using specialized RDF shredders, RDF is created from non-recyclable industrial and commercial waste and is frequently utilized in cement production and power plants. The cement industry, with its high energy demand, increasingly relies on RDF. These fuels have a high calorific value and provide an environmentally friendly alternative to fossil fuels. They enhance thermal utilization and boost the efficiency of clinker production in calciners, pre-burners, and kilns.
Refuse-derived fuel (RDF) production with WEIMA waste shredder
Efficient shredding of post-consumer waste
A crucial step in the recycling process is the shredding of post-consumer waste. WEIMA’s shredders enable the efficient processing of packaging, disposable products and other post-consumer materials. This waste is shredded to make it usable for recycling or the production of refuse-derived fuel (RDF). Shredding reduces the size of the material, which facilitates further processing and minimizes the amount of waste sent to landfill. This promotes the circular economy and reduces the use of raw materials.
Post-consumer waste before the recycling process
No mountain of waste too big
With WEIMA, waste can be efficiently processed for energy recovery using robust shredding solutions. This allows waste to be used as a substitute fuel in energy-intensive industries, which reduces the consumption of fossil fuels and protects the environment.
WEIMA also offers technologies for pre- and post-shredding that enable materials to be optimally prepared for recycling and energy recovery processes. This leads to a more sustainable use of resources and more economical waste recycling.
Customer applications and examples
From the secondary fuel industry and waste disposal
Fire and flame for substitute fuel
The shredding of material streams forms the cornerstone of every recycling process. This is where industrial shredders come into play. With the PowerLine, PreCut and FineCut shredders, WEIMA demonstrates the potential of single and multi-stage waste processing.
From stand-alone shredders to complete waste processing plants
WEIMA offers shredders for every recycling task, adapted to individual requirements. In addition to stand-alone solutions, WEIMA also provides multi-stage system solutions in the form of complete systems. We are supported by an extensive supplier and service network that we have built up over the last few decades. This includes specialists in the fields of conveying technology, sorting, separation, screening technology, washing technology, metal detection, extrusion, heating and pelletizing. As a joint project team, we have implemented numerous successful projects worldwide and guarantee tailor-made solutions for every waste processing application.
Multi-stage waste shredding offers great advantages, especially for complex material flows. With the WEIMA M8 or the PreCut-seriesthe pre-shredding takes place, which prepares coarse materials to the appropriate size. The WEIMA PowerLine series ensures uniform shredding in the second stage before the WEIMA FineCut Shredder for secondary shredding. This process creates optimum conditions for the recycling or energy recovery of refuse-derived fuels (RDF). This ensures maximum efficiency and flexibility in waste processing.
WEIMA waste shredder | Pre-shredding, primary shredding & secondary shredding
M8 series
The WEIMA M8.28 shredder with twin-shaft technology is ideal as a pre-shredder. It shreds coarse material streams with high throughput and robustness. Subsequent steps are sorting, separation and secondary shredding.
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PreCut series
Particularly robust shredding machines are required for the pre-shredding of waste fractions that are often heavily contaminated. With the PreCut series, you get a shredder that shreds material to a grain size of up to 400 mm.
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PowerLine series
The universal shredders in the PowerLine series can handle any type of waste, including contaminated materials from the post-consumer sector. The 800 mm diameter rotor is available with a hydraulic drive from Hägglunds or a high-torque drive from Baumüller.
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FineCut series
The WEIMA FineCut series is perfect for secondary shredding in multi-stage production lines. They process pre-shredded material at high rotor speeds and produce grain sizes between 15 and 150 mm.
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Frequently asked questions (FAQ) on waste recycling and refuse-derived fuels (RDF)
What is refuse-derived fuel (RDF)?
Refuse-derived fuel (RDF) is a fuel that is obtained from household, industrial and municipal waste. It is often used in cement, lime and coal-fired power plants and is processed using methods such as pre-sorting, pre-shredding, air separation and metal separation.
What is mechanical-biological waste treatment (MBT)?
Mechanical-biological waste treatment (MBT) processes household waste (MSW) and commercial waste similar to household waste. Organic and inorganic fractions are separated, with the coarse fraction being used as fuel in power plants.
What is Municipal Solid Waste (MSW)?
Municipal Solid Waste (MSW) refers to household or municipal waste that is collected by private or municipal waste service providers. Organic components are composted, while the rest is used as fuel.
What is Solid Recovered Fuel (SRF)
Solid Recovered Fuel (SRF) is a high-quality fuel produced from waste. It must meet strict European quality requirements and is divided into different quality classes according to calorific value, chlorine and mercury content.
What is co-processing in cement production and how is it used?
The term co-processing describes a globally recognized technology that is used in energy-intensive industries (EII) such as cement production to recover energy and materials from waste and industrial by-products. The mineral substances in the waste replace primary raw materials (e.g. limestone) in the cement kiln, while the combustible materials provide the energy required for the production of clinker. No residues are produced and even highly toxic waste is destroyed. Co-processing thus makes it possible to avoid landfilling and waste incineration of waste such as sewage sludge, solvents, plastics from industry or mineral waste.
What is pre-processing?
Pre-processing prepares waste before it is used in cement kilns. This includes shredding, mixing and drying the waste to achieve a uniform particle size. WEIMA shredders achieve a homogeneous material quality that meets the technical requirements of cement production. This guarantees the efficient production of refuse derived fuels (RDF) and supports the reduction of fossil fuels.
What are the advantages of co-processing in the cement industry?
Co-processing in cement production has many advantages: The high temperatures and long dwell time in the kiln also completely destroy toxic residues. There are no residues that need to be recycled or even disposed of. The use of co-processing technology also avoids the use of fossil fuels and consequently reduces greenhouse gas emissions. In addition, cement manufacturers can massively reduce their energy costs thanks to secondary fuels from waste.
Do you want to tackle your waste challenge?
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Success stories
What our customers think
Away from the landfill: Greenpartners recycles 1.300 tons of waste per month into alternative fuel
Greenpartners Co, Ltd from Hwaseong, South Korea, specializes in the recycling of industrial waste. Instead of disposing of waste in landfill sites, it is converted into fuel – and thus into valuable energy resources. The company relies on a WEIMA PowerLine 2500 shredder with hydraulic drive.
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Safely Managing Hazardous Waste: Dekasan Utilizes WEIMA Shredder for RDF Production
In Bursa, Turkey, Dekasan Waste Management relies on a WEIMA PowerLine 2000 single-shaft shredder to process industrial waste, including materials containing hazardous and toxic substances.
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From Production Waste to Biomass Fuel
With plans to implement a waste handling facility, a luxury yacht manufacturer installed a biomass system to generate energy from their production waste. Consisting of mixed wood-based materials, including large sheets of skeletal waste from various CNC machining centres, they were looking to easily and effectively convert their waste into a uniform product, which could be easily transported and used within their biomass system.
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XXL Tilting Table for Insulation Boards Shredding at UNILIN
UNILIN Insulation relies on a WEIMA WLK 1500 shredder for shredding production scrap and waste from insulation board production.
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Power(Line) for SRF production
The Binn Group, Scotland’s leading independent provider of integrated recycling and resource management solutions, shreds industrial waste with a WEIMA PowerLine 2000 for further processing into secondary fuel.
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Polish CEMEX cement plant relies on WEIMA
Two WEIMA PowerLine 3000 single-shaft shredders with a powerful hydraulic drive used in secondary shredding absolutely take center stage here….
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Cement production in the land of the Pharaohs
LaFarge, worldwide-leading building materials producer with its head office in Paris has successfully installed…
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Shredding industrial waste in Brittany, France
Its main purpose is to produce valuable fuel for nationally and internationally operating cement manufacturers from domestic, household and industrial…
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For a Clean Environment
There is always rush hour on the AmeyCespa plant site – every single day. The activity is mainly caused by…
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Waste shredding protects resources in Indonesia
Recently, the company successfully inaugurated a modern recycling center in collaboration with its environmental technology partner Geocycle in Bogor near…
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