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Heidelberg partners with Untha to manufacture alternative fuel in India - Waste Today Magazine

Heidelberg Materials, Heidelberg, Germany, has developed a single-step alternative fuel production line in India with the help of Untha shredding technology.  

The system has been installed at the Yerraguntla cement plant in Andhra Pradesh, India, owned and operated by Zuari Cement, a Heidelberg Materials Group company. The Yerraguntla site has a cement manufacturing capacity of approximately 7.8 million tons per year. The plant can process 22 tons of 6 to 31 pounds per cubic foot density material per hour, producing a renewable fossil fuel substitute to fuel the cement plant. 

The facility contains a XR3000C shredder from Austria-based Untha that is designed for continuous operation in 122-degree temperatures. With infeed and discharge conveyors, including a magnetic belt for metal separation, Heidelberg says the plant can achieve an approximately 3-inch output in a single pass. The segregated metal content is separated and the residual on-specification fraction is used by Zuari Cement as refuse-derived fuel (RDF). 

“When we began the search for a shredder for this facility, we had stringent requirements,” says Robert Sweigart, alternative fuels expert at Heidelberg Materials. “We sought heavy duty technology that can withstand the pressures of shredding unsorted waste and achieve refined fuel in impressive quantities in only one step. 

“We found the Untha XR3000C to have a number of technical advantages over competitors. The machine operates at a lower speed without compromising on capacity, for example, which results in lower wear. This means more uptime and lower whole life running costs,” he adds. 

According to Heidelberg, the Untha XR3000C shredder has been engineered to handle a range of input materials, including those notoriously considered too difficult to process. Zuari Cement says it has used the machine to shred municipal solid waste (MSW), industrial plastics, textiles, tires, rubber, paper and biomass materials requiring further refinement for optimal coprocessing. 

“This shredder is easy to install, operate and maintain, meets our expectations in terms of performance and allows us to vastly improve our flexibility to co-process various kinds of alternative fuels available in the market,” says Manish Shah, head of the India Technical Center. “The goal is for our coprocessing facility to produce 8,000 to 10,000 tonnes [8,818.49 to 11,023.11 tons] of RDF per year.” 

Untha has commissioned alternative fuel production shredders in countries throughout Asia, with more than 13,000 shredders now in operation worldwide, the company says. 

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