4T/H RDF Fuel Pellet Production Line in Colombia

Project Background: A Circular Economy Solution for Colombian Industry

Colombia's robust agricultural and light manufacturing sectors are the backbone of its economy in regions like Antioquia. However, this economic activity generates consistent and voluminous by-products. Historically, these materials—used coffee sacks, damaged wood pallets, and mixed packaging waste—were landfilled or openly burned, representing both an environmental liability and a lost economic opportunity. Simultaneously, Colombia's industrial sector, particularly cement production, faces energy costs that are volatile and often high.

Our client, a cooperative with a forward-thinking leadership team, recognized a strategic opportunity. By investing in an RDF fuel pellet production line in Colombia, they could simultaneously solve a waste problem, create a new revenue stream, and contribute to the national agenda for sustainable industry. The primary drivers were:

• Waste Management Cost Reduction: Converting a recurring disposal expense into a profitable product.
• Energy Independence & Cost Stability: Providing a locally sourced, predictable-cost alternative fuel to a strategic industrial partner.
• Environmental Leadership: Demonstrating a commitment to circular economy principles, reducing landfill use, and lowering the carbon footprint of local industry.

Initial discussions with RICHI Machinery began in February 2023, following the cooperative's feasibility study. A detailed project proposal was submitted and accepted in May 2023, with the equipment supply and technical supervision contract finalized in July 2023.

Project Overview and Core Specifications

This project was an expansion, adding a new production line within the cooperative's existing facility. The primary goal was to create a dedicated stream for processing specific, high-calorific-value industrial waste into RDF-5 pellets (densified), meeting the strict quality specifications of the offtaker cement kiln.

Raw Material: Sourcing from Colombia's Productive Heartland

The success of this RDF fuel pellet production line in Colombia is intrinsically linked to the quality and consistency of its feedstock. The cooperative's membership provides a reliable and homogenous supply chain, a critical advantage over facilities that rely on mixed municipal solid waste.

Sourcing and Pre-processing:

• A key innovation was the implementation of a "clean stream" protocol. Members are required to source-segregate the waste, delivering it free of contaminants like food residue, metals, and plastics other than the targeted types.
• This minimizes the need for complex sorting at the plant and ensures a higher quality, more consistent final product.
• The inherent calorific values of these materials (Jute/Sisal: ~17,500 kJ/kg, Wood: ~18,600 kJ/kg, Cardboard: ~16,700 kJ/kg) blend naturally to produce an RDF pellet well within the required 14,650 - 18,836 kJ/kg range.

Facility Integration and Process Flow

The project involved the construction of an 865 m² dedicated bay adjacent to the main facility. The layout was designed for a logical, unidirectional flow of material to maximize efficiency and minimize contamination.

The RICHI RDF Pellet Line: A Deep Dive into the Process

The selected technology for this RDF fuel pellet production line in Colombia is a mechanical densification process, renowned for its robustness and ability to handle tough, fibrous materials without the need for external binders.

1. Pre-Inspection & Unloading: Incoming bales of jute, wood, and cardboard are inspected for contamination before being unloaded in the receiving bay.
2. Primary Coarse Shredding: A RICHI high-torque, low-speed shear shredder performs the initial size reduction, tearing apart the bulky coffee sacks and wood pieces into a coarse flake. This is a critical first step to ensure consistent feeding of the secondary shredder.
3. Secondary Fine Shredding: The coarse material is then conveyed to a high-speed hammer mill. This stage pulverizes the material into a uniform "fluff" with a particle size generally under 30mm, creating the ideal feedstock for the densification process.
4. Densification & Pelletizing: This is the core of the operation. The shredded material is fed into the RICHI RDF extrusion machine. Here, it is subjected to extreme pressure and forced through a hardened steel die. The combination of pressure and the natural binders (lignin) present in the wood and paper components causes the material to heat up and fuse into solid, durable pellets of the specified size (10cm x 3.5cm x 3.5cm). The process is autogenous—it generates its own heat through friction—requiring no external fuel or binders.
5. Cooling & Packaging: The newly formed pellets are hot and soft. They are discharged into a dedicated cooling conveyor where ambient air is blown through them, solidifying and stabilizing the pellets. Once cooled, they are automatically weighed and packaged into durable 1-tonne bulk bags for easy handling and transport.

Environmental Management and Operational Stewardship

• Dust Control: The primary dust generation points (the shredders and transfer points) are fully enclosed and connected to a dedicated cyclone separator and bag-house filter system. The cleaned air is discharged through a 15-meter stack. A mobile fog cannon is also used in the receiving bay to suppress any fugitive dust during material handling.
• Noise Control: The production hall is a fully enclosed structure. Key equipment is mounted on vibration dampeners, and the operation is scheduled to align with the existing facility's daytime operating hours.
• Waste Management: The process is remarkably efficient, with the pelletized product being the primary output. Any minimal non-conforming material is fed back into the process. The plant operates on a near-zero waste basis.
• Water Usage: The production process is entirely dry, requiring no process water.

Product Quality and Market Application

The sole offtaker for the fuel is a major cement producer located within 100km of the plant. The RDF pellets are used to replace a portion of the coal in the kiln, reducing the cement plant's fossil fuel consumption, operating costs, and net CO2 emissions.

Economic Viability and Investment Breakdown

Investment Prospects in Colombia and Concluding Remarks

The successful commissioning of this RDF fuel pellet production line in Colombia highlights a significant and replicable opportunity within the country and across Latin America. Colombia's growing industrial and agricultural sectors ensure a steady supply of suitable waste materials, while its mining and heavy industry provide a ready market for alternative fuels. Government policies are increasingly favoring circular economy models, and carbon reduction initiatives are adding further momentum.

This project is a prime example of industrial symbiosis, turning a local waste challenge into a sustainable energy solution. It demonstrates that environmental responsibility and economic profitability can go hand-in-hand.

Why RICHI Machinery was the Technology Partner of Choice:

• The client selected RICHI Machinery for our proven expertise in designing robust, low-maintenance shredding and extrusion systems specifically for challenging, fibrous materials.
• We delivered a turnkey solution that was installed on schedule and reached its operational targets immediately.
• Our regional partner in Latin America provides ongoing technical support and spare parts, ensuring long-term operational reliability and peace of mind.

For agricultural cooperatives, waste management companies, and industrial developers across the region, this project serves as a blueprint. RICHI Machinery possesses the specific technology and project execution experience to transform your waste streams into a valuable, sustainable fuel.

Contact RICHI Machinery today to discuss how we can engineer a profitable RDF fuel pellet production line tailored to your local feedstock and market conditions.

RICHI Machinery – Engineering Value from Waste, Powering Sustainable Industry.