Energy Recovery in the Rexine Industry: Comparative Insights into RDF and Coal-Based Combustion Systems

Abstract

The growing interest in sustainable industrial solutions has motivated the development of Refuse-Derived Fuel (RDF) as an alternative to traditional fossil fuels. This paper aims to assess the technical and environmental feasibility of RDF as a substitute for coal in the rexine production process. Sample RDFs were subjected to proximate and ultimate analyses to determine their fuel properties. The proximate analysis indicated 34.24% moisture, 19.15% ash, and 24.61% volatile matter. The ultimate analysis revealed 30.47% carbon, 4.28% hydrogen, and a low sulfur content of 0.65%, suggesting a high combustion value with reduced pollutant emissions. Industrial trials were conducted in a 350 TPD boiler unit, and emissions were measured using continuous gas analyzers and gravimetric methods, following CPCB guidelines. The investigation confirmed that particulate matter (40.4 mg/Nm³), NO₂ (260.2 mg/Nm³), SO₂ (110.8 mg/Nm³), and CO (80 mg/Nm³) emissions remained within acceptable limits. Notably, CO₂ emissions from RDF combustion were almost 50% lower than those from coal. Cost-benefit analysis further demonstrated potential fuel cost savings of 40–60% when using RDF instead of coal. In conclusion, the results establish RDF as a clean, economical, and regulation-compliant energy feedstock for the rexine industry, aligning with the goals of a circular economy and sustainable energy transition.

Major Findings: Refuse-Derived Fuel (RDF) offers a sustainable alternative to coal in energy-intensive industries like rexine production. It reduces environmental pollution, supports circular economy goals, and enhances energy security. Despite technical and policy barriers, RDF demonstrates economic viability, lower emissions, and aligns with India's waste management and climate commitments.