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RDF Fired Boiler – Refuse Derived Fuel Steam Boiler

RDF Fired Boiler – Refuse Derived Fuel Steam Boiler

18,000,000.00

COMBIPOWER-RSG

  • Reliable and most efficient world-class design
  • Dynamically air-cooled reciprocating step grate furnace technology
  • Optimum combustion and maximum heat transfer by radiation
  • Lower radiation loss—limited quantity of refractory lining
  • Adequate heating surface
  • Highest possible heat extraction
  • Quiet combustion
  • Independent regulation of fuel and combustion air
  • Steady combustion and high tolerance of fuel size in given band
  • Solid construction and easy maintenance
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RDF Fired Boiler (Refuse-Derived Fuel)

Advanced Waste-to-Energy | High-Efficiency Steam for the Circular Economy

At IndianBoilers.com, we bridge the gap between waste management and industrial power. Our RDF Fired Boilers are precision-engineered to utilize Refuse-Derived Fuel—a high-energy fuel produced by shredding and dehydrating solid waste (MSW) and removing non-combustibles like glass and metal.

While standard biomass boilers struggle with the heterogeneous nature of municipal waste, our RDF units are built with robust combustion technology designed specifically to handle varying calorific values, ensuring consistent steam pressure for your most demanding industrial processes.

Key Features & Performance

  • Engineered for Consistency: RDF is a “standardized” waste fuel. Our boilers capitalize on its uniform particle size to deliver higher thermal efficiency compared to raw waste incinerators.
  • Specialized Grate Systems: Available with Reciprocating or Traveling Grate technology, designed to handle the unique ash fusion temperatures of RDF and prevent grate-clogging.
  • Corrosion-Resistant Design: RDF can contain traces of chlorine and sulfur. We utilize Inconel cladding or high-grade alloy coatings in the superheater and furnace sections to protect against high-temperature corrosion.
  • High Thermal Efficiency: Achieves 82% to 85% efficiency through advanced air-staged combustion and integrated heat recovery systems (Economizers & Air Pre-heaters).
  • Advanced Emission Control: Equipped with a multi-stage flue gas cleaning system, including Bag Filters, Wet Scrubbers, and Selective Catalytic Reduction (SCR) to meet stringent CPCB/PCB norms.
  • Automated Fuel Management: Features heavy-duty, PLC-controlled feeding systems that manage the low bulk density of RDF pellets or fluff for steady-state operation.

Core Industry Applications

The RDF Fired Boiler is a powerhouse for:

  • Cement Plants: Ideal for co-processing or providing captive power using municipal waste fuel.
  • Large Paper & Pulp Mills: Managing massive steam loads while reducing dependency on expensive coal.
  • Municipal Waste-to-Energy Plants: The core component for converting city waste into grid-ready electricity.
  • Chemical & Textile Clusters: Providing low-cost thermal energy for high-consumption industrial zones.

Advantages

  1. Future-Proof Technology: As landfill costs rise and carbon taxes emerge, our RDF boilers offer a hedge against future environmental regulations.
  2. Turnkey Solutions: From fuel shredding and sorting advice to final steam generation, we provide complete engineering support.
  3. High Plant Availability: Designed for 8000+ operational hours per year with specialized online cleaning systems (soot blowers) to handle high ash loads.

Operating Range

  • Capacity – 5 THP to 20 THP
  • Fuel- wood pellets, Agri-pellets, biomass fuel, wood chips, Biomass agro fuels, coal etc.
  • Pressure- 10.54 Kg/cm² to 21 Kg/cm²

Technical Specifications

Specification Unit CPD-RSG-40 CPD-RSG-60 CPD-RSG-80 CPD-RSG-100 CPD-RSG-120 CPD-RSG-150 CPD-RSG-200
General
Steam Output From & at 100°C Kg/hr 4000 6000 8000 10000 12000 15000 20000
Working Pressure Kg/CM² 10.54 10.54 10.54 10.54 10.54 10.54 10.54
Steam Temperature °C 183 183 183 183 183 183 183
No’s Passes No’s Four Four Four Four Four Four Four
No’s of Furnace No’s 1 1 1 1 1 1 1
No’s of Furnace Zone No’s 4 4 4 4 4 4 4
Steam Outlet MM 100 125 150 200 200 200 250
HTA M² 160 240 320 400 480 600 800
Type of Crushed Fuel
Fuel
Crushed Briquette, Boimass Pellet, Rice husk, Plam kernel shell
Boilers Efficinecey with APH
On Crushed Briquette % 78 +/-2 78 +/-2 78 +/-2 78 +/-2 78 +/-2 78 +/-2 78 +/-2
On Pellet % 78 +/-2 78 +/-2 78 +/-2 78 +/-2 78 +/-2 78 +/-2 78 +/-2
On Rice Husk % 78 +/-2 78 +/-2 78 +/-2 78 +/-2 78 +/-2 78 +/-2 78 +/-2
On Plam kernel shell % 75 +/-2 75 +/-2 75 +/-2 75 +/-2 75 +/-2 75 +/-2 75 +/-2
Fuel Consumption
Briquette (4000) Kg/hr 692 1038 1385 1731 2077 2596 3462
Pellet (4500) Kg/hr 615 923 1231 1538 1846 2308 3077
Rice Husk (3000) Kg/hr 923 1385 1846 2308 2769 3462 4615
Plam kernel (4000) Kg/hr 720 1080 1440 1800 2160 2700 3600
Electrical Load
Feed Water Pump H.P. 6.00 7.50 7.50 10.00 15.00 15.00 20.00
I.D. fan without BF H.P. 20.00 30.00 40.00 50.00 60.00 75.00 100.00
P.A. Fan H.P. 10.00 15.00 20.00 25.00 30.00 40.00 50.00
S.A. Fan H.P. 10.00 15.00 20.00 25.00 30.00 40.00 50.00
Furnace Movement H.P. 4.00 6.00 6.00 8.00 8.00 12.00 20.00
Wet ash Remover H.P. 2.00 2.00 2.00 3.00 3.00 5.00 5.00
Fuel Feeder systems H.P. 3.00 5.00 7.50 10.00 10.00 15.00 15.00
Total Electric Load H.P. 55.00 80.50 103.00 131.00 156.00 202.00 260.00
NOTE: In view of constant endeavors to improve our products, we reserve the right to alter or change above specifications without prior notice.

Frequently Asked Questions

RDF has a higher and more consistent calorific value than raw MSW because non-combustibles (glass, metal, stones) and wet organics are removed. This allows for higher efficiency and smaller furnace designs.

Depending on the processing level, the GCV of RDF ranges from 2500 to 3800 Kcal/kg, making it a powerful alternative to low-grade coal and biomass.

Yes. All our RDF boilers are manufactured under Indian Boiler Regulations (IBR), ensuring they meet the safety standards required for high-pressure industrial steam and power generation.

Our boilers can be configured to fire RDF Fluff (loose shreds) or RDF Pellets/Briquettes. Fluff is often used in larger traveling grate boilers, while pellets are ideal for smaller industrial units.

We typically recommend a Traveling Grate or Reciprocating Grate. These systems provide the constant agitation needed to prevent the plastic content in RDF from melting and sealing off the airflow.

Plastics create high-intensity heat. We design the furnace with water-cooled walls and specialized refractory to manage the rapid thermal release and protect the boiler structure.

Yes. Many plants co-fire RDF with Coal or Biomass. Our control systems can manage "Mixed Fuel" ratios to maintain steady steam pressure regardless of the fuel blend.

RDF ash can be sticky due to low melting point silicates. We use larger tube pitches and integrated Soot Blowers to ensure that ash deposits are regularly removed from the heat transfer surfaces.

To ensure complete destruction of complex organic molecules and odors, we design our furnaces to maintain a temperature of 850°C to 1000°C for at least 2 seconds.

Burning RDF releases Chlorine (HCl), which is highly corrosive. We use Inconel cladding on critical superheater tubes and maintain the tube skin temperature within a "safe zone" to prevent acid attack.

RDF fluff can be "stringy." We use Non-clogging Drag Chain Conveyors and rotary air-lock feeders to ensure a consistent, jam-free flow of fuel into the furnace.

RDF typically produces 10% to 15% ash. We provide automated Dry or Wet Ash Handling Systems to manage this volume efficiently.

No. By using VFD-controlled ID/FD fans and secondary air nozzles, we ensure a perfect air-to-fuel ratio for clean, complete combustion.

Due to the chemical nature of the fuel, we recommend quarterly internal inspections and an annual shutdown for detailed checking of the refractory and superheater sections.

Beyond high-temperature combustion, we provide Activated Carbon Injection and Lime Scrubbers to neutralize acid gases and capture heavy metals and toxins.

Industries often receive RDF at a lower cost than coal (sometimes even receiving a "tipping fee" to take it). Most plants recover their capital investment in 18 to 24 months through fuel savings.

Absolutely. Using RDF contributes to the Circular Economy and significantly reduces the carbon footprint by diverting waste from landfills, which is a major win for corporate sustainability goals.

A typical setup includes a Multi-cyclone Collector, a Dry/Semi-Dry Scrubber, and a High-Efficiency Bag Filter to meet the most stringent environmental norms.

Based in Ahmedabad, we have extensive experience in handling difficult, high-volatile fuels. We offer a rugged, IBR-certified design that is specifically optimized for the unique chemical profile of Indian RDF.

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