Exploring Refuse-Derived Fuel Production from Seafood-Processing Sludge and Landfill-Mined Plastic Waste Co-Pelletization

This study explores the co-pelletization of sludge with landfill-mined plastic waste as a method to create high-energy refuse-derived fuel (RDF), addressing both plastic and sludge waste streams. Key variables used in RDF pelletization included sludge-to-plastic mixing ratios (50:50, 75:25, and 100:0 wt%), mold temperatures (100 °C and 120 °C), and compression pressures (60–80 MPa). Results showed that the characteristics of pellets improved considerably as the mass percentage of plastic waste increased. The 75% sludge mixture produced pellets with high compressive strength (15.9–16.4 MPa), indicating rigid and ductile properties, and achieved a calorific value of up to 33.4 MJ/kg. Mercury levels of the RDF (0.02–0.04 mg/MJ) met solid recovered fuel standards. However, the elevated chlorine content (>3 wt%db) highlighted the necessity of removing PVC from the plastic waste before pelletization. Carbon emission factors for the pellets (23–25 kg CO2/GJ) were comparable to commercial RDFs and notably lower than coal, demonstrating their potential as a sustainable alternative fuel source. An assessment of the entire production and utilization chain, including sludge drying, plastic sorting, pelletization, and combustion, revealed that co-pelletization reduces greenhouse gas emissions by more than 24.3% compared to current practices.