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

The growing interest in sustainable industrial solutions has motivated the development of refuse-derived fuel (RDF) as an alternative to traditional fossil fuels, which are nonrenewable. This study aimed to assess the technical and environmental feasibility of using RDF as a substitute for coal in the production of rexine. The sample RDFs were subjected to proximate and ultimate analyses to determine their fuel properties. 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 the CPCB guidelines. The investigation confirmed that particulate matter (40.4 mg.Nm- ³), NOX (260.2 mg.Nm- ³), SO₂ (110.8 mg.Nm-³), and CO (80 mg.Nm- ³) emissions were within acceptable limits. 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 rexin industry, aligning with the goals of a circular economy and sustainable energy transition.