Applications
The ToronRDF™ line serves both fuel producers who sell into the alternative fuel market and industrial energy users who process waste on their own site.
- Cement Manufacturing: supplies high-calorific RDF and SRF to rotary kilns as a partial replacement for coal and petroleum coke in the main burner and precalciner
- Solid Fuel Fired Power Plants: produces sized fuel with consistent moisture and particle geometry for grate and fluidized bed combustion systems
- Dust Fired Power Plants: delivers finely shredded fuel suited to pulverized firing systems that require a narrow particle size window
- Gasification Plants: prepares a homogeneous, metal-free feedstock that supports stable syngas output and protects reactor internals
- Lime Production: substitutes processed waste fuel for conventional fuel in lime kilns to lower per-ton energy cost
- Iron and Steel Plants: feeds alternative fuel into high-temperature furnace processes where fossil fuel substitution reduces operating expense
- Municipal Waste Management: processes household and commercial collection waste at transfer stations and materials recovery facilities to divert tonnage from landfill
- Bulky Waste and Furniture Processing: breaks down mattresses, carpets, sofas, and mixed furniture that standard collection equipment cannot handle
- Industrial Solid Waste Handling: treats production offcuts, packaging waste, and mixed factory residues generated on manufacturing sites
- Paper Mill Reject Processing: recovers energy from pulper ropes, plastic rejects, and fiber residues that mills otherwise send to disposal
- Waste Tire Processing: reduces scrap tires and rubber waste into a high-energy fuel component after wire separation
- Biomass Residue Recovery: processes waste wood, pallets, railway sleepers, and agricultural residues into a burnable fraction
Theory and Method
Mechanical waste treatment separates a mixed stream by exploiting differences in physical properties: particle size, magnetic susceptibility, electrical conductivity, and aerodynamic behavior. No single machine isolates a fuel fraction from raw municipal waste, so the line applies each property in sequence. Coarse shredding comes first and reduces every item below 300 mm, which gives the downstream stages a predictable size range to act on. Fine shredding comes last and cuts the cleaned combustible fraction to the window a burner or kiln feed system accepts.
The trommel screen sorts by size. An inclined rotating drum lifts material along its wall and drops it as the drum turns, so particles repeatedly meet the perforated surface. Fine, dense fragments such as sand, grit, and broken glass pass through the apertures, while the lighter combustible fraction travels the length of the drum and discharges at the far end. Overband magnets and magnetic drums then capture ferrous items, since the applied field attracts steel strongly enough to lift it clear of the belt.
Air classification separates by terminal velocity rather than size. Each particle settles at a rate set by the balance between aerodynamic drag and its own weight, so a light plastic film and a dense stone of similar dimensions behave differently in a controlled airstream. The separator carries light combustibles upward toward the outlet while heavy inerts fall to the discharge conveyor. An optional eddy current separator then repels aluminum and other conductive metals off the belt using currents induced inside the particles themselves.
Key Features
The ToronRDF™ line combines heavy-duty size reduction with layered separation stages, and every module can be specified to suit the waste stream on site.
- Hydraulic Twin-Rotor Pre-Shredder: two slow-turning rotors deliver consistent high torque at any speed, opening baled goods, mattresses, and bulky waste down to a manageable size
- Automatic Stop on Unshreddable Material: the drive halts immediately when reinforced concrete, machine parts, or similar objects enter the chamber, protecting rotors and knives from damage
- Interchangeable Shredder Screens: swapping the bottom screen changes the output particle size, so a single machine serves several fuel specifications without mechanical modification
- Customizable Trommel Aperture: screen perforation is specified to the feedstock, letting operators tune how much sand, grit, and glass leaves the fuel fraction
- Overband or Drum Magnetic Separation: ferrous metals are pulled from the stream and chuted to a container for resale, keeping steel out of the fuel and away from downstream knives
- Optional Eddy Current Separator: recovers aluminum and other non-ferrous metals from the dry, evenly spread material stream for additional revenue
- Controlled Pressure Air Separator: combined positive and negative pressure lifts the light combustible fraction and drops heavy inerts, sharpening the split between fuel and residue
- Enclosed Scraper Conveyors: sealed chain conveyors contain dust and odor, occupy little floor space, and accept feed or discharge at multiple points along their run
- Three-Stream Output Separation: the process divides raw waste into combustible fuel, recyclable metals, and inert landfill residue in one pass
- Uniform Output Sizing: repeated size control across two shredding stages produces fuel with a narrow particle distribution that feeds evenly into burners
- Broad Material Adaptability: the line handles plastics, fiber, rubber, wood, textiles, and food waste within the same mixed stream
- Optional Biological Drying Stage: moisture reduction ahead of mechanical treatment raises calorific value and improves separation efficiency on wet municipal waste
- Configurable Layout: stage sequence and equipment selection are adjusted to waste composition, site footprint, and throughput target
- Low Maintenance Design: simple mechanical construction and accessible wear parts keep long-term running costs and downtime under control
Technical Specifications
System Overview
| Parameter | Specification |
|---|
| System Type | Mechanical waste treatment line for RDF and SRF production |
| Reference Throughput | Up to 40 t/h (installed reference configuration) |
| Processable Feedstock | Municipal solid waste, bulky waste and furniture, industrial solid waste, waste tires, paper mill waste, biomass |
| Output Streams | Combustible RDF/SRF fraction, ferrous metals, non-ferrous metals, inert landfill residue |
| Process Sequence | Feeding, pre-shredding, size screening, ferrous separation, air classification, non-ferrous separation (optional), fine shredding, enclosed transport |
| Final Fuel Particle Size | 30 to 100 mm, adjustable by screen change |
| Optional Pre-Treatment | Biological drying for moisture content reduction |
| Fuel Substitution Rate | Approximately 1.3 tons SRF replaces 1 ton of coal |
| Installation | Modular, configured to site footprint and throughput requirement |
| Target Industries | Cement, solid fuel fired power, dust fired power, gasification, lime, iron and steel |
Machine Line-Up
The line is built from seven core modules plus one optional separation stage. Each module is specified below with its function, working method, and technical parameters.
1. Feeding Conveyor
A front loader or grab charges the feeding conveyor, which meters material into the pre-shredder at a controlled rate. Steady feeding prevents surge loading and keeps the shredder operating within its torque band.
| Parameter | Specification |
|---|
| Function | Receives loader or grab charge and meters feed into the pre-shredder |
| Feed Method | Front loader or hydraulic grab |
| Discharge | Direct into pre-shredder hopper |
| Configuration | Belt or chain type, sized to line throughput |
2. Pre-Shredder
 | The pre-shredder handles the coarsest work in the line. Two slow-turning rotors, driven by a hydraulic unit, cut bulky and baled material into fragments the downstream stages can process. Hydraulic drive holds high torque across the full speed range and stops the rotors instantly when unshreddable material enters, which protects the cutting chamber from damage. |
| Parameter | Specification |
|---|
| Function | Primary size reduction and volume reduction of bulky mixed waste |
| Output Size | Below 300 mm |
| Rotor Configuration | Twin slow-speed rotors |
| Drive System | Hydraulic power unit |
| Torque Characteristic | Consistent high torque at any rotor speed |
| Protection | Immediate stop when unshreddable material is detected |
| Accepted Materials | Household waste, bulky waste, commercial and industrial waste, waste wood, mattresses, carpets, mixed construction waste, railway sleepers, baled goods, rolled goods |
| Duty Rating | Continuous industrial operation |
3. Trommel Screen
 | The trommel is an inclined rotating drum with a perforated sheet metal surface. Material entering the drum slides down and forward as the drum turns, meeting the screen surface repeatedly. Particles smaller than the aperture drop through into a bunker below, removing sand, grit, glass, and other non-combustibles. The remaining combustible fraction discharges from the far end of the drum and continues along the line. |
| Parameter | Specification |
|---|
| Function | Separation by particle size, removal of fine non-combustible material |
| Screen Type | Perforated sheet metal drum, inclined and rotating |
| Screen Aperture | Customizable to feedstock and fuel specification |
| Reference Aperture | Approximately 20 mm (installed reference configuration) |
| Fine Fraction Removed | Non-combustibles below the selected aperture, mainly sand, grit, and broken glass |
| Drum Length | 8,000 mm (reference configuration) |
| Drum Diameter | 2,200 mm (reference configuration) |
| Underflow Handling | Discharged to bunker, removed by front loader |
| Overflow Handling | Combustible fraction discharged at drum outlet to next stage |
4. Magnetic Separator
 | A magnetic field lifts ferrous items out of the passing material stream. Captured metal is guided through a chute into a container below and sold as recyclable scrap. Removing steel at this point also protects the knives in the fine shredder downstream. Two configurations are available depending on burden depth and layout. |
| Parameter | Specification |
|---|
| Function | Recovery of ferrous metals from the material stream |
| Available Types | Overband magnetic separator or magnetic drum separator |
| Separated Output | Ferrous scrap discharged by chute to collection container |
| Secondary Benefit | Protects downstream shredder knives from metal contact |
| Position | After trommel screening, ahead of air classification |
5. Air Separator
 | The air separator works on aerodynamic principles. Controlled positive pressure and negative pressure act together on the material stream, and each particle responds according to the balance between drag force and its own weight. Light combustible material rises with the upward airflow and travels through the outlet to the next stage. Heavy material resists the airflow and slides down onto the discharge conveyor for removal. |
| Parameter | Specification |
|---|
| Function | Density and aerodynamic separation of light combustibles from heavy inerts |
| Working Principle | Controlled positive pressure and negative pressure airflow |
| Light Fraction Path | Carried upward by airflow, transported through outlet to next stage |
| Heavy Fraction Path | Slides down to discharge conveyor for removal |
| Removed Material | Stones, ceramics, dense inert residue |
| Position | After ferrous separation, ahead of fine shredding |
6. Eddy Current Separator (Optional)
The eddy current separator recovers aluminum and other conductive metals that magnetic separation leaves behind. Material arriving from the air classifier is dry and evenly spread, which is the condition this technology performs best under. Placement within the line depends on waste composition and is set during system design.
| Parameter | Specification |
|---|
| Function | Recovery of aluminum and other non-ferrous conductive metals |
| Status | Optional stage |
| Feed Source | Discharge from air classification stage |
| Position | Customized to waste composition and layout |
| Performance Condition | Dry, evenly distributed material stream |
| Additional Capture | Residual ferrous particles missed upstream |
7. RDF Single-Shaft Shredder
 | The single-shaft shredder produces the finished fuel. Material passes through the cutting chamber and stays there until it is small enough to pass the bottom screen, which gives a controlled and repeatable particle size. Changing the screen changes the output size, so one machine can serve several fuel contracts. The shredder is hydraulically driven and stops automatically when reinforced concrete blocks or similar objects are detected. Shredded fuel discharges onto a chain conveyor. |
| Parameter | Specification |
|---|
| Function | Final size reduction of the cleaned combustible fraction into RDF or SRF |
| Rotor Configuration | Single shaft |
| Output Size | 30 to 100 mm |
| Size Adjustment | Bottom screen exchange |
| Drive System | Hydraulic |
| Protection | Automatic stop on detection of unshreddable material |
| Discharge Method | Chain conveyor |
| Processable Materials | Plastics, paper, textiles, fiber, rubber, wood, food waste |
| Customization | Cutting chamber and screen selection matched to processing requirement |
| Maintenance Profile | Accessible wear parts, low long-term maintenance cost |
8. Embedded Scraper Conveyor
 | The scraper conveyor moves material between stages inside a closed shell. A scraper chain runs through the housing, driven at one end and held under load by a tensioning device. The sealed construction contains dust and odor, and the compact profile suits sites where floor space is limited. Feed and discharge points can be placed at several positions along the run. |
| Parameter | Specification |
|---|
| Function | Enclosed transport of material between processing stages |
| Main Components | Closed shell housing, scraper chain, drive unit, tensioning device |
| Sealing | Fully enclosed, contains dust and odor during transport |
| Footprint | Compact cross-section, suited to constrained layouts |
| Feed Points | Multiple positions along the conveyor run |
| Discharge Points | Multiple positions along the conveyor run |
| Maintenance | Simple structure, accessible for installation and service |
Optional Biological Drying Stage
Wet municipal waste carries moisture that lowers calorific value and interferes with screening and air classification. A biological drying stage placed ahead of mechanical treatment reduces moisture content before the waste reaches the process line.
| Parameter | Specification |
|---|
| Function | Moisture content reduction ahead of mechanical treatment |
| Status | Optional stage |
| Benefit to Fuel | Raises net calorific value of the finished RDF or SRF |
| Benefit to Process | Improves screening and air separation efficiency |
| Secondary Use | Allows the organic fraction to contribute as an energy source |
| Position | Ahead of pre-treatment and mechanical separation |
