SRF Fuel Pellet Production Line Project in Turkey

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Project Background

The SRF Fuel Pellet Production Line in Turkey was initiated by a forward-looking industrial enterprise aiming to address both energy and waste management challenges in Turkey. The client, a medium-to-large-scale energy solutions company located in western Turkey, identified a growing market demand for high-calorific alternative fuels, particularly for industrial boilers, cement factories, and small power plants.

Turkey generates substantial volumes of non-recyclable but combustible industrial residues, including wood offcuts, shredded paper, plastic residues, and residual municipal solid waste. By transforming these materials into Solid Recovered Fuel (SRF) pellets, the project not only provides an environmentally responsible solution to industrial waste management but also contributes to Turkey’s energy diversification strategy, reducing reliance on imported coal and fossil fuels.

The decision to adopt a fully automated, large-scale production line with a designed capacity of 15 t/h was driven by:

• The need to handle 100,000 tons of feedstock per year efficiently.
• Compliance with national environmental standards.
• The desire to deliver uniform, high-quality SRF pellets suitable for industrial fuel applications.

This SRF fuel pellet production line in Turkey project aligns with Turkey’s waste-to-energy policy, offering economic, environmental, and social benefits while establishing a benchmark for similar initiatives in the region.

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Engineering Content and Scale

The SRF fuel pellet production line in Turkey project makes full use of an existing 6,055 m² industrial building that has been reinforced and upgraded for SRF production. The facility includes:

• Main Production Workshop (5,705 m², 12m height)
  • 1# Raw Material Warehouse (1,300 m²) – storage of mixed textile residues and wood offcuts.
  • 2# Raw Material Warehouse (990 m²) – primarily textile waste and auxiliary feedstocks.
  • Sorting Zone (500 m²) – manual and semi-automated sorting of unsuitable materials (plastics, leather, cardboard).
  • Main Processing Hall (1,800 m²) – housing crushing, screening, mixing, and pelletizing systems.
  • Finished Product Warehouse (400 m²) – for SRF pellets before dispatch.
• Supporting Facilities
  • Office building (300 m²)
  • Electrical supply system (connected to municipal grid, no backup generator)
  • Internal water supply (municipal water, 916 tons/year usage)
  • Internal drainage system with stormwater/industrial separation
  • No separate dormitories or canteen—employees commute from nearby towns.
• Environmental Facilities
  • Bag filter + alkaline scrubber system (capacity: 15,000 m³/h) for dust and odor removal.
  • Spraying system with plant-based odor neutralizer.
  • Solid waste storage rooms (general 216 m², hazardous 5 m²).
  • Noise reduction and vibration isolation equipment.

The layout ensures fully indoor storage and processing, eliminating any outdoor dumping. Both raw materials and finished SRF pellets are stored in controlled indoor environments with maximum pile heights (raw material ≤3m, pellets ≤4.5m).

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Raw Materials

The SRF fuel pellet production line in Turkey project utilizes a carefully selected mix of industrial and municipal residues, chosen for their combustible properties and availability in Turkey. Material pre-treatment and moisture management are critical for achieving optimal pellet quality.

Storage and Handling:
Raw materials are stored in covered, ventilated warehouses totaling 3,500 m², ensuring protection from moisture and contamination. Conveyors and automated feed systems maintain a continuous supply to the crushing and pelletizing units, supporting the line’s 15 t/h capacity.

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Main Equipment and Facilities

The SRF fuel pellet production line in Turkey is designed for fully automated operation, integrating high-efficiency equipment tailored to SRF pellet production. Key components include:

Energy and Water Consumption:

Environmental Control:
Approximately USD 65,000 of the total investment is allocated to dust collection, odor control, and waste management systems. Industrial dust is captured via bag filters and cyclones at crushing and pelletizing stages. Odor control units ensure minimal emissions, meeting Turkish environmental standards. Noise reduction measures include soundproof enclosures and vibration damping for major equipment.

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Production Process Flow

The SRF Fuel Pellet Production Line in Turkey follows a highly automated process flow, ensuring uniform pellet quality and minimal environmental impact.

Shredding

Large, heterogeneous industrial residues are first fed into the industrial shredders, reducing particle size to <50 mm. This stage addresses bulky waste handling and ensures smooth downstream processing. Noise generation is controlled through equipment enclosures.

Crushing

Shredded material is processed in multifunctional crushers to achieve a particle size of 3–8 mm, ideal for pelletization. Crushers are equipped with sealed inlets and outlets to minimize dust escape. Dust is captured by closed wind dust towers, and noise is mitigated with vibration-dampening mounts.

Pelletizing

Crushed material is transported via screw conveyors into pellet machine hoppers. Inside the SRF pellet machine, high pressure and friction between rollers and die generate heat (up to 120°C), softening fibers and sterilizing material. Uniform 6–10 mm SRF pellets are produced without external heat sources. Dust and noise are managed through integrated systems.

Cooling and Hardening

Pellets are transferred to steam cooling and hardening dust towers for 3–5 minutes, ensuring optimal hardness and temperature reduction. Residual dust and heat are extracted through strong suction ducts. Minimal emissions are reported.

Inspection and Packaging

Finished pellets are inspected for size, calorific value, and moisture content. Substandard pellets are recycled back into the line. Qualified pellets are automatically bagged and palletized, stored in 1,200 m² warehouse ready for dispatch.

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Labor and Operations

The facility operates two shifts per day, with 25 skilled operators managing automated equipment. Each shift runs 16 hours, totaling 4,800 operating hours per year, achieving the designed annual output of 100,000 tons. Staff are trained in:

• Equipment operation and preventive maintenance
• Safety protocols and emergency response
• Environmental compliance and quality control

Automation reduces manual handling and ensures consistent pellet quality.

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Market Prospects in Turkey

Turkey’s industrial sector and energy policy increasingly support waste-to-fuel solutions. The SRF pellet market is particularly promising due to:

• High demand from cement, ceramic, and power industries
• Government incentives for renewable and alternative fuels
• Substantial industrial waste availability in urban and industrial regions

With 100,000 tons of SRF pellets produced annually, this facility can supply multiple industrial clients, generating a stable revenue stream while reducing landfill disposal costs. Turkey’s ongoing energy diversification and waste management policies make SRF production an attractive long-term investment.

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Conclusion

The SRF Fuel Pellet Production Line in Turkey showcases the integration of industrial automation, advanced environmental controls, and sustainable waste management. The project not only converts non-recyclable industrial residues into high-quality SRF pellets but also contributes to Turkey’s energy independence and environmental sustainability.

• Key Advantages:
  • High-efficiency automated production
  • Compliance with Turkish environmental and safety standards
  • Large annual production capacity of 100,000 tons
  • Sustainable utilization of industrial waste

With RICHI Machinery’s turnkey solutions, this project exemplifies professional engineering design, high-quality equipment, and long-term operational support, establishing a benchmark for similar SRF fuel initiatives across Turkey and Europe.