Shredder boosts waste-derived fuel production by 700% at CENOSA plant

Honduras, 16.09.2019

UNTHA XR3000 at CONOSA plant

Landfill capacity in Honduras is in short supply, which was one of the key drivers for the build of a new USD 3.5m facility, owned by cement manufacturing firm CENOSA.

Capable of receiving and processing pre-sorted complex waste from the industrial sector and municipalities, the Cortés plant took 14 months to come to fruition and relied on a global collaboration between OHL Spain, Austrian-headquartered shredding specialist UNTHA, Samson from England and Firefly ab from Sweden.

With the potential to handle 24,000 tonnes of waste per year, it was crucial that the very best processing technology was procured for this complex job.

“We had a big vision for this facility and build it with overcapacity” said Ing. Jorge Alberto De Jesus Bueso, head of environmental management and alternative fuels at CENOSA. “Municipalities in Honduras no longer have the capacity to receive large volumes of industrial waste, especially special residues – high volume- and potentially hazardous materials from the textiles sector and other industries respectively”.

“Because we are already extremely experienced in CDR production, and we aim to be the most environmentally-conscious business in the world of cement, we therefore started making plans to increase our capacity and – hopefully – drive the country’s agenda in reduction of emission of greenhouse gases and protection of the natural resources forward.”

Following rigorous industry research, CENOSA chose to invest in the globally-acclaimed UNTHA XR3000C waste shredder – a solution that has been installed in hundreds of sites on almost every continent worldwide.

Impressed with the low energy consumption of the electric-driven machine, it soon became clear that the ongoing running cost of the shredder would quickly accelerate CENOSA’s payback period. Calculations to date show that while CENOSA’s operational shredding cost was previously $34 per tonne – inclusive of labour, vehicles and energy – the XR has now reduced this to $13.88 per tonne.

Currently configured to process 8 tonnes of waste per hour, the XR also presents a notable uplift in capacity from the 1 tonne per hour capabilities CENOSA previously had. And when typically running for 8 hours daily, the operational savings could therefore reach over $1200 per day.

“We are currently estimating that our entire project investment could have paid for itself in only 3.5 years,” continued Jorge. “But we’ve specifically selected hard-wearing, long-lasting technology that should support our mission much further into the future. The system has robust foreign object protection mechanisms in place, is easy to maintain and can process a variety of materials with ease.”

The shredding line can handle textile waste, clothing, contaminated rags, plastics, construction timber, cardboard, agrowaste, pallets, tyres, rubber conveyors and foam.

“This was an ambitious project, but we are extremely proud of bringing the facility online. We’re prolonging Honduras’ landfill capacity, while reducing the country’s reliance on fossil fuels and CO2 levels due to the biogenic carbon content of the waste,” added Jorge. “Now, we need more waste producers to come forward to help us make a real difference in the target of implementing a complete residues’ managing system.”