Cemex Colombia

References

Energy-efficient RDF production for cement plant

The production of cement, concrete, and other building materials is energy intensive. CEMEX Colombia is committed to sustainability: With the UNTHA XR3000C, the company recycles commercial waste, old tires, mattresses, and bulky waste into high-quality substitute fuels – thereby reducing CO₂ emissions and production costs.

Mattresses Rubber & Tyres C&I Waste

The client

About the buyer

CEMEX Colombia – a subsidiary of the Mexican building materials group CEMEX with over 2,800 employees – has been producing cement, concrete, and other building materials for the construction industry for more than 25 years. To meet its energy needs, the company uses processed commercial and industrial waste, scrap tires, and other high-calorific materials as substitute fuels (RDF/SRF).

The problem

Initial situation

For the treatment of heterogeneous waste materials, a shredder was needed that could process a wide variety of materials and produce substitute fuels of different qualities – suitable for use in the main burner and calciner. CEMEX's goal was to make the energy supply for cement production more sustainable and reliable.

REQUIREMENTS

Single-stage shredding process
Processing of different, heterogeneous material streams
Production of different RDF qualities
Low energy consumption / OPEX below €5/t
High availability for smooth processes

The solution

Why opt for an UNTHA shredder?

After thoroughly evaluating various systems, CEMEX Colombia opted for UNTHA's XR3000C, which processes a wide range of materials flexibly and efficiently. The XR is a fully electric single-shaft shredder whose C-cutting mechanism produces a homogeneous output material with a grain size of 45–130 mm (depending on the perforated screen). Interchangeable screens enable the production of different RDF qualities, ensuring optimal energy yield in the main burner and calciner. Low-maintenance and user-friendly operation minimizes downtime and ensures reliable processes even in 24/7 operation. Approximately 2,000 tons of material are shredded every month.

Another success factor was the comprehensive support provided by UNTHA Ibérica, which personally assisted CEMEX throughout the project and provided support with service and spare parts supply.

The shredded material is used as an alternative fuel in our cement kilns, replacing coal as the main fuel and significantly reducing our carbon footprint. This measure prevents thousands of tons of waste from going to landfill, gives the materials a new purpose, and promotes more sustainable solutions in the construction sector.