In this context, major European operators are undertaking strategic investments. This is the case of the German company PreZero, which has decided to build in Spain the country’s largest Solid Recovered Fuel (SRF) production facility. SRF represents a high-efficiency energy resource for heat and electricity generation. Its use fully aligns with strategies aimed at reducing the share of fossil fuels in the energy mix, as encouraged by public authorities.
Located in the heart of the Zona Franca de Barcelona, the new facility is considered one of the most advanced in the country for producing SRF from non-recyclable industrial waste. It marks a strategic milestone in the transition toward a circular economy. The site will soon be complemented by Barcelona’s first biomethane unit, named Bioenergy, enabling the direct injection of renewable gas into the natural gas grid. With a total investment exceeding €42 million and the creation of more than 85 direct jobs, the two projects aim to convert industrial waste into alternative energy and renewable gas.
A European showcase for energy recovery
The PreZero plant has been designed for continuous operation, 24 hours a day and 365 days a year. It features a processing capacity of approximately 30 tonnes of non-recyclable waste per hour, representing nearly 200,000 tonnes annually. This continuous production enables significant output volumes: up to 70,000 tonnes of SRF produced each year, along with the recovery of more than 40,000 tonnes of recyclable materials.
Produced from a blend compliant with European standards (plastics, textiles, paper), SRF is primarily intended for energy-intensive industries, particularly cement plants and thermal energy production facilities.
To deliver this project, PreZero entrusted plant integration to Bianna and optical sorting to Pellenc ST. At the core of the process are Pellenc ST machines. In total, six optical sorters ensure maximum recovery of recyclable materials and the preparation of an SRF stream compliant with cement industry requirements.
The equipment supplied by Pellenc ST belongs to the COMPACT+™ range, designed for constrained and dusty industrial environments. These machines stand out for their ease of integration, low energy consumption, and optimised maintenance costs, notably through reduced compressed air consumption and wear parts. All sorters are equipped with the new FLOW detection chain, combining a spectrometer covering an extended NIR/VIS spectrum with high-precision focused lighting. This configuration significantly improves the purity of recovered fractions.
Smart control and SRF traceability
All optical sorters have been configured to connect to the SMART&SHARE™ SaaS application. Operators therefore have access to dedicated indicators for monitoring SRF quality: lower heating value (LHV), chlorine content, PVC rate, moisture, and biogenic carbon content. Thanks to customized reports and smart alerts, operators can precisely control SRF stream quality and adapt it to the specific requirements of end users.
An exemplary collaboration
The teams from PreZero, Bianna, and Pellenc ST unanimously emphasize that the project’s success is based on a relationship of trust and close collaboration between operator, integrator, and technology provider. Each partner mobilized its expertise to achieve the expected performance levels within the required timeframe.
“The plant thus becomes an example of tripartite cooperation capable of addressing today’s environmental challenges” says Juan A. Gázquez Serrano, Director of Industrial Business North, PreZero Iberica.
With this installation, the Zona Franca de Barcelona strengthens its position as a benchmark hub for industrial innovation and sustainable energy transformation.
The SRF sector now appears as a forward-looking solution and a credible alternative to fossil fuels. By combining material recovery and energy recovery, the three partners contribute to reducing landfill dependency and greenhouse gas emissions, while strengthening the region’s energy independence.
