Transforming Waste to Fuel: Arcler’s AFR System for UAE Cement
The cement industry in the UAE is undergoing a transformative shift toward decarbonisation. Following the UAE’s Industrial Decarbonisation Roadmap announced at COP28 in 2023, the government is now implementing a national strategy to reduce CO₂ emissions across heavy industries, including cement down to 2.9 Gt by 2050. This change is not optional. As of May 2025, under the Federal Law on the Reduction of Climate Change Effects, all industrial plants must report and reduce greenhouse gas (GHG) emissions, or face penalties of up to AED 2 million.
In this context, AFR (Alternative Fuels and Raw Materials) is emerging as a key solution. But successful implementation requires more than just switching fuels; it requires robust AFR pre‑processing infrastructure that ensures consistency, safety, and performance. That’s exactly where Arcler’s AFR plant solutions deliver unmatched value.
What Is AFR? Understanding Its Role in the Cement Industry
AFR, or Alternative Fuels and Raw Materials, refers to energy-rich waste materials that can be used in place of conventional fossil fuels like coal or natural gas in cement kilns. These feedstocks not only help reduce costs but also play a vital role in minimizing environmental impact especially as governments push for decarbonisation in energy-intensive industries.
Common AFR materials include:
- Refuse-Derived Fuel (RDF)
- Biomass
- Used tires
- Industrial sludge
- Plastics and packaging waste
In the UAE cement industry, AFR is becoming increasingly important. With rising CO₂ regulations and energy price volatility, using waste-derived fuels helps cement producers cut emissions, align with national climate policies, and improve sustainability credentials.
However, raw waste is rarely ready for use directly. To ensure safety, efficiency, and consistency in fuel performance, waste must go through an AFR pre-processing plant which brings us to why this infrastructure is critical in the UAE context.
Why UAE Cement Plants Need AFR Pre‑Processing Systems
Cement plants in the UAE including those operated by Arkan, UCC, and Fujairah Cement: are among the largest in the GCC, with kilns processing between 7,000 to 10,000 tons/day. These high throughput operations consume vast amounts of energy and are under pressure from multiple fronts:
- Overcapacity: Leading to thinner margins and aggressive market competition
- Fuel price volatility: Particularly with coal, natural gas, and oil
- Tougher climate regulations: The UAE’s 2024 law enforces strict emissions reporting, with penalties of up to AED 2 million
- Sustainability demands: Public and global scrutiny over the sector’s high carbon footprint
This is where AFR pre-processing becomes a necessity not just an add-on.
Arcler’s modular AFR plants are specifically engineered to serve the operational scale and waste challenges of UAE cement producers. These systems:
- Shred, sort, and homogenize diverse waste streams
- Remove contaminants like metals, glass, and stones
- Deliver consistent, kiln-ready fuel that supports higher Thermal Substitution Rates (TSR)
By adopting Arcler’s pre-processing technology, UAE cement plants can shift from reactive compliance to proactive cost savings, process stability, and climate leadership.
AFR Pre-Processing: Turning Waste into Energy in the UAE Cement Industry
In the UAE’s push toward industrial decarbonisation, AFR (Alternative Fuels and Raw Materials) is more than a trend; it’s a solution cement producers can’t afford to ignore. But using waste as fuel doesn’t start at the kiln. It begins with proper pre-processing.
An AFR pre-processing plant transforms waste materials like plastics, RDF (Refuse-Derived Fuel), tyre chips, industrial sludge, and biomass into clean, consistent fuel ready for cement kilns. The process improves energy yield and protects the production line, two things every cement operator in the Gulf prioritizes.
At Arcler, we specialize in advanced, turnkey AFR systems designed to handle the unique waste profiles and operational demands of the UAE and GCC regions.
Inside Arcler’s AFR Plant How It Works from Start to Fuel
Every step in Arcler’s AFR pre-processing plant is designed for precision, efficiency, and fuel quality. Here’s how we turn low-grade waste into high-performance fuel for co-processing:
Step-by-Step Process:
1. Primary Shredding
Large, mixed waste is broken down into smaller, manageable sizes—making it easier to sort and separate.
2. Metal Separation (OBMS)
Using an over-band magnetic separator, ferrous metals are removed to protect downstream equipment and improve fuel purity.
3. Disc Screening
Materials are screened based on size. Fines under 50–80mm go to the fuel stream. Oversized particles are redirected for further shredding.
4. Density Separation
Heavy, non-combustible items like stones, glass, and inerts are extracted, leaving behind lightweight, high-calorific material ideal for cement kilns.
5. Fine Shredding
The material is finely shredded to achieve a consistent particle size (up to 95% uniformity), optimized for kiln feeding.
6. Drying Unit
Moisture is reduced to increase the calorific value of the fuel, ensuring efficient combustion and fewer emissions during co-processing.
This integrated approach ensures that AFR alternative fuels meet strict performance and safety criteria while helping UAE cement producers increase their Thermal Substitution Rate (TSR).
Benefits of AFR Usage in UAE Cement Plants
With rising fuel costs, tightening environmental laws, and growing pressure to decarbonize, AFR adoption is no longer optional; it’s strategic. Here’s how Arcler’s AFR pre-processing plant delivers value to UAE and GCC cement producers:
Cost Reduction
By replacing coal or natural gas with pre-processed AFR, plants significantly reduce fuel expenses, especially important in a competitive, over-capacitated UAE market.
Emission Compliance
Clean, consistent AFR supports carbon reduction goals under the UAE’s Federal Climate Change Law of 2024, helping plants avoid fines of up to AED 2 million and benefit from potential carbon credits.
Operational Stability
Pre-processed AFR leads to smoother kiln operations, reduced stoppages, and longer refractory life, all resulting in higher productivity.
Thermal Substitution Rate (TSR) Improvement
A properly installed AFR system increases TSR, enabling more fossil fuel replacement without compromising performance.
Sustainability & ESG Alignment
Cement producers adopting AFR enhance their ESG score, align with COP28 commitments, and position themselves as sustainability leaders in the region.
Why Arcler Is the Right Partner for UAE Cement Producers
The Gulf’s cement sector needs more than equipment; it needs expertise. Arcler offers:
- Proven experience with AFR integration in cement, steel, and power industries
- Full turnkey execution from engineering to commissioning
- Custom-built systems for Gulf waste profiles and climate
- Fast implementation with modular design
- Post-installation optimization & long-term support
Whether you’re in Abu Dhabi, Fujairah, or Ras Al Khaimah, Arcler helps you transition from waste management challenges to fuel autonomy and compliance confidence.
Final Thoughts – AFR The Future of Cement in the UAE
The UAE is one of the most active regions globally in industrial decarbonisation. With mandatory emissions reporting, cost pressure, and government-backed climate targets in motion, the cement sector must act fast.
AFR usage in the UAE cement industry is gaining momentum but it’s only effective with the right pre-processing infrastructure. Arcler’s AFR solutions offer exactly what cement producers need: compliance, efficiency, and cost savings in one seamless system.
Ready to Transform Waste into Energy?
Contact Arcler today for a site-specific assessment, feasibility study, or a full proposal for your AFR pre-processing plant. Explore Arcler’s AFR Solutions
