What is an Alternate Fuel Recovery Facility (AFR)?

An Alternate Fuel Recovery Facility (AFR) is a specialized waste processing plant. Its main purpose is to recover fuel-like materials from mixed waste—materials that can be burned to produce energy. These recovered materials are mostly plastics, textiles, rubber, and other dry, non-recyclable, high-calorie waste.

Instead of letting this waste end up in a landfill, an AFR facility processes it and turns it into RDF (Refuse Derived Fuel). This fuel is then used in high-energy industries like cement plants and power plants to replace fossil fuels like coal or oil.

Why are AFR Facilities So Important?

AFR facilities are a critical part of the modern waste management industry and the circular economy.

  • Reduces Landfill Waste: It diverts massive volumes of non-recyclable waste from landfills.
  • Lowers Pollution: Less waste in landfills means fewer harmful greenhouse gas emissions (like methane).
  • Saves Natural Resources: Using RDF reduces the need for virgin fossil fuels.
  • Improves Recycling: The AFR process also separates valuable recyclables (like metals) from the waste stream.
  • Supports the Circular Economy: Waste is transformed from a liability into a valuable resource.

Waste Sources for an AFRF

AFR facilities are designed to handle complex, mixed waste from various sources:

  • Municipal Solid Waste (MSW): Pre-sorted dry waste from household garbage.
  • Industrial & Commercial Waste: Offcuts and non-recyclable waste from factories, shops, and offices.
  • Non-Recyclable Plastics & Textiles: Items like dirty wrappers, foam, or end-of-life clothes.
  • Packaging Waste: Multi-layered materials, cartons, etc.

Essential Equipment in an AFRF

A modern AFRF relies on a series of robust machines working in sequence.

EquipmentPurpose
Feed HopperA large bin where waste is first dumped and fed into the system.
Bag OpenerOpens plastic bags to release the contents for sorting.
Primary ShredderA powerful machine that cuts large waste into smaller pieces (150–300 mm).
Ballistic SeparatorSeparates waste by shape and weight (e.g., 2D films vs. 3D bottles).
Disc Screen / Trommel ScreenSeparates waste by size. Smaller particles fall through.
Air Density SeparatorUses air to separate light items (plastic, foam) from heavy ones (stones, glass).
Magnetic SeparatorUses magnets to pull out ferrous metals (iron, steel).
Optical SorterUses sensors to identify and separate different types of plastic or paper.
Secondary ShredderMakes the combustible material even smaller (30–50 mm) for a uniform fuel.
Dust & Odor ControlUses fans, filters, and sprays to maintain clean air in the facility.

How an AFRF Works: The Step-by-Step Process

  1. Waste Reception: Trucks unload mixed waste into the feed hopper.
  2. Bag Opening & Pre-shredding: Bags are opened, and a primary shredder cuts the waste into smaller, more manageable pieces.
  3. Mechanical Separation: The waste passes through a series of machines (like disc screens, ballistic separators, and air separators) to divide it into streams:
    • Combustibles (plastics, paper, textiles)
    • Inert materials (sand, glass, stones)
    • Recyclables (metal, paper)
  4. Metal Recovery: Magnetic separators pull out iron and steel for recycling.
  5. Secondary Shredding: The remaining combustible material is put through a secondary shredder to create small, uniform pieces (now called RDF) that burn efficiently.
  6. Storage & Dispatch: The final RDF is stored in bunkers and transported to end-users.

Industry Applications: Where is the Fuel Used?

The RDF produced at an AFRF is a valuable commodity for high-energy industries.

IndustryHow RDF is UsedWhy They Use RDF
Cement PlantsBurned in kilns to heat limestoneSaves on coal costs and reduces CO₂
Power PlantsBurned to produce electricityTurns waste into a stable energy source
Steel PlantsUsed as a furnace pre-heaterCuts overall energy costs
Waste-to-Energy UnitsRDF is incinerated to create heatReduces landfill waste drastically

Benefits and Challenges of AFRF Operations

Key Benefits:

  • Reduces the need for landfills.
  • Turns waste into a valuable energy source.
  • Helps the environment by reducing emissions.
  • Creates “green” jobs for operators and maintenance staff.
  • Improves overall recycling rates.

Common Challenges:

  • High Setup Cost: Advanced machinery and automation are expensive.
  • Wet Waste: Moisture in the waste reduces the fuel quality (calorific value).
  • Segregation Difficulty: Highly mixed waste is hard to sort efficiently.
  • Market Dependency: Requires stable buyers (like cement plants) to be viable.

The Future of AFRF

Innovations are making AFRF technology even more efficient:

  • AI & Smart Sorting: Using machine learning and cameras for faster, more accurate separation.
  • Solar Drying Systems: Using solar heat to reduce moisture in the waste.
  • Data Monitoring: Using IoT sensors to track performance in real-time.
  • Carbon Credit Systems: Earning carbon credits by replacing fossil fuels with RDF.

Duromech: Engineering the Heart of Your AFRF

The success of an Alternate Fuel Recovery Facility (AFRF) depends entirely on the durability and efficiency of its equipment. This machinery must handle the toughest, most abrasive, and most complex waste streams 24/7 without breaking down.

At Duromech, we specialize in engineering the core components of waste-to-energy plants.

  • Our heavy-duty primary shredders are designed to tear through raw municipal and industrial waste.
  • Our screening solutions (Trommels and Disc Screens) are built to separate materials effectively at high volumes.
  • Our secondary shredders ensure a consistent, uniform, and high-quality final RDF product.

To build a waste-to-energy plant that is profitable and reliable, you need machinery built to last. Contact Duromech today to discuss the shredding and sorting solutions for your AFRF project.