Combustion of palm oil decanter cake (PODC) is a propitious alternative waste to energy means. However, the mono-combustion of PODC prompt severe ash slagging behavior which give rise to reduction in heat transfer and also shorten the lifespan of combustion reactors. In this study, alum sludge (AS) was introduced at different proportion of 30, 50 and 70 to revamp the slagging characteristics of PODC during combustion. The addition of AS improved ash fusion temperature of PODC during co-combustion as ash fusion temperature increased significantly under high AS dosage. Slagging and fouling indices showed that at 50 AS addition, slagging tendency of the co-combustion ashes can be ignored. The predictive model for PODC-AS combustion showed good correlation coefficient with 0.89. Overall, co-combustion of PODC and AS is an ideal ash related problem-solving route. The proposed PODC slagging preventive method by AS was based on: (1) limited amount of aluminum content in PODC-AS system resulted in development of refractory ash (2) reduction in proportion of basic oxide which act as ash bonding glue played important role in the regulation of slagging (3) reduction of cohesive bond by formation of spongy and porous structure which prevented ash slagging. © 2023 Elsevier Ltd