Comprehensive Evaluation of Waste-Derived Fuels As Sustainable Alternatives in Cement Production

Abstract

The cement industry accounts for approximately 7–8% of global carbon dioxide (CO₂) emissions, primarily due to the energy-intensive clinker production process and reliance on fossil fuels. The environmental impact of this industry is particularly evident in the release of greenhouse gas (GHG) emissions. Therefore, the industry is exploring ways to reduce its energy costs and reliance on traditional fuels and mitigate environmental concerns by using waste-derived materials as a fuel substitute for cement production. In response to increasing environmental pressures, the substitution of fossil fuels with alternative fuels (AF) such as refuse-derived fuel (RDF), biomass, sewage sludge (SS), and used tires has emerged as a viable decarbonization strategy. This paper aims to provide a comprehensive analysis of AFs within the cement industry by reviewing previous studies, focusing on their GHG emissions and the technical, environmental, and economic implications of AFs adoption in cement kilns. A structured literature analysis was employed to evaluate fuel types, heating values, thermal substitution rates, combustion stability, and their effects on clinker quality. Data trends indicate that thermal substitution rates exceeding 80% are achievable with RDF and tire-derived fuels under optimized conditions, while biomass and SS require pretreatment for stable combustion. Environmental assessments report up to 30% reduction in CO₂ emissions and significant decreases in SOx and NOx with proper blending. The review also highlights key gaps in regional adoption and long-term performance evaluations. It concludes by recommending targeted policy support, plant-specific feasibility assessments, and integrated LCA-MCDM frameworks to scale the sustainable use of Afs.