Thermo-Energetic and Environmental Assessment of Alternative Fuels in Cement Clinker Production: A Review

Cement clinker production is a thermal- and emissions-intensive process requiring high-temperature heat for drying, calcination, and sintering. This review provides a process-based assessment of refuse-derived fuel (RDF), solid recovered fuel (SRF), tire-derived fuel (TDF), and biomass as partial substitutes for coal and petcoke in modern dry-process cement kilns. The study synthesized the evidence from plant-scale trials, pilot and laboratory experiments, process modeling, computational fluid dynamics, emissions studies, life-cycle assessment (LCA), techno-economic analysis (TEA), and regional case studies to evaluate alternative fuels across fuel properties, kiln-zone suitability, process stability, clinker quality, emissions performance, and environmental outcomes. The review shows that stable co-processing generally requires fuels with net calorific values above 14 MJ kg−1 and moisture contents below 15%, although TDF can provide 26–33 MJ kg−1 and sustain high-energy kiln duty when sulfur, zinc, and steel residues are controlled. RDF, SRF, and biomass require pre-processing, homogenization, calibrated dosing, and continuous fuel-quality monitoring to limit incomplete burnout, deposit formation, volatile circulation, and clinker-quality variation. LCA studies show that 20% RDF thermal substitution can reduce global warming potential by about 3.3–4.2%, increasing to approximately 6.7% when avoided landfill methane credits are included. Modern abatement systems can maintain particulate matter at about 10–30 mg Nm−3 and PCDD/F below 0.1 ng TEQ Nm−3 under stable operation. The review concludes that alternative fuels are quality-dependent co-processing options whose mitigation role is complementary to clinker-factor reduction, energy-efficiency improvement, low-clinker binders, electrified heating, oxy-fuel calcination, and carbon capture.