Higher TSR in Cement Plants: The Key to Profitability, Efficiency & Sustainability

Lessons Learned and Key Insights in Higher TSR in Cement Plants: The Key to Profitability, Efficiency & Sustainability

The cement industry is facing significant challenges—rising input costs, energy price volatility, subdued demand, and oversupply are squeezing margins. At the same time, decarbonization pressures are increasing. In this evolving landscape, Thermal Substitution Rate (TSR) optimization is emerging as a key driver of profitability, efficiency, and sustainability. Leading cement plants achieving TSR >50% are unlocking significant operational and financial benefits while reducing their carbon footprint.

The key lies in getting the parameters right.

1. Fuel Preprocessing Excellence

A well-optimized Alternative Fuel and Raw Material (AFR) preprocessing system is critical for achieving higher TSR levels.

Calorific Value (CV) Consistency

• Leading cement plants with TSR >50% ensure alternative fuel CV remains within ±500 kcal/kg of primary fuels, preventing combustion fluctuations.
• Large variations in fuel CV cause process instability, impacting clinker quality and increasing kiln shutdown frequency.

Particle Size Distribution (PSD) Optimization

• Refuse-Derived Fuel (RDF) and biomass fuels must be shredded to: <50mm for rotary kilns <20mm for calciner feeding
• Poor size distribution increases unburnt losses, reducing TSR potential and overall combustion efficiency.

Chlorine and Alkali Control

• High Cl content (>0.7%) from plastics or industrial sludge requires raw mix adjustments to prevent coating build-up and kiln downtime.
• Plants managing Cl input <0.7% avoid volatile cycle disruptions, ensuring smoother operations.

Waste Heat Contribution

• 5-7% of total Specific Heat Consumption (SHC) demand can be offset by optimized AFR pre-drying and torrefaction.
• Leveraging waste heat from preheaters for pre-drying enhances fuel quality and combustion efficiency.

2. Synchronized Process Parameters

To maximize TSR without compromising kiln stability, synchronized process control is essential.

Kiln Flame Temperature & Retention Time

• Alternative fuels impact combustion kinetics. Plants with TSR >50% operate at: Peak flame temperatures of 1800-2000°C Residence times of 4.5-5 seconds, ensuring complete burnout
• Maintaining these conditions prevents clinker quality issues and excessive CO emissions.

Primary Air Optimization

• AFR adoption should not exceed 12-15% primary air ratio to maintain stable combustion.
• Computational Fluid Dynamics (CFD) studies show that optimizing secondary air flow can improve combustion efficiency by up to 8%.

CO and NOx Emission Control

• NOx levels must be monitored using staged combustion techniques.
• High TSR plants have demonstrated 15-25% NOx reduction through optimized secondary air and burner configurations.

3. Advanced Technologies & R&D for High TSR Plants

Innovative technologies play a crucial role in maximizing TSR while maintaining process stability.

Multi-Channel Burners

• Modern multi-channel burners enable better mixing of AFR with primary fuels, improving combustion efficiency.
• Plants upgrading to multi-fuel burners have seen a 3-4% improvement in SHC reductions.

AI-Driven Process Control

• Advanced kiln AI models predict AFR CV variations within ±3% accuracy, allowing real-time fuel feed rate adjustments.
• Plants using AI-driven fuel mix control report a 2-3% reduction in specific fuel consumption (SFC).

Waste Heat Recovery (WHR) Synergies

• WHR + TSR >50% setups achieve thermal efficiency improvements of 6-8%, lowering total heat input while maintaining clinker quality.
• Heat integration strategies reduce reliance on fossil fuels, supporting decarbonization goals.

4. The Business Case: TSR and Profitability

With the right approach, higher TSR is a direct margin booster for cement plants.

Energy Cost Savings

• A 20% TSR increase can cut fuel costs by $2-4 per ton of clinker, depending on regional fuel pricing.

Carbon Credit Revenue

• With the EU ETS carbon price exceeding €85/t CO?, high TSR plants gain substantial financial advantages through carbon credit incentives.

Lower SHC & Operational Stability

• Plants achieving TSR >50% have reported SHC reductions of 3-5%, reducing fuel demand while enhancing process efficiency.
• Lower SHC also translates to reduced kiln refractory wear and extended equipment lifespan.

Conclusion: TSR is a Competitive Advantage, Not a Compromise

To stay competitive, cement manufacturers must shift their mindset—higher TSR is not just about compliance with sustainability goals, but a strategic lever for cost savings, profitability, and efficiency. By adopting optimized fuel preprocessing, synchronized process control, and advanced digital technologies, plants can maximize TSR, reduce emissions, and strengthen their bottom line.

Cement plants that embrace higher TSR today will lead the industry tomorrow.

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