Fuel Substitution in Cement Production: A Comparative Life Cycle Assessment of Refuse-Derived Fuel and Coal

Cement production in Africa remains carbon-intensive, primarily due to the use of coal-based thermal energy. This study conducts a comparative cradle-to-gate life cycle assessment (LCA) of cement production using 100% coal (Scenario A) against partial substitution with refuse-derived fuel (RDF) at a 20% thermal input rate (Scenario B), with case studies in South Africa and Ethiopia. The LCA, modeled in SimaPro 9.2.0.1 with Ecoinvent v3.7.1 and regional data, evaluates midpoint environmental impacts across the following five stages: raw materials, clinker production, electricity, fuel use, and transportation. The results show that Scenario B reduces the global warming potential (GWP) by 3.3–4.2% per kg of cement, with minimal increases in other impact categories. When avoided landfill methane is accounted for, GWP reduction improves to 6.7%. Fossil resource depletion drops by 10%, and toxicity and particulate emissions show marginal improvements. Economic analysis under South Africa’s 2025 carbon policy reveals a modest net cost increase of $2–3 per ton of cement and an abatement cost of $64–87 per ton of CO₂. The study provides new insights by harmonizing LCA models across national contexts, linking emissions reductions to economic instruments, and quantifying the co-benefits of RDF for waste management. The results support RDF co-processing as a scalable mitigation strategy for the African cement sector, recommending substitution rates of 15–30%, policy alignment, and enhancement of the RDF supply chain to maximize impact.