ThermalForge: Offline Industrial Decarbonisation Workbench
Decarbonisation ROI before capital is committed. Native Rust desktop engineering workbench with MACC curve simulation & kiln thermal stability.
Lead Systems & Computational Architect
2026 – Present • Open Source v1.0.0
Heavy Industry Decarbonisation & Thermal Systems
Decarbonising cement and steel involves multimillion-dollar capital commitments where unverified fuel switching risks kiln freezing, refractory degradation, or double-counted emissions reductions. ThermalForge answers critical engineering questions with zero cloud exposure. Built in Rust 2021 with immediate-mode egui, it features deterministic Marginal Abatement Cost Curve (MACC) generation with interaction cascading (efficiency -> waste heat recovery -> fuel switching -> carbon capture), 3-fuel combustion stoichiometry (coal, biomass, RDF), 24-hour thermal stability projection simulating fuel moisture variability, least-squares kiln telemetry calibration with RMSE evaluation, a multi-plant local SQLite scenario vault, and zero-dependency vector PDF and CSV report generation.
An offline desktop application for plant engineers, energy managers, and sustainability teams in cement and steel. Simulates marginal abatement cost curves (MACC), 3-fuel combustion stoichiometry, and 24-hour thermal stability with 0% cloud and 0% telemetry.
CHALLENGE & ARCHITECTURAL SOLUTION
Decarbonising cement and steel involves multimillion-dollar CapEx decisions. Traditional spreadsheets are fragmented, error-prone, double-count energy savings, and fail to predict if substituting coal with biomass or municipal waste will drop burning zone temperatures below sintering thresholds (1400°C+). Furthermore, corporate IP and plant confidentiality prevent engineers from uploading operational data to cloud SaaS platforms.
Engineered ThermalForge as a self-contained, air-gapped native desktop workbench in Rust 2021 and immediate-mode egui. It combines deterministic thermodynamic mass and energy balances with least-squares calibration and sequenced MACC economics in sub-30ms execution loops with zero telemetry.
ARCHITECTURAL BLUEPRINTS
Deterministic Stoichiometric & Combustion Balance
Solves exact ultimate analysis balances (C, H, O, S, ash, moisture) to compute stoichiometric air requirements, flue gas volumes, theoretical flame temperatures, and burning-zone coupling in constant time.
Sequenced MACC Interaction Modeling
Applies decarbonisation strategies in thermodynamic order (efficiency -> waste heat recovery -> fuel switching -> carbon capture), ensuring later technologies only claim remaining emissions and power demands.
24-Hour Moisture Stochastic Stability Projection
Simulates fuel moisture swings over a 24-hour operational window, evaluating burning-zone thermal inertia against clinker sintering limits to flag marginal or unstable combustion regimes.
Zero-Dependency PDF & Calamine Excel Ingestion
Emits publication-ready vector PDF reports and tabular CSVs using custom pure-Rust writers without external dependencies, while calamine provides round-trip ingestion of .xlsx, .xls, .ods, and .csv files.
THE SIX DECARBONISATION MODULES
Deterministic thermodynamic calculations, marginal abatement cost curves, and 24-hr stability simulations. Zero Electron, zero web views, zero accounts, and zero telemetry.
Marginal Abatement Cost Curve
Sorts eco-strategies by net cost per tonne of CO2 avoided. Applies interactive adoption sliders, capital recovery factors (CRF), and sensitivity tornado bars against the plant carbon price.
Three-Fuel Blending & Stoichiometry
Combines coal, biomass, and refuse-derived fuel (RDF/MSW) using lab ultimate analysis (LHV, C, H, O, S, ash, moisture) to compute stoichiometric air, flue gas mass, and theoretical flame temperature.
24-Hour Thermal Stability Projection
Simulates stochastic fuel moisture variations over 24 hours to test thermal inertia. Automatically classifies kiln operation as Stable, Marginal, or Unstable against the clinker sintering baseline.
Kiln Baseline Telemetry Calibration
Least-squares regression fitting the burning-zone baseline and flame-to-kiln coupling factor to physical plant thermocouple measurements, with RMSE fit diagnostics and plausibility guards.
Multi-Plant Scenarios & Delta Diff
Persists plants and named operational plans in a bundled SQLite database. Features side-by-side scenario diffing with instant parameter divergence readouts and immutable change tracking.
Vector PDF & Excel Data Ingestion
Pure-Rust vector PDF and CSV report generator with zero external rendering dependencies. Ingests plant lab sheets (.xlsx, .xls, .ods, .csv) with round-trip schema template verification via calamine.
| Quantity | Mathematical Formulation | Physical Engineering Objective |
|---|---|---|
| Abatement Cost | (CapEx × CRF + ΔOpEx) / CO₂ avoided | Annualized capital recovery factor CRF = r / (1 - (1 + r)^-n) per net tonne avoided. |
| Stoichiometric Air | (2.664 C + 7.937 H + 0.998 S - O) / 0.232 | kg air per kg fuel for complete combustion based on ultimate elemental analysis. |
| Flue Gas Mass | 1 + air × (1 + excess air) - ash | Total wet exhaust gas mass determining ID fan capacity and velocity constraints. |
| Flame Temperature | T_air + LHV / (flue gas × cp) | Adiabatic theoretical flame temperature driving radiant heat transfer to clinker. |
| Burning Zone Temp | T_base + coupling × (T_flame,blend - T_flame,coal) | Calibrated clinker sintering zone temperature evaluated against 1400°C threshold. |
| Moisture Correction | LHV' = (LHV + 2.442 M)(1 - M') / (1 - M) - 2.442 M' | Corrects effective heating value dynamically as fuel moisture fluctuates in real time. |
| Thermal Substitution | 1 - (x_coal × LHV_coal) / LHV_blend | Exact fraction of fossil heat successfully replaced by alternative biomass or RDF. |
Kiln Insulation
Reduces shell radiation losses, lowering total fuel energy requirement before alternative blend sizing.
VFDs & Motors
Upgrades raw mill, fan, and separator drives, shrinking plant base electricity consumption.
WHR Power
Converts preheater and clinker cooler exhaust into electricity, strictly capped at residual grid demand.
Biomass / RDF
Substitutes fossil coal with alternative fuels, credited only against the reduced post-insulation thermal demand.
Carbon Capture
Sized only for remaining residual stack CO₂, eliminating over-sizing and CapEx waste.
# Clone and run the optimized ThermalForge desktop workbench
$ git clone https://github.com/TIRK3Y/ThermalForge.git
$ cd ThermalForge && cargo run --release
# Run full deterministic test suite & strict clippy lint check
$ cargo test && cargo clippy --all-targets -- -D warnings
CORE SYSTEM CAPABILITIES
Deterministic Marginal Abatement Cost Curve (MACC) engine with capital recovery factor (CRF) and cashflow modeling
Strategy interaction pipeline applying measures in fixed sequence to eliminate double-counting of savings
Three-fuel combustion mass & energy balance: coal, biomass, and refuse-derived fuel (RDF/MSW) with ash/moisture correction
24-hour thermal stability projection classifying combustion regimens as Stable, Marginal, or Unstable against sintering limits
Kiln calibration engine performing least-squares regression between plant telemetry and model predictions with RMSE readouts
Local SQLite scenario vault storing multi-plant metrics, named plans, and side-by-side delta comparisons
Air-gapped security model: 100% offline, 0% telemetry, zero network requests, keeping proprietary plant data strictly confidential
Built-in zero-dependency vector PDF & CSV report export and multi-format Excel (.xlsx, .xls, .ods, .csv) ingestion via calamine
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