Cement Manufacturers Association (CMA)

25 Commissioning of JSWCEMENT Nagpur Plant (RAJASTHAN, INDIA) A Next-generation Pyro Process Line Ashok Kumar Dembla, Prakash Patil, Deepti Varshney Humboldt Wedag India Private Limited, India 04 1. Abstract The commissioning of an 8,000 t/day clinker pyroprocessing line at JSW Cement's greenfield facility in Nagaur, Rajasthan, marks a significant achievement for Humboldt Wedag India. Successfully brought into operation during February–March 2026, the project was executed by Humboldt Wedag India along with the team of JSW. The plant incorporates KHD's latest-generation preheater and rotary kiln system, engineered to deliver high thermal efficiency, optimized fuel consumption, and consistent clinker quality. In addition, the facility is equipped with advanced material handling systems and modern process control technologies, ensuring reliable and efficient performance across a wide range of feed and fuel conditions. 2. Introduction Humboldt Wedag India (KHD India) is the Indian arm of KHD Humboldt Wedag, a globally established technology and service provider for the cement industry with a legacy spanning over 170 years. KHD delivers end-to-end solutions covering design, engineering, equipment supply, project execution, and lifecycle services for cement plants. With a strong local engineering base and execution expertise, HWIndia has developed proven capability in commissioning large-scale clinkerisation units, including high-capacity pyroprocessing lines upto 12,000 t/day. Its track record reflects reliable project delivery, rapid stabilization, and achievement of guaranteed performance parameters under diverse operating conditions. KHD's technological portfolio is centred on high- efficiency, low-emission cement production. Key features include multi-stage preheater systems with high-efficiency cyclones, calciner designs optimized for fuel flexibility (including alternative fuels), and energy-efficient rotary kiln systems. The company's proprietary solutions such as low pressure-drop cyclone design, advanced combustion systems, and optimized heat recovery contribute to reduced specific fuel consumption. In addition, KHD integrates state- of-the-art process control and digital optimization platforms to ensure stable operation, consistent clinker quality, and minimized emissions. These technologies collectively enable robust plant performance while supporting the industry's transition toward more sustainable and energy-efficient cement manufacturing. The latest is the recent commissioning of JSW clinkerisation unit along with the material handling system. The later section discusses the details of the JSW plant in Nagaur.