Cement Manufacturers Association (CMA)

26 3. Project Outline: JSWCement Nagaur Integrated Facility The core philosophy for the Nagaur project was to establish a new global benchmark in low- carbon cement production. The selection of plant and machinery, specifically the KHD Humboldt Wedag pyro processing line, was driven by the goal of achieving minimum thermal and electrical energy consumption. The facility integrates a 6-stage preheater and a high-efficiency rotary kiln designed to exceed environmental standards for dust emissions (targeting <30 mg/Nm³) and NOx emissions through advanced Pyroclon Low NOx firing technology. A key feature of the project is the seamless integration of a Waste Heat Recovery System (WHRS). Unlike traditional retrofits, the WHRS was envisaged alongside the main pyro line to optimize thermal exchange. By combining energy-efficient kiln technology with maximum heat recovery potential, the plant significantly reduces its reliance on grid power, reinforcing JSW's commitment to "green" manufacturing. The project followed an accelerated execution schedule, transitioning from a greenfield site to an operational plant in record time.The plant was brought to life just 23.5 months after the start of civil works, demonstrating world-class project management in the Rajasthan desert terrain. 4. Project Technology & Scope Matrix JSW Cement collaborated with Humboldt Wedag India (a KHD subsidiary) as the primary technology partner for material handling & Pyroprocessing Line. The core of the JSW Cement Nagaur facility is built around a state- of-the-art KHD pyro processing line with a clinker production capacity of approximately 8,000 tons per day (TPD). This single-train installation is engineered for high efficiency, operational stability, and sustainability, making it a benchmark in modern cement manufacturing. Key technical components include: • Six-Stage Preheater with Pyro clone Technology: A highly efficient multi-stage preheater system designed to maximize heat exchange between kiln gases and raw meal, ensuring low specific heat consumption and stable operation under varying load conditions. • High-Capacity Rotary Kiln: A robust, energy-efficient rotary kiln engineered for consistent clinker quality, long refractory life, and reliable performance under high production demands. • Pyro clone Low NOx Calciner: An advanced calciner system designed to achieve low NOx emissions while supporting high levels of alternative fuel co-processing, enabling improved Thermal Substitution Rate (TSR) without compromising combustion efficiency. • Clinker Cooler: A high-efficiency clinker cooler designed for optimal heat recovery, ensuring maximum recuperation of thermal energy to the kiln system and supporting integration with the Waste Heat Recovery System (WHRS). • High-Efficiency Cyclones (HE Technology): Uses a double separator in the top cyclone stage to achieve a dust separation efficiency of 96%, reducing dust losses to below 25 g/m³. KHD's advanced cyclone design to achieve superior separation efficiency, reducing dust carryover, minimizing pressure drop, and enhancing overall system performance. • Advanced Firing System (Pyro jet® Burner): Equipped with high-momentum burners for precise flame control, efficient combustion of conventional and alternative fuels, and reduced primary air consumption, contributing to improved thermal efficiency. • Integrated Power Recovery (WHRS) Recovery: An 18 MW Waste Heat Recovery System captures heat from preheater exhaust gases and cooler vent air, converting it into clean power and significantly reducing the plant's dependence on external electricity sources. This advanced pyro processing configuration at JSW Nagaur reflects a strong focus on energy efficiency, environmental compliance, and operational excellence, positioning the plant as a leading example of next-generation cement manufacturing in India.