Cement Manufacturers Association (CMA)

28 6. Technology Highlight 6.1 High-Efficiency (HE) Cyclone Design The JSW Nagaur pyro line incorporates KHD's latest-generation HE cyclones in a 6-stage preheater, featuring optimized inlet geometry and immersion tubes for high separation efficiency with low pressure drop. This reduces kiln fan power consumption, stabilizes draft and gas flow, and improves clinker quality. Enhanced top-stage collection minimizes dust carryover to the WHRS, improving thermal recovery and lowering operating costs. 6.2 PYRO-JET® Burner The KHD PYRO-JET® burner improves combustion efficiency with 3–5% lower primary air, reducing specific heat consumption (~4 kcal/kg clinker) and NOx emissions. It produces a short, stable flame for uniform heat distribution, enhancing clinker quality and reducing free lime. Multi-fuel capability supports higher TSR and lowers waste gas volume, reducing fan load and overall energy consumption. 6.3 Waste Heat Recovery System (WHRS) An 18 MW WHRS captures heat from preheater (~280°C) and cooler exhaust gases (400–450°C) to generate captive power via a steam cycle. Integrated with the pyro line, it reduces grid dependence, specific power consumption, thermal losses, and CO ₂ emissions, while conserving significant fossil fuel. This system supplied by HWI is under commissioning. 6.4 Alternative Fuels (AFR) Utilization The plant is designed for up to 30% TSR using a robust AFR system with NCV of ~2200–2500 kcal/kg, these fuels replace coal, lowering CO ₂ emissions, stabilizing fuel costs, and supporting circular economy objectives. This utilisation can be extended with installation of Pyrorotor in future and necessary provision already taken care by HWI in design. 6.5 Environmental Compliance The plant maintains PM emissions below 15 mg/Nm³ using bag filters and ESPs, supported by continuous emissions monitoring. It operates as a Zero Liquid Discharge facility using treated municipal water. Noise levels comply with 85 dB(A) and decarbonization targets include 30% TSR. 7. Conclusions Humboldt Wedag India (HW India), in collaboration with JSW Cement, has successfully commissioned the Nagaur Pyro Line, establishing a new benchmark for sustainable and advanced cement manufacturing in North India. Delivered as part of KHD Humboldt Wedag's global technology portfolio, the project reflects HW India's capability to execute large-scale clinkerisation lines with a strong focus on energy efficiency, operational reliability, and rapid performance stabilization. The plant integrates advanced engineering with circular economy principles and stringent quality standards. It has been designed to achieve industry-leading performance, consistently operating above its 8,000 TPD rated capacity while maintaining power and heat consumption well below design benchmarks. The facility is equipped with state-of-the-art KHD technologies, including a 6-stage preheater system with high-efficiency cyclones, a Low NOx calciner optimized for fuel flexibility and reduced emissions, and a robust material handling system ensuring stable and reliable operation. In addition, the installation of an 18 MW Waste Heat Recovery System significantly enhances overall energy efficiency and contributes to lowering the plant's carbon footprint. This successful commissioning further demonstrates HW India's expertise in delivering high-efficiency, environmentally responsible cement plants, supporting JSW Cement's vision of green manufacturing and reinforcing the joint commitment toward a Net Zero future.