Sharjah Cement Factory, UAE
Alternative-fuel upgrade
Mechanical, civil and structural design to enable AF firing in the calciner, with a calciner extension to support AF capacity.
0 to 18 TPH SMW firing
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Cement plant engineering, from process to installed equipment
A single-window partner for pyro-process upgrades, alternative-fuel projects, critical spares and turnkey supply. Engineered in the UAE and India, delivered worldwide.
- Cement-industry specialistsGenuine pyro-process depth: calciner, kiln, cooler, burner, refractory
- Single-window deliveryEngineering, manufacturing, supply and site erection under one accountable team
- UAE + India hubsCost-competitive Indian manufacturing with worldwide supply reach
- 10+ yearsOf cement process and project-execution experience
A cement specialist that engineers from process fundamentals
ETR Engineering is a cement-industry engineering specialist with operating hubs in Sharjah (UAE) and India, formed to give plant owners and EPC contractors a faster, more responsive route to engineering, manufacturing and critical-spares supply. Our team carries more than a decade of hands-on experience in cement process, pyro-engineering and project execution, backed by an established network of qualified manufacturing partners across India.
We work across the whole pyro-process line (preheater, calciner, rotary kiln, clinker cooler and burner) and extend into alternative-fuel systems, refractory engineering, material handling, structural steel and critical spares. Because engineering, supply and erection sit under one roof, responsibility never falls between contracts: you get shorter lead times, competitive landed cost and a single point of accountability.
Why partner with ETR
| Strength | What it means for you |
|---|---|
| True process engineering | Genuine pyro-process expertise (calciner, NOx, burners, refractory), not just fabrication to print. |
| One accountable partner | Engineering, manufacturing, supply and erection coordinated under a single point of contact. |
| Lower landed cost | Direct access to vetted Indian manufacturers means competitive pricing on equipment and spares. |
| Shorter lead times | Parallel engineering and a ready supplier network, vital for planned and emergency shutdowns. |
| Obsolete-part recovery | Reverse engineering and 3D scanning regenerate drawings for legacy equipment OEMs no longer support. |
| Responsive support | Decisions and updates within hours, from engineers who understand plant operations. |
From process analysis to installed equipment
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Engineering
Pyro-process upgrades, calciner & burner modification, NOx mitigation, CFD/FEA, refractory engineering and mill audits.
Civil & Structural
Greenfield and upgrade design, preheater columns, industrial sheds, Tekla fabrication & erection drawings, third-party approval.
Design & Digital
3D scanning, reverse engineering, GA & detailed drawings in SolidWorks and AutoCAD, clash-checked 3D models.
Manufacturing & Supply
Gates, valves, expansion joints, fans, dampers, pulleys and full kiln and mill spares.
The cement pyro line
- Preheater
- Calciner
- Rotary kiln
- Burner
- Cooler
Everything in the pyro line, preheater to cooler
ETR engineers and supplies across the complete pyroprocessing chain.
Preheater & cyclones
Modification, top-cyclone optimisation and pressure-drop reduction, validated with CFD where performance is critical.
- Top-cyclone modification and optimisation
- Pressure-drop and false-air reduction
- Separation-efficiency improvement
- As-built reconstruction via 3D scanning
ReferenceSharjah Cement Factory, UAE: top-cyclone modification and preheater tower 3D scan
View equipmentCalciner
Calciner extensions and top-stage modifications to add capacity, enable alternative-fuel firing and improve specific fuel consumption.
- Calciner extension for AF capacity
- Top-stage and feed-pipe modification
- Tertiary-air and combustion optimisation
- NOx-mitigation concepts
ReferenceSharjah Cement Factory, UAE: calciner extension for AF capacity and lower fuel consumption
View equipmentRotary kiln
Reliability and safety upgrades plus shell, tyres, support and thrust rollers, girth gear and pinion, seals and drive components.
- Girth-gear guard design and safety upgrades
- Support-roller, tyre and shell components
- Kiln inlet and outlet seals
- Reverse-engineered girth gear and pinion
ReferenceSharjah Cement Factory, UAE: girth-gear guard that eliminated oil and grease leakage
View equipmentClinker cooler & AQC duct
Cooler modification and air-quench-cooler duct redesign to resolve recurring failures from improper expansion-joint and support placement.
- AQC duct redesign and support correction
- Cooler modification
- Refractory detailing
- Expansion-joint placement engineering
ReferenceSharjah Cement Factory, UAE: AQC duct redesign to end recurring failures
View equipmentKiln burner
Burner modification and heat-exchanger design to support fuel flexibility, flame shaping and alternative-fuel firing.
- Burner modification
- Heat-exchanger design
- Flame shaping and fuel flexibility
- Refractory detailing for burners
ReferenceFLSmidth, India: refractory engineering and detail drawings for burners and HAG units
View equipmentAlternative fuel (AF) firing
Complete AF systems that reduce fuel cost and emissions, from feasibility and flowsheet through feeding, storage and firing.
- AF feasibility and flowsheet design
- Solid-waste and liquid firing systems
- Feeding, storage and conveying
- Calciner firing enablement
ReferenceSharjah Cement Factory, UAE: from no AF firing to 18 TPH of solid municipal waste
View equipment79%86%
At Sharjah Cement, ETR raised top-cyclone separation efficiency from 79% to 86% through CFD-based analysis and modification.
Material handling, structures & mining support
Material handling & conveying
Belt conveyors, bucket elevators, feeders, weighers and complete mill-feed systems.
Material handling
Structural steel & civil
Preheater columns, PEB and industrial sheds, platforms, galleries and transfer structures.
Structural steel
Mining support
Mill internals, reverse-engineered spares and heavy structural fabrication.
MiningTo keep cement plants running and improving, supplying dependable engineering, equipment and spares with the speed and accountability our customers' operations demand.
10+
Years Cement & Pyro
UAE + India
Operating Hubs
18+
Projects Delivered
Worldwide
Supply Reach
Trusted by cement producers and global OEMs
Selected clients include Sharjah Cement Factory (UAE), HeidelbergCement (India), Zuari Cement (India), FLSmidth (India) and ASQUARE Engineering (UAE).
Featured case studies
Sharjah Cement Factory, UAE
Top-cyclone CFD optimisation
CFD-based analysis and modification of the preheater top cyclone, reducing system pressure drop for better thermal efficiency.
79% to 86% separation
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FLSmidth, India
Refractory engineering
Ongoing refractory engineering and detail drawings for coolers, preheaters, HAG units and burners, delivered to a global OEM's standards.
2024-26 multiple projects
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HeidelbergCement, India
AF material-handling feasibility
Feasibility study for an alternative-fuel material-handling system supporting a higher thermal substitution rate.
25% to 35% TSR
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Sharjah Cement Factory, UAE
AQC duct & girth-gear works
AQC duct redesign to end recurring failures, plus a kiln girth-gear guard that eliminated oil and grease leakage and improved safety.
2026 delivered
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Sharjah Cement Factory, UAE
VRM mill-feed conveying system
Complete mechanical and civil design and supply of a slag and clinker conveying line feeding the VRM, with a full 3D engineering model.
650 MT structural supply
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Inspected at source. Engineered to operating conditions.
Components are dimensionally and quality-checked at partner plants before despatch, so issues are caught before they ship. Designs are engineered to real operating conditions and validated by a decade of cement-plant experience, with drawing-controlled traceability and third-party approval available for civil and structural work. Site erection is planned and supervised with safety as the first priority on every lift.
- Inspection at sourceEvery component is verified against controlled drawings.
- Traceable engineeringDrawing-controlled and traceable from engineering through supply.
- Safety-led erectionSafety is the first priority on every lift and installation.
Let's engineer your next project together.
Talk to us about upgrades, alternative-fuel projects, critical spares or turnkey supply. We'll respond fast.