Narendra Singh
Rathor
Founder & Principal Consultant — 52+ years of engineering leadership across mineral processing, cement, and fertilizer industries.
Engineering Visionary
With over 52 years in the field, Narendra Singh Rathor has made significant contributions to the Fertilizer, Cement and Mineral Processing industries. His expertise encompasses teaching, operation, maintenance, erection & commissioning and project execution — particularly in developing Iron Ore Beneficiation and Pelletization Projects.
He conceived, developed, designed, and implemented many exemplary & efficient Iron Ore, Manganese Ore, Silica Sand, Kaolin Clay Beneficiation and Pelletization projects with many special features. He has worked for more than 500 days with Chinese Technology Suppliers & Machinery Manufacturers.
BENCO / I.I.T. – B.H.U. Varanasi
BENCO / I.I.T. – B.H.U. Varanasi
University of Gorakhpur
Age: 78 Years
Organisations Served (1972–1989)
Prior to founding his consultancy, N.S. Rathor held senior roles at India's largest fertilizer and cement plants.
| Organisation | Role | Sector |
|---|---|---|
| M.M.M. Engineering College, Gorakhpur | Lecturer | Education |
| Fertilizer Corporation of India Ltd. — Gorakhpur Unit | Junior / Assistant Engineer | Fertilizer |
| Fertilizer Corporation of India Ltd. — Sindri Modernisation Project | Project Engineer | Fertilizer |
| U.P. State Cement Corporation Ltd. — KCCP Dalla & Chunar | Unit Head (Technical) | Cement |
| IPI Tata Sponge Iron Project | Unit Head (Technical) | Steel/DRI |
| Larsen & Toubro Ltd. — Awalpur Cement Works (3200 TPD) | HOD, Instrumentation & Control System | Cement |
| Gujarat Ambuja Cement — First Plant, Kodinar | Senior Manager & HOD, I&C | Cement |
Landmark Achievements at Key Organisations
At every organization he served, N.S. Rathor established new benchmarks in performance and successfully solved problems that had challenged OEMs, Consultants, and Research Institutions for years.
- Rectified and performed component-level repair of Servo Jet Temperature Controllers, Gas Analysers & Electronic Weighing Systems.
- Import-substituted L.I.T. Chambers for high-temperature, high-pressure & highly corrosive applications.
- Balancing of cooling tower fans, performed vibration analysis and reduced vibration levels in high-pressure pipelines of Naphtha pumps.
- Modified the cooling systems for field mounted control panels to improve the performance of Gas Analysers
- Completed erection & commissioning of the Instrumentation & Control System of the Urea Plant ahead of Electrical & Mechanical jobs.
- Commissioning activities were done departmentally by in-house trained manpower — without any assistance from OEMs.
- Erection & commissioning of Instrumentation, Control Systems, Power Electronics & ESPs completed in parallel with Electrical & Mechanical work — zero extra days for testing or calibration.
- Repaired & commissioned a 200 KW Thyristor Converter Kiln Drive that had been lying rejected and damaged since 1975 — saving 2 months of production loss in the old Dalla unit.
- Identified the cause of Cement Mill Girth Gear failure that had remained unresolved for 6 years despite the best efforts of WIL (OEM), Holtec (Plant Consultant & Designer), NCBM, KCP and NML.
- Identified the cause of inefficient ESP operation that could not be diagnosed for 6 years by Voltas (OEM), Holtec, and other leading organisations.
- Modified the design of the Slag Dryer combustion chamber arch to deliver 10x longer life (previously only 6 months).
- Properly commissioned the Mill automatic baring mechanism and internal water spray systems — 5 years after the mill's original commissioning.
- Erection & commissioning of Instrumentation & Control Systems, Power Electronics Equipment and ESPs completed alongside Electrical & Mechanical work — zero extra days for testing or calibration.
- L&T experienced such a possibility for the first time in their 30 years of cement plant & machinery business.
- Troubleshooted the Hydraulic drive system of the Push Feeder of the Limestone Crusher and assisted in commissioning other hydraulic & pneumatic systems.
Multi-Industry Consulting Before Mineral Processing
Before focussing exclusively on mineral beneficiation, N.S. Rathor served as a consultant across cement, fertilizer, coal, railway and automation industries.
China Technology
Partnership
N.S. Rathor has spent more than 500 days in China, evaluating large numbers of Technology Suppliers & Machinery Manufacturers — Thus assisting in selection of best technologies and equipment if required ensuring only the best-in-class equipment reaches Indian projects.
He has also shared knowledge and know-how on the Hematite Iron Ore Pelletization Process to leading pellet plant design institutes in China — a testament to his globally recognised expertise.
Building Industry
Leaders
Throughout his career, N.S. Rathor has demonstrated a distinguished ability to train and develop manpower. In every organisation, commissioning activities were completed departmentally — by in-house trained staff without OEM assistance.
Engineers with average academic backgrounds, after being trained and working with N.S. Rathor, outperformed their colleagues and reached the highest positions — including Unit Head and Global Head — in prestigious cement plants of India (1 MTPA to 3 MTPA capacity).
"The mark of a true engineer is not just solving problems, but building people who can solve problems independently."
— N.S. Rathor's Philosophy
What Sets N.S. Rathor Apart
Engineering India's Best Cement Plant
At Gujarat Ambuja Cement's first plant at Kodinar, Gujarat (1984–86), N.S. Rathor developed and implemented an improved Process & Instrumentation Control system using indigenously available hardware — contributing to the highest productivity of man and machinery.
As a result, this plant proved to be the best-performing cement plant in India and among the three best cement plants in the world — creating a history of operating 341 days in a year.
— Record: 341 operating days/year · Ranked among 3 best cement plants globally