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Case Study: Extending the life of gear unit

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The bearings, monitoring system or oil system have, of course, been upgraded constantly over the years to remain state-of-the-art. However, the basic principle of the current CPU gears is still based on the original 1966 design. Martin Baechler details the overhaul process of one such two-stage planet gear unit that was recently carried out at Orient Cement.

The first two-stage planet gear unit for the cement industry was developed in 1966 by MAAG ZahnrSder AG (now FLSmidth MAAG Gear) in Zurich, Switzerland. These gear units of type CPU consist of two series-connected planet stages, each with 3 planets and a rotating planet carrier. They replaced traditional, multistage, spur gear units for the central drive of ball mills. Thanks to their higher power density and better efficiency, these gear units are able to transfer more power and take up less space.

This design is very robust and durable. It is proved by the fact that the first two units built in 1967 are still in use in Belgium after over 46 years of operation. More than just periodic inspection and maintenance work is required if a gear unit is to be operated far beyond its normal service life under the tough environmental and operating conditions in the cement industry. The service life can only be extended if the entire gear unit is completely overhauled. Overhauls reduce the overall wear in the gear unit. The wear parts are replaced and the gear unit is serviced so that it is ready for the next operating period. If overhauls are planned in advance, they can be carried out in periods of low demand and also ensure that the gear unit continues to operate without problems. They help reduce maintenance costs, extend the service life of the plant and contribute to avoiding unexpected downtime. Orient Cement in India recently benefited from all of these advantages.

Orient Cement, a far-sighted cement producer

Orient Cement was founded in 1979. It has operated a cement factory in Devapur, in Adilabad district in central India since 1982, and a split-grinding unit in Jalgaon, Maharashtra, since 1997. Orient Cement pursues a clear growth strategy. Between 1990 and 2009, total production capacity was continuously increased to 5 million tonnes of cement a year by upgrading the existing cement lines and adding a new line. To achieve the target of 15 million tonnes a year by 2020, Orient Cements focus is not only on the construction of new production sites. It is equally important to secure the existing production capacity. This requires the maintenance of the existing systems. Only high-quality, well-maintained production plants are able to produce the desired quality and quantity of cement reliably and with optimum efficiency. For this reason, Orient Cement recently had the gear unit of a raw meal mill completely overhauled.

The gear unit, of type CPU-30-2, was designed and produced in 1987 by FLSmidth MAAG Gear in Switzerland. The design differs from the standard CPU series because at that time motors with the required output of 3800 kW were not available. A drive with two parallel motors, each with an output of 1900 kW, was developed for Orient Cement. As its first reduction, this CPU does not have a planet stage. It has two input pinions that mesh with a common gearwheel. The accumulated power is transferred to the second stage, a planetary gear with rotating planet carrier, via a gear coupling. The input speed of 992 RPM is reduced to the mill speed of 14.76 RPM in the two gear stages.

Complete overhaul of a two-stage central drive

After first operation, the gear unit was inspected during the warranty period after 6,000 and 12,000 operating hours. It then ran for more than 10 years without problems, maintained by the local maintenance team. The first major inspection by FLSmidth MAAG Gear took place in 2005 and the gear unit was found to be in good condition.

As recommended by FLSmidth MAAG Gear, a complete overhaul was carried out in September 2013 after approximately 134,000 operating hours or a service life of 26 years. Roughly six months beforehand, a service engineer from FLSmidth MAAG Gear produced an initial analysis of the gear unit on site and established that all necessary spare parts for the overhaul were available locally.

When the service engineers arrived in Devapur, the gear unit had already been prepared for the overhaul. The raw mill was stopped and the auxiliary drives and the power supply of the main motors had been removed by Orient Cement employees. The overhaul work was completed in just 10 days. The oil pipes and connection couplings had to be removed first to allow the gearing and the bearings of the two gear stages to be inspected. The three planet axles in the second stage also serve as journals and are therefore coated with a layer of white metal. As part of this overhaul, Orient Cement inspected the journals using ultrasound to ensure that the white metal layer was still in perfect condition. The gearing of the sun pinion of the second stage was also inspected using ultrasound as it is the gearing subject to the highest load in the gear. All sliding bearings in both gear stages were completely replaced. The gear unit was also cleaned and small parts and wearing parts were replaced. When the gear stages were assembled, the internal alignment of the gearwheels and the tooth contacts were reset.

The gear unit was completely assembled in the last 3 days of the mills downtime. The service engineers first assembled the two gear stages again and set the tooth contact and backlash correctly. The gear unit was provisionally aligned and braced on the foundation. Wearing parts such as O-rings and coupling bolts in the output coupling were replaced before the coupling was installed. The cleaned and inspected couplings were filled with new lubricating grease and the alignment between the motors, the gear unit and the mill was restored. The oil pipes were then connected and flushed with the oil. The rotational direction test on the motors was the last job before the load test and the resumption of operation of the raw meal mill.

Conclusion

After this 10-day complete overhaul, the Orient Cement gear unit has new bearings, all the wearing parts have been replaced and the alignment of the gearing has been restored to the original setpoint. The alignment with the drive motors and the mill has also been checked and is in the permissible range. The gear unit is not new but it is fit for the next stage of its life. With good care and the necessary maintenance, it will continue to operate well until the next complete overhaul is due after 80,000 hrs or 12 years.

Concrete

We consistently push the boundaries of technology

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Swapnil Jadhav, Director, SIDSA Environmental, discusses transforming waste into valuable resources through cutting-edge technology and innovative process solutions.

SIDSA Environmental brings decades of experience and expertise to the important niche of waste treatment and process technologies. As a global leader that is at the forefront of sustainable waste management, the company excels in recycling, waste-to-energy solutions and alternative fuel production. In this conversation, Swapnil Jadhav, Director, SIDSA Environmental, shares insights into their advanced shredding technology, its role in RDF production for the cement industry and emerging trends in waste-to-energy solutions.

Can you give us an overview of SIDSA Environmental’s role in waste treatment and process technologies?
SIDSA is a leading innovator in the field of waste treatment and process technologies, dedicated to delivering sustainable solutions that address the growing challenges of waste management.
SIDSA is a more than 52-year-old organisation with worldwide presence and has successfully realised over 1100 projects.
Our expertise is in the engineering and development of cutting-edge systems that enable the conversion of waste materials into valuable resources. This includes recycling technologies, waste-to-energy (W2E) systems, and advanced methods for producing alternative fuels such as refuse derived fuel (RDF). The organisation prioritises environmental stewardship by integrating energy-efficient processes and technologies, supporting industrial sectors—including the cement industry—in reducing their carbon footprint. Through our comprehensive approach, we aim to promote a circular economy where waste is no longer a burden but a resource to be harnessed.

How does SIDSA Environmental’s shredding technology contribute to the cement industry, especially in the production of RDF?
SIDSA’s shredding technology is pivotal in transforming diverse waste streams into high-quality RDF. Cement kilns require fuel with specific calorific values and uniform composition to ensure efficient combustion and operational stability, and this is where our shredding systems excel. In India, we are segment leaders with more than 30 projects including over 50 equipment of varied capacity successfully realised. Some of the solutions were supplied as complete turnkey plants for high capacity AFR processing. Our esteemed client list comprises reputed cement manufacturers and chemical industries. Our technology processes various types of waste—such as plastics, textiles and industrial residues—breaking them down into consistent particles suitable for energy recovery.

Key features include:

  • High efficiency: Ensures optimal throughput for large volumes of waste.
  • Adaptability: Handles mixed and heterogeneous waste streams, including contaminated or complex materials.
  • Reliability: Reduces the likelihood of operational disruptions in RDF production. By standardising RDF properties, our shredding technology enables cement plants to achieve greater energy efficiency while adhering to environmental regulations.

What are the key benefits of using alternative fuels like RDF in cement kilns?
The adoption of RDF and other alternative fuels offers significant advantages across environmental, economic and social dimensions:

  • Environmental benefits: Cement kilns using RDF emit fewer greenhouse gases compared to those reliant on fossil fuels like coal or petroleum coke. RDF also helps mitigate the issue of overflowing landfills by diverting waste toward energy recovery.
  • Economic savings: Alternative fuels are often more cost-effective than traditional energy sources, allowing cement plants to reduce operational expenses.
  • Sustainability and resource efficiency: RDF facilitates the circular economy by repurposing waste materials into energy, conserving finite natural resources.
  • Operational flexibility: Cement kilns designed to use RDF can seamlessly switch between different fuel types, enhancing adaptability to market conditions.

What innovations have been introduced in waste-to-energy (W2E) and recycling solutions?
SIDSA’s machinery is meticulously engineered to handle the complex requirements of processing hazardous and bulky waste.

This includes:

  • Robust construction: Our equipment is designed to manage heavy loads and challenging waste streams, such as industrial debris, tires and large furniture.
  • Advanced safety features: Intelligent sensors and automated controls ensure safe operation when dealing with potentially harmful materials, such as chemical waste.
  • Compliance with standards: Machinery is built to adhere to international environmental and safety regulations, guaranteeing reliability under stringent conditions.
  • Modular design: Allows for customisation and scalability to meet the unique needs of various waste management facilities.

How does your organisation customised solutions help cement plants improve sustainability and efficiency?
We consistently push the boundaries of technology to enhance waste management outcomes.
General innovations and new product development focus on:

  • Energy-efficient shredders: These machines consume less power while maintaining high throughput, contributing to lower operational costs.
  • AI-powered sorting systems: Utilise advanced algorithms to automate waste classification, increasing material recovery rates and minimising errors.
  • Advanced gasification technologies: Convert waste into syngas (a clean energy source) while minimising emissions and residue.
  • Closed-loop recycling solutions: Enable the extraction and repurposing of materials from waste streams, maximising resource use while reducing environmental impact.

What future trends do you foresee in waste management and alternative fuel usage in the cement sector?
Looking ahead, several trends are likely to shape the future of waste management and alternative fuels in the cement industry:

  • AI integration: AI-driven technologies will enhance waste sorting and optimise RDF production, enabling greater efficiency.
  • Bio-based fuels: Increased use of biofuels derived from organic waste as a renewable and low-carbon energy source.
  • Collaborative approaches: Strengthened partnerships between governments, private industries and technology providers will facilitate large-scale implementation of sustainable practices.
  • Circular economy expansion: The cement sector will increasingly adopt closed-loop systems, reducing waste and maximising resource reuse.
  • Regulatory evolution: More stringent environmental laws and incentives for using alternative fuels will accelerate the transition toward sustainable energy solutions.

(Communication by the management of the company)

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Concrete

FORNNAX Technology lays foundation for a 23-acre facility in Gujarat

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FORNNAX Technology, a leading manufacturer of recycling equipment in India, has marked a major milestone with the Groundbreaking (Bhoomi Pujan) ceremony for its expansive 23-acre manufacturing facility in Gujarat. Specialising in high-capacity shredders and granulators, FORNNAX is strategically positioning itself as a global leader in the recycling industry. The new plant aims to produce 250 machinery units annually by 2030, making it one of the largest manufacturing facilities in the world.
The foundation stone for this ambitious project was laid by Jignesh Kundaria, CEO and Director, alongside Kaushik Kundaria, Director. The ceremony was attended by key leadership members and company staff, signifying a new chapter for FORNNAX as it meets the growing demand for reliable recycling solutions. Speaking on the occasion, Jignesh Kundaria stated, “This marks a historic moment for the recycling sector. Our high-quality equipment will address various waste categories, including tyre, municipal solid waste (msw), cables, e-waste, aluminium, and ferrous metals. this facility will strengthen our global presence while contributing to India’s Net Zero emissions goal by 2070.”
FORNNAX is actively expanding its footprint in critical markets such as Australia, Europe and the GCC, forging stronger sales and service partnerships. The facility will house an advanced Production Department to ensure seamless manufacturing.

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Concrete

Decarbonisation is a focus for our R&D effort

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Dyanesh Wanjale, Managing Director, Gebr. Pfeiffer discusses the need to innovate grinding technologies to make the manufacturing process more efficient and less fuel consuming.

Gebr. Pfeiffer stands at the forefront of grinding technology, delivering energy-efficient and customised solutions for cement manufacturers worldwide. From pioneering vertical roller mills to integrating AI-driven optimisation, the company is committed to enhancing efficiency and sustainability. In this interview, we explore how their cutting-edge technology is shaping the future of cement production.

Can you tell us about the grinding technology your company offers and its role in the cement industry?
We are pioneers in grinding technology, with our company being based in Germany and having a rich history of over 160 years, a milestone we will celebrate in 2024. We are widely recognised as one of the most efficient grinding technology suppliers globally. Our MBR mills are designed with energy efficiency at their core, and for the past five years, we have been focused on continuous improvements in power consumption and reducing the CO2 footprint. Innovation is an ongoing process for us, as we strive to enhance efficiency while supporting the cement industry’s sustainability goals. Our technology plays a critical role in helping manufacturers reduce their environmental impact while improving productivity.

The use of alternative fuels and raw materials (AFR) is an ever-evolving area in cement production. How does your technology adapt to these changes?
Our vertical roller mills are specifically designed to adapt to the use of alternative fuels and raw materials. These mills are energy-efficient, which is a key advantage when working with AFR since alternative fuels often generate less energy. By consuming less power, our technology helps bridge this gap effectively. Our solutions ensure that the use of AFR does not compromise the operational efficiency or productivity of cement plants. This adaptability positions our technology as a vital asset in the industry’s journey toward sustainability.

What are some of the challenges your company faces, both in the Indian and global cement industries?
One of the major challenges we face is the demand for expedited deliveries. While customers often take time to decide on placing orders, once the decision is made, they expect quick deliveries. However, our industry deals with heavy and highly customised machinery that cannot be produced off the shelf. Each piece of equipment is made-to-order based on the client’s unique requirements, which inherently requires time for manufacturing.
Another significant challenge comes from competition with Chinese suppliers. While the Indian cement industry traditionally favoured our technology over Chinese alternatives, a few customers have started exploring Chinese vertical roller mills. This is concerning because our German technology offers unmatched quality and longevity. For example, our mills are designed to last over 30 years, providing a long-term solution for customers. In contrast, Chinese equipment often does not offer the same durability or reliability. Despite the cost pressures, we firmly believe that our technology provides superior value in the long run.

You mentioned that your machinery is made-to-order. Can you elaborate on how you customise equipment to meet the specific requirements of different cement plants?
Absolutely. Every piece of machinery we produce is tailored to the specific needs of the customer. While we have standard mill sizes to cater to different capacity requirements, the components and configurations are customised based on the client’s operational parameters and budget. This process ensures that our solutions deliver optimal performance and cost efficiency. Since these are heavy and expensive items, maintaining an inventory of pre-made equipment is neither practical nor economical. By adopting a made-to-order approach, we ensure that our customers receive machinery that precisely meets their needs.

The cement industry is focusing not only on increasing production but also on decarbonising operations. How does your company contribute to this dual objective, and how do you see this evolving in the future?
Decarbonisation is a key focus for our research and development efforts. We are continuously working on innovative solutions to reduce CO2 emissions and improve overall sustainability. For example, we have significantly reduced water consumption in our processes, which was previously used extensively for stabilisation. Additionally, we are leveraging artificial intelligence to optimise mill operations. AI enables us to monitor the process in real-time, analyse feedback, and make adjustments to achieve optimal results within the given parameters.
Our commitment to innovation ensures that we are not only helping the industry decarbonise but also making operations more efficient. As the cement industry moves toward stricter sustainability goals, we are confident that our technology will play a pivotal role in achieving them.

Can you provide more details about the use of digitalisation and artificial intelligence in your processes? How does this improve your operations and benefit your customers?
Digitalisation and AI are integral to our operations, enabling us to offer advanced monitoring and optimisation solutions. We have developed three distinct models that allow customers to monitor mill performance through their computer systems. Additionally, our technology enables real-time feedback from our German headquarters to the customer. This feedback highlights any inefficiencies, such as when a parameter is outside the optimal range,
and provides actionable recommendations to address them.
By continuously monitoring every parameter in real time, our AI-driven systems ensure that mills operate at peak efficiency. This not only enhances production but also minimises downtime. I am proud to say that our mills have the lowest shutdown rates compared to other manufacturers. This reliability, combined with the insights provided by our digital solutions, ensures that customers achieve consistent and efficient operations. It’s a game-changer for reducing costs and enhancing overall productivity.

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