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Gears and Drive Systems

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ICR explores the challenges faced in maintaining gears and drive systems and optimising the manufacturing process.

Cement making process is cumbersome and involves the use of heavy machinery from raw material handling to finished product dispatches. Most of the tasks in the cement and concrete industry are performed in the toughest conditions with involvement of heavy loads, extreme temperatures, pressure, dust etc., in order to run the small and big tasks of the process. It thus becomes extremely important to rely on intelligently engineered and efficient gears and drives for the robust equipment and machinery to keep the systems running and make the production process as smooth as possible in the given conditions.
The gears and drive system of a cement making plant can make or break the process. Thus, it is essential that keen attention is paid to the quality, maintenance and durability of these gears and drives, so that they support the heavy duty applications of the industry.
A cement plant functions on heavy equipment from raw material stage to dispatches. Gears and drives are required in all of them like conveyors, stackers, feeders, impactors, crushing hammer, reclaimers, pulleys, separators, loaders etc. All of these require strong holdings with gears to enable the processing of cement at various stages.
Cement gears are made from high-quality forged rims in electro-welded carburised steel structure using a special process and quality ground. Welds of the cement gearbox are performed by a complete preheating and cooling process due to the different carbon contents and different thermal expansion system of each bearing.

Equipment focussed
A horizontal ball mill is used for grinding of raw material and clinker. The lateral drives required for this equipment are ring gears, pinions, pillow blocks, gear reducers, auxiliary drives and a range of integrated side drives. The central drives required for the functioning are split torque gear reducers, gear couplings, grid couplings and auxiliary drives for power ranging. An alternative to horizontal ball mill is the vertical ball mill that requires bevel-helical-planetary gear reducers.
Kilns used in the cement manufacturing system process raw materials through precalciners before entering a rotating horizontal cement kiln. This would require conventional drive systems, which include ring gears, pinions with pillow blocks, main gear reducers, couplings and auxiliary drives. These drive systems enable the absorption of shell movements and deformation generated by the process.

Key Gears and Drives
Planetary Gearbox:
This gearbox, with advanced research and development in the field of engineering, supports high flexibility and customisation to suit various mountings for particular applications, high efficiency, high torque to weight ratio (compact) and wide range of gear ratios. They can be offered in multiple input and output configurations. They contain co-axial drives, ability to handle high overhang load capacity and modular construction.
Bevel Planetary Drives: These drives are designed in consideration to fit in space constraint areas and to perform heavy duty tasks like crushing of clinker and raw materials. Key features of these drives include extended shaft available for encoder or brake mounting, motor orientation in multiple directions, a right angle drive and availability in different mountings, foot and flange with different input and output configurations. They have a high reliability and are best suitable for slow speed applications and high torque requirements.
Planetary Geared Motors: Suitable for various industry applications, these geared motors have a high torque to weight ratio. They are designed in a modular format and could be back stropped as well. The benefits of planetary geared motors include repair of individual motors, ease of maintenance, suitable for rugged constructions and adaptable for various mounting positions.

Challenges
While gears and drives support the functioning of various equipment in cement plants, they come with their own set of challenges. operating in extreme environments and for extended periods of time, these kilns are subjected to a significant amount of stress, which leads to wear and tear and eventually failure that becomes a cost center to the business.
Mechanical challenge in the rotary kiln management maintaining the efficient operation of girth gear and pinion meshing. Misalignment during production creates uneven and unstable stress concentration on the teeth, resulting in component damage. Sudden temperature changes on the shell circumference close to the girth gear.
Conveyor belts through the cement plant carry heavy loads and are mostly located in areas from where raw material is obtained. Driven by motors and built with bearings, they have to be greased in a certain frequency for maintenance and prevention of damage from dust. Since conveyors are often outside and open to all weather conditions, it is not uncommon to choose a water-resistant grease to inhibit water ingress. Open gears and gearboxes in multiple equipment of the cement plant require regular maintenance and greasing to keep them from incurring frictional damage and wear.
Other typical challenges with gears and drives in the cement plant include loosening of nuts, bolts, springs, plates, spring rods, flywheel, bearings, shaft, coupling housing, hammer rotor etc., which would require them to be fixed and regularly checked.
Gear knocking, gear tooth wear, gear deformation, gear pitting and spalling leads to expenses and replacement costs. These bearings are replaced frequently to ensure all equipment in the cement plant runs without any hindrance.

-Kanika Mathur

Concrete

Cement Makers Reaffirm Commitment to Sustainable Growth

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World Environment Day spotlight on innovation and circularity

On World Environment Day, the Indian cement industry reiterated its commitment to supporting India’s climate ambitions through sustainable manufacturing, resource efficiency and the adoption of cleaner technologies.

The Cement Manufacturers’ Association (CMA) said the sector remains aligned with the Government of India’s Net Zero commitments and is accelerating efforts to reduce its environmental footprint while supporting the country’s infrastructure and development agenda.

Parth Jindal, President, CMA and Managing Director, JSW Cement, said the industry is increasingly adopting cleaner technologies, improving energy efficiency and expanding the use of alternative fuels and raw materials. He also highlighted the growing importance of circular economy practices, where industrial by-products and waste streams from one sector are utilised as resources in another.

“The Indian Cement Industry is aligned to the Government’s commitments on carbon mitigation and is accelerating the adoption of cleaner technologies, resource efficiency and circular economy practices while actively exploring the potential of Carbon Capture, Utilisation and Storage (CCUS) as a critical pathway for deep decarbonisation,” said Jindal.

He added that coprocessing industrial waste and by-products helps conserve natural resources, reduce disposal requirements and lower the environmental footprint across multiple sectors.

According to Jindal, sustainability is no longer limited to manufacturing processes but is increasingly influencing investment decisions, innovation strategies and long-term growth plans within the industry.

Echoing similar views, Dr Raghavpat Singhania, Vice President, CMA and Managing Director, JK Cement, said sustainable development extends beyond emissions reduction and must also focus on responsible resource utilisation and waste minimisation.

“Sustainability in the built environment cannot be measured by emissions alone. It is equally about how efficiently we use resources, how effectively we minimise waste and how responsibly we create the infrastructure that will serve future generations,” said Singhania.

He noted that the cement industry is advancing its sustainability agenda through greater resource efficiency, increased circularity, technological innovation and continuous improvements in manufacturing practices. As a key contributor to India’s infrastructure development, the sector has a critical role to play in balancing economic growth with environmental responsibility.

On the occasion of World Environment Day, industry leaders reaffirmed their commitment to supporting India’s climate goals while delivering the materials required for resilient, durable and sustainable infrastructure.

 

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Concrete

Building a Greener Future Together

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Environmental sustainability requires immediate action, not just long-term commitments and discussions. Recycling, circular economy practices, and technology-driven waste management can help industries reduce environmental impact while supporting sustainable growth.

Author: Jignesh Kundaria, Director and CEO, Fornnax Technology

World Environment Day serves as an important reminder that environmental sustainability can no longer remain confined to discussions, reports, or long-term commitments. The environmental challenges facing the world today demand immediate, measurable, and collective action. Across industries and communities, waste generation continues to outpace our ability to process it responsibly, placing increasing pressure on ecosystems, natural resources, public health, and the well-being of future generations.

One of the most significant shifts required today is a change in how society perceives waste. Rather than being viewed as a material to be discarded, waste must be recognised as a valuable resource that can contribute to both economic growth and environmental protection when managed through the right technologies and systems. This mindset forms the foundation of the circular economy model that countries across the world are increasingly adopting to reduce landfill dependence, recover valuable materials, and create more sustainable industrial ecosystems.

India has made meaningful progress in strengthening awareness around sustainability, recycling, and environmental responsibility over the past decade. Significant efforts are being made to formalise the recycling sector through improved infrastructure, technology adoption, policy implementation, and broader stakeholder participation. These developments are creating a stronger foundation for responsible waste management and resource recovery across the country.

However, achieving long-term environmental impact requires collaboration from all stakeholders. Industries, policymakers, technology providers, and communities must work together with greater accountability to strengthen recycling ecosystems, encourage responsible waste management practices, and create sustainable outcomes through consistent execution rather than temporary interventions.

As someone closely associated with the recycling industry, I firmly believe that technology will play a decisive role in addressing future environmental challenges. Advanced recycling systems have the potential to recover valuable resources, reduce pollution, minimise landfill burdens, and conserve energy, creating a more sustainable future for generations to come. This belief is deeply reflected in Fornnax’s motto, “Committed to Create a Green Future,” which embodies our commitment to building long-term environmental value through innovation and responsible action.

At the same time, technology alone cannot deliver meaningful change. Real progress requires intent, awareness, participation, and a shared sense of responsibility. Sustainable development can only be achieved when innovation is supported by collective action and a genuine commitment to environmental stewardship.

On this World Environment Day, let us move beyond conversations and take meaningful steps towards creating a cleaner, greener, and more sustainable planet. By embracing innovation, strengthening recycling ecosystems, and acting responsibly today, we can create lasting environmental impact and secure a better future for generations to come.

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Concrete

JK Lakshmi Advances LC3 Cement Expansion

Company highlights commercial production and research partnerships

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The meeting reviewed progress in limestone calcined clay cement (LC3) technology and its commercial adoption in India’s cement sector, focusing on low-carbon alternatives to conventional binders. JK Lakshmi Cement noted that limestone calcined clay cement can reduce carbon dioxide emissions by up to 40 per cent compared with conventional cement and said this reduction supports industry decarbonisation. The company highlighted that it was among the first two cement manufacturers in India to move LC3 into commercial production after the Bureau of Indian Standards approved the technology as a cement standard.

Vinita Singhania said the transition of LC3 from research to commercial production reflected collaboration between industry, academia and international institutions. Maya Tissafi acknowledged JK Lakshmi Cement’s role in advancing LC3 adoption in India and its contribution in taking the technology from laboratory trials to commercial implementation. Both representatives underlined the growing relevance of sustainable construction materials as India expands infrastructure and urban development.

The meeting explored continued collaboration with Swiss research institutions such as EPFL, EMPA and ETH Zurich alongside Indian academic partners and development organisations. JK Lakshmi Cement has been associated with the LC3 initiative since 2014 and worked with EPFL, IIT Delhi, IIT Madras, Development Alternatives and Technology and Action for Rural Advancement. The company conducted one of the earliest industrial trials of LC3 and recently announced commercial production of Green Pro LC3 cement from its Jaykaypuram plant in Rajasthan.

India remains the world’s second-largest cement producer and expansion of infrastructure, urbanisation and housing demand continue to support long-term sector growth, increasing interest in low-carbon technologies. The company reported an annual turnover of more than Rupees (Rs) 60 bn and current cement capacity of about 18 million (mn) tonnes (t) per annum, with a target of reaching 30 million (mn) tonnes (t) by 2030. Apart from grey cement, the company also makes ready-mix concrete, gypsum plaster, wall putty, primers, adhesives and fly ash blocks, and both sides concluded on the need for continued collaboration to develop sustainable construction solutions.

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