Sew-Eurodrive reported Aug. 25 that cement kilns operate under extreme temperatures and require continuous rotation for reliable operation. Many plants still rely on legacy drivetrain systems with external auxiliary drives, clutches, backstops and couplings that are maintenance-intensive and difficult to upgrade. When critical components become obsolete, it adds that replacement often requires extensive equipment and foundation modifications.

Because this was also the case for one of Argos Cement’s U.S. plants, Sew-Eurodrive recently implemented a solution that replaced its legacy drivetrain with a single integrated solution that eliminated more than 5,000 pounds of auxiliary equipment, preserved the existing foundation, and cut lead time by more than half.

Argo’s existing kiln drive system consisted of approximately eight separate drivetrain components mounted on individual foundations, including an auxiliary drive, clutch, backstop, couplings and support structures. When the primary gearbox became obsolete, it faced either a costly replacement, requiring major foundation and drivetrain modifications, or seeking a solution that modernized the system without disrupting existing infrastructure. 

Retrofit and results

Because it was the only supplier able to provide a true drop-in replacement without major structural changes, Sew-Eurodrive reports it delivered a fully integrated ML-Series kiln-drive solution with a built-in auxiliary drive system (Figure 1). More specifically, its new ML-Series integrated gear unit has a 350-hp motor, 1,200 rpm output speed, 29.21 ratio, and 1,165,000 lb-in of output torque.

• Integrated auxiliary drive with internal gearing,
• Internal clutch with automatic engagement/disengagement,
• Built-in centrifugal brake and backstop,
• Drop-in retrofit with a custom base, extended output shaft, and existing height/alignment maintained,
• Reuse of existing motors to reduce cost and simplify installation, and
• Complete engineered system delivered as one integrated solution, rather than just a gearbox.

Thanks to these replacements and its single, integrated drive solution, Sew-Eurodrive reports that Argos reduced installation risk, reduced costs and delivery time, and increased long-term reliability. Other improvements included:

• Drop-in replacement preserved the existing plant layout with no reconfiguration required;
• Simplified drivetrain by replacing approximately eight components with one integrated unit;
• Reduced lead time from 52 weeks to 25 weeks;
• Decreased project costs by eliminating external clutches, backstops and other auxiliary components;
• Cut installation time and downtime with minimal alignment requirements; and
• Improved reliability with fewer components and failure points.