How Bearing Selection Drives Energy Efficiency in Cement Plants
Cement production is inherently energy-intensive, with energy costs comprising a substantial portion of overall operational expenses. In fact, in the cement industry, the total energy consumption accounts for 50-60% of the overall manufacturing cost. Optimizing energy efficiency has become increasingly important as the cement industry strives to reduce its carbon footprint and enhance profitability. One critical, yet often overlooked, factor in improving energy efficiency is the selection of bearings.
The right bearing type can significantly enhance the energy efficiency of cement plants by:
- Reducing friction
- Improving machine reliability, and
- Minimizing downtime
Understanding Bearing Types and Their Roles
Bearings are crucial components in the machinery of cement plants, ensuring the smooth operation of rotating equipment such as kilns, crushers, conveyors, and mills. Different types of bearings are employed depending on the specific application, each offering unique benefits to enhance energy efficiency.
Here are some examples of commonly used bearings in cement applications:
For heavy radial and axial loads
Our cylindrical roller bearings are designed to handle extremely heavy radial loads and axial forces when used as support or locating bearings. Radial loads are transferred via the race, while axial loads are managed by the rolling-element end faces and ribs. Their low friction coefficient and efficient load distribution contribute to reduced energy consumption, making them ideal for energy-conscious cement operations.
For special loads and long service life
Designed for the highest loads, our spherical roller bearings are ideal for heavy machinery like rotary kilns, where high stresses and shaft misalignments occur. Their reliability under extreme conditions makes them indispensable in cement plants, ensuring continuous operation with minimal energy waste.
Maintenance-free and environmentally friendly with long service life
Spherical plain bearings have low friction and wear, providing long service life and excellent sealing. Their simple design and ability to handle heavy loads without complex lubrication make them a practical, maintenance-free choice for energy-sensitive applications in cement plants.
Energy Savings through Reduced Friction
One of the primary ways in which bearings contribute to energy efficiency is by reducing friction. High-friction bearings can lead to increased energy consumption, accelerated wear and tear, and higher operational costs. By selecting bearings engineered for low friction, with advanced lubrication systems, cement plants can achieve smoother operation and lower energy demands.
This reduction in friction not only saves energy but also extends the lifespan of both the bearings and the machinery they support.
The Role of Bearing Lubrication
Lubrication is vital to bearing performance and energy efficiency. Proper lubrication reduces friction and wear, prolonging the life of both the bearing and the equipment it supports. Advanced lubrication systems, such as automatic dispensers or high-performance greases, ensure that bearings operate under optimal conditions, thus reducing energy consumption. Effective lubrication also minimizes maintenance needs, further contributing to the operational efficiency of cement plants.
Learn more about our lubrication solutions: https://medias.schaeffler.com.au/en/lubricate
Impact on Equipment Reliability and Maintenance
Selecting the appropriate bearings directly impacts the overall reliability of cement plant equipment. Bearings that are designed to withstand the challenging conditions of cement production – such as exposure to dust, high temperatures, and heavy loads – reduce the likelihood of equipment failure.
This enhanced reliability not only minimizes unexpected downtime but also ensures that the plant operates more energy-efficiently, as consistent machine performance reduces the need for energy-intensive start-ups and shutdowns.
Learn more about our OPTIME Condition Monitoring solution: https://medias.schaeffler.com.au/en/monitor
Bearing Selection Assistant: A Key Tool for Optimization
To support the process of selecting the optimal bearing for specific applications, Schaeffler, the motion technology company, offers the Bearing Selection Assistant. This engineering tool aids users in identifying the most suitable bearing based on bearing characteristics (load, lubrication, coating etc.) and type (ball, roller, plain etc.).
By leveraging this tool, cement plant operators can make informed decisions that enhance energy efficiency and operational performance.
Learn more about Bearing Selection Assistant here: https://medias.schaeffler.com.au/en/selectionassistant?sort=name-asc.
Case Studies: Real-World Applications
1. Replacement of Spherical Roller Bearing by Split Spherical Roller Bearing
BHP Billiton Base Metals, a major producer of copper, silver, lead, uranium, and zinc, operates Australia’s largest underground mine. Most of its 4,000 employees live in a township 16 km from the site. The main ore conveyor, critical to production, is driven by a shaft-mounted gearbox with limited access to the drive end bearing assembly. After over 12 years of operation without maintenance, condition monitoring by Schaeffler revealed a failing drive end bearing. Schaeffler replaced the used spherical roller bearing with a split spherical roller bearing, significantly reducing repair time and costs, and provided professional installation.
Click here to read the full story.
2. Vibration Monitoring of Rolling Bearings on High-Pressure Grinding Roller
Schaeffler’s SmartCheck successfully identified early signs of bearing damage in high-pressure grinding roller mills, enabling preventive maintenance that avoided costly unplanned downtime. Despite the challenging conditions of high vibrations and slow speeds, the system demonstrated its ability to provide continuous monitoring and early detection, ensuring high operational reliability and significant cost savings for cement plant operators.
Caption: Monitoring of grinding roller bearings using SmartCheck
Click here to read the full story.
Conclusion
In cement manufacturing, where energy efficiency is paramount, the selection of the right bearing type plays a critical role in reducing energy consumption and operational costs. By understanding the unique benefits of various bearing types – such as cylindrical roller bearings, spherical roller bearings, and plain bearings – cement plants can make informed decisions that lead to significant energy savings. Proper lubrication and reliable bearing performance further enhance these savings, contributing to the overall efficiency and profitability of the plant. Schaeffler's advanced bearing solutions offer the cement industry a pathway to achieving greater energy efficiency and reduced operational costs, supporting a more sustainable and economically viable future.
Learn more about our bearing solutions for the cement industry here: https://medias.schaeffler.com.au/en/raw-materials/cement
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