Gear Up For Success

Maintenance and replacement of large gear units in cement plants is a major task that requires thorough planning, technical coordination, and cost-efficient arrangements, with a focus on minimising downtime.

MAAG prioritises client needs through maintained open communication channels and prompt responses to operational challenges. Collaborative efforts between MAAG’s sales and engineering teams ensure durable, competitive solutions tailored to client requirements. This article highlights a recent successful gear unit replacement project undertaken by MAAG for a cement producer in Iraq.

Project overview

A cement plant in Iraq – one of the region’s largest, with high production capacity to meet market demands – faced significant constraints due to an outdated gearbox. The plant’s technical team sought alternative solutions, engaging MAAG’s regional sales team to identify optimal replacement options.

Client requirements

As a leading cement producer, the client demanded high standards for performance, technical specifications, safety factors, durability, and engineering quality. Emphasis was also placed on post-installation communication and support from the gear supplier’s aftermarket services.

Solution implementation

Following detailed technical discussions and studies, the IronDrive-4350/A was selected for replacement, renowned for exceptional durability among vertical roller mill (VRM) gear units. Cost-effectiveness was ensured by reusing existing components: oil units, piping, output couplings, auxiliary drives, and foundations. The client approved the solution, and the order was finalised.

Fabrication and delivery

MAAG started fabrication and adhered to the agreed delivery timeline. Throughout the production period, regular updates and manufacturing-step approvals were provided. A successful test run was conducted under client supervision at MAAG’s workshop in Poland. Timely shipment followed, supported by seamless coordination and documentation between MAAG and the Iraqi client.

Installation and results

Mr. Witold Malecki, a seasoned MAAG gear expert with over 30 years of extensive experience in the field, supervised the gearbox replacement project. His vast knowledge and expertise were instrumental in ensuring the smooth execution of the installation. The entire process was meticulously planned and executed, resulting in the successful completion of the installation within an impressive time frame of just 15 days.

Once the new MAAG gear was installed, the mill resumed operations seamlessly. The results were impressive: the feed rate increased by an average of 17 tph, significantly enhancing the plant’s productivity.

Additionally, the specific energy consumption (SEEC) was reduced by 1.37 kW/t, reflecting a substantial improvement in energy efficiency. These improvements boosted productivity, cut energy costs, and aligned with the client’s sustainability objectives by reducing the plant’s overall energy footprint.

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Read the article online at: https://www.worldcement.com/special-reports/28042025/gear-up-for-success/