Refurbishment of Kiln Drive Gears

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FL Smidth Cement(Australia) contacted AIE regarding the urgent manufacture of components for a kiln drive unit. Having successfully met their requirements we were subsequently contacted by leading cement, concrete, aggregate and lime producer Holcim (New Zealand) Ltd to carry out the refurbishment of its cement kiln drive gears. We were chosen as we have a successful history of completing these types of refurbishments in a short turn around time.

Scope of the refurbishment:

The pinion had come loose on the shaft and the teeth of the pinion were badly worn. As the keys were not able to be removed by normal means, the shaft was cut between the two gears and machined in our CNC machining centre to reduce key pressure before pressing out the shaft.

  • 800mm diameter and a face width of 400mm
  • The main drive gear was 2 metres in diameter
  • The new shaft was 330mm and 2 metres in length

The limited time frame for the job and the logistics of transporting the items between the North & South Islands meant careful planning was required by both parties. AIE staff worked around the clock to ensure that dispatch times were met thus minimising downtime for our customer. Holcim contracted a freight company to uplift the components from their Westport Works to meet the Inter-Island ferry crossing and then on to Kawerau. This process was then repeated on completion of the job. Understanding the customer’s requirements and open communication enabled AIE to achieve the desired outcome.