A demanding industry requires a versatile solution portfolio ...

Drive Technology \ Drive Automation \ System Integration \ Services

A demanding industry requires a versatile solution portfolio

Solutions for the aluminum industry

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As a successful international family-owned company, we work day in, day out to keep our

customers moving. For many years now, we have been supplying various sectors –

including the aluminum industry – with solutions from a wide-ranging portfolio that

covers everything from automation technology and gearmotors through to service. We

work with aluminum manufacturers who need to be able to rely unconditionally on their

equipment.

Catering to aluminum and equipment manufacturers alike, we develop customized solutions based on our experience, products, and services.

Operating both globally and locally, we are committed to customer proximity and to partnership in the truest sense of the word.

Aluminum industry

Solutions from SEW‑EURODRIVEfor the aluminum industry

More than 17 000employees

16 production plants51 countries80 Drive Technology Centers

Global service Since 1931

SEW‑EURODRIVE at a glance

3 4 53 Aluminum industry

• Our expertise and resources, for quality that makes you stand

out from the competition.

• High-tech solutions that minimize your project-specific risk.

• The best delivery times on the market, delivering cost savings

and making you more flexible.

• A comprehensive solution portfolio, ensuring SEW-EURODRIVE

will quickly provide you with an ideal solution – without

time-consuming research and development work.

• The latest trends and innovations, meaning the drive solutions

of tomorrow are available today.

• Customized training to prepare your employees for challenging

projects.

• Order- and user-specific documentation, providing the best

conditions for a smooth startup.

• Local availability, with plants and branches around the world

that ensure we are always nearby.

Teamwork – equipment manufacturers and SEW‑EURODRIVE

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Teamwork – aluminum manufacturers and SEW‑EURODRIVE

• Robust and durable solutions that ensure smooth production

day after day.

• The most reliable delivery on the market to make sure

there are no delays to your scheduled maintenance work.

• Remaining lifetime analyses on your existing drive units

(including third-party products).

• Solutions for replacing and modernizing existing drive

systems, increasing the capacity of your equipment if required.

• Damage analyses.

• Customized training for your staff.

• A systematic overview of all existing drive units at your

factory – including recommended repairs and replacements –

updated on an ongoing basis and available online.

• Suggestions for optimizing your current maintenance

concept, safe in the knowledge that SEW-EURODRIVE supplies

high-quality replacement drives and parts at short notice

whenever required. We are your ideal partner for gear unit

repairs (including third-party products).

• Spare parts such as bearings, seals, gear wheels, and pinion

shafts.

• Repairs to drive systems, replacing internal components

and overhauling gear units.

• Solutions from our modular product system or, if required,

customized solutions to meet your needs.

We are well aware that machine availability is the top priority for aluminum manufacturers.

We offer you:

We aim to make a success of your project

and offer you:

6 7Aluminum industry – ore handling solutions

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Ore handling

The aluminum ore bauxite is the raw material for producing primary aluminum. Mainly

extracted using open-pit mining, it is transported along miles of belt conveyors to interim

storage facilities at nearby refineries (or ports).

SEW-EURODRIVE offers a wide range of solutions for the raw material handling

applications illustrated above and listed here.

Solutions for other applications not shown in the illustration above:

– Apron feeders

– Rail car unloading stations

– Many other solutions

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A Belt conveyors

Bridge-type bucket wheel reclaimer:– Bucket wheels– Belt conveyor– Rake hoists– Travel drives

Scraper reclaimer:– Bucket chain– Boom hoist– Travel drives

Stacker:– Belt conveyors– Boom hoist– Slewing gear– Travel drive

X series P series Gearmotors series

– Energy-efficient helical and bevel-helical gear unit solutions – Thermally optimized solutions for challenging applications– Drive units requiring minimal maintenance

– Compact planetary gear unit solutions for slow-turning applications such as apron feeders

– Customized gear unit solutions to meet your requirements

Ú Your benefits in a nutshell: • High machine availability for raw material handling • Robust, durable products for minimized operating costs • Optimized, field-tested cooling properties minimize the technical risk • Easy maintenance of drive components

SEW-EURODRIVE offers a wide range of raw material handling solutions for all torque ranges. We supply complete drive systems with motor, gear unit, couplings, and base frame as a single package.

Take your pick from our modular system:– Flexible and hydraulic input couplings– Brake units– Backstops– Sealing systems– Multiple output shaft options

– Output couplings– Diverse cooling options and a wide range

of mounting options– Condition monitoring systems

We use proven, state-of-the-art calculation tools to optimize the design of our drives.

Our components

Torque range: 50 Nm – 631 kNmGear ratio range: 1.3 – 27 000

Rohmaterialförderung und -verteilung in die Hochöfen Unser Beitrag: Lösungen für Bandförderer, Winden und Verteilersysteme

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8 9Aluminum industry – ore processing solutions

2 Turning ore into alumina

Segmented girth gears MD series Agitator gear unit series

Pitch diameter: up to 16 m and larger after consultation

– The segmented girth gear concept offers many different flexible combination options

– Virtually wear-free ADI girth gears are possible, subject to appropriate dimensioning, loading, and lubrication

– Products are based on a modular system with a high level of customer-specific modifications

– The design and selection process meets the latest standards and individual customer requirements

Ú Your benefits in a nutshell: • Robust, durable products for high machine availability • Customized solutions with application-specific gear units • Short delivery times and low logistics costs, especially for girth gears • Simplified girth gear assembly and maintenance

SEW-EURODRIVE provides not only the girth gear itself, but the entire drive package. The basic gear unit is also supplied on request, complete with drive pinion, base, casing, and many other options.

The pinion can be mounted directly on the input shaft or separately (pedestal bearing). A great deal of consultation is normally required for drive solutions that involve girth gears, so we support equipment manufacturers and operators in all

applications to identify the best solution from a technical perspective and in terms of cost ef-ficiency. Our specialists oversee every step of the process – from initial consulting all the way through to professional assembly and startup.

Possible scope of delivery

– Segmented girth gears− Input pinion and, if required, pedestal bearing− Girth gear fastening parts: mounting springs or mounting flange− Main gear unit− Motors− Auxiliary drives− Lubrication system– Base frame− Couplings and covers– Condition monitoring– Installation, including startup of the entire drive system

A Ball mills

Mixers

Thickeners

Rotary kilns

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C

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Torque range: 6 – 2584 kNmGear ratio range: 6 – 450


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The first step is to crush the raw material – bauxite – in several stages to achieve the grain size required for further processing. Subse-

quent process steps such as heating, precipitation, classification, filtration, cooling, and crystallization increase the aluminum concen-

tration, while burning in a rotary kiln, sintering, or calcination ultimately produces aluminum oxide (alumina) in the form of a fine-grained

white powder.

SEW-EURODRIVE offers a wide range of solutions for the processing applications illustrated above.

Solutions for other applications not shown in the illustration above:

– Crushers

– Separators

– Filters

– etc.

10 11Aluminum industry – port handling solutions

Port handling3

Drive units for use at ports are subject to very high demands. They need to operate reliably

in humid, salt-laden air, handling several tons of material and passing ships through the

port shortly.

Drives from SEW-EURODRIVE are used to open and close the grab, raise and lower it, as

well as to move the trolley and the entire crane. In addition to being used in grab cranes

like the one illustrated above, our drives are also found in every conceivable kind of equip-

ment for loading and unloading ships.

A Main hoist

Boom hoist

Grab

Main travel drive

Trolley travel drive

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C

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ML series Hoist gear unit series Travel drive gear unit series


– Drives designed and optimized for intermittent duty– Application-specific gear unit for hoists with an increased center distance

– Turnkey solutions optimized to suit the customer’s travel profile– Application-specific gear unit designs

Regardless of your cranes’ operating conditions, our gear units are designed to fully meet your expectations.

Ú Your benefits in a nutshell: • Robust, coordinated drive components ensure maximum availability • Design and selection in line with the latest version of FEM 1.001 / EN 13001 / DIN 15020 • Surface protection meets the requirements for port environments • Global service

Take your pick from our modular system:– Sealing systems– Multiple output shaft options– Motors– Input couplings– Brake units– Output couplings– Brackets– Condition monitoring systems

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B

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12 13Aluminum industry – primary production solutions

Primary production 4

A Hoist

Trolley travel drive

Bridge travel drive

Roller tables

B

C

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X series Travel drive gear unit series Roller table gear unit series


– Drives designed and optimized for intermittent duty– Helical and bevel-helical gear units with pre-defined or customer-specific shaft center distances

– Differential, synchronous, and shiftable gear units– Turnkey solutions optimized to suit the customer’s travel profile– Application-specific gear unit designs

Ú Your benefits in a nutshell: • Robust, coordinated drive components ensure maximum availability • Compact solutions minimize the installation space required • Design and selection in line with the latest version of FEM 1.001 / EN 13001 / DIN 15020 • Short delivery times for standard products and spare parts

Take your pick from our product portfolio:– Standard gear units / gearmotors– Application-specific gear units– Drive packages– Control technology– Condition monitoring systems– Services

In aluminum mills, aluminum is extracted from aluminum oxide in an electrolytic process

with a ratio of 2:1. The cast slabs and blocks from primary production undergo further

processing at aluminum plants. These plants use three main processes – rolling, extrusion,

and casting – to produce aluminum in its final form, which can be anything from foil for

household use to all kinds of profiles and customized sheeting for the aircraft, automotive,

and construction industries.

SEW-EURODRIVE offers a wide range of solutions for the indoor crane technology and

roller table applications illustrated above, but also for storage applications not shown and

much more besides.

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14 15Aluminum industry – production solutions

Production – rolling process 5a

Before the slabs from primary production can be rolled, they need to be brought to the

temperature required for further processing. This is done in a reheating furnace. During

rolling – the most important step in hot-strip processing – the aluminum slab is rolled

between two rotating rolls and elongated by means of compression.

The aluminum strips obtain their final strength and quality during cold-strip processing in

cold-rolling mills and on stretch-bend-leveling lines with their bridle rolls. Coilers are used

to roll up the finished strips and foils – which are several thousand meters long in most

cases – ready for onward transportation.

SEW-EURODRIVE offers a wide range of solutions for the rolling applications illustrated

above, but also for applications not shown, such as roller tables, cross-transfer units,

shears, levelers, strip accumulators, and much more besides.

A Reheating furnace– Walking beam– Slewing gear

Mill stands

Bridle rolls

Coilers

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C

D

X series P series

– Drives designed and optimized for intermittent duty– Application-specific design and selection based on individual customer requirements (external forces and impacts)– Customized gear unit solutions for your requirements, such as power-split gear units

– Design based on customer-specific load spectrums with varying torques and speeds– Compact planetary gear unit solutions for slow-turning applications

Ú Your benefits in a nutshell: • Coordinated drive components for both normal and unplanned torque requirements ensure reliable furnace operation at all times • Intermittent operation means drives with an adapted output can be selected, which has the benefit of significantly cutting costs • Optimized provisioning means spare parts are available immediately • Global service

Application-specific gear units up to 50 metric tons


Application-specific gear units

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D D D D

16 17Aluminum industry – production solutions

Production – extrusion 5b Production – casting5c

Extrusion involves using a punch to push a block heated to deformation temperature

through a die. The die determines the external form of the extruded profile. Mandrels with

different shapes can be used to create cavities. This production process can produce

aluminum in virtually any conceivable shape.

SEW-EURODRIVE offers a wide range of solutions for various extrusion applications, such

as indoor cranes, roller tables, and much more besides.

The properties of aluminum need to be modified for some end products, for example to

increase its strength or gloss level and/or make it easier to form. This involves adding

other metals to the aluminum melt to produce all kinds of alloys.

Cast products with a huge variety of cross-sections and alloys are used in the automotive,

transport, and construction industries, in heat transfer applications, for electronics

products, and in aircraft construction.

SEW-EURODRIVE offers a wide range of solutions for various casting applications, such as

indoor cranes, roller tables, and much more besides.

18 19Life Cycle Services

In view of the high capital intensity of aluminum processing equipment, a coordinated

service and maintenance concept is vital to ensure profitability. The aim is to avoid costly

downtime, minimize disruption, and take proactive measures to safeguard the output of

this equipment.

We are here for you!

SEW‑EURODRIVE – reliable, professional, and fast

The maintenance and development of equipment for aluminum production are key value-adding factors for companies operating in the alumi-num industry. We help prepare your equipment

for the high demands and ensure everything operates reliably, assisting you with startup, repairs, inspection, maintenance, and retrofits to modernize your equipment.

Leave nothing to chance – leave it to the service staff of SEW-EURODRIVE. Your personal contact is there for you whenever required. Our services are an integral part of our portfolio and are closely dovetailed with our

products to ensure you can get everything you need from one place. SEW-EURODRIVE has been synonymous with drive and automation technol-ogy expertise for almost 90 years.

Ú You can depend on our service team’s professionalism and personal consulting to maximize system availability, minimize maintenance requirements, and provide reliable support that safeguards your production processes.

20 21

– Gear unit diagnostics via examination with an inspection scope

– Oil quality analysis – Oil change and disposal of waste oil

– Vibration monitoring to detect early signs of damage

– Preparation of an inspection and maintenance plan

Boost your productivity and energy efficiency, cut your maintenance costs, and benefit from long-term parts availability. Our retrofit service offers everything from a single source, including

customized consulting and engineering, state-of-the-art drive technology, programming and visualization, complete installation, and startup.

Before After

Before After

Ú Your benefits in a nutshell: • Peace of mind – thanks to rapid, dependable assistance that ensures your

production process continues operating reliably. • Everything from a single source – services are closely dovetailed with our

product portfolio. • Expertise and advice – our personal consultation and wide-ranging expertise

in drive and automation technology provide you with a firm foundation. • A dedicated contact – we are here for you and fully committed, worldwide.

Inspection and Maintenance Service

Retrofit – updates your equipment with

state‑of‑the‑art technology

Life Cycle Services

– Central and decentralized repair work– Emergency repairs during which only critical

components are repaired/replaced– Functional repairs with a warranty for service

and replaced components

– As-new repairs with a warranty for the entire drive

– If speed is of the essence, request a rush order or our on-site service

Repairs, if needed, including third‑party products

Startup –

for maximum reliability and efficiency

We will help you with startup.– Installation and laser alignment– Verification of installation– Initial oil filling– Production guidance/monitoring

We work hand in hand with you to optimize all parameters and, naturally, take the latest safety regulations into account.

Example: repair

Inspection and Maintenance Service

Example: retrofit

news

news

SEW-EURODRIVEDriving the world

Drive Technology \ Drive Automation \ System Integration \ Services

How we’re driving the world

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SEW‑EURODRIVE is right there for you

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