Bearing Failure in Separator for Cement Plants

In cement manufacturing, separators like SEPAX are essential for maintaining grinding circuit efficiency and product consistency. They control particle size distribution and reduce agglomeration, directly impacting mill throughput and power consumption. Mechanical issues, especially bearing wear, can increase power draw, reduce fines recovery, and, in severe cases, halt production altogether.

The Crisis:
At a 5000 TPD cement plant, UptimeAI flagged early signs of separator degradation. The operations team observed:

  • Rising Vibration Levels: From 3.5 mm/sec to 4.2 mm/sec

  • Elevated Bearing Temperature: From 65°C to 82°C

A bearing failure would have led to a 48-hour mill shutdown. With an average cement production cost of $45–$55 per ton and daily output of 5,000 tons, the projected production loss alone was $450K–$550K. This does not include equipment damage, emergency repair costs, or restart losses.

Learn how UptimeAI enabled the plant operations team to isolate the root cause and schedule proactive maintenance, avoiding unplanned downtime and saving over $150,000 in failure-related costs.

 

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