David Strain, technical director at electric motor and gearbox provider Technidrive, explores how drum drive gearboxes are essential to cutting emissions in heavy industries. Heavy industries like quarrying and recycling have already made strides in reducing greenhouse gas emissions. However, to meet national and global climate targets, these sectors must continue improving. Switching to electrified conveyors is crucial to industrial decarbonisation, but it comes with unique challenges.
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Emission Reduction Progress in Mining and Waste Management
The UK mining and quarrying sector has significantly reduced its carbon dioxide (CO₂) emissions since the 1990s. According to the Office for National Statistics, the industry nearly halved its emissions from just under 29,200 tonnes in 1998 to just over 15,500 tonnes in 2021. Meanwhile, the waste sector achieved a 74% reduction in emissions between 1990 and 2022. Yet, there is still a long road ahead. McKinsey estimates that the mining sector must reduce emissions by 85% by 2050 to meet climate targets, and sectors like quarrying and recycling must meet similar goals.
The Case for Electrified Conveyors in Heavy Industry
Moving materials around mines, quarries, and recycling facilities consumes significant energy. A study presented at the 12th International Symposium Continuous Surface Mining found that in-pit transport accounted for around 40% of the German mining industry’s power demand and half of its costs. The study estimated that transitioning from diesel mine trucks to electrified belt conveyors powered by renewable energy could reduce emissions by 96%. However, simply switching to conveyors alone may not suffice. A 2022 study published in Energies found that belt conveyors at a Polish mine still accounted for half of its energy consumption. More energy-efficient drive systems, such as gearboxes, are essential to reducing a conveyor’s energy use and emissions, underscoring the need for industrial decarbonisation.
Challenges in Electrifying Conveyor Systems
Replacing diesel trucks with belt conveyors can significantly reduce energy costs and emissions. For many companies in heavy industries, switching from hydraulic conveyors to mobile electrified conveyors is the next logical step. However, electrification poses certain challenges.
Mobile electric conveyors are typically larger and heavier than their hydraulic counterparts, requiring components like electric motors and gearboxes to remain compact and lightweight to avoid adding to the conveyor's size and weight. Drive systems must also be energy-efficient to minimize power consumption. Another challenge relates to the wide variation in speed and torque requirements; feeders often require high torque at low speeds, while transfer stockpile conveyors generally need lower torque but higher speeds. Drive systems must be flexible enough to meet these varying requirements.
Drum Drive Gearboxes: A Compact and Reliable Solution
Conventional gearbox units, including bevel helical, parallel helical, or shaft mount designs, often present challenges due to their size and structure. These drives, which are usually installed outside the conveyor head drum, add weight to the structure and consist of multiple parts, such as shafts and bearings, that require regular lubrication—leading to higher maintenance costs and downtime. Additionally, exposed oil seals in these drives are prone to failure in environments like quarries and recycling plants, where dust and water are prevalent.
Drum drive gearbox solutions, such as the Drum Drive from Technidrive, present a lighter and more compact alternative, with up to 72% less mass than traditional helical gearboxes. By integrating the final stage reducer inside the drive, these solutions have a minimal footprint and can be installed directly within the conveyor head drum. Acting as a bearing, these units eliminate the need for shafts and bearings, translating to lower weight, fewer upfront costs, and reduced maintenance, thus promoting reliability and extended uptime in industrial decarbonisation.
Custom Gearbox Solutions for Various Applications
Drum drive gearboxes are designed to endure challenging environments while providing flexibility. The latest track drive gearbox units range from low-speed, high-torque solutions to high-speed, low-torque models. For instance, the 80A Drum Drive, ideal for feeders, operates with a power range of 0.12-11 kW and a torque range of up to 12,000 Nm. The 80M model, suitable for higher-speed conveyors, operates with a power range between 2.2 kW and 18.5 kW and a torque capacity of up to 7,000 Nm. There are also specific gearbox solutions for winch applications, capable of providing up to 42,000 Nm of torque, and complete drum units with integrated gearing designed for medium to large belt conveyors in rugged conditions.
Enhancing Efficiency with Energy-Saving Motors
The latest track drive gearboxes prioritize energy efficiency in heavy industries. Drum drives are compatible with advanced motor technologies, including high-efficiency permanent magnet (PM) motors and hybrid motors using ferrite or neodymium magnets, along with synchronous reluctance (SynRM) motors. These options enable high Ecodesign energy efficiency, significantly reducing both energy consumption and CO₂ emissions in line with decarbonisation goals.
Achieving Decarbonisation in Heavy Industries
Heavy industries will continue their efforts to reduce carbon footprints as part of broader industrial decarbonisation. Given that conveyors contribute substantially to energy consumption, they must play a central role in emissions reduction efforts. Drive solutions like Technidrive’s Drum Drive help conveyors meet this goal by maximising efficiency, reducing maintenance costs, and enhancing reliability. These innovative solutions empower quarries and recycling plants to achieve sustainability and lower their total cost of ownership through reduced downtime.
