Energy efficiency is a growing concern in the mining industry, especially in Africa, where power supplies are often limited and intermittent, owing to substandard generation, transmission and distribution infrastructure.

“The continent’s infrastructure cannot allow for the operation of inefficient equipment. SEW-EURODRIVE is well positioned to reduce power demand in the mining industry while maintaining effective operations through its product offering,” says motors and drives manufacturer SEW-EURODRIVE mechanical business development manager Edwin Weyers.

For example, IE1 motors only offer 80% efficiency, whereas IE3 motors operate at an efficiency greater than 90%. Weyers argues that the 10% difference is significant when considering a plant that potentially requires 80 MW/h.

“The reduction in demand on the national grid means more energy is made available to power a small town nearby, simply through improving the efficiency of mining equipment. Operationally, there’s no difference for the client.”

The adoption of more energy efficient products in the mining industry is also driven by investors placing greater pressure on mining companies to improve their environmental, social and governance (ESG) commitments. This is in addition to the financial benefits of reducing operating costs and the consumption of grid-based power and back-up energy supplies such as diesel.

Although SEW-EURODRIVE has supplied its own IE3 motors for the last seven years already, IE3 motors are now stipulated as the minimum requirement under the new minimum energy performance standards (MEPS), highlights Weyers, adding that the company’s mining clients already comply with MEPS.

“We’re in a phase where our new projects are being executed with IE4 motors. But motors are only a portion of our portfolio, which also includes variable speed drives (VSDs) and gear units.”

While VSDs allow for improved energy efficiency by enabling a piece of equipment to vary its output according to demand, SEW-EURODRIVE also offers its MoviLink Digital Data Interface (DDI) cable for motors and DriveRadar solution for industrial gear units. The DDI cable enables direct digital integration between drive components, allowing for seamless data transmission and simplified diagnostics without the need for additional sensors, while DriveRadar is a predictive maintenance and condition monitoring system that uses real-time data to optimise equipment uptime and performance.

Advancing Performance

Weyers explains that significant capacity is dedicated to improving the energy efficiency of SEW-EURODRIVE’s overall product offering through a team of researchers and engineers based in Germany.

An example of the company’s recent advancements is SEW-EURODRIVE’s X.e Series helical gear units, which surpass the company’s X Series with improved gearing topography and assembly.

Further, SEW GearOil has also been developed by tribologists specifically to improve the performance of SEW-EURODRIVE’s standard, servo and industrial gear units. This innovation extends oil life by about 50%, mitigating the need to drain oil after 500 hours of operation, as necessitated by other oil brands, notes Weyers.

“SEW-EURODRIVE is also probably one of the only gearbox manufacturers that has adjusted its assembly procedures to consider the application and operating conditions of a gearbox.”

While the company’s gearing is designed to deliver infinite gearing life, subject to the needed maintenance procedures being followed and the use of SEW GearOil, it has also developed special assembly procedures using bearings that can last even longer.

“When a client switches from our X Series to X.e, the gearbox doesn’t necessarily look different or require modifications on the client’s part, despite considerable time and money having been spent in the background to realise improvements and reduce total cost of ownership,” says Weyers.

Invested in Sustainability

He adds that SEW-EURODRIVE’s Phase 2 facility – dedicated to after-sales servicing, repair, remanufacturing and training – in Aeroton, Johannesburg – is nearing completion and clearly illustrates the company’s intention to invest towards the reduction of cost of ownership and sustainability.

“We understand that not everyone can afford to simply replace equipment, so we are setting up the necessary support system. This facility will not only include repairs services but will also provide training through our DriveAcademy, aiding sustainability. This will help educate people so that they understand the effects of using the correct equipment for the correct application as well as how to maintain this.”

Additionally, SEW-EURODRIVE is helping its clients meet their ESG and energy transition goals by supplying compact technology that reduces the cost and carbon emissions associated with transport while also assembling equipment in-country.

“We can assemble equipment to order in less than a day, depending on clients’ requirements. This also provides substantial flexibility in terms of terminal box positions, whether clients require feet, or want it to be flange mounted.