Extending Bearing Life and Reducing Costs in Cement Slurry Pumps
A leading cement plant in the United States was facing recurring downtime and rising maintenance costs due to frequent premature bearing failures in their slurry pumps. The bearings were lasting only two to three months, far below the expected service life, due to a combination of the harsh conditions on site and the contamination in the slurry pumps. Having to replace the bearings so frequently was not only disrupting production but also driving up costs significantly.
The cement plant asked NSK to investigate the issue and suggest a solution which would improve the reliability of the pump system. Our expert engineering team conducted a detailed Application Review and determined that contamination was the key factor in the bearing’s premature failure.
To solve the problem, NSK recommended replacing the existing bearings with Angular Contact Ball Bearings (ACBB) made from High Toughness (HTF) steel, a material specifically developed to withstand extreme operating environments. HTF steel is made via an innovative heat-treatment- and material technology that provides increased resistance to wear, contamination and fatigue, allowing bearings made from it to last far longer than conventional alternatives.
"By combining advanced material technology with expert guidance, we can help customers reduce costs and keep critical equipment running smoothly"
Anton Mozhaev, NSK Europe’s Sector Manager for Cement
In addition to the Angular Contact Ball Bearings, NSK also provided on-site training to the plant's maintenance team, focusing on proper installation techniques and best practices for bearing handling and maintenance. The hope was that this training would ensure that the improved performance of the bearings could be sustained over time.
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‘This case highlights how NSK can bring our product quality and industry expertise to bear in order to measurably improve performance and reliability,’ commented Anton Mozhaev, NSK Europe’s Sector Manager for Cement. ‘By combining advanced material technology with expert guidance, we can help customers reduce costs and keep critical equipment running smoothly—even in the most challenging environments.’
The plant adopted NSK’s recommendations and immediately saw results. The Angular Contact Ball Bearings lasted twice as long as their predecessors and, as a direct result, unplanned downtime and maintenance was drastically reduced. The enhanced reliability of the components translated into total cost savings of €51,476, underscoring the long-term value of investing in high-performance parts and expert support.
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