OK vertical roller mill

 or portland cement, slag and blended cements

F

Energy efficient
Flexible
Reliable

OK VERTICAL ROLLER MILL

Quality & profit improving features

MAIN FEATURES
O
 K vertical roller
mills use 30-50% less
energy than ball mill
systems
Simple layout and
fewer machines in the
mill circuit ensure high
run-factor and low
maintenance costs
Excellent drying
capability when
grinding blast
furnace slag or
blended cements
with wet components
Roller and table profile
improve operating
stability and reliability
Consistent cement
quality with easy
to adjust quality
parameters
Special design features
for iron removal
during slag grinding
minimise wear
Optimal wearprotection on all
internal surfaces
Space-saving
design reduces civil
construction costs
Flexibility to operate
with two or four
rollers guarantees
long term availability

Application advantages
Proven commercially, the OK mill is the premier roller mill for finish grinding of portland cement, slag and blended cements.
With a 30-45% reduction in the energy
requirements for cement grinding and
40-50% for slag as compared with traditional ball mill operations, the OK mill can
contribute significantly to your profitability
and competitiveness.

The design combines the drying, grinding and separation processes into just one
unit, thus simplifying the plant layout. A
low noise level makes outdoor installation
feasible, substantially reducing civil construction costs and improving the working
environment.
Because of its highly effective drying
performance, the OK mill is a natural choice
for grinding blended cements with one or
more wet components.

Design advantages
The OK mill uses a hydro-pneumatic system to press its grinding rollers against the
material bed on the rotating grinding table.
The grooved roller profile has two grinding zones, an inner and an outer. This
creates a high and concentrated grinding
pressure on the outer path, allowing air to
escape into the grooved centre. The inner
path serves to prepare the grinding bed, by
compressing the feed material as it moves
under the rollers into the high pressure
grinding zone.
Segmented roller wear parts are made
of the hardest possible material without
risk of cracking and are very well suited for
hard facing. Moreover, the segments are
reversible, so their full width can be utilised.
These features ensure maximum longevity.

OK 36-4 mill under erection

Operating advantages
The rollers are in a lifted position when
the mill is started, ensuring trouble-free
start-up. This eliminates the need for an
auxiliary drive. A control system monitors
the machinery and facilitates operation.

Swing-out system for

roller replacement

Main hydraulic
loading system

Product

Feed inlet
Rotary
feed sluice
Separator

Grinding roller
Main hydraulic
loading system
Nozzle ring

Grinding table

Roller stopper

Roller shape & curved table profile

Mill design for versatile applications,

simple operation and long life
Mill arrangement
Clinker, gypsum,
slag, additive

Finished product

Cold air
intake

Hot air
for
drying

Nozzle

Table
Air inlet

Discharge chute
for iron particles
To magnetic separator

1 OK mill
2 Dynamic separator
3 Bag filter
4 Fan
5 Magnetic separator

Clinker
Gypsum
Pozzolana
Limestone
PFA
Slag

A+B

OK mill feed composition

E
Plant

Nozzle ring bypass system

For slag grinding, a specially designed
nozzle ring bypass allows the iron particles
to segregate through nozzles without airflow and subsequently be removed by a
magnetic separator to minimise wear of the
mill internals.

One mill, many products

Mill arrangement and nozzle ring bypass system

(%)
100
90
80
70
60
50
40
30
20
10
0

This schematic illustrates a typical grinding

installation. The arrangement is very simple
and the operation is correspondingly flexible
and reliable. To maintain the appropriate
temperature in the mill circuit for example
to ensure adequate dehydration of the
gypsum when grinding cement the layout
is prepared with provisions for recirculation
of hot exit gas to the mill inlet. In case the
mill feed is wet slag or includes a significant
portion of wet additives, additional heat
must be provided, for instance from a heat
generator. Otherwise, if the mill feed is very
hot, the mill exit temperature controls a
damper for cold air intake.

The OK mill efficiently grinds blended

cements, with a wide range of additives
such as slag, puzzolana, limestone and fly
ash. Its versatility is demonstrated by the
ability to switch between a wide variety of
mixes, and to vary the particle size to meet
individual needs.

Examples of adjustments of particle size distribution when grinding to the same Blaine
surface. The required steepness of the
particle size distribution curve is attained by
adjustment of the separator rotor speed,
the mill airflow rate and the grinding pressure, in combination with the appropriate
height of the dam ring.

Optimisation of operation
Adjustment of mill airflow and grinding
pressure for optimisation of the operation, including adjustment of particle size
distribution, can be made immediately.
Adjustment of the dam ring, however,
requires a mill stop, but only for a few
hours. Switching between different types
of products, for example from portland
cement to slag, only requires easily made
operating adjustments. Adjustment of the
dam ring is not required. However, if the
mill is to operate for a long time with one
specific product only it may be expedient to
adjust the dam ring to optimise the mill for
operation with this specific product.

0.1
0.1

OK
OK mill
millsteep
steepPSD
PSD
Typical
Typicalball
ballmill
millPSD
PSD
OK
OK mill
millflat
flatPSD
PSD

11

Residue (%)
Residue (%)

Particle size distribution

55
10
10
20
20
30
30
40
40
50
50
60
60
70
70
80
80
90
90

95
95
96
96
97
97
98
98
99
99

1
1

10
10
Particle size (m)
Particle size (m)

100
100

Roller body protector

Wear liners
The wear liners of the grinding table and
the rollers are of the segmented type and
are therefore easy to replace when worn
out. Furthermore, the wear segments of the
rollers can be reversed to utilise both sides
of the segments and thereby achieve higher
utilisation.
For mills grinding very abrasive materials,
like slag, hardfacing is an interesting and
viable means of achieving a high availability of the grinding system, optimising the
grinding process and saving refurbishment
costs.
Hardfacing is an economical alternative
to changing wear parts and is very suitable
for the high chrome cast iron grinding parts
used in the OK mill. Being of the segmented type the wear liners can be hardfaced
numerous times throughout their life.

Hardfaced segments

Performance and experience

Typical specific energy consumption (kWh/t) motor input

Portland cement

Blaine (cm /g)

3,300

Slag*

4,000

4,000

5,000

OK mill Ball mill OK mill Ball mill OK mill Ball mill OK mill Ball mill

Mill

17.6

34.2

21.3

44.9

25.7

51.8

32.2

71.1

Fan etc.

6.9

3.2

8.3

4.9

9.4

7.6

13.0

12.3

Total

24.5

37.4

29.6

49.8

35.1

59.4

45.2

83.4

*Slag with 8% moisture

Examples of compressive strength (kgf/cm2)

Portland cement

Blaine (cm2/g)

3,300

Blended cement
3,700

4,000

Slag cement*
3,800

OK mill Ball mill OK mill Ball mill OK mill Ball mill

3 days

155

145

225

220

115

110

7 days

255

245

275

260

195

190

28 days

430

420

350

330

425

425

*50/50 clinker and slag mixture

Typical wear rates (g/t cement) of wear parts

Portland cement

Roller

Without hardfacing
With hardfacing
*50/50 clinker and slag mixture

Twin mill installation

OK 30-4 Installation

Table

Slag*
Roller

Table

0.5

0.5

2.5

3.0

Dimensions and characteristics

The capacity range depends on fineness, grindability and additives (types and proportion of mill feed)
OK mill

size

25-3

27-4

30-4

33-4

36-4

39-4

42-4

45-4

Mill motor, installed

kW

1350

1800

2350

3000

3750

4600

5500

6500

Airflow, approx., mill outlet

Nm3/s

30

40

50

65

80

100

120

145

Cement, capacity range

t/h

45-90

60-125 80-165 105-210 130-260 160-315 190-380 225-450

Slag, capacity range

t/h

35-60

45-90

OK mill

size

25-3

27-4

30-4

33-4

36-4

39-4

42-4

45-4

13.7

13.9

15.5

17.3

19.0

20.6

23.7

26.7

12.1

12.2

13.5

15.3

16.8

18.4

21.2

23.1

5.2

6.0

6.7

7.6

8.4

9.2

11.0

12.1

8.2

7.0

7.8

8.5

9.4

10.2

10.9

11.7

60-115 75-145 95-180 110-220 130-265 155-315

Dimensions

OK mill number represents mean

grinding track diameter

27-4
30-4
33-4
36-4
39-4
42-4
45-4

25-3

 Proven technology
Flexible operation
Designed for grinding blended
cements or slag
Excellent drying capacity
Easy maintenance and optimum
utilisation of wear parts

OK 33-4 for slag

Our brochure makes no offers, representations or warranties (express or implied),

and information and data contained in this brochure are for general reference only
and may change any time. Please contact us for specific information or data that
may relate to your interests.

DENMARK
www.flsmidth.com
For a full list of
FLSmidth Group Companies,
visit www.flsmidth.com

FLSmidth A/S
Vigerslev All 77
DK-2500 Valby
Copenhagen
Tel: +45 36 18 10 00
Fax: +45 36 30 18 20
E-mail: info@flsmidth.com

USA

The OK mill is manufactured by FLSmidth under patent

& license from Earthtechnica Co., Ltd & Taiheiyo Cement Corp.

FLSmidth Inc.
2040 Avenue C
Bethlehem, PA 18017-2188
Tel: +1 610-264-6011
Tel: +1 800-523-9482
Fax: +1 610-264-6170
E-mail: info-us@flsmidth.com

INDIA

FLSmidth Private Limited

FLSmidth House
34, Egatoor, Kelambakkam
(Rajiv Gandhi Salai - Chennai)
Tamil Nadu 603 103
Tel: +91-44-4748 1000
Fax: +91-44-2747 0301
E-mail: indiainfo@flsmidth.com

07-08-258 www.zerodesign.dk

View of rollers inside an OK mill