OK vertical roller mill

Quality & profit improving features

Main features
- OK 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 wear-protection 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.

OK 36-4 mill under erection

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. Re-positioning of rollers is possible for evening out wear. These features ensure maximum longevity. 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.

Product

Feed inlet

Rotary feed sluice Separator

Grinding roller Nozzle ring Grinding table Roller stopper Main hydraulic loading system

Roller shape & curved table profile

Main hydraulic loading system

Swing-out system for roller replacement

Mill design for versatile applications, simple operation and long life
Mill arrangement 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. 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 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. Particle size distribution 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.

Clinker, gypsum, slag, additive

3 4
Finished product Hot air for drying Cold air intake

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

Nozzle

Table

Air inlet

Discharge chute for iron particles

To magnetic separator Mill arrangement and nozzle ring bypass system

(%) 100 90 80 70 60 50 40 30 20 10 0 Clinker Gypsum Pozzolana Limestone PFA Slag

A+B

E Plant

OK mill feed composition

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. 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. 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.

0.1 1 5 10 20 30 40 50 60 Residue (%) 70 80

90

95 96 97 98

99 1 10 100

Particle size (m)

OK mill steep PSD

Typical ball mill PSD

OK mill at PSD

Seal between housing and roller.

Hardfaced segments

Performance and experience

Typical specific energy consumption (kWh/t) motor input
Portland cement Blaine (cm2/g) OK mill Mill Fan etc. Total *Slag with 8% moisture 17.6 6.9 24.5 3,300 Ball mill 34.2 3.2 37.4 OK mill 21.3 8.3 29.6 4,000 Ball mill 44.9 4.9 49.8 OK mill 25.7 9.4 35.1 4,000 Ball mill 51.8 7.6 59.4 OK mill 32.2 13.0 45.2 Slag* 5,000 Ball mill 71.1 12.3 83.4

Examples of compressive strength (kgf/cm )

Portland cement Blaine (cm2/g) OK mill 3 days 7 days 28 days *50/50 clinker and slag mixture 155 255 430 3,300 Ball mill 145 245 420 Blended cement 3,700 OK mill 225 275 350 4,000 Ball mill 220 260 330 OK mill 115 195 425 Slag cement* 3,800 Ball mill 110 190 425

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

Portland cement Roller Without hardfacing With hardfacing *50/50 clinker and slag mixture 1 0.5 Table 1 0.5 Roller 5 2.5 Slag* Table 6 3.0

Twin mill installation

OK 30-4 Installation

Dimensions and characteristics

The capacity range depends on fineness, grindability and additives (types and proportion of mill feed)
OK mill Mill motor, installed Airflow, approx., mill outlet Cement, capacity range Slag at 420 m2/kg Gear Output kW t/h 1544 51 2161 72 2829 94 3590 119 4446 148 5412 180 6488 216 7763 258 size kW Nm /s t/h
3

25-3 1350 30 45-90

27-4 1800 40 60-125

30-4 2350 50 80-165

33-4 3000 65 105-210

36-4 3750 80 130-260

39-4 4600 100 160-315

42-4 5500 120 190-380

45-4 6500 145 225-450

Dimensions
OK mill A B C D size m m m m 25-3 13.7 12.1 5.2 8.2 27-4 13.9 12.2 6.0 7.0 30-4 15.5 13.5 6.7 7.8 33-4 17.3 15.3 7.6 8.5 36-4 19.0 16.8 8.4 9.4 39-4 20.6 18.4 9.2 10.2 42-4 23.7 21.2 11.0 10.9 45-4 26.7 23.1 12.1 11.7

OK 33-4 for slag

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

View of rollers inside an OK mill.

Slag mill inspection.

The OK mill is manufactured by FLSmidth under patent & license from Earthtechnica Co., Ltd & Taiheiyo Cement Corp. Copyright 2010 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This 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 at any time.

www.flsmidth.com

Project Centre Denmark FLSmidth A/S Vigerslev All 77 DK-2500 Valby Copenhagen Tel: +45 3618 1000 Fax: +45 3630 1820 E-mail: info@flsmidth.com

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

Project Centre 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

C 12-10 300-2-ENG V2