OK vertical roller mill

For portland cement, slag & blended cements

■ Low energy consumption
■ Compact and space-saving design
■ Smooth and reliable operation
 Quality & profit improving features

• OK vertical roller Application advantages The design combines the drying, grinding
OK VERTICAL ROLLER MILL

mills use 30-50% less Proven commercially, the OK series is the and separation processes into just one
energy than ball mill premier roller mill for finish grinding of unit, thus simplifying the plant layout. A
systems. It’s good for portland cement, slag, and blended low noise level makes outdoor installation
profits, good for the cements. With a 30-40% reduction in the feasible, substantially reducing civil
environment. energy requirements for cement grinding construction costs and improving the
• Space-saving design and 40-50% for slag as compared with working environment.
reduces civil traditional ball mill operations, the OK Because of its highly effective drying
construction costs. mill can contribute significantly to your performance, the OK mill is a natural choice
• Simple layout and profitability and competitiveness. for grinding blended cements with one or
operation with fewer more wet components.
machines in the circuit
ensure high run-factor. Design advantages
• Excellent drying Depending on its size, the OK mill has three
makes the mill well or four rollers. They are hydro-pneumatically
suited for grinding pressed against the material bed on the
blast furnace slag or rotating grinding table.
blended cements from A patented grooved roller profile creates
one or more wet a high and concentrated grinding pressure
components. on the outer path, allowing air to escape in
• Low vibration made the middle. The inner path serves to even
possible by specially out and consolidate the material before it
designed roller and continues to the next roller.
table profiles ensures The segmented roller wear parts can be
operating reliability. made of even the hardest material without
• Curved table increases OK 36-4 mill under erection risk of cracking and are very well suited for
retention time and hard facing. Moreover, the segments are
grinding bed thickness reversible, so their full width can be utilized.
for smooth operation. These features ensure maximum longevity.
• Easy to adjust Blaine
and particle size distri- Operating advantages
bution for required The rollers are in a lifted position when the
cement quality. mill is started, ensuring trouble-free start-
• During slag grinding, up. This eliminates the need for an auxiliary
wear is minimized via drive. A control system supervises the
a special by-pass that machinery and facilitates operation.
removes iron particles
from the grinding
table.
• All exposed surfaces
are wear-protected. Swing-out system for Main hydraulic
roller replacement loading system
 Product

Feed inlet

Rotary
Separator feed sluice

Grinding roller Main hydraulic

loading system

Nozzle ring

Grinding table

Roller stopper

Patented roller shape & curved table profile

Mill design for versatile applications,
simple operation and long life
Mill arrangement
Clinker, gypsum, This schematic illustrates a typical grinding
slag, additive
3 installation. The arrangement is very simple
4 and the operation is correspondingly easy
Finished product 2 and reliable. To maintain a proper tempera-
Hot air
Cold air ture in the mill circuit – among others to
for
intake 1 ensure an adequate dehydration of the
drying
5
gypsum when grinding cement – the layout
is prepared with provisions for recirculation
of hot mill exit gas to the mill inlet. In case
the mill feed is wet slag or includes a signif-
icant portion of wet additives, additional
Nozzle
heat must be provided, for instance from a
heat generator. Otherwise, if the mill feed is
very hot, the mill exit temperature controls
Table
a damper for cold air intake.
Air inlet

Nozzle ring bypass system

Discharge chute For slag grinding, a specially designed
for iron particles
nozzle ring bypass allows the iron particles
To magnet separator to segregate through nozzles without
airflow and subsequently be removed by
1 OK mill a magnetic separator to minimize wear
2 Dynamic separator
of the mill internals.
3 Bag filter
4 Fan
5 Magnetic separator One mill, many products
The OK mill efficiently grinds blended
Mill arrangement and nozzle ring bypass system cements, with a wide range of additives
such as slag, puzzolana, limestone and fly
ash. Its versatility is demonstrated by the
(%)
100 ability to switch between a wide variety
Clinker
90 of mixes, and to vary the partical size to
80 Gypsum
70 Pozzolana meet individual client needs.
60
Limestone
50
40 PFA
30 Slag
20
10
0
A+B C D D E E F F F
Plant

OK mill feed composition

 OK mill steep PSD
Particle Size Distribution (PSD) Typical ball mill PSD
Examples of adjustments of particle size 0.1
OK mill flat PSD
distribution when grinding to the same 1

Blaine surface. The required steepness of 5

10
the particle size distribution curve is 20
attained by adjustment of the separator 30
40
rotor speed, the mill airflow rate and the
50
grinding pressure, in combination with 60

Residue (%)
the appropriate height of the dam ring. 70
80
Optimisation of operation
Adjustment of mill airflow and grinding 90
pressure for optimisation of the operation,
95
including adjustment of particle size 96
distribution, can be made immediately. 97
Adjustment of the dam ring obviously 98
requires a mill stop, however, only for a few
hours. Switch between different types of 99
1 10 100
products, say from portland cement to slag, Particle size (µm)
requires an adjustment of the grinding
pressure. Adjustment of the dam ring is not
Easily adjustable dam
required. However, if the mill is to operate ring and nozzle ring
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 segmented type and
therefore easy to replace when worn out.
The wear segments of the rollers can
further be reversed to utilise both sides
of the segments – wear is most significant
on the outer part of the rollers – and
thus achieve a high utilisation of the
wear segments.
For mills grinding very abrasive materials,
Hardfaced
like slag, hardfacing is an interesting and rebuilt table
viable means of achieving a high availability and roller.
of the grinding system, optimising the grind-
ing process and saving refurbishment costs.
It is an economical alternative to chang-
ing wear parts and very suitable for the
high chrome cast iron grinding parts used
in the OK mill. Being of segmented type
the wear liners can be hardfaced numerous
times throughout their life.
Performance and experience

Typical specific energy consumption (kWh/t) motor input

Portland cement Slag*

Blaine (cm /g) 2
3,300 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 Blended cement Slag cement*

Blaine (cm2/g) 3,300 3,700 4,000 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) without hardfacing of wear parts

Portland cement Slag

Roller Table Roller Table
1 1 5 6

OK mill with minimal weather protection

OK separator
Dimensions and characteristics

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

OK mill size 19-3 22-3 25-3 27-4 30-4 33-4 36-4 39-4
Mill motor, installed kW 675 975 1350 1800 2350 3000 3750 4600
Airflow, approx., mill outlet Nm3/s 13 19 26 36 47 60 75 91
Separator motor, min. installed kW 32 52 69 110 136 165 197 234
Cement, capacity range t/h 20-40 30-55 45-75 60-100 80-135 105-170 130-215 160-260
Slag, capacity range t/h 15-25 25-40 35-50 45-70 60-90 75-115 95-140 110-170

Dimensions

OK mill size 19-3 22-3 25-3 27-4 30-4 33-4 36-4 39-4
A m 10.2 12.3 14.8 15.7 17.3 18.3 19.5 21.2
B m 8.7 10.4 12.1 13.0 14.4 15.8 16.6 18.0
C m 3.7 4.0 4.4 4.8 5.3 5.8 6.3 6.9
D m 6.3 7.3 8.2 7.0 7.8 8.5 9.4 10.2

OK mill number represents mean

grinding track diameter

27-4
30-4
33-4 19-3
36-4 22-3
39-4 25-3
• Proven technology
• Very suitable for grinding blended
cements or slag
• Compact grinding installation
• Suitable for grinding moist feed
• Easy maintenance and optimum
utilization of wear parts

View of rollers inside an OK mill OK 27-4 mill for slag cement in Argentina

The OK mill is manufactured by F.L.Smidth under patent

Data in this brochure is intended for preliminary project planning only. Manufacturer
reserves the right to modify equipment details and/or specifications without notice. & license from Kobe Steel Ltd. & Taiheiyo Cement Corp.
07-01-252 Gramstrup Design ApS

USA INDIA DENMARK

F.L.Smidth Inc. Fuller India Limited F.L.Smidth A/S
2040 Avenue C Capital Towers Vigerslev Allé 77
www.flsmidth.com
Bethlehem, PA 18017-2188 180, Kodambakkam High Road DK-2500 Valby
Tel: +1 610-264-6011 Nungambakkam Copenhagen
Up-to-date addresses of worldwide
subsidiaries and sales offices are Tel: +1 800-523-9482 Chennai 600 034 Tel: +45 36 18 10 00
available from our website
Fax: +1 610-264-6170 Tel: +91 44-827-6030/8228623 Fax: +45 36 30 18 20
E-mail: [email protected] Fax: +91 44-827-9393 E-mail: [email protected]
E-mail: [email protected]