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The FLSmidth OK mill

The high-effiency and reliable roller mill for cement and slag grinding

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First FLSmidth vertical mill (1922)

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ATOX Raw Mill

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OK Mill layout Simple and space-saving layout


Proven technology based on a
license (1993) from Onoda and

Kobe Steel, Japan

High efficiency separator Equivalent or better cement quality


than tube mill cement

Energy saving. 25% to 45% in kWh


compared to Ball Tube Mills

Very suitable for grinding blended


cement or slag

Easily controllable particle size


distribution

Easy maintenance due to


swing-in/out roller support system
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FLSmidth OK mill
Separator Separator drive

Grinding roller

Mill outlet

Rocker arm

Mill feed inlet

Gear box

Grinding table

Mill stand

Hydraulic system

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OK Mill - a Unique design developed specifically for cement and slag grinding

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OK Vertical mill grinding parts Pressure distribution

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OK mill efficiency compared to ball mills


70

65

Spec. Energy Cons.,Total, kWh/t

60

55

Ball mill

50

45

45 %
40 35

OK mill
33 %

30

25

20 2500 2700 2900 3100 3300 3500


2

3700

3900

4100

4300

4500

Blaine, cm /g
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Importance of cement grinding on total plant power consumption


Cement storage / dispatch 1% Cement grinding 44%

Raw material preparation 38%

with OK mill
Clinker production 17%

with ball mill

Cement grinding 36%

Cement storage / dispatch 1% Raw material preparation 44%

Clinker production 19%

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CO2 reduction substituting ball mill with OK mill Example


60,000

CO2 reduction, t CO2 per year

50,000

Clinker production capacity: 1.5 mill t/year Cement type: Ordinary Portland Cement EF = Emission Factor (tCO2/MWh)

EF = 1.0

40,000

EF = 0.75

30,000

EF = 0.5
20,000

10,000

0 2500
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3000

3500

4000

4500

5000

Blaine, cm2/g

Clinker replacement materials for blended cement


It is good for the environment: Saving of raw materials Energy saving Reduced CO2 emission Waste utilization (slag and fly ash)

OK mill is very suitable for grinding of blended cement: It is more versatile than a ball mill. Separate drying facilities are not required. It is easy to change from one product type to another product with practically no transition periods between products. Besides pure slag it can grind any type blended of cement with additives such as limestone, pozzolana, fly ash and slag; even with high water content

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OK mills - Composition of mill feed


100 90 80 70 60 50 40 30 20 10 0 A+B C C D D D E F+G+ H I+J I+J

Plant
Clinker, % Gypsum, % Limestone, % Pozzolana, % Slag, % Fly ash, %

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OK mill performance
Capacity, t/h Guarant. Achieved 1 Slag cement 145 192 2 OPC 170 189 3 OPC 170 189 Slag cement 55 60 4 Slag 45 51 5 OPC 66 70 6 OPC 145 161 7 Blended 140 155 8 Blended 170 172 9 OPC 118 144 10 Blended 120 130 11 Blended 150 154 12 Slag 84 91 13 OPC 150 150 14 OPC 152 155 15 OPC 154 166 16 Blended 120 123 17 OPC 180 186 18 OPC 175 194 19 OPC 180 182 20 OPC 180 189 21 Blended 120 138 (a): With gypsum (b): Without gypsum
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Entry

Cement type

+ 9 % + 3 % - 14 %

Blaine kWh/t Guarant. Achieved Garant. Achieved 3670 3550 37.1 28.3 3000 2900 26.3 23.0 3000 3300 26.3 24.3 4000 4105 36.0 34.4 4000 3982 44.0 40.3 3800 3800 34.3 31.0 3000 3060 24.8 21.8 17.6 (Mill) 7% > 45 6.2% > 45 17.2 (Mill) 4400 4378 None 27.4 3900 3900 25.7 3450 3900 26.8 22.8 3200 3650 22.9 18.3 4600 (a) 4210 (b) 32.5 (M+S) 31.1 (M+S) 3300 3350 19.7 18.0 3800 4024 36.7 29,4 3750 3743 n/a 29,4 3450 3700 26.8 23.5 3000 3050 29 21.5 3000 3050 n/a 22,6 3200 3300 33 25,4 3200 3230 33 26,0 3650 3702 27 20,0

Easy commissioning of mill First 40 days of OK mill operation


250.0 5000

200.0

4000
3800 - Guar.

Guar. - 168

Production

150.0

3000

100.0

2000

50.0

1000

0.0

2/1 2/3 2/5 2/7 2/9 2/11 2/14 2/16 2/18 2/20 2/22 2/24 2/26 2/28 3/3 3/5 3/7
Date, 2006
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Blaine

OK mill product quality


Plant Cement type Mill Fineness . PSD Blaine(m2/kg) Res. 45 m (%) PSD / d-50% (m) PSD / d (m) PSD / n-value Dehydr./Prehydr. Gypsum (%) Hemihydr. (%) Prehydr. (%) Cement testing (EN / ISO) Water to NC (%) Initial set (h:min) Final set (h:min) Str.-1day (MPa) Str.-2 days (MPa) Str.-3 day (MPa) Str.-7 day (MPa) Str.-28 day (MPa) Plant A OPC BM 375 5.3 13.4 17.7 1.05 0.1 1.5 0.25 OK 377 1.3 12.0 16.3 1.10 2.0 0.5 0.15 BM-1 399 5.4 13.6 18.6 1.11 1.2 2.3 Plant B Blended BM-2 OK-1 436 5.6 12.8 17.8 1.07 0.9 2.3 399 7.4 14.1 19.4 1.07 1.9 1.7 Plant C Blended BM OK 437 2.4 11.7 16.3 1.01 4.0 2.0 0.29 385 3.2 13.0 17.6 1.05 3.5 1.5 0.20

OK-2 376 4.5 14.9 19.5 1.06 3.2 1.0 -

Conclusion: Quality of cements produced in OK mills is very similar to those produced in ball mills 29.8 28.4 26.9 28.8 with high 39.0 efficiency separators 42.8 39.4 36.1 35.7 37.5 39.8 41.7
60.5 60.3 50.0 47.9 49.2 50.3 50.5

27.0 2:05 2:50 19.0 27.6

26.5 1:50 2:40 18.8 28.8

29.5 2:35 3:20 13.8

29.0 2:25 3:10 12.1

31.0 3:05 4:00 10.6

32.5 3:15 4:20 10.2

27.5 1:20 2:30 15.5 32.1

27.5 1:45 2:30 14.8 32.5

52.0

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Sale of ball mills and VRM for cement grinding ex. China
80 70 60 50 40 30 20 10 0 2003 2004 2005 2006 2007 BM VRM

Number of mills sold

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OK mills sold July 2008

OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

OK OK

OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

OK OK

All together 92 FLSmidth OK mills sold world wide

Summary of experiences with OK Mills commissioned by FLSmidth


The production is above guaranteed The spec. energy consumption below guaranteed It grinds all kind of cements with additives The operational parameters can be adjusted to meet quality requirements It can be operated with two rollers only It is reliable in operation, easy to operate and easy to maintain
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Thank you for your attention

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