OK vertical roller mill

the OK mill is a natural choice for grinding blended cements with one or more wet components. With a 30-45% reduction in the energy requirements for cement grinding and 40-50% for slag as compared with traditional ball mill operations.Space-saving design reduces civil construction costs . grinding and separation processes into just one unit.Excellent drying capability when grinding blast furnace slag or blended cements with wet components .Consistent cement quality with easy to adjust quality parameters .Roller and table profile improve operating stability and reliability . Because of its highly effective drying performance.Special design features for iron removal during slag grinding minimise wear . The design combines the drying. 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 OK mill is the premier roller mill for finish grinding of portland cement. A low noise level makes outdoor installation feasible. thus simplifying the plant layout.Flexibility to operate with two or four rollers guarantees long term availability Application advantages Proven commercially. OK 36-4 mill under erection .2 Quality & profit improving features Main features . slag and blended cements.Optimal wear-protection on all internal surfaces .OK vertical roller mills use 30-50% less energy than ball mill systems . substantially reducing civil construction costs and improving the working environment.Simple layout and fewer machines in the mill circuit ensure high run-factor and low maintenance costs . the OK mill can contribute significantly to your profitability and competitiveness.

This eliminates the need for an auxiliary drive. 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 . 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. A control system monitors the machinery and facilitates operation. The inner path serves to prepare the grinding bed. allowing air to escape into the grooved centre. This creates a high and concentrated grinding pressure on the outer path. an inner and an outer. These features ensure maximum longevity. Re-positioning of rollers is possible for evening out wear. Operating advantages The rollers are in a lifted position when the mill is started.3 The grooved roller profile has two grinding zones. ensuring trouble-free start-up.

slag. In case the mill feed is wet slag or includes a significant portion of wet additives. Clinker. and to vary the particle size to meet individual needs. Its versatility is demonstrated by the ability to switch between a wide variety of mixes. 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. simple operation and long life Mill arrangement This schematic illustrates a typical grinding installation. gypsum. limestone and fly ash. One mill. for instance from a heat generator. Particle size distribution Examples of adjustments of particle size distribution when grinding to the same Blaine surface. many products The OK mill efficiently grinds blended cements. puzzolana. Otherwise. if the mill feed is very hot. Nozzle ring bypass system For slag grinding. with a wide range of additives such as slag. The arrangement is very simple and the operation is correspondingly flexible and reliable. the mill exit temperature controls a damper for cold air intake. The required steepness of the particle size distribution curve is attained by adjustment of the separator rotor speed. additional heat must be provided.4 Mill design for versatile applications. the mill airflow rate and the grinding pressure. additive 3 4 Finished product Hot air for drying Cold air intake 1 OK mill 2 1 5 2 Dynamic separator 3 Bag filter 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 C D D E Plant E F F F OK mill feed composition . in combination with the appropriate height of the dam ring. 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.

Being of the segmented type the wear liners can be hardfaced numerous times throughout their life. For mills grinding very abrasive materials. for example from portland cement to slag. Adjustment of the dam ring is not required. 0. requires a mill stop.5 Optimisation of operation Adjustment of mill airflow and grinding pressure for optimisation of the operation. including adjustment of particle size distribution. 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. Hardfaced segments . Adjustment of the dam ring. 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. however. Switching between different types of products. like slag. only requires easily made operating adjustments.1 1 5 10 20 30 40 50 60 Residue (%) 70 80 90 95 96 97 98 99 1 10 100 Particle size (µm) OK mill steep PSD Typical ball mill PSD OK mill flat PSD Seal between housing and roller. optimising the grinding process and saving refurbishment costs. However. can be made immediately. but only for a few hours. hardfacing is an interesting and viable means of achieving a high availability of the grinding system. 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.

6 Performance and experience Typical specific energy consumption (kWh/t) motor input Portland cement Blaine (cm2/g) OK mill Mill Fan etc.9 24.0 45.000 Ball mill 44.6 6.1 12.4 OK mill 21.3 29.300 Ball mill 145 245 420 Blended cement 3.8 OK mill 25.6 4.2 37.000 Ball mill 51.700 OK mill 225 275 350 4.000 Ball mill 220 260 330 OK mill 115 195 425 Slag cement* 3.6 59.2 Slag* 5.4 35.7 9.2 13.4 OK mill 32.2 3.8 7.300 Ball mill 34.800 Ball mill 110 190 425 2 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 3. Total *Slag with 8% moisture 17.4 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 3.0 Twin mill installation OK 30-4 Installation .5 Table 1 0.1 4.5 Slag* Table 6 3.9 4.3 8.5 Roller 5 2.9 49.3 83.000 Ball mill 71.

1 5.5 36-4 19.7 23.7 12. installed Airflow.5 6.3 15.4 9. grindability and additives (types and proportion of mill feed) OK mill Mill motor.7 7..9 45-4 26.0 7.2 27-4 13.2 6.9 12.8 8.5 13.2 8.2 42-4 23.4 39-4 20.7 Dimensions and characteristics The capacity range depends on fineness.0 16.6 18.1 12.2 11.2 10. mill outlet Cement.0 10.3 7.8 33-4 17. 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 13.0 30-4 15.4 9.6 8.7 OK 33-4 for slag OK mill number represents mean grinding track diameter C 27-4 30-4 33-4 36-4 39-4 42-4 45-4 25-3 B A D D . approx.1 11.7 21.

Excellent drying capacity .com C 12-10 300-2-ENG V2 .flsmidth. Slag mill inspection.com Project Centre India FLSmidth Private Limited FLSmidth House 34. Copyright © 2010 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. and information and data contained in this brochure are for general reference only and may change at any time.Flexible operation .com Project Centre Denmark FLSmidth A/S Vigerslev Allé 77 DK-2500 Valby Copenhagen Tel: +45 3618 1000 Fax: +45 3630 1820 E-mail: info@flsmidth.Proven technology . Egatoor. Kelambakkam (Rajiv Gandhi Salai. This brochure makes no offers. Chennai) Tamil Nadu – 603 103 Tel: +91-44-4748 1000 Fax: +91-44-2747 0301 E-mail: indiainfo@flsmidth.. The OK mill is manufactured by FLSmidth under patent & license from Earthtechnica Co. Ltd & Taiheiyo Cement Corp.. PA 18017-2188 Tel: +1 610-264-6011 Fax: +1 610-264-6170 E-mail: info-us@flsmidth.com Project Centre USA FLSmidth Inc.Designed for grinding blended cements or slag .Easy maintenance and optimum utilisation of wear parts View of rollers inside an OK mill. 2040 Avenue C Bethlehem. www. representations or warranties (express or implied).