The FLSmidth OK Mill

for
Cement and Slag Grinding

10 November 2010
Presentation Content

General, Key Points

Mechanical features and maintenance

Product Quality

10 November 2010
OK Roller Mill

10 November 2010
OK Mill Capacity Range
OPC Cement
Mill size
OK 45-4

OK 42-4

OK 39-4

OK 36-4

OK 33-4

OK 30-4

OK 27-4

OK 25-3

OK 22-3

OK 19-3

0 50 100 150 200 250 300 350 400 450

t/h

10 November 2010
OK Mill Capacity Range
Slag

Mill size
OK 45-4

OK 42-4

OK 39-4

OK 36-4

OK 33-4

OK 30-4

OK 27-4

OK 25-3

OK 22-3

OK 19-3

0 50 100 150 200 250

t/h

10 November 2010
OK Mills Installed and Available Power
Mill size Motor size Avail. Power
OK (kW) (kW)
19-3 675 602
22-3 975 869
25-3 1350 1196
27-4 1800 1653
30-4 2350 2152
33-4 3000 2733
36-4 3750 3394
39-4 4600 4145
42-4 5500 4984
45-4 6960 5928
Available power is used for capacity
calculations in combination with material
characteristics and grindability
10 November 2010
 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. 20% to 40% 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

10 November 2010
 Mill outlet
Separator drive
OK Roller
Mill Details
Rotary sluice
Separator rotor

Mill feed inlet

Separator

Grinding roller

Separator reject
Grinding table

Roller stopper

Mill stand Swing out cylinder

Main drive
Hydraulic system
Unique design developed specifically
for cement and slag grinding ……

10 November 2010
OK Roller Mill – Roller and Table profile

10 November 2010
OK Vertical mill grinding parts
Pressure distribution

10 November 2010
 Optimum Design of Rollers and Table
A B
Blaine Maximum
4500 [cm2 /g] acceptable
vibrations

4000

3500
D
3000 C C D
A
B
0
100 200 300
Capacity [kg/h]

10 November 2010
OK Mills
Best vs. Competitor
Grinding VRM
Efficiency

40
Spec. Energy Cons., Total, kWh/t

Spherical roller
35

Flat roller OK
30

25

20

15
2500 3000 3500 4000 4500 5000
Blaine
OK mill efficiency compared to ball mills
70

65 For OPC
60
Spec. Energy Cons.,Total, kWh/t

55
Ball mill
50

≈ 50 %
45

40

35
OK mill
30
≈ 33 %
25

20
2500 2700 2900 3100 3300 3500 3700 3900 4100 4300 4500
2
Blaine, cm /g
10 November 2010
 OK mill versus ball mills
Specific energy consumption
EXAMPLES

Plant AA BB CC DD
Cement type OPC OPC OPC Slag cement
Type of mill BM OK BM OK BM OK BM OK

Blaine, cm2/g 3200 3200 3700 3700 3880 3900 3640 3640

kWh/t
Mill 32.5 22.2 39.2 21.1 35.2 18.3 34.4 17.2
Total 38.5 28.9 42.3 32.2 42.4 25.7 40.0 25.7

Conclusion: The energy consumption

of the OK mill system is 25% to 40%
lower than for the ball mill system
10 November 2010
 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+ I+J I+J
H
Plant

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

10 November 2010
Reliability …..

10 November 2010
 OK mill performance
Entry Cement type Capacity, t/h Blaine kWh/t
Guarant. Achieved Guarant. Achieved Garant. Achieved
1 Slag cement 145 192 3670 3550 37.1 28.3
2 OPC 170 189 3000 2900 26.3 23.0
3 OPC 170 189 3000 3300 26.3 24.3
Slag cement 55 60 4000 4105 36.0 34.4
4
Slag 45 51 4000 3982 44.0 40.3
5 OPC 66 70 3800 3800 34.3 31.0
6 OPC 145 161 3000 3060 24.8 21.8
7 Blended 140 155 7% > 45 µ 6.2% > 45 µ 17.2 (Mill) 17.6 (Mill)
8 Blended 170 172 4400 4378 None 27.4
9 OPC 118 144 3900 3900 - 25.7
10 Blended 120 130 3450 3900 26.8 22.8
11 Blended 150 154 3200 3650 22.9 18.3
12 Slag 84 91 4600 (a) 4210 (b) 32.5 (M+S) 31.1 (M+S)
13 OPC 150 150 3300 3350 19.7 18.0
14 OPC 152 155 3800 4024 36.7 29,4
15 OPC 154 166 3750 3743 n/a 29,4
16 Blended 120 123 3450 3700 26.8 23.5
17 OPC 180 186 3000 3050 29 21.5
18 OPC 175 194 3000 3050 n/a 22,6
19 OPC 180 182 3200 3300 33 25,4
20 OPC 180 189 3200 3230 33 26,0
21 Blended 120 138 3650 3702 27 20,0
(a): With gypsum (b): Without gypsum + 9 % +3% - 14 %
10 November 2010
 Easy commissioning of mill
First 40 days of OK mill operation
250.0 5000

200.0 4000
3800 - Guar.

Guar. - 168

150.0 3000
Production

Blaine
100.0 2000

50.0 1000

0.0 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
10 November 2010
 Example of smooth commissioning

OK 36 Mill in USA Cement sales Roller and table

decrease, mill liner rewelding
capacity reduced 16-19 January
6000.0 200.0

180.0
5000.0
160.0

140.0
4000.0
120.0

Capacity, t/h
Blaine

3000.0 100.0

Guaranteed performance: 154 t/h; Blaine 3750 cm2/g 80.0

2000.0 Average achieved over the first 24 weeks: 157 t/h; Blaine 3790 cm2/g
60.0

40.0
1000.0
20.0

0.0 0.0
8-1 8-14 8-22 8-28 9-4 9-12 9-18 9-25 10-1 10-7 10- 10- 10- 11-1 11-7 11- 11- 11- 12-4 12- 12- 12- 12- 1-4 1-10 1-22
13 19 25 13 22 28 11 17 23 29

10 November 2010
 OK mills recently commissioned
Duration from 1. start
Plant Cement type Capacity, t/h Blaine to operation with
guaranteed performance
Guarant. Achieved Guarant. Achieved
Saloniki 1 Blended 120 130 3450 3900 ~ 4 weeks (1)
Dongjun Slag 84 91 4600 4210 (a) < 3 weeks
Dongjun OPC 150 150 3300 3350 < 3 weeks
Mojave OPC 152 155 3800 4024 ~ 1 week
Lehigh UB OPC 154 166 3750 3743 ~ 3 weeks
Saloniki 2 Blended 120 123 3450 3700 < 2 weeks
FFCC OPC 180 186 3000 3050 ~ 1 day
Khairpur OPC 175 194 3000 3050 ~ 13 weeks (2)
Maple Leaf 1 OPC 180 182 3200 3300 ~ 1 week
Maple Leaf 2 OPC 180 189 3200 3230 ~ 9 weeks (3)
Zlatna Blended 120 138 3650 3702 ~ 5 weeks (4)
(a) Without gypsum

(1) Customer’s preference was on other products than contractual fed mix
(2) Irregular supply of feed materials from external supplier
(3) Same time as kiln – not much focus (first of two mills to start)
(4) Problems with transport equipment (client’s supply)

Average duration of commissioning (incl. performance test): 4 weeks

10 November 2010
 Run factor similar to the simple Ball Mill
100

90

80

70
Run factor, %

60
OK mill
50
Ball mill
40

30

20

10

0
1999 2000 2001 2002
10 November 2010
 Operation on 2 rollers – if needed

Condition Production % Res. Blaine kWh/t kWh/t kWh/t kWh/t Grinding

t/h 45µ cm²/g Mill Fan Sep Total Aid %
2 rollers 92 3,8 3600 15,2 13,6 0,7 29,4 0,025

4 rollers 144 3,5 3800 16,1 8,7 0,6 25,4 0,025

Guarantee 140 7,0 17,2 0,6

Data from industrial mill OK 33-4.

In case 1 roller is down for maintenance, the mill can continue operating on 2
rollers with a production of app. 65 – 70% of nominal.

10 November 2010
Mechanical design
features …..

10 November 2010
OK mill layout
Cement grinding (without slag)

Metal detector Magnetic separator

10 November 2010
 The ROKSH

The new generation

High efficiency dynamic
Separator for the OK-Mill

Lower gas velocities

Lower energy consumption

Cost optimal wear protection

10 November 2010
 ROKSH main parts

Separator outlet

Drive station Inspection door

Access platforms Bearing arrangement

Separator casing Louvres

Coarse return cone Rotor

Coarse return outlet

10 November 2010
Air velocities in the ROKSH
Reduced air velocities gives:

Less wear

Lower differential pressure

Lower separator power

Reduced mill fan power

Overall reduced operation
costs

Separator outlet: 19m/s

Through rotor vanes: 2.5 m/s
Through guide vanes: 11 m/s
Separator inlet: 5.4 m/s
Mill housing: 2.7-3.8 m/s

10 November 2010
ROKSH optimum wear protection

Based on experiences with more than

85 ROKS and OKS separators sold

Densit Wear flex 2000 wear lining

•Separator outlet

Hard faced plate (Chromium Carbide)

•Separator top section
•Coarse return outlet
•Rotor vanes
•Upper part of reject cone
Ceramic Alumina tiles
•Separator bearing arrangement
•Supports

10 November 2010
OK mill - nozzle ring
Designed to minimize abrasive blasting
of key components

10 November 2010
OK Mill New Nozzle Ring

10 November 2010
OK mill - nozzle ring

10 November 2010
OK Mill - housing/roller seal

Improved roller/housing seal

10 November 2010
OK Mill - housing/roller seal

Flexible housing/roller seal

 Durable
 Easy to maintain
 No ingress of false air

10 November 2010
 OK Mill - rotary feed sluice

Designed for air heating in case of sticky feed materials

10 November 2010
 OK Mill - rotary feed sluice

Lined with chromium carbide composite wear plate for

enhanced durability
Removable side walls for ease of maintenance

10 November 2010
 OK mill - Rotary feed sluice

Removable sides for easy

maintenance
10 November 2010
Dry fly ash injection

10 November 2010
Maintenance …..

10 November 2010
 Cement Mills - Maintenance Costs

0.8 Over 4 years Over 14 months

0.73

0.7
Maintenance costs, EUR/t

0.6
0.6

0.5

0.42
0.4
0.36

0.3

0.2

0.11
0.1

0
BM BM+RP 1 BM+RP 2 OK 1 OK 2
10 November 2010
 OK mills versus ball mills
Maintenance of wear parts (cont’d)

Cost of wear parts:

OPC, 3200 – 3600 cm2/g (Blaine) EUR per ton of cement

Ball mills 0.15 – 0.20
Hardfacing not applied 0.15 – 0.20
OK mills
Hardfacing applied 0.10 – 0.15

10 November 2010
 Maintenance of wear segments

Extensive wear ⇒ Deterioration of performance:

Lower capacity

Higher specific energy consumption

Higher level of vibrations

Remedy of wear:

(Reversal of roller segments)

Hardfacing of roller and table segments – by far the
preferred method

10 November 2010
OK Mill - Typical Wear Pattern

10 November 2010
Hardfacing of rollers and grinding table

Dual headed
welding gun

10 November 2010
Roller being hard-
faced in situ

10 November 2010
Hardfaced Roller
OK 27-4

10 November 2010
OK 27-
27-4 Hardfacing after 350 Hours of Operation

10 November 2010
 Segments vs. Tyres

• No risk of thermal cracking during operation/welding

• Numerous re-welding’s possible (typical ~ 10)
• Lower lifetime cost

10 November 2010
 Hydraulic maintenance cylinder

A maintenance cylinder
with a separate pump
station is supplied for
swinging out the rollers.
This gives easy access to
maintenance/replacement
of segments etc.

10 November 2010
Lifetime of wear parts. 1
Clinker grinding:
A typical wear rate is around 1 g/t giving a life time of around 12.000
hours without hardfacing.
Hardfacing usually reduces wear to about 50%.
Hardfacing can usually be performed up to 10 times on the rollers,
and 25 times on the table has been achieved.
Typical example:
OK 27-4 clinker 3800-4000 Blaine
Mill start 05/1999 Hours Ton g/t
Reversal 08/2000 8336 547098
Table hardfacing 12/2000 10300 662883 0,76
Roller hardfacing 01/2002 18072 1179723 0,47
10 November 2010
Product quality

10 November 2010
 OK mill – product quality

Plant Plant A Plant B Plant C

Cement type OPC Blended Blended
Mill BM OK RP+BM-1 RP+BM-2 OK-1 OK-2 RP+BM OK
Fineness . PSD
Blaine(m2/kg) 375 377 399 436 399 376 437 385
Res. 45 µm (%) 5.3 1.3 5.4 5.6 7.4 4.5 2.4 3.2
PSD / d-50% (µm) 13.4 12.0 13.6 12.8 14.1 14.9 11.7 13.0
PSD / d’ (µm) 17.7 16.3 18.6 17.8 19.4 19.5 16.3 17.6
PSD / n-value 1.05 1.10 1.11 1.07 1.07 1.06 1.01 1.05
Dehydr./Prehydr.
Gypsum (%) 0.1 2.0 1.2 0.9 1.9 3.2 4.0 3.5
Hemihydr. (%) 1.5 0.5 2.3 2.3 1.7 1.0 2.0 1.5
Prehydr. (%) 0.25 0.15 - - - - 0.29 0.20
Cement testing
(EN / ISO)
Water to NC (%) 27.0 26.5 29.5 29.0 31.0 32.5 27.5 27.5
Initial set (h:min) 2:05 1:50 2:35 2:25 3:05 3:15 1:20 1:45
Final set (h:min) 2:50 2:40 3:20 3:10 4:00 4:20 2:30 2:30
Str.-1day (MPa) 19.0 18.8 13.8 12.1 10.6 10.2 15.5 14.8
Str.-2 days (MPa) 27.6 28.8 32.1 32.5
Str.-3 day (MPa) 29.8 28.4 26.9 28.8
Str.-7 day (MPa) 39.0 42.8 39.4 36.1 35.7 37.5 39.8 41.7
Str.-28 day (MPa) 60.5 60.3 50.0 47.9 49.2 50.3 50.5 52.0

Conclusion: Quality of cements produced in OK

mills is very similar to those produced in ball 10 November 2010

mills with high efficiency separators

 OK Mill - Particle Size Distribution
Inclination of PSD Curve n (RRSB)

Height of dam ring Airflow [%]

1,4 1,3
100
Low
1,3 1,2
80
Medium

1,2 1,1
High

1,1 1,0
78 83 89 100 60 80 100
Grinding pressure [%] Separator speed [%]

10 November 2010
 OK Mill - Dam Ring and Nozzle Ring

Dam ring Grinding

height pressure
Cement grinding Low High

Slag grinding High Low

Segmented dam
ring, easy to
adjust in height

10 November 2010
 Cement Quality / Particle Size Distribution

Effects of steeper (narrower) PSD :

• Cement properties :

- Steeper strength development curve

- Higher (late) strength at fixed Blaine
- Lower (early) strength at fixed sieve residue (45 µm)

- Higher water demand for normal consistency of paste

but not necessarily for concrete
 Comparison of cement quality

Ball Mill ( BM (CM1 )):

UM 42 x 13 with Sepax IC-335

Vertical Roller Mill ( OK ) :

OK 27-4

10 November 2010
 Plant A
Cements

Ordinary Portland Cement (OPC)

Clinker : 96 %
Gypsum : 4%

SSA (Blaine) : 370 m2/kg

10 November 2010
 Cements . Plant A

Particle Size Distribution (RRSB-grid)

0.1
1
5
10
20
30
Residue (%)

40
50 BM (CM1)
60
70
80
OK
90
95
96
97
98
99

0.1 1 10 100 1000

Particle size (µm)

10 November 2010
 Cements . Plant A
Fineness data

BM (CM1) OK
Specific Surface (Blaine) : m2/kg 375 377
Air Jet Sieving :
90 µm % 0.2
63 µm % 1.2 0.1
45 µm % 5.3 1.3
32 µm % 15.1 9.3
Laser Diffraction :
d(50%) µm 13.4 12.0
d'-RRSB µm 17.7 16.3
n-RRSB 1.05 1.10
Sm m2/kg 367 372

10 November 2010
 Cements . Plant A
Setting

BM (CM1) OK
Water to N.C. % 27.0 26.5
Initial set h:min 2:05 1:50
Final set h:min 2:50 2:40

10 November 2010
 Cements . Plant A
Compressive strength

70
Compressive strength [EN 196] (MPa)

BM (CM1)
60 OK

50

40

30

20

10

0
1d 2d 7d 28d

10 November 2010
 Cement Quality / OK mills
OK Mill - Ball Mill comparisons

Conclusion :

An investigation on cement samples from plants having an

OK mill and a ball mill unit producing cement from the same
raw materials have indicated, that the OK mill cements
tended to have a slightly steeper (narrower) particle size
distribution and a lower dehydration level of the gypsum.

However, the resulting cement properties were similar to

those of the cements produced in the ball mill installations.

10 November 2010
Final remarks

10 November 2010
Repeated sale of OK mills after commissioning of
customer’s first OK mill
Customer Plant Country Year Mill size
Polyiur India 1996 OK 36-4
Chettinad
Palayam India 1999 OK 36-4
Ecorama Argentina 1996 OK 27-4
Loma Negra
Catamarca Argentina 2008 OK 33-4
1996 OK 33-4
Progreso, San Miguel Guatamala
1999 OK 33-4
Juan Minetti, Campana Argentina 1998 OK 36-4
Holcim Apasco, Ramos Arizpe Mexico 2000 Ok 36-4
Faraz Firouzkuh Iran 2003 OK 36-4
Ste. Genevieve USA 2006 4 x OK 36-4
Boyaca Columbia 2008 OK 36-4
Kamari Greece 1998 OK 27-4
2002 OK 30-4
Titan Cement Saloniki Greece
2005 OK 30-4
Zlatna Bulgaria 2005 OK 30-4
Tanda India 2002 OK 30-4
Jaypee Cement
Bhilai India 2007 2 x OK 42-4

10 November 2010
 Sale of ball mills and VRM for cement grinding ex. China

80

70

60
Number of mills sold

50

40 BM
VRM

30

20

10

0
2003 2004 2005 2006 2007 2008

10 November 2010
Summary of Experience with OK Mills commissioned by
F.L.Smidth

All the mills have proved capable of producing above the

guaranteed output at the required fineness

Their spec. energy consumption is at or below the estimated

low level

The OK mill has proved suitable for grinding not only slag and
Ordinary Portland Cement, but also blended cements with a
wide range of additives such as slag, pozzolana, limestone and
fly ash.

10 November 2010
Summary of Experience with OK Mills commissioned by
F.L.Smidth (cont’d)

The mill’s operational parameters can be adjusted to attain an

end product that complies with the client’s specific
requirements

During maintenance of one or two rollers, the mill can

continue to operate with two rollers only, at a somewhat
reduced capacity

The mill is reliable in operation, easy to operate and easy to

maintain

10 November 2010
 OK mills sold – Marts 2010

OK OK OK OK
OK OK OK
OKOK
OK OK
OK OK OKOKOK OK OK
OK OK OKOK
OK OK OK OK OK OK OK OK
OK
OKOK
OK
OKOK OK OK OK OK OK
OK
OK
OK
OK OK OK OK
OK OK OK OK OK
OK OK OK OK OK
OK OK OKOK OK
OK OK OK
OK
OK
OK OK OK
OKOK
OK OK
OK
OK

OK OK
OK
OKOK
OK
OK
OK
OK
OK
OK
OK

All together 100 FLSmidth OK mills sold world wide

10 November, 2010
Thank you for your attention

10 November 2010