The FLSmidth OK Mill

for
10 November 2010
for
Cement and Slag Grinding
Presentation Content
General, Key Points
Mechanical features and maintenance
10 November 2010
Product Quality
OK Roller Mill
10 November 2010
OK Mill Capacity Range
OPC Cement
OK 33-4
OK 36-4
OK 39-4
OK 42-4
OK 45-4
Mill size
10 November 2010
0 50 100 150 200 250 300 350 400 450
t/h
OK 19-3
OK 22-3
OK 25-3
OK 27-4
OK 30-4
OK 33-4
OK Mill Capacity Range
Slag
OK 33-4
OK 36-4
OK 39-4
OK 42-4
OK 45-4
Mill size
10 November 2010
0 50 100 150 200 250
t/h
OK 19-3
OK 22-3
OK 25-3
OK 27-4
OK 30-4
OK 33-4
OK Mills Installed and Available Power
Mill size
OK
Motor size
(kW)
Avail. Power
(kW)
19-3 675 602
22-3 975 869
25-3 1350 1196
27-4 1800 1653
10 November 2010
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
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
OK Mill OK Mill layout layout
10 November 2010
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
OK Roller
Mill Details
Separator drive
Rotary sluice
Mill feed inlet
Grinding roller
Mill outlet
Separator
Separator rotor
Separator reject
Mill stand
Main drive
Hydraulic system
Swing out cylinder
Roller stopper
Grinding table
Unique design developed specifically
for cement and slag grinding
10 November 2010
for cement and slag grinding
OK Roller Mill Roller and Table profile
10 November 2010
OK Vertical mill grinding parts
Pressure distribution
10 November 2010
A B
4500
4000
Blaine
[cm
2
/g
]
Maximum
acceptable
vibrations
Optimum Design of Rollers and Table
10 November 2010
C D
200
300
100
3500
3000
0
A
B
C
D
Capacity [kg
/h]
30
35
40
S
p
e
c
.

E
n
e
r
g
y

C
o
n
s
.
,

T
o
t
a
l
,

k
W
h
/
t
Spherical roller
Flat roller
OK
OK Mills vs. Competitor VRM
Best Grinding Efficiency
15
20
25
30
2500 3000 3500 4000 4500 5000
Blaine
S
p
e
c
.

E
n
e
r
g
y

C
o
n
s
.
,

T
o
t
a
l
,

k
W
h
/
t
OK mill efficiency compared to ball mills
50
55
60
65
70
S
p
e
c
.

E
n
e
r
g
y

C
o
n
s
.
,
T
o
t
a
l
,

k
W
h
/
t
Ball mill
For OPC
10 November 2010
20
25
30
35
40
45
2500 2700 2900 3100 3300 3500 3700 3900 4100 4300 4500
Blaine, cm
2
/g
S
p
e
c
.

E
n
e
r
g
y

C
o
n
s
.
,
T
o
t
a
l
,

k
W
h
/
t
OK mill
33 %
50 %
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

10 November 2010

Blaine, cm
2
/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
50
60
70
80
90
100
OK mills - Composition of mill feed
10 November 2010
0
10
20
30
40
A+B C C D D D E F + G +
H
I + J I + J
Plant
Clinker, % Gypsum, % Limestone, % Pozzolana, % Slag, % Fly ash, %
Reliability ..
10 November 2010
Reliability ..
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 6.2% > 45 17.2 (Mill) 17.6 (Mill)
8 Blended 170 172 4400 4378 None 27.4
9 OPC 118 144 3900 3900 - 25.7
OK mill performance
10 November 2010
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 %
150.0
200.0
250.0
3000
4000
5000
3800 - Guar.
Guar. - 168
Easy commissioning of mill
First 40 days of OK mill operation
10 November 2010
0.0
50.0
100.0
150.0
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
P
r
o
d
u
c
t
i
o
n
0
1000
2000
3000
B
l
a
i
n
e
Example of smooth commissioning
OK 36 Mill in USA
5000.0
6000.0
140.0
160.0
180.0
200.0
Roller and table
liner rewelding
16-19 January
Cement sales
decrease, mill
capacity reduced
10 November 2010
0.0
1000.0
2000.0
3000.0
4000.0
8-1 8-14 8-22 8-28 9-4 9-12 9-18 9-25 10-1 10-7 10-
13
10-
19
10-
25
11-1 11-7 11-
13
11-
22
11-
28
12-4 12-
11
12-
17
12-
23
12-
29
1-4 1-10 1-22
B
l
a
i
n
e
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
C
a
p
a
c
i
t
y
,

t
/
h
Guaranteed performance: 154 t/h; Blaine 3750 cm
2
/g
Average achieved over the first 24 weeks: 157 t/h; Blaine 3790 cm
2
/g
OK mills recently commissioned


Plant Cement type Capacity, t/h Blaine
Duration from 1. start
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
10 November 2010
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) Customers 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 (clients supply)

Average duration of commissioning (incl. performance test): 4 weeks
60
70
80
90
100
R
u
n

f
a
c
t
o
r
,

%
Run factor similar to the simple Ball Mill
10 November 2010
0
10
20
30
40
50
60
1999 2000 2001 2002
R
u
n

f
a
c
t
o
r
,

%
OK mill
Ball mill
Operation on 2 rollers if needed
Condition Production
t/h
% Res.
45
Blaine
cm/g
kWh/t
Mill
kWh/t
Fan
kWh/t
Sep
kWh/t
Total
Grinding
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
10 November 2010
4 rollers 144 3,5 3800 16,1 8,7 0,6 25,4 0,025
Guarantee 140 7,0 17,2 0,6
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.
Data from industrial mill OK 33-4.
Mechanical design
10 November 2010
Mechanical design
features ..
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
10 November 2010
Lower gas velocities
Lower energy consumption
Cost optimal wear protection
ROKSH main parts
Access platforms
Drive station
Bearing arrangement
Inspection door
Separator outlet
10 November 2010
Coarse return cone
Separator casing
Rotor
Louvres
Coarse return outlet
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
10 November 2010
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
ROKSH optimum wear protection
Densit Wear flex 2000 wear lining
Separator outlet
Based on experiences with more than
85 ROKS and OKS separators sold
10 November 2010
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
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
10 November 2010
Improved roller/housing seal
Flexible housing/roller seal
OK Mill - housing/roller seal
10 November 2010
Durable
Easy to maintain
No ingress of false air
OK Mill - rotary feed sluice
10 November 2010
Designed for air heating in case of sticky feed materials
OK Mill - rotary feed sluice
10 November 2010
Lined with chromium carbide composite wear plate for
enhanced durability
Removable side walls for ease of maintenance
OK mill - Rotary feed sluice
10 November 2010
Removable sides for easy
maintenance
10 November 2010
Dry fly ash injection
Maintenance ..
10 November 2010
Maintenance ..
Cement Mills - Maintenance Costs
0.6
0.73
0.5
0.6
0.7
0.8
M
a
i
n
t
e
n
a
n
c
e

c
o
s
t
s
,

E
U
R
/
t
Over 4 years Over 14 months
10 November 2010
0.36
0.42
0.11
0
0.1
0.2
0.3
0.4
BM BM+RP 1 BM+RP 2 OK 1 OK 2
M
a
i
n
t
e
n
a
n
c
e

c
o
s
t
s
,

E
U
R
/
t
OK mills versus ball mills
Maintenance of wear parts (contd)
OPC, 3200 3600 cm
2
/g (Blaine) EUR per ton of cement
Cost of wear parts:
10 November 2010
OPC, 3200 3600 cm
2
/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

Maintenance of wear segments
Extensive wear Deterioration of performance:
Lower capacity
Higher specific energy consumption
Higher level of vibrations
10 November 2010
Higher level of vibrations
Remedy of wear:
(Reversal of roller segments)
Hardfacing of roller and table segments by far the
preferred method
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 OK 27--4 Hardfacing after 350 Hours of Operation 4 Hardfacing after 350 Hours of Operation
10 November 2010
Segments vs. Tyres
No risk of thermal cracking during operation/welding
Numerous re-weldings 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
10 November 2010
This gives easy access to
maintenance/replacement
of segments etc.
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,
10 November 2010
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
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 m (%) 5.3 1.3 5.4 5.6 7.4 4.5 2.4 3.2
PSD / d-50% (m) 13.4 12.0 13.6 12.8 14.1 14.9 11.7 13.0
PSD / d (m) 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
10 November 2010
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
mills with high efficiency separators
OK Mill - Particle Size Distribution
Height of dam ring
1,4
Low
Airflow [%]
1,3
100
Inclination of PSD Curve n (RRSB)
Height of dam ring
1,4
Low
Height of dam ring
1,4
Low
Airflow [%]
1,3
100
Airflow [%]
1,3
100
Inclination of PSD Curve n (RRSB)
10 November 2010
78
1,1
Grinding pressure [%]
1,2
1,3
83 89 100
Low
Medium
High
60
1,1
Separator speed [%]
1,2
1,0
80
100
80
78
1,1
Grinding pressure [%]
1,2
1,3
83 89 100
Low
Medium
High
78
1,1
Grinding pressure [%]
1,2
1,3
83 89 100
Low
Medium
High
60
1,1
Separator speed [%]
1,2
1,0
80
100
80
60
1,1
Separator speed [%]
1,2
1,0
80
100
80
OK Mill - Dam Ring and Nozzle Ring
Dam ring
height
Grinding
pressure
Cement grinding Low High
Slag grinding High Low
Dam ring
height
Grinding
pressure
Cement grinding Low High
Slag grinding High Low
10 November 2010
Slag grinding High Low
Segmented dam
ring, easy to
adjust in height
Slag grinding High Low
Segmented dam
ring, easy to
adjust in height
Cement Quality / Particle Size Distribution
Effects of steeper (narrower) PSD :
Cement properties :
- Steeper strength development curve - Steeper strength development curve
- Higher (late) strength at fixed Blaine
- Lower (early) strength at fixed sieve residue (45 m)
- Higher water demand for normal consistency of paste
but not necessarily for concrete
Comparison of cement quality
Ball Mill ( BM (CM1 )):
10 November 2010
UM 42 x 13 with Sepax IC-335
Vertical Roller Mill ( OK ) :
OK 27-4
Plant A
Cements
Ordinary Portland Cement (OPC)
10 November 2010
Clinker : 96 %
Gypsum : 4%
SSA (Blaine) : 370 m2/kg
Cements . Plant A
Particle Size Distribution (RRSB-grid)
0.1
1
5
10
20
30
40
R
e
s
i
d
u
e

(
%
)
10 November 2010
40
50
60
70
80
90
95
96
97
98
99
0.1 1 10 100 1000
Particle size (m)
R
e
s
i
d
u
e

(
%
)
BM (CM1)
OK
Cements . Plant A
Fineness data
BM (CM1) OK
Specific Surface (Blaine) : m2/kg 375 377
Air Jet Sieving :
90 m % 0.2
10 November 2010
63 m % 1.2 0.1
45 m % 5.3 1.3
32 m % 15.1 9.3
Laser Diffraction :
d(50%) m 13.4 12.0
d'-RRSB m 17.7 16.3
n-RRSB 1.05 1.10
Sm m2/kg 367 372
Cements . Plant A
Setting
BM (CM1) OK
Water to N.C. % 27.0 26.5
10 November 2010
Initial set h:min 2:05 1:50
Final set h:min 2:50 2:40
Cements . Plant A
Compressive strength
50
60
70
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
n
g
t
h

[
E
N

1
9
6
]

(
M
P
a
)
BM (CM1)
OK
10 November 2010
0
10
20
30
40
50
C
o
m
p
r
e
s
s
i
v
e

s
t
r
e
n
g
t
h

[
E
N

1
9
6
]

(
M
P
a
)
1d 2d 7d 28d
Cement Quality / OK mills
OK Mill - Ball Mill comparisons
Conclusion :
An investigation on cement samples from plants having an
10 November 2010
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.
Final remarks
10 November 2010
Repeated sale of OK mills after commissioning of
customers 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
10 November 2010
Progreso, San Miguel Guatamala
1999 OK 33-4
Juan Minetti, Campana Argentina 1998 OK 36-4
Apasco, Ramos Arizpe Mexico 2000 Ok 36-4
Faraz Firouzkuh Iran 2003 OK 36-4
Ste. Genevieve USA 2006 4 x OK 36-4
Holcim
Boyaca Columbia 2008 OK 36-4
Kamari Greece 1998 OK 27-4
2002 OK 30-4
Saloniki Greece
2005 OK 30-4
Titan Cement
Zlatna Bulgaria 2005 OK 30-4
Tanda India 2002 OK 30-4
Jaypee Cement
Bhilai India 2007 2 x OK 42-4

50
60
70
80
N
u
m
b
e
r

o
f

m
i
l
l
s

s
o
l
d
Sale of ball mills and VRM for cement grinding ex. China
10 November 2010
0
10
20
30
40
N
u
m
b
e
r

o
f

m
i
l
l
s

s
o
l
d
2003 2004 2005 2006 2007 2008
BM
VRM
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
10 November 2010
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.
Summary of Experience with OK Mills commissioned by
F.L.Smidth (contd)
The mills operational parameters can be adjusted to attain an
end product that complies with the clients specific
requirements
During maintenance of one or two rollers, the mill can
continue to operate with two rollers only, at a somewhat
10 November 2010
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
OK mills sold Marts 2010
OK
OK
OK
OK
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
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
10 November, 2010
O
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
All together 100 FLSmidth OK mills sold world wide
OK
OK
OK
OK
OK
OK
OK
OK
Thank you for your attention
10 November 2010