Ok Mill

THE OK-Mill

OK Roller Mill  Proven

technology based on a license from Onoda and Kobe Steel, Japan  Very suitable for grinding blended cement or slag  Suitable for grinding moist feed  Energy saving. 20% to 40% in kWh  Installed power 1350 to 4400 kW  Production range 40 - 240 ton/hr OPC  Easy maintenance and optimum utilisation of wear parts

OK Mill layout • Simple and space-saving layout • Specially shaped vibration-proof grinding bed geometry

• High efficiency separator • Longer life due to highly wear resistant grinding segments

• Equivalent or better cement quality than tube mill cement

• Easily controllable particle size distribution

• 30~40% energy saving compared with tube mill system

• Easy maintenance due to swing-in/out roller support system

Air Lock ROTARY FEED SLUICE SUITABLE FOR STICKY MATERIAL SIMPLER THAN A TRIPLE FLAP SLUICE LESS FALSE AIR CELLS LINED WITH FLEXIBLE, WEAR RESISTANT RUBBER INJECTION OF COMPRESSED AIR FOR PREVENTING EARLY BUILD-UP OF STICKY MATERIAL

High Efficiency ROKS Separator

ROKS Separator Features

Adjustable Louvers

Typical OK Mill Flow Sheet

OK 33-4 Mill installation in Guatemala

OK Mill - Rollers and Table Geometry

Applying Grinding Forces

OK Mill - Grinding Pressure Distribution

Main dimensions Dp = Power diameter

OK Mill, Nozzle Ring and Roller Detail

PROBLEMS TO BE SOLVED in CEMENT GRINDING WITH a ROLLER MILL

Vibrations Cement quality Slightly narrower P.S.D. Dehydration of Gypsum

MAIN CONSTRUCTION FEATURES OF OK MILL Roller Shape with Groove Wedge Shape between Roller and Table Vibration proof Dynamic separator built in High separation efficiency

Optimum P.S.D.

Optimising Grinding Geometry

A

C

B

D

OK Mills - Control of Particle Size Distribution N-value - Dependence on Dam Ring and Grinding Force. High dam ring Medium dam ring Low dam ring

N-value 1.4

1.3

1.2

% compressive force 1.1 78

83

89

100

Influence of DEG on Production

PRODUCTION RATE / %DEG 120 115 110 105 100 95 90 85 80 75 70

Vibration velocity / % DEG 5

4,5

4

3,5

3 0,01

0,02

0,03

0,035

0,01

0,02

0,03

0,035

Results from OK Mill operation with two or four Rollers

Measured Wear after 6000 Hours of Operation. Total 1 g/t OK 33-4 San Miguel. Blended Cement

Pressure distribution and wear

Typical wear profiles

Roller being hardfaced in situ

Rebuilt roller OK 27-4

OK 27-4 hardfacing after 350 operation hours

OK 36-4 Mill, Campana

OK Mill with Rollers in Maintenance Position

OK Mill Separators, FMS for Slag, OKS for Cements

OKS separator

FMS separator

Industrial Size OK mills sold CLIENT

PLANT

COUNTRY YEAR

TYPE

Motor Power

(NO. MILL/SEP.)

(kW)

APPLICATION

Nippon Steel Chemical Co., Ltd. Kimitsu Plant

Japan

1986

1-OK36-4/OKS70

3,000

Blast Furnace Slag

Daiichi Cement Plant Co., Ltd.

Japan

1987

1-OK27-4/FMS54

1,600

Blast Furnace Slag

Nippon Steel Chemical Co., Ltd. Tobata Plant

Japan

1988

1-OK36-4/FMS70

3,300

Blast Furnace Slag

Onoda Cement Co., Ltd.

Ofunato Plant

Japan

1988

1-OK36-4/OKS70

3,000

Cement Clinker

Daiichi Cement Co., Ltd.

Kawasaki Plant

Japan

1988

1-OK27-4/OKS50

1,800

Blast Furnace Slag

Asia Cement Mfg. Co., Ltd..

Jaechon Plant

Korea

1989

1-OK36-4/OKS70

3,000

Cement Clinker

Onoda Cement Co., Ltd.

Tsukumi Plant

Japan

1989

1-OK36-4/OKS70

3,000

Blast Furnace Slag

Onoda Cement Co., Ltd.

Ofunato Plant

Japan

1990

1-OK25-3/0KS50

1,400

Blast Furnace Slag

Asia Cement Mfg. Co., Ltd

Jaechon Plant

Korea

1991

1-OK36-4/OKS70

3,000

Cement Clinker

Kobe Steel

Kakogawa

Japan

1993

1-OK36-4/FMS72

3,300

Blast Furnace Slag

Madras

Alathiyur Works

India

1995

1-OK33-4/OKS70

2,900

Cement + Flyash

Chettinad Cement

Polyiur

India

1996

1-OK36-4/OKS74

3,300

Cement

ACC

Sindri Plant

India

1996

1-OK27-4/FMS54

1,800

Slag

Cementos Progreso

San Miguel

Guatemala

1996

1-OK33-4/OKS70

3,000

Blended Cement

Ecocemento S.A.

Ecorama

Argentina

1996

1-OK27-4/FMS54

1,800

Slag and blended cement

Hanil Cement Manufacturing

Hanil

Korea

1996

1-OK36-4/OKS70

3,000

Cement Clinker

Titan Cement

Kamari

Greece

1998

1-OK27-4/OKS56

1,800

Cement Clinker

Juan Minetti S.A.

Campana

Argentina

1998

1-OK36-4/OKS74

3,750

Slag/Cement Clinker

Cementos Progreso

San Miguel

Guatemala

1999

1-OK33-4/OKS70

3,000

Blended Cement

Phoenix Cement Company

Clarkdale, Arizona

USA

1999

1-OK33-4/OKS70

3,000

Cement Clinker

Chettinad Cement

Palayam

India

2000

1-OK36-4/ROKS40

3,750

Blended Cement

Apasco

Ramos Arispe

Mexico

2000

1-OK36-4/OKS74

3,750

Cement + Flyash

Kawasaki Plant

OK 36-4 Mill under Erection

OK mill 27-4 in Ecorama, Argentina

OK 36-4 Campana Argentina

OK 27-4 Titan Kamari

OK Mill operation data for Clinker Size OK36-4

OK33-4

Customer Chettinad Cement (India) Asia Cement (Korea) Hanil Cement (Korea) Onoda Cement Ofunato (Japan) Madras Cement (India)

Production (t/h)

Blaine (cm2/g)

Mill (kWh/t)

Separator (kWh/t)

Fan (kWh/t)

Total (kWh/t)

Grinding Aid (%)

170

3046

14.5

0.7

6.8

22.0

0.03

154

3450

19.1

0.2

6.8

26.1

0.02

150

3293

16.8

0.1

9.0

25.9

0.02

135

3210

22.1

0.2

5.5

27.8

0.02

155

2800

16.1

0.7

6.3

23.1

0.02

163 (20%, flyash)

3200

15.6

0.7

6.0

22.3

0.02

3768

17.6

0.4

7.8

25.8

0.025

Cementos Progreso 160 (Guatemala) (15%, pozzolana)

Comparison data for Clinker Type of Cement

Mill OK Mill

Separator Blaine Production Mill Power (rpm) (cm2/g) (t/h) (kW) 71.7

Mill (kWh/t)

Aux. (kWh/t)

Total (kWh/t)

3210

135.5

3000

22.1

5.7

27.8

3280

99.2

3300

33.3

5.5

38.8

4390

103.3

2800

27.1

5.7

32.8

4350

21.0

950

45.2

7.5

52.7

Ordinary Tube Mill OK Mill High early strength

Tube Mill

92.6

Quality data for Cement Type of

Mill

Water/ Cement

Setting time (hr - min)

Compressive strength (kgf/cm2)

Mortar flow

(cm2/g)

30m

15m

(%)

Initial

Final

(mm)

OK Mill

3210

19,3

51,3

28,5

2-19

3-10

Tube Mill

3280

20,3

53,2

28,4

2-24

OK Mill

4350

5,0

34,4

30,8

Tube Mill

4350

5,2

35,6

30,8

Cement

Ordinary

Blaine

Residue (%)

1 day

3 days

7 days

28 days

256

151

255

431

3-29

253

142

243

420

1-32

2-27

247

181

311

399

485

1-47

2-39

250

169

292

385

480

High early strength

OK Mill operation data for Slag Size

Customer

Production (t/h)

Blaine (cm2/g)

Mill (kWh/t)

Separator (kWh/t)

Fan (kWh/t)

Total (kWh/t)

OK36-4

Noppon Steel Chemical Kimitsu (Japan)

106

4350

29,0

0,4

7,7

37,1

Noppon Steel Chemical Tobata (Japan)

105

-6m, 30% -16m, 65%

28,4

0,7

6,6

35,7

Onoda Cement Tsukumi (Japan)

96

4435

30,4

1,0

9,3

40,7

Daiichi Cement No.1 (Japan)

50

4175

31,0

0,4

8,0

39,4

Daiichi Cement No.2 (Japan)

55

4300

27,4

1,0

7,1

35,5

ACC (India)

58

3872

17,2

0,4

6,2

23,8

Onoda Cement Ofunato (Japan)

37

4619

28,6

0,9

12,1

41,6

OK27-4

OK25-3

Quality data for Slag cement Blast furnace slag cement type B

Slag powder

Setting time (hr - min)

Compressive strength (kgf/cm2)

Blaine

Residue on (%)

Blaine

Water/ Cement

(cm2/g)

6mm

(cm2/g)

(%)

Initial

Final

3 days

7 days

28 days

4430

71,2

3720

29,5

3-30

4-40

138

215

416

4680

69,5

3800

29,6

3-30

4-30

146

233

427

4840

67,0

3900

29,8

3-20

4-30

154

244

441

COMPARISON TABLE (kWh/t cement) Actual data in Japanese cement plants Item

Tube Mill

OK Mill

Mill

31,9 ~ 33,2

22,2

Pregrinding

-

-

Separator

1

0,2

1

1

Fan Auxiliaries Total

3,5 1,5 37,9 ~ 39,2

5,5 1 28,9

3,5 1,5 34,8

3,5 1,5 34

Pregrinding 25,3

24

Polycom Roller Press CKP Roller Mill

OK Mill Feed Composition, % 100 90 80 70 60 50 40 30 20 10 0 A

B

C

C

D

D

E

Plant

Clinker Limestone

Gypsum PFA

Puzzolana Slag

OK Mill Feed Composition, % 100 90 80 70 60 50 40 30 20 10 0 A and B

C

D

D

E

Plant Clinker Limestone

Gypsum PFA

Puzzolana Slag

E

Energy Consumption (kWh/t), Motor Input 90

Blaine Surface, cm2/g: 4000

Cement (OPC)

Slag

80

70

60

50

40

30

20

10

0 OK Mill

Ball Mill

OK Mill Mill

Fan, etc.

Ball Mill