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    OK Mill

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    Hazem Hasan
    The document discusses the OK-Mill, a proven roller mill technology for grinding cement or slag. Key advantages of the OK-Mill include its simple and space-saving layout, highly wear resistant grinding segments that provide longer life, and the ability to achieve 30-40% energy savings compared to tube mill systems. The OK-Mill allows for easy control of particle size distribution and maintenance through its swing-in/out roller support system.

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    OK Mill

    Uploaded by

    Hazem Hasan
    500 views52 pages
    The document discusses the OK-Mill, a proven roller mill technology for grinding cement or slag. Key advantages of the OK-Mill include its simple and space-saving layout, highly wear resistant grinding segments that provide longer life, and the ability to achieve 30-40% energy savings compared to tube mill systems. The OK-Mill allows for easy control of particle size distribution and maintenance through its swing-in/out roller support system.

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    erfgerte yutytu

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    OK mill

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    The document discusses the OK-Mill, a proven roller mill technology for grinding cement or slag. Key advantages of the OK-Mill include its simple and space-saving layout, highly wear resistant grinding segments that provide longer life, and the ability to achieve 30-40% energy savings compared to tube mill systems. The OK-Mill allows for easy control of particle size distribution and maintenance through its swing-in/out roller support system.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    500 views52 pages

    OK Mill

    Uploaded by

    Hazem Hasan
    The document discusses the OK-Mill, a proven roller mill technology for grinding cement or slag. Key advantages of the OK-Mill include its simple and space-saving layout, highly wear resistant grinding segments that provide longer life, and the ability to achieve 30-40% energy savings compared to tube mill systems. The OK-Mill allows for easy control of particle size distribution and maintenance through its swing-in/out roller support system.

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    © All Rights Reserved
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    Download as ppt, pdf, or txt
    of 52

    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 B

    C D
    OK Mills - Control of Particle Size Distribution
    N-value - Dependence on Dam Ring and Grinding Force.

    High dam ring


    N-value Medium dam ring
    Low dam ring
    1.4

    1.3

    1.2

    % compressive force
    1.1
    78 83 89 100
    Influence of DEG on Production

    PRODUCTION RATE / %DEG Vibration velocity / % DEG


    120 5
    115
    110
    4,5
    105
    100
    95 4
    90
    85
    80 3,5
    75
    70 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 hard-
    faced 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
    TYPE Motor Power
    CLIENT PLANT COUNTRY YEAR (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. Kawasaki Plant 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
    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

    Production Blaine Mill Separator Fan Total Grinding


    Size Customer
    (t/h) (cm2/g) (kWh/t) (kWh/t) (kWh/t) (kWh/t) Aid (%)
    Chettinad Cement
    OK36-4 170 3046 14.5 0.7 6.8 22.0 0.03
    (India)
    Asia Cement
    154 3450 19.1 0.2 6.8 26.1 0.02
    (Korea)
    Hanil Cement
    150 3293 16.8 0.1 9.0 25.9 0.02
    (Korea)
    Onoda Cement
    135 3210 22.1 0.2 5.5 27.8 0.02
    Ofunato (Japan)
    Madras Cement
    OK33-4 155 2800 16.1 0.7 6.3 23.1 0.02
    (India)
    163
    3200 15.6 0.7 6.0 22.3 0.02
    (20%, flyash)
    Cementos Progreso 160
    3768 17.6 0.4 7.8 25.8 0.025
    (Guatemala) (15%, pozzolana)
    Comparison data for Clinker
    Type of Separator Blaine Production Mill Power Mill Aux. Total
    Mill
    Cement (rpm) (cm2/g) (t/h) (kW) (kWh/t) (kWh/t) (kWh/t)

    OK Mill 71.7 3210 135.5 3000 22.1 5.7 27.8


    Ordinary
    Tube
    3280 99.2 3300 33.3 5.5 38.8
    Mill

    OK Mill 92.6 4390 103.3 2800 27.1 5.7 32.8


    High early
    strength Tube
    4350 21.0 950 45.2 7.5 52.7
    Mill
    Quality data for Cement
    Water/ Setting time Mortar Compressive strength
    Residue (%)
    Type of Mill Blaine Cement (hr - min) flow (kgf/cm2)

    Cement (cm2/g) 30m 15m (%) Initial Final (mm) 1 day 3 days 7 days 28 days

    Ordinary OK Mill 3210 19,3 51,3 28,5 2-19 3-10 256 151 255 431

    Tube Mill 3280 20,3 53,2 28,4 2-24 3-29 253 142 243 420

    OK Mill 4350 5,0 34,4 30,8 1-32 2-27 247 181 311 399 485
    High early
    strength
    Tube Mill 4350 5,2 35,6 30,8 1-47 2-39 250 169 292 385 480
    OK Mill operation data for Slag
    Production Blaine Mill Separator Fan Total
    Size Customer
    (t/h) (cm2/g) (kWh/t) (kWh/t) (kWh/t) (kWh/t)
    Noppon Steel Chemical
    OK36-4 106 4350 29,0 0,4 7,7 37,1
    Kimitsu (Japan)
    Noppon Steel Chemical -6m, 30%
    105 28,4 0,7 6,6 35,7
    Tobata (Japan) -16m, 65%
    Onoda Cement
    96 4435 30,4 1,0 9,3 40,7
    Tsukumi (Japan)
    Daiichi Cement
    OK27-4 50 4175 31,0 0,4 8,0 39,4
    No.1 (Japan)
    Daiichi Cement
    55 4300 27,4 1,0 7,1 35,5
    No.2 (Japan)
    ACC
    58 3872 17,2 0,4 6,2 23,8
    (India)
    Onoda Cement
    OK25-3 37 4619 28,6 0,9 12,1 41,6
    Ofunato (Japan)
    Quality data for Slag cement

    Slag powder Blast furnace slag cement type B


    Residue Water/ Setting time Compressive strength
    Blaine on (%) Blaine Cement (hr - min) (kgf/cm2)

    (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 Pregrinding
    Mill 31,9 ~ 33,2 22,2 25,3 24

    Pregrinding - - Polycom Roller Press CKP Roller Mill

    Separator 1 0,2 1 1
    Fan 3,5 5,5 3,5 3,5
    Auxiliaries 1,5 1 1,5 1,5
    Total 37,9 ~ 39,2 28,9 34,8 34
    OK Mill Feed Composition, %

    100

    90

    80

    70

    60

    50

    40

    30

    20

    10

    0
    A B C C D D E
    Plant

    Clinker Gypsum Puzzolana


    Limestone PFA Slag
    OK Mill Feed Composition, %

    100

    90

    80

    70

    60

    50

    40

    30

    20

    10

    0
    A and B C D D E E
    Plant

    Clinker Gypsum Puzzolana


    Limestone PFA Slag
    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 Ball Mill

    Mill Fan, etc.

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