OK Mill Symposuim Indonesia2

Presentation ContentGeneral, Key Points Mechanical features and maintenance 10 November 2010 Product Quality... • Simple and space-saving layout• Proven technology based on a license 199

The FLSmidth OK Mill

for for Cement and Slag Grinding

Presentation Content

General, Key Points

Mechanical features and maintenance

10 November 2010

Product Quality

OK Roller Mill

OK Mill Capacity Range

OK Mill Capacity Range

OK Mills Installed and Available Power

Mill size

OK

Motor size (kW)

• 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

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

Grinding table

Unique design developed specifically for cement and slag grinding ……

for cement and slag grinding ……

OK Roller Mill – Roller and Table profile

10 November 2010

OK Vertical mill grinding parts

Pressure distribution

Optimum Design of Rollers and Table

C D

Capacity [kg /h]

OK mill efficiency compared to ball mills

OK mill versus ball mills

Specific energy consumption

Conclusion: The energy consumption

of the OK mill system is 25% to 40%

lower than for the ball mill system

Reliability …

Reliability …

Entry Cement type Capacity, t/h Blaine kWh/t

Guarant Achieved Guarant Achieved Garant Achieved

200.0

250.0

3000 4000 5000

3800 - Guar.

Guar - 168

Easy commissioning of mill

First 40 days of OK mill operation

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

25

10-1 7

11-13

22

28

11-4 11

17

23

29 1-4 1-10 1-22

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

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

Operation on 2 rollers – if needed

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

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

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

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

Coarse return cone

Separator casing

Rotor Louvres

Coarse return outlet

Air velocities in the ROKSH

Reduced air velocities gives:

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

ROKSH optimum wear protection

Densit Wear flex 2000 wear lining

•Separator outlet

Based on experiences with more than

85 ROKS and OKS separators sold

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

OK mill - nozzle ring

10 November 2010

OK Mill - housing/roller seal

Improved roller/housing seal

Flexible housing/roller seal

OK Mill - housing/roller seal

OK Mill - rotary feed sluice

Designed for air heating in case of sticky feed materials

OK Mill - rotary feed sluice

OK mill - Rotary feed sluice

Removable sides for easy

maintenance

10 November 2010

Dry fly ash injection

Maintenance …

Maintenance …

Cement Mills - Maintenance Costs

OK mills versus ball millsMaintenance of wear parts (cont’d)

Cost of wear parts:

OK mills

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

Hardfacing of rollers and grinding table

Dual headed welding gun

10 November 2010

Roller being

hard-faced in situ

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

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

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,

Product quality

OK mill – product quality

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

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

60 1,1

60 1,1

OK Mill - Dam Ring and Nozzle Ring

Dam ringheight

Grindingpressure

Dam ringheight

Grindingpressure

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 )):

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)

Clinker : 96 % Gypsum : 4%

SSA (Blaine) : 370 m2/kg

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

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

Repeated sale of OK mills after commissioning of customer’s first OK mill

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

Summary of Experience with OK Mills commissioned by

F.L.Smidth

guaranteed output at the required fineness

low level

10 November 2010

low level

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 (cont’d)

end product that complies with the client’s specific

requirements

continue to operate with two rollers only, at a somewhat

continue to operate with two rollers only, at a somewhat

reduced capacity

maintain

OK mills sold – Marts 2010

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

OKOK

OK OK

OK OK

OK OK

OK OK

OK

Thank you for your attention