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.