Kaolin Grinding Plant

Kaolin, also known as “china clay,” is a white, fine-grained clay primarily composed of kaolinite minerals. Alongside mica, quartz, and calcium carbonate, it ranks among the four major non-metallic minerals. Possessing excellent plasticity, refractory properties, adsorption capacity, and stability, it finds extensive applications in ceramics, papermaking, coatings, rubber, construction materials, and cosmetics industries. This article focuses on the process flow and core equipment of kaolin grinding plants.

From Ore to Fine Powder: Detailed Explanation of Core Processes in Kaolin Grinding Plants

As the bridge connecting raw ore to high-end applications, the core processes in kaolin grinding plants determine the final product quality. Every step from crushing to calcination requires precise control. The value of kaolin is closely related to its particle size—the finer the particles, the higher the value.

Klinker Mill Process Flow

From raw ore to finished powder, kaolin undergoes a complete processing chain including primary crushing, fine grinding, classification separation, and calcination.

1. Raw Material Preparation and Crushing
   Raw kaolin ore undergoes coarse crushing in a jaw crusher, followed by medium and fine crushing in a hammer crusher. The crushed material is screened to remove impurities and substandard particles. Soft kaolin requires no crushing and can proceed directly to subsequent stages.
2. Grinding Processing (Core Stage)
   Grinding plants select different pulverization methods based on final product specifications. Common approaches include wet grinding with ball mills or dry grinding with Raymond mills. These methods yield distinct particle morphologies and may be combined as needed.
3. Purification and Bleaching
   This step is optional based on product requirements. Products demanding high whiteness undergo chemical bleaching. Wet processes typically incorporate hydrocyclones for sand removal and classification purification.
4. Dewatering and Drying
   The wet-ground slurry is dewatered using filter presses before entering dryers or rotary kilns to produce dry powder.

Core Equipment of Kaolin Grinding Plants

Ball Mill: The Mainstay of Wet Grinding

Ball mills are suitable for large-scale continuous production and can process materials of varying hardness and moisture content. They are particularly favored for wet grinding processes when producing ultrafine powders with high fineness requirements and narrow particle size distribution. The grinding process achieves refinement of kaolin slurry through rotational impact within the cylinder, with the resulting fineness meeting the demands of high-end coating-grade kaolin for papermaking.

Raymond Mill: The Mainstay of Dry Grinding

Raymond mills suit small-to-medium production lines, processing non-flammable/non-explosive mineral materials with Mohs hardness below 7 and moisture content under 6%. As the mainstream equipment for kaolin dry processing, it crushes materials through compression between grinding rollers and rings. It features a compact footprint and high grinding efficiency.

Equipment Selection and Process Optimization Recommendations

Select process routes based on product positioning:

Standard ceramic or filler-grade products can use “dry Raymond milling” to reduce costs;

Premium coating-grade kaolin requires “wet ball milling + classification + bleaching”.

● Energy Efficiency & Environmental Trends:

Recommend energy-efficient ball mills (e.g., ceramic ball mills), variable frequency control systems, and waste heat recovery units to lower energy consumption and carbon emissions.
● Smart Upgrades:

Implement DCS or PLC automation systems for real-time monitoring and automatic adjustment of grinding parameters, enhancing product quality stability.

Conclusion

Kaolin grinding plants transform natural ore into high-value products through crushing, grinding, classification, and drying processes. Ball mills and Raymond mills, as core equipment, ensure dual improvements in product fineness and production capacity. CHUNLEI Machinery remains committed to providing customized kaolin processing solutions, backed by automated production lines and an experienced technical team. Should you have related requirements, please feel free to contact us. We will help you achieve both cost reduction and efficiency gains while advancing sustainable development.