The process of kaolin production is a complex one, requiring high expertise in both science and technology. In this comprehensive blog post, TLD Vietnam will delve deeper into the detailed and complex production procedures of kaolin.

The Basic Definition Of Kaolin

Kaolin is a clay mineral. It is a stacked up silicate layer with one tetrahedral sheet linked through oxygen to a single octahedral sheet of Alumina. Rocks that are prosperous in Kaolin contents are normally termed as china clay. It is one of the most common mineral forms found widespread all over the world.

Kaolin is generally extracted by the open pit mining process. According to its origin, the mining techniques may vary. The mining process consists of several steps.

Read more: Mineral Extraction

Several Steps Needed When manufacturing

Exploration

The initial step in mining is exploration, where geologists examine the Earth’s surface to determine the presence of kaolin. The outcrops, stream beds and road cuts are some of the clues for the presence of the kaolin. After this the sample is taken for laboratory testing. The ore for the sample is extracted through core drilling and auger drilling.

In core drilling, the machine is designed to drill out the cylinder of the material like a hole saw. In case of auger drilling, the rotating helical screw blade drills the ground to extract the ore.

Resource development

The next step after exploration is developing the resources. To estimate the mineral resources before mining the area, a close-spaced drilling process is required. Several important aspects are taken into consideration during this phase, including the drill hole estimation, the tonnage and grade, as well as the economic viability involving the thickness and quality of kaolin clay. 

The process of resource development can be done with two different methods. The first one is based on conventional approaches by delivering maps, spreadsheets, and cross-sections. Meanwhile, the second method is done by utilizing 2D or 3D technologies; one of the most popular ones is using a computer-driven geostatistical modeling technique.

Open pit mining

After considering the social and environmental impact, the mining is done. In open pit mining, the surface material covering the deposits of the ore is removed through the drilling process. The material surrounding the rock can also be eradicated by using the explosives. Subsequently, the underlying deposits are extracted using specialized equipment.

Closure and rehabilitation

Another crucial step that shouldn’t be missed is the process of closure and restoration. This stage is performed after removing the mineral by grading and revegetating the mining land. Kaolin mining sites are commonly restored into a community recreation area, wildlife habitat creation, or an area for farming, hunting, and fishing. 

For industrial companies, this step is as important as the mining itself. In fact, it should be carried out carefully to maintain significant resources of the mining life cycle. Because of this reason, industries usually make use of sustainable land-management practices. It is aimed to reduce the risks of long-term environmental issues that may occur after finishing the mining project. 

Processing Of Kaolin

After the mining procedure is carried out, the next step to completion is processing the kaolin. Aiming to enhance and control various properties contained in the clay, the mining industry divides the process into three basic types: wet, dry, and thermal processing with chemical treatment.

Wet processing

Beginning with wet processing, a dispersed mineral-water suspension is created and then filtered through screens, hydro-separators, or hydro-cyclones. The primary aim of this initial phase is to eliminate grits or large mineral particles.

In subsequent stages, the kaolin devoid of grits is categorized into fractions based on specific particle sizes. Once fractionation is accomplished, the process proceeds to eliminate mineral impurities, such as iron oxides and iron hydroxides.

Dry processing

Dry processing is considered less expensive than wet processing because it involves fewer stages. The procedure begins by milling the crude kaolin, classifying the air to remove the grits, and drying the kaolin to reduce its moisture. Compared to wet processing, the final products of dry processing are usually less bright and have higher contents of grits. Therefore, its market price is relatively lower.

Thermal processing with chemical treatment

Also known as the calcination procedure, thermal processing with chemical treatment involves high-temperature firing by combining wet and dry processing stages. This process is regarded as the most widely used kaolin processing because it results in better, brighter, whiter, and harder contents.

High-temperature firing in thermal processing is useful to enhance kaolin’s chemical resistance and mechanical properties. For this reason, the final products of this process generally come with a high level of rigidity, toughness, and dimensional stability.

Looking at the procedures, it’s fair to say that the kaolin industry is closely linked to complexity. However, throughout the years, the kaolin mining industry has improved its understanding of mining and processing methods. It leads to innovative approaches that can be beneficial for business.

In Conclusion

It’s important to note that kaolin processing methods differ based on the quality and its intended use. Various industries, including ceramics, paper, paints, rubber, and cosmetics, may incorporate additional processing steps or treatments to customize the kaolin for their particular requirements.

The production process of kaolin requires specialized techniques and industrial equipment. Nowadays, it plays a vital role in modern life and is utilized in various fields. By comprehensively understanding the production process, we can make technological advancements to manufacture this mineral with higher efficiency.

TLD Vietnam – Commitment To Sustainable Mineral Exploitation

The growing demand for minerals has led to a massive expansion in mining activities worldwide. Being a leading manufacturer and supplier of Kaolin, TLD Vietnam is always aware of our responsibility to protect the environment, especially in mineral exploitation. We are committed to implementing stringent measures to mitigate the negative impacts of our activities on the ecosystem.

We aim to minimize the potential risk to the surroundings and contribute to ecological preservation. Our goal is to balance the demand for minerals with our unwavering commitment to protecting and preserving the environment for future generations.

With years of experience, our experts will help you choose the right solution for your business. Don’t hesitate to ask us for any concern. We’re here to assist you.