Washed Kaolin Production Line and Process Solution

Washed Kaolin Production Line Solution is designed to produce high-quality clay for Paper, Ceramics, and Coatings.

This solution utilizes a wet process of "Pulping - Classification - Magnetic Separation - Dewatering". It effectively removes sand, iron, and titanium impurities, achieving high whiteness and purity.

Step 1: Pulping & Washing

Goal: Disperse clay into a slurry and remove coarse grit.

• Pulping: Raw ore is mixed with water in a Pulper to form a slurry.
• Roughing: A Spiral Washer removes heavy coarse sand (+2mm).
• Screening: A Trommel Screen removes organic trash and roots.

Step 2: Hydrocyclone Classification

Goal: Separate fine Kaolin (-0.045mm) from fine sand (silica).

• Equipment: Hydrocyclone Group.
• Process: The slurry is pumped at high pressure. Fine clay exits as Overflow (Product), while heavier silt and sand exit as Underflow (Waste). This ensures the product meets the -200 mesh requirement (75-80%).

Step 3: Magnetic Separation (Whitening)

Goal: Remove Iron and Titanium to improve whiteness.

• Equipment: Electromagnetic Slurry Magnetic Separator.
• Function: High gradient magnetic fields capture microscopic iron particles that cause discoloration, critical for ceramic and paper grades.

Step 4: Thickening & Dewatering

• Thickening: High-Efficiency Thickener increases slurry density.
• Filtration: Plate and Frame Filter Press produces filter cakes with ≤ 10% moisture.

Project: High-Grade Ceramic Kaolin Plant

A client required a plant to process raw clay into ceramic-grade powder.

• Process: Washing -> Cyclone Classification -> Iron Removal.
• Result: Whiteness increased from 75% to 90%.
• Efficiency: Water recycling rate achieved 85%.

Q1: What is the difference between Washed and Calcined Kaolin?

A: Washed Kaolin is hydrous (contains crystal water) and is purified by water. Calcined Kaolin is heated to high temperatures (1000°C+) to remove water, increasing whiteness and hardness for paint/rubber industries.

Q2: How do you remove sand (grit) from Kaolin?

A: Grit removal (Desanding) is done in stages. First, Spiral Washers or Trommels remove coarse sand (>50 mesh). Then, Hydrocyclones remove fine sand (-325 mesh) based on centrifugal force.

Q3: How much water is required?

A: Wet processing requires significant water (approx. 3-5 tons per ton of ore). However, our design includes Thickeners and water recycling systems to recover 85-90% of the process water.

Get Your Custom Kaolin Plant Design

We customize the solution based on your raw clay properties and final whiteness requirements.
Contact us for the optimal process design and quotation.

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