Kaolin wet processing plant design
June.12,2020
This project adopts self-developed new technologies, new processes and new equipment, and eliminates outdated technologies, processes, equipment and production capacity. The new type of pulping machine developed in this project is used for the dispersion of minerals in the process of raw material pulping, which is shorter than the original pulping time, and the separation of minerals and impurities is more complete, which is helpful for the separation operation of the subsequent process. The development of new sorting equipment for small-caliber high-pressure cyclones has improved the classification of finer grade minerals. The high-end kaolin production line will use new drying technology to save 70% of the land than the original drying and increase the drying efficiency by 50%. The automation of the entire production line has been increased, reducing production and management costs, while improving the stability of the production process. The project uses self-developed patented technology, which is arranged in sequence according to the principle of flow-in-sequence slurry flow. The raw material pretreatment workshop is arranged at the highest place, and then is the pulping workshop, sorting workshop, ultrafine grinding workshop, superconducting magnetic separation workshop, filter press workshop, drying workshop, rolling and packing workshop, and tailings treatment workshop. For details, see the general layout drawing.
| Category | Annual output (t per year) | Application field |
| First grade kaolin | 120000 | Functional ceramics, high-grade refractory materials for glass melting furnaces, high-performance glass fibers and products, ultra-thin ceramic plates, petrochemicals, papermaking, rubber, plastics, fillers, glass fibers |
| Second grade kaolin | 80000 | Ceramics, refractory and other fields |
| Construction sand | 50000 | Ceramics, refractory and other fields |
Major equipment
Pulp and sorting system
The raw materials of the pulping and sorting system are fed from the raw material warehouse through the plate feeder to the pounding tank for pounding, and then the slurry is transported to the buffer tank by the scraping blade on the pounding machine. Under the action of water and a small amount of dispersing agent, The agglomerated or agglomerated kaolin clay quickly disintegrates and separates. The ore pulp is filtered by a 32-mesh sieve and then flows into the buffer tank from the tortuous groove. It is sent to the three-stage roughing device (Ø200, 606EX, 600EX three cyclones) and Two-stage selection device (Ø25, Ø10 two kinds of cyclones), the underflow of each level of cyclones is recovered by Ø150 cyclones.
Spiral classifier to remove coarse sand
The raw particles of kaolin clay such as quartz, feldspar, mica and other impurities have coarser particle sizes, generally larger than 325 mesh, while the particles of kaolin have finer particle sizes, mainly concentrated in -2μm. A spiral classifier can remove most of the quartz and feldspar coarse sand.
Sorting of hydrocyclone
The hydrocyclone is used for separation. The operation is to remove kaolin fine sand (fine-grained quartz, feldspar and other impurities). Generally, hydrocyclones with different diameters such as Ø75, Ø50, and Ø25 are used for multiple sorting.
The filter press dehydration and drying system
filter press dehydration operation adopts a large automatic unloading chamber filter press. The filter cake that automatically falls off directly falls into the mud basket, and is transferred to the lifting machine through the chain transmission mechanism, and then transferred to the program car. Dry in the drying room. The drying room will be built on the north side of the main process filter press workshop with an area of about 1635m2. The dried materials are still transported to the lowering machine by the program car. The dry material on the tray is turned 180º into the hopper and crushed by the improved dumper. The crushed material is transported to the large barrel silo and silo by the bucket elevator The bottom plate feeder conveys the material to a small hopper and enters the automatic packaging machine for packaging, which is a granular product.
Ore dressing wastewater purification workshop
The amount of beneficiation wastewater generated daily is relatively large, and it needs large amount of wastewater treatment equipment to achieve it. The project design adds 2000m3 of return pool and 6 pumps. More than 95% of the treated beneficiation wastewater is recycled as beneficiation water, and 5% is discharged. The sludge in the sedimentation tank is kaolin with smaller particles. After concentration and pressure filtration, it can be sold as a secondary product of kaolin.
