china clay presentation

• ‘China clay’ and ‘Kaolin’ are often used almost synonymously.

• The word ‘Kaolin’ originates from Chinese ‘kauling’ (meaning high ridge). China Clay (kaolin) is a general term applied to naturally occurring clay.

• Specific gravity 2.6

• Fusion point is 1785°C.

• It is produced by the weathering of feldspathic constituent of different rocks

RESOURCES

• China clay resources in the country as per UNFC system as on 1.4.2005 have been placed at 2595.66 million tonnes,

• The reserves are only about 8% rest resources at 222 million tonnes.

Out of the total reserves

• About 102 million tonnes under proved category.

• About 121 million tonnesunder probable category.

• Spread over in a number of States Kerala holds about 24%;West Bengal (16%) ; Rajasthan (14%) ; Orissa (11%) and Karnataka (10%).

  Reserves Remaining resources Total resources

All India : Total 222121 2373540 2595661

Andhra Pradesh 11908 61767 73675

Assam 131 3912 4043

Bihar 0 1438 1438

Chhattisgarh 2678 12088 14766

Delhi 79 5210 5289

Goa 0 16 16

Gujarat 67190 43958 111148

Haryana 36 12029 12065

Jammu & Kashmir 0 28122 28122

Jharkhand 30647 159493 190140

Karnataka 7687 249369 257056

Kerala 9551 621101 630652

Madhya Pradesh 1386 11774 13161

Maharashtra 772 6477 7248

Manipur 0 2520 2520

Meghalaya 0 88875 88875

Orissa 39373 238789 278162

Punducherry 0 2940 2940

Rajasthan 42292 329418 371710

Tamilnadu 0 56897 56897

Uttar Pradesh 0 25065 25065

West Bengal 8390 412281 420671

Reserves/ resources of China Clay as on 1.4.2005000 Tonnes

STATE WISE RESOURCES OF CHINA CLAY

0

100000

200000

300000

400000

500000

600000

700000

States

To

nn

es

Kaolin is commercially valued for:

• whiteness • fine particle size • brightness, • glossiness, • abrasiveness • viscosity. • chemically inert • Do not swell with the addition• of water.

PRODUCTION• Kaolin is produced in the country in crude & processed forms.Crude Production 2006-07• Gujarat 46% • Kerala 20%• Rajasthan 15% • West Bengal 8% • Jharkhand 5% • Andhra Pradesh 4% • Chhattisgarh, Karnataka,

Madhya Pradesh, Maharashtra and Orissa 2%.Processed Production 2006-07 • Kerala 75% • Jharkhand 11% • Gujarat 9%• West Bengal 2%• Orissa 1%• Karnataka 2%

Production of Kaolin,Total TONNES

State 2004-05 2005-06 2006-07

All India : Total 933654 1335744 1301199

Andhra Pradesh 53170 29628 47059

Chhattisgarh 2970 1405 2149

Gujarat 226063 417188 503783

Jharkhand 60685 118931 79398

Karnataka 12372 12166 4090

Kerala 334111 474594 398428

Madhya Pradesh 15522 16835 14319

Maharashtra 890 380 372

Orissa 8006 4431 2712

Rajasthan 152699 178936 162516

West Bengal 67166 81250 86373

PR0DUCTION OF CHINA CLAY,Total,2006-07

Andhra Pradesh

Chhattisgarh

Rajasthan

West Bengal

Kerala

Jharkhand

Maharashtra

Madhya Pradesh

Orissa

Karnataka

Gujarat

Production of China ClayNatural and Processed

In tonnes

State 2005-06 2006-07

Natural Processed Natural Processed

India 934263 401481 1049707 251492

Andhra Pradesh 29628 - 47059 -

Chhattisgarh 1405 - 2149 -

Gujarat 388605 28583 479915 23868

Jharkhand 48313 70618 51159 28239

Karnataka - 12166 - 4090

Kerala 192620 281974 210446 187982

Madhya Pradesh 16835 - 14319 -

Maharashtra 380 - 372 -

Orissa 2751 1680 1017 1695

Rajasthan 178936 - 162516 -

West Bengal 74790 6460 80755 5618

PRODUCTION OF NATURAL AND PROCESSED CHINA CLAY,2006-07

Kerala Jharkhand Gujarat

West Bengal Karnataka Orissa

Andhra Pradesh Chhattisgarh Madhya Pradesh

Maharashtra Rajasthan

PROCESSED

NATURAL

Resources v/s Production 000 Tonnes

States Resources Production 1.4.2005 2006-07

Andhra Pradesh 73675 47Assam 4043 NILBihar 1438 NILChhattisgarh 14766 2Delhi 5289 NILGoa 16 NILGujarat 111148 504Haryana 12065 NILJammu & Kashmir 28122 NILJharkhand 190140 79Karnataka 257056 4Kerala 630652 398Madhya Pradesh 13161 14Maharashtra 7248 0.3Manipur 2520 NILMeghalaya 88875 NILOrissa 278162 3Punducherry 2940 NILRajasthan 371710 163Tamilnadu 56897 NILUttar Pradesh 25065 NILWest Bengal 420671 86

RESOURCES v/s PRODUCTION

Gujarat Kerala RajasthanWest Bengal Jharkhand Andhra PradeshMadhya Pradesh Karnataka OrissaChhattisgarh Maharashtra AssamBihar Delhi GoaHaryana Jammu & Kashmir ManipurMeghalaya Punducherry TamilnaduUttar Pradesh

RESOURCES

PRODUCTION

MINING

•China clay deposits worked in India are mostly of pocket-type.

•Opencast manual mining is followed in most kaolin mines.

•The most common practice is to dig trial pits for locating clay pockets or beds which are gradually enlarged into pits of various dimensions.

• Clay and overburden are quarried in benches.

•The natural china clay is being processed in the country mostly by the conventional method of levigation /washing.

• In addition, hi-tech processes, such as,

Mozeley hydrocyclone separator,

high-intensity magnetic separator,

bleaching (chemical decolourisation),

spray drying and calcination are being practised.

•There is a need to use more sophisticated processing techniques like ultra froth-flotation, cryo-filter, etc.

PROCESSING

PROCESSING (contd.)

China clay exhibits a marked whiteness and fine particle size in its natural size in its natural state, which properties are optimised during subsequent processing. These two key properties principally determine the commercial value of china clay and distinguish it from other clays, such as ball clay and fireclay. Though the clays have been since ancient times in pottery industry, production of modern whiteware commenced in India in the middle of 19th century at Pathargatta in Bihar.

PRODUCTS OF CHINA CLAY

USES

• China clay (Kaolin) is used in a number of industries in

both crude and processed forms. Major use for crude chinaclay is in cement industry insecticide and refractory are other user .

• ceramic industry is Major consumer of processed form of chinaclay. Besides ceramics, paper, paint, rubber, plastic, fibre glass,cosmetics,

pharmaceuticals and textiles consume processed china clay.

• Other uses of chinaclay are in ink, ultramarine, synthetic zeolites, catalyst, water filter candles, soaps and detergents and explosives and pyrotechnic industry.

Uses of China Clay Major Uses

• Ceramic & refractories

• Paper filling• Paper coating• Rubber filler• Plastic filler• Paint filler

Minor Uses

• Adhesives• Cement• Fabrics• Ink• Leather• Medicines• Oil secondary recovery• Pozzolana• Pesticides• Soaps• Cardboard coating• Fire retardant building material

Specifications of China Clay required in Different Industries

Industry Bureau of Indian Standard Specification No.

CeramicsGrades I II III

2840(1993)

Paper Coating Gr.-1Filler in Paper,Rubber, textile Gr. II

505(1995)

Paint Grade Gr. I & II 68(1979)

Cosmetics 1463(1983)

Explosives 7589(1974)

CONSUMPTION• The main consuming industry for raw china clay is the china clay

processing/refining plants.• Cement, refractories and pesticides industries are other consumer

of raw china clay• The consumption of kaolin by various industries increased to 486

Thousand tonnes in 2005-06, from 438, Thousand tonnes in 2004-05. • Cement accounted for 49%, • Ceramic 30%, • Pesticide 5%, • Paint 5%, • Refractory 5% • Paper 4% • Cosmetics, rubber, abrasive, asbestos products, chemical, dry cell

batteries, electrical, electrode and glass industries together about 2%

CONSUMPTION OF CHINA CLAY (In ‘000 tonnes)

Industry 2005-06 %

All Industries

486 -

Cement 238 49

Ceramics 147 30

Paint 23 5

Paper 20 4

Pesticides 25 5

Refrac-tories

23 5

Others 10 2

0

50

100

150

200

250

Cem

ent

Cer

amic

s

Pes

tici

des

Pai

nt

Ref

ract

ori

es

Pap

er

Oth

ers

CONSUMPTION OF CHINA CLAY BY INDUSTRIES,2005-06

Industry-wise uses of China clay

Ceramics Ceramic products are porcelain-wares, table wares, sanitary wares,

glazed tiles, flooring & wall tiles and electrical insulation. The properties required for use in ceramic industry are :

• Plasticity

• Drying capacity

• Amenability to firing

• Firing colour.

In the manufacture of insulators electrical properties such as conductivity, dielectric content, power factor and others are important. Manufacture of ceramics needs various combinations of these properties to suit the particular manufacturing process to achieve certain properties in the finished products.

Paper• China clay is used for paper coating to provide a smooth even surface and to impart glaze. • Various grades of better quality china clay offine mesh are used depending upon the quality of the paper required to be manufactured. • The whiteness, ink absorption, chemical inertness, uniformity of particle size and retentive properties determine the suitability of china clay for use in paper coating.

Rubber and plasticIn rubber and plastic industry, it is used as a filler and as a reinforcing and stiffening agent. China clay gives good electrical resistance and improves the resistance of plastic sheet(PVC) in cable. Thus it operates as a functional extender rather than just a filler. Electrical impact resistance, gloss and stiffness and brittleness are other properties which are imparted to plastic (PVC) by china clay.

Paint China clay is used as a filler extender in paint manufacture with

titanium dioxide, talc and calcium carbonate. The advantage of china clay as a filler used in exterior paints over the other filler materials mentioned above is due to its superior weatherability and dry-hiding power. Water washed china clay is compatible with water-based paints which are used to over-come the pollution problems and health risks associated with solvent based paints. The properties like antisetting and tinting effect, colloidal nature, softness, freedom from grit, white colour and fine size are some of the qualities of china clay which make it suitable for use in paint and distemper manufacture.

Insecticides, pharmaceuticals and cosmetics

• Used in the manufacture of disinfectant like D.D.T. It is also utilized for the manufacture ofcosmetics and pharmaceutical products like face powder, talcum powder, tooth paste, tooth powder,adhesives, surgical plaster, lotion and ointment for external use and porcelain in the dental preparation. It is used in the purification of substances like caffeine, cantheridin and santouin in toxicological analysis. China clay absorbs toxins and bacteria responsible for various types of intestinal infections hence it is used in the therapeutic intestinal absorbent preparations. Textile Mixed with some adhesives, china clay is used for filling, sizing and backing textiles of various kinds.

Refractory In the manufacture of refractory bricks, the coarse fraction of china

clay from the sedimentation tank is used. Refractories used as kiln furniture are produced from china clay and talc with suitable calcined grog. China clay has limited uses in refractories industry, its main application being in the production of insulation bricks.

Cement China clay is invariably used in the manufacture of white cement. The

ordinary portland cement industry requires alumina and silica as constituents in the manufacture of cement to maintain silica module. China clay with other clays provides a low cost source of raw material to the cement industry. Calcined china clay is also used as pozzolanic material in the manufacture of portland pozzolana cement.

Other Uses Ink : Water washed and chemically bleached

china clay is used largely in printing inks.

Ultramarine : The purer type of china clay forms

the essential raw material for the manufacture of

ultramarine.

Synthetic zeolites : New uses of china clay are in the manufacture of synthetic zeolites. It is a major breakthrough in the industrial application of china clay. Calcined china clay is used as a source of alumina and silica to produce zeolites. Synthetic zeolites are used in the refineries and petrochemical industries as molecular sieves which are becoming widely used.

Catalyst: The relatively new field is the chemical modification of china clay to make it an effective catalyst for use in petroleum refining. China clay is treated with sulphuric acid and calcined to produce the catalyst.

Water filter candles : They are prepared from china clay which is mixed with wood powder, burnt and made into moulds used in water filtering. It is an extended product of ceramics.

Explosive and pyrotechnic industry : Widely used in explosive formulations, both commercial and military.

Soaps and detergent : In the manufacture of soaps and detergents as dehydrating agent.

Fibre glass :Air floated or spray dried china clay is used in the fibre glass manufacture as a filler.

TRADE

Exports of Kaolin (Total),2005-06(In ‘000 tonnes)

Major Country

Qty

All Countries

65

Bangladesh 30

UAE 20

Srilanka 2

Nepal 2

Jordan 2

Others 9

0

5

10

15

20

25

30

Ban

gla

des

h

UA

E

Sri

lan

ka

Nep

al

Jord

an

Oth

ers

EXPORTS OF CHINA CLAY ,2005-06 (000 tonnes)

Imports of Kaolin (Total),2005-06(In ‘000 tonnes)

Major Country

Qty

All Countries

41

USA 13

Ukraine 12

China 5

Brazil 5

Others 6

0

2

4

6

8

10

12

14

US

A

Uk

rain

e

Ch

ina

Bra

zil

Oth

ers

IMPORTS OF CHINA CLAY ,2005-06 (000 tonnes)

CHINA CLAY ART WORK