Typical plant configuration
Equipment list for ~1,000 t/day Indian kaolin ore washing and fine-processing line (kaolin & quartz sand)
Equipment list for a typical ~1,000 t/day raw kaolin ore washing and fine-processing plant in India, recovering both refined kaolin and quartz sand. This is a reference configuration, not a quotation; each plant is sized to the customer’s ore after testing.
Process outline
Raw ore is pulped and screened, sand is washed and dewatered, and the kaolin fraction is ground, classified by hydrocyclones, desliming cone, hydraulic classifier and spiral chutes, then purified by PTMS high-intensity electromagnetic separators before dewatering in filter presses. See also kaolin magnetic separation and quartz sand processing.
Equipment list
| No. | Equipment | Model / specification | Unit power (kW) | Qty | Notes |
|---|---|---|---|---|---|
| 1 | Feed hopper | 50 m³ | 15 | 1 | Customer self-made |
| 2 | Pulper | 1.5 × 1.5 m | 22 | 1 | |
| 3 | Pulper | 1.5 × 1.5 m | 22 | 1 | |
| 4 | Pulper | 1.5 × 1.5 m | 37 | 1 | |
| 5 | Dewatering screen | 1.5 × 5 m | 8 | 1 | |
| 6 | Dewatering screen | 1.5 × 6 m | 15 | 1 | |
| 7 | Linear screen | 2 × 4 m | 4 | 1 | 30 mesh |
| 8 | Linear screen | 2 × 4 m | 4 | 1 | 60 mesh |
| 9 | High-frequency screen | Type 1230 | 5 | 2 | |
| 10 | Rotary safety screen | 2 × 3 m | 4 | 4 | |
| 11 | Spiral sand washer | 1.5 × 9 m | 30 | 1 | |
| 12 | Gear-driven ball mill | 2.7 × 4.5 m | 320 | 1 | |
| 13 | Alumina balls & liners | 36 t | — | 1 | |
| 14 | Hydrocyclone | 500 | — | 1 | |
| 15 | Hydrocyclone | 150 | — | 6 | |
| 16 | Hydrocyclone | 75 | — | 12 | |
| 17 | Desliming cone | φ4 m | — | 1 | |
| 18 | Hydraulic classifier | φ3 m | — | 1 | |
| 19 | Spiral chute | φ1200 | — | 12 | |
| 20 | Magnetic separator | Type 1200 | 180 | 3 | PTMS electromagnetic slurry separator |
| 21 | Filter press | Type 125 | 5.5 | 1 | |
| 22 | Filter press | Type 250 | 11.5 | 1 | |
| 23 | Transfer tank agitator | For 20 m³ tank | 7.5 | 6 | Agitator only; tank customer self-made |
| 24 | Transfer tank agitator | For 30 m³ tank | 7.5 | 4 | |
| 25 | High-level tank agitator | For 4 m³ tank | 5.5 | 1 | |
| 26 | Dispersion tank agitator | For 30 m³ tank | 7.5 | 2 | |
| 27–35 | Process tanks and pools | Per design | — | Per design | Customer self-made civil works |
| 36 | Dosing system | — | 4.4 | 1 | |
| 37 | Belt conveyor | 800 type, 20 m | 15 | 2 | With VFD |
| 38 | Slurry pump | 4/3 | Per design | Per design | With VFD |
| 39 | Slurry pump | 6/4 | Per design | Per design | With VFD |
| 40 | Slurry pump | 8/6 | Per design | Per design | With VFD |
| 41 | Two-stage high-pressure pump | — | 30 | Per design | |
| 42 | Two-stage high-pressure pump | — | 37 | Per design | |
| 43 | Process water pump | 374 m³/h, 28 m head | 45 | 1 | |
| 44 | Cooling water pump | 4", 184 m³/h, 17 m head | 15 | 1 | |
| 45 | Cooling tower | 200 T | 4 | 1 | |
| 46 | Screw air compressor | — | 37 | 1 | |
| 47 | Air receiver tank | 1 m³ | — | 2 |
Approximate total installed power: about 1,886 kW. “Per design” items are sized during detailed engineering.
PTMS equipment in this line
- Magnetic separators — high-intensity water-cooled electromagnetic slurry separators
- Filter presss — PTMS membrane filter press for kaolin dewatering
- Screening — PTMS vibratory sieve for fine grading of finished product