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Kaolin, also called china clay, soft white clay that is an essential ingredient in the manufacture of china and porcelain and is widely used in the making of ceramics, paper, rubber, paint, and many other products.
Kaolin as found in nature usually contains varying amounts of other minerals such as muscovite, quartz, feldspar, and anatase. In addition, crude kaolin is frequently stained yellow by iron hydroxide pigments. It is often necessary to bleach the clay chemically to remove the iron pigment and to wash it with water to remove the other minerals in order to prepare kaolin for commercial use.
When kaolin is mixed with water in the range of 20 to 35 percent, it becomes plastic (i.e., it can be molded under pressure), and the shape is retained after the pressure is removed. With larger percentages of water, the kaolin forms a slurry, or watery suspension. The amount of water required to achieve plasticity and viscosity varies with the size of the kaolinite particles and also with certain chemicals that may be present in the kaolin.
Kaolin is used extensively in the ceramic industry, where its high fusion temperature and white burning characteristics makes it particularly suitable for the manufacture of whiteware (china), porcelain, and refractories. The absence of any iron, alkalies, or alkaline earths in the molecular structure of kaolinite confers upon it these desirable ceramic properties. In the manufacture of whiteware the kaolin is usually mixed with approximately equal amounts of silica and feldspar and a somewhat smaller amount of a plastic light-burning clay known as ball clay. These components are necessary to obtain the proper properties of plasticity, shrinkage, vitrification, etc., for forming and firing the ware. Kaolin is generally used alone in the manufacture of refractories.
Substantial tonnages of kaolin are used for filling rubber to improve its mechanical strength and resistance to abrasion. For this purpose, the clay used must be extremely pure kaolinite and exceedingly fine grained. Kaolin is also used as an extender and flattening agent in paints. It is frequently used in adhesives for paper to control the penetration into the paper. Kaolin is an important ingredient in ink, organic plastics, some cosmetics, and many other products where its very fine particle size, whiteness, chemical inertness, and absorption properties give it particular value.
Ball Clays are fine grained, highly plastic clays and are typically used in the manufacture of ceramic whiteware and sanitaryware. A rare mineral, Ball Clay is found in select places around the world. In India, the richest deposits are found in Gujarat and Rajasthan
Ball Clay is a variety of Kaolinite, like china-clay. It differs from china-clay in having high plasticity and less refractoriness. In chemical composition, ball and china clays do not differ greatly except that the former contains a larger proportion of silica. It has derived its name from the practice of removing it in the form of ball-like lumps from the clay pits in the UK.
Ball clays are kaolinitic sedimentary clays that commonly consist of 20-80% kaolinite, 10-25% mica, 6-65% quartz. Localized seams in the same deposit have variations in composition, including the quantity of the major minerals, accessory minerals and carbonaceous materials such as lignite. They are fine-grained and plastic in nature, and, unlike most earthenware clays, produce a fine quality white-coloured pottery body when fired, which is the key to their popularity with potters. Ball clays are relatively scarce deposits due to the combination of geological factors needed for their formation and preservation.