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Kaolin, also known as kaolinite or china clay, is one of the world's most common minerals. It is found and mined in several countries, including Australia, Brazil, Bulgaria, China, and the United States. In Australia, kaolin deposits can be found in the Poochera Halloysite-Kaolin Project on the Eyre Peninsula in South Australia. This project involves a proposed shallow open-pit mine for the extraction of high-quality halloysite-kaolin. The deposit consists of bright white kaolinised granite, which is estimated to have a combined resource of 9.7 million tonnes within the Carey's Well deposit.
| Characteristics | Values |
|---|---|
| Location | Carey's Well deposit, Eyre Peninsula, South Australia |
| Mine type | Shallow open-pit |
| Deposit | Bright white kaolinised granite |
| Mineral composition | Kaolinite, halloysite, feldspar |
| Production rate | 227,000tpa of refined premium halloysite-kaolin |
| Processing methods | Dry-processing, wet-processing |
| Global production in 2021 | 45 million tonnes |
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What You'll Learn
Kaolin deposits in Australia
Kaolin is a type of clay that has been used in the production of glossy white paper, as well as in clay-based ceramics, cement, and fibreglass. Deposits of kaolin can be found in various locations across Australia.
One notable deposit is the Poochera Halloysite-Kaolin Project located on the Eyre Peninsula in South Australia. This project involves a proposed shallow open-pit mine for the extraction of halloysite-kaolin, a type of kaolin with a unique molecular structure known as nanotubes. The deposit is situated within the Carey's Well deposit, which is located in the western part of the peninsula. The project is expected to have a production rate of 227,000 tonnes per annum of refined premium halloysite-kaolin.
Another significant deposit is the Weipa kaolin in northern Queensland, which was once a supplier of kaolin to the paper industry in Asia. However, production from this area ceased in 1998 due to market pressure and limited opportunities for expansion. The Skardon River kaolin deposit, located north of Weipa, is also a potential source of kaolin, but development has been challenging due to the oversupply of kaolin in the paper industry.
In addition to these deposits, there are also smaller kaolin resources located in other parts of Australia. For example, hydrothermally altered massive sillimanite bodies near Williamstown in South Australia have been mined since the early 1900s to produce a mixed kaolin/sillimanite product. This high-alumina kaolin, marketed as 'kaosil', is used in specialist refractories and insulating ceramics capable of withstanding high thermal shock.
The discovery of these kaolin deposits in Australia has not only facilitated local industry and trade but has also presented opportunities for innovation in nanotechnology. The unique molecular structure of halloysite-kaolin, found in deposits like those on the Eyre Peninsula, has sparked interest in its potential applications in advanced nanotechnologies for carbon emission reduction.
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The Poochera Halloysite-Kaolin Project
The project contains two major geographic areas and has five tenements spread across 2,069 square kilometres. A new 481-square kilometre tenement application for land with potential for high-quality halloysite-kaolin is pending approval from the regulator. The main focus area is located 130 kilometres away from the town of Ceduna and 635 kilometres from Adelaide. The Carey's Well deposit is located in the western part of the peninsula, 45 kilometres east of Streaky Bay. The deposit is open to the north, north-east, and south-east.
The project is expected to have an initial life of 15 years and provide jobs for 30 to 40 people. The mining method will involve open-pit mining of two shallow open pits in 11 stages, using excavators and trucks to transport ore and waste to stockpiles. Limited blasting may also be employed to target the near-surface harder calcrete and silcrete rocks above the kaolinised granite. The processing plant will be built near the pits, with the partners intending to design and construct the project infrastructure based on the engineering, procurement, and construction management (EPCM) model.
The Poochera project will use either dry-processing or wet-processing techniques. The dry-processing plant design includes a front-end loader, an apron feeder, a single drum beaker, heat supply and recovery equipment, a feed conveyor, a dryer, a classifier, and a bagging filter system. The wet-processing technique yields a higher recovery rate of 90% metallurgical recovery of kaolin clay and a filter cake kaolin clay grade of 85%. The utilisation rate for the dry-processing method is expected to be 91.3%. The results from the wet-processing will be studied further in the pre-feasibility study.
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Kaolin mining in Australia
Kaolin, or kaolinite, is a common mineral that is found and mined all over the world, including in Australia. In Australia, kaolin can be found in the Poochera Halloysite-Kaolin Project on the Eyre Peninsula in South Australia. The project is a proposed shallow open-pit mine that comprises the Carey's Well deposit, which is located on the western part of the peninsula. The deposit is a sub-horizontal zone of bright white kaolinised granite resting on unweathered granite. The project is expected to have an average production rate of 227,000tpa of refined premium halloysite-kaolin.
The Poochera project contains two major geographic areas and has a total of five tenements spread across 2,069km². The main focus area is located 130km away from the town of Ceduna and 635km from Adelaide. The bright white kaolin deposit is situated 45km east of Streaky Bay on the EL 5814 Tootla tenement within the Poochera project. A new 481km² tenement application for land with potential for high-quality halloysite-kaolin is pending approval from the regulator.
The mining method to be employed in the project will include the use of excavators and trucks to transport ore and waste to stockpiles. Mining may also include limited blasting to target the near-surface harder calcrete and silcrete rocks that lie above the kaolinised granite. The mine will employ either dry-processing or wet-processing. The dry-processing plant design includes a front-end loader that will feed the hopper, an apron feeder and single drum beaker, heat supply and recovery equipment, a feed conveyor, a dryer, a classifier, and a bagging filter system. The reject sand from the processing is sent for backfilling into the voids. The product will be delivered to ports using road trains.
Kaolin is an important raw material in many industries and applications. Commercial grades of kaolin are supplied and transported as powder, lumps, semi-dried noodles, or slurry. Global production of kaolin in 2021 was estimated to be 45 million tonnes, with a total market value of US $4.24 billion. Kaolinite clay occurs in abundance in soils that have formed from the chemical weathering of rocks in hot, moist climates, such as in tropical rainforest areas.
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Kaolin processing methods
Kaolin, also known as china clay, is a hydrated aluminium silicate crystalline mineral formed from weathered granite. It is one of the most common minerals on Earth and is widely used in various industrial processes. The extraction and processing of kaolin are crucial for maintaining a consistent supply of premium-grade material.
Kaolin processing typically involves multiple stages, including mining or extraction, crushing or grinding, purification, drying, and packaging. Here is a detailed overview of common kaolin processing methods:
Mining or Extraction
The first step in kaolin processing involves the extraction of kaolinite clay from the ground. This can be done through various methods, depending on the location and depth of the kaolin deposits. Open-pit mining, also known as surface mining, is commonly used for near-surface deposits. This method utilises large equipment, such as loaders and excavators, to remove overburden and extract the kaolin. Underground mining, on the other hand, is employed for deeper deposits, requiring the creation of tunnels and the use of specialised equipment.
Crushing or Grinding
Once the kaolin has been extracted, it is typically crushed to reduce the particle size. Jaw crushers and ball mills are commonly used for this process, breaking down large chunks of kaolin into smaller pieces. The crushed kaolin particles are then ground into a fine powder using grinding mills. This grinding process increases the surface area of the kaolin particles, improving their performance in various applications.
Purification
Purification is a critical step in kaolin processing, as kaolin often contains impurities like sand, mica, and other minerals. This step involves techniques such as desanding and froth flotation to remove these unwanted substances. In desanding, the kaolin slurry is passed through equipment like hydrocyclones or sedimentation tanks, allowing the heavier impurities to settle while the lighter kaolin particles are separated. Froth flotation is used to remove additional impurities, such as iron oxides and titanium minerals. Chemical reagents are added to the slurry, which selectively bind to these impurities. Air bubbles are then introduced, and the impurities are skimmed off the surface along with the bubbles.
Drying
After purification, the kaolin slurry undergoes a dewatering process to reduce its moisture content. This can be achieved through various drying methods, such as spray drying or rotary drying, depending on the desired moisture level.
Packaging and Shipping
The final processed kaolin is then packaged according to customer requirements, typically in bags or bulk containers. It is then ready for shipment to customers or storage until further use.
It is important to note that kaolin processing methods can vary depending on the specific requirements of the industry utilising the material. For example, industries such as ceramics, paper, paints, rubber, and cosmetics may have additional processing steps to tailor the kaolin to their specific needs.
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Kaolin's global production
Kaolin is a clay derived from the mineral kaolinite, which is formed by the hydrothermal weathering of igneous rocks such as granite. It has a variety of applications, including in the paper industry, where it is used as a filler or coating to enhance gloss, smoothness, brightness, and paint absorbency. Kaolin is also used in the production of fibreglass, which is employed in the automotive, marine, and aerospace industries.
The United States is one of the world's top producers of kaolin. According to the US Geological Survey (USGS), kaolin production in the country decreased from 2017 to 2020, with a significant decline of 9.7% in 2020 attributed to the COVID-19 pandemic. In 2017, companies like Imerys, Quarzwerke (Sibelco), and BASF dominated the global market, collectively accounting for over 26% of global production. Imerys alone held a 16.3% market share. Other notable producers include KaMin and Thiele Kaolin Co., both based in the US.
The Asia-Pacific region, including countries like China, India, Vietnam, Malaysia, and South Korea, is also a significant contributor to the kaolin market. In 2021, this region accounted for approximately 50% of the global volume share due to robust economic growth and increasing industrialisation. China, in particular, has witnessed the growth of the kaolin industry due to the expanding number of ceramic manufacturing companies.
In Australia, the Poochera Halloysite-Kaolin Project in South Australia is a notable example of kaolin production. This project involves a proposed shallow open-pit mine in the western part of the Eyre Peninsula, focusing on the Carey's Well deposit. The deposit consists of bright white kaolinised granite, and the project is expected to yield 227,000 tonnes per annum of refined premium halloysite-kaolin. The mining method will include dry or wet processing, with the dry-processing plant designed to have a throughput of 500,000 tonnes per annum.
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Frequently asked questions
Kaolin, or kaolinite, is found in the Poochera Halloysite-Kaolin Project on the Eyre Peninsula, South Australia.
The Poochera project contains two major geographic areas in the western province of South Australia. The project is a joint venture between Andromeda Metals and Minotaur Exploration, with the former acquiring a 51% equity interest in April 2018. The project is expected to involve open-pit mining of two shallow open pits in 11 stages.
Kaolin is an important raw material in many industries. Commercial grades of kaolin are supplied and transported as powder, lumps, semi-dried noodles, or slurry.
