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Kaolin Drying Production Line: Applicable Industries, Core Advantages & Comparative Analysis
Release time:
2025-08-27
It introduces the applicable industries, core advantages, comparison with traditional processes and customer cases of the kaolin drying production line, and provides customized solutions.
Kaolin, as a high-quality non-metallic mineral with excellent whiteness, plasticity, and chemical stability, is widely used in industries such as papermaking, ceramics, coatings, and cosmetics. The kaolin drying production line developed by our company targets the high moisture content of kaolin slurry (about 70% initial moisture) and adopts a "filter cake forming + direct hot air drying" integrated process. It efficiently reduces the moisture content of kaolin to less than 1% (adjustable according to needs) while ensuring product purity and whiteness. Below is a detailed analysis of its applicable industries, core advantages, and technical comparisons.
1. Applicable Industries of Kaolin Drying Production Line
The production line is tailored to the drying needs of kaolin in different application scenarios, with strong adaptability to raw material properties (such as filter cake moisture, particle size) and product quality requirements. Its main applicable industries are as follows:
| Industry | Application Scenario | Core Requirements for Kaolin | How the Production Line Meets Requirements |
|---|---|---|---|
| Papermaking | Coating kaolin (for paper surface coating)、Filling kaolin (for paper body filling) | - Coating grade: Whiteness ≥90%, particle size D90 ≤2μm, moisture ≤1% (to avoid paper surface cracking) - Filling grade: Purity ≥95%, low impurity content (to ensure paper strength) | 1. Hot air purification (dust content ≤30mg/Nm³) avoids secondary pollution of kaolin; 2. Precise temperature control (±3℃) prevents kaolin oxidation and whiteness loss; 3. Drying terminal moisture is stable at 0.5-1%, meeting paper processing requirements. |
| Ceramics | Ceramic green body (tiles, sanitary ware)、Glaze raw material | - High plasticity: Moisture after drying needs to be uniform (avoiding green body deformation during firing) - Low iron content: Purity ≥96% (to prevent ceramic surface color spots) | 1. Filter cake forming system controls initial moisture at 35%, ensuring uniform subsequent drying; 2. High-temperature gas purification device removes iron-containing impurities in hot air; 3. Dryer internal structure design (special lifting plates) ensures full material dispersion and uniform moisture. |
| Coatings & Inks | Water-based coatings、Solvent-based inks (as matting agent, pigment carrier) | - Whiteness ≥92%, fineness ≥325 mesh (to ensure coating coverage) - Moisture ≤0.8% (to avoid coating delamination or foaming) | 1. Hot air temperature (300-400℃) is adjustable to match the heat sensitivity of kaolin (no thermal decomposition); 2. Tail gas treatment system (cyclone + bag filter) recovers fine kaolin powder, improving product yield; 3. Stable drying effect ensures consistent fineness and whiteness of finished products. |
| Cosmetics & Daily Chemicals | Facial cleansers (abrasive), toothpaste (filler), powder products (texture regulator) | - Food-grade purity: Heavy metal content ≤10ppm, no microbial contamination - Ultra-low moisture: ≤0.5% (to extend product shelf life) | 1. Closed drying process + 304 stainless steel equipment materials avoid material pollution; 2. High-efficiency hot air supply (thermal efficiency ≥97%) ensures rapid moisture removal without damaging kaolin structure; 3. Post-drying cooling system controls product temperature ≤40℃, preventing moisture absorption during packaging. |
| Rubber & Plastics | Rubber additives (reinforcing agent), plastic fillers (whitening agent) | - Particle size uniformity (D50: 5-10μm)、Moisture ≤1.2% (to avoid rubber vulcanization defects) | 1. Screw conveyor with variable frequency control ensures stable feeding and uniform particle size; 2. Dryer's multi-layer air distribution design realizes full contact between hot air and materials, improving drying efficiency; 3. Low operating cost (energy-saving 20% compared to traditional processes) reduces the overall production cost of rubber and plastic enterprises. |
2. Core Advantages of Kaolin Drying Production Line
Compared with traditional kaolin drying equipment (such as single-drum dryers, rotary kilns), our production line has obvious advantages in energy saving, product quality, and operation stability, specifically reflected in the following aspects:
| Advantage Category | Specific Performance | Value for Customers |
|---|---|---|
| High Energy Efficiency & Energy Saving | 1. Direct-fired hot air supply + waste heat recovery: Thermal efficiency ≥97%, 20% higher than heat exchange systems; 2. Frequency conversion control for fans and conveyors: Reduces no-load energy consumption by 15-20%; 3. Automatic temperature adjustment: Avoids energy waste caused by overheating. | For a medium-sized kaolin plant (annual output 50,000 tons), it can save about 800,000-1.2 million yuan in energy costs annually. |
| Excellent Product Quality | 1. Hot air dust content ≤30mg/Nm³: Ensures product purity ≥95%, whiteness loss ≤1%; 2. Temperature stability ±3℃: Prevents kaolin from being over-burned or under-dried; 3. Terminal moisture controllable (0.5-3%): Meets the needs of different downstream industries. | Helps customers enter high-end markets (such as cosmetics, high-grade paper), increasing product added value by 10-30%. |
| Stable & Reliable Operation | 1. Equipment materials: Dryer cylinder adopts 316L stainless steel (wear-resistant, corrosion-resistant), service life ≥10 years; 2. PLC automatic control: Real-time monitoring of temperature, pressure, and moisture, with fault alarm and interlock protection; 3. Low failure rate: Key components (burner, fan) adopt international brands (Siemens, Weishaupt), reducing maintenance frequency. | Reduces equipment downtime to ≤50 hours/year, ensuring continuous production and on-time delivery for customers. |
| Environmental Protection & Compliance | 1. Tail gas treatment: "Cyclone separator + bag filter + activated carbon adsorption" ensures dust emission ≤10mg/Nm³, meeting GB 16297-1996 《Integrated Emission Standard of Air Pollutants》; 2. No waste water discharge: The water from the filter press is recycled to the slurry system; 3. Low noise: All fans are equipped with sound insulation covers, noise ≤85dB. | Helps customers pass environmental protection inspections smoothly, avoiding production suspension risks due to non-compliance. |
| Flexible & Customizable | 1. Capacity customization: 5-50 tons/hour (single line), supporting multi-line parallel expansion; 2. Process adjustment: According to kaolin types (soft kaolin, hard kaolin), adjust drying temperature and air speed; 3. Auxiliary functions: Optional automatic packaging, iron removal, and particle size classification modules. | Adapts to the production needs of small and medium-sized enterprises (SMEs) and large-scale industrial plants, reducing initial investment waste. |
3. Comparative Analysis with Traditional Drying Processes
To further highlight the technical advantages of our kaolin drying production line, we compare it with two traditional processes (single-drum dryer and heat exchange hot air dryer) from 6 core dimensions:
| Comparison Dimension | Our Kaolin Drying Production Line | Traditional Single-Drum Dryer | Traditional Heat Exchange Hot Air Dryer |
|---|---|---|---|
| Thermal Efficiency | ≥97% (direct-fired + waste heat recovery) | 60-70% (large heat loss from cylinder) | 75-80% (heat loss from heat exchanger) |
| Product Whiteness | Loss ≤1% (clean hot air + low-temperature drying) | 3-5% (easy to be contaminated by flue gas) | 2-3% (heat exchanger may cause impurity mixing) |
| Energy Consumption (per ton of kaolin) | 80-100 m³ natural gas | 130-150 m³ natural gas | 110-130 m³ natural gas |
| Equipment Service Life | ≥10 years (316L stainless steel) | 5-6 years (carbon steel cylinder, easy to corrode) | 7-8 years (heat exchanger prone to scaling) |
| Environmental Emission | Dust ≤10mg/Nm³ (multi-stage purification) | Dust 50-80mg/Nm³ (simple cyclone separation) | Dust 30-50mg/Nm³ (lack of deep purification) |
| Investment Recovery Period | 1.5-2 years | 2.5-3 years | 2-2.5 years |
4. Customer Case Reference
Case 1: A papermaking kaolin enterprise in Jiangxi
Demand: Drying 10 tons/hour of kaolin filter cake (initial moisture 35%), requiring finished product moisture ≤1%, whiteness ≥92%.
Solution: Our 10t/h kaolin drying production line (equipped with double-stage hot air purification + automatic moisture control).
Effect: Energy consumption per ton of product is reduced by 22% compared to the original single-drum dryer; product qualification rate reaches 99.5%, and it has successfully supplied high-grade coating kaolin to a leading papermaking enterprise.
Case 2: A cosmetics raw material manufacturer in Guangdong
Demand: Food-grade kaolin drying, requiring heavy metal content ≤10ppm, moisture ≤0.5%.
Solution: Closed drying system + 304 stainless steel equipment + post-drying iron removal module.
Effect: The product meets the EU ECOCERT standard, enters the European cosmetics market, and the production line operates stably for 3 years with a failure rate of less than 2%.
As a professional supplier of thermal engineering equipment, we provide customers with "turnkey solutions" from process design, equipment manufacturing to on-site commissioning. If you have customized needs for kaolin drying capacity, product quality, or environmental protection standards, please contact our technical team for a one-stop service.
Author: Hangzhou Thermal Engineering Technology Co., Ltd.
Source: Open Website
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