Classification and dewatering
of non-metallic minerals
Tailored calcium carbonate and kaolin treatment for industrial needs
In the production of non-metallic
minerals, classification and dewatering
are two process steps that can
significantly affect your profitability.
As drying is an energy-intensive step,
effective dewatering ensures fast
and more economical processing.
To further maximize the commercial
value of your end-product, accurate
control of the classification step
makes sure that you obtain the final
particle size and purity needed to
meet specific target application
requirements.
Using Alfa Laval decanter centrifuges
ensures continuous, operator-friendly
minerals dewatering with accurate
control in a fully enclosed process step,
which contributes to a better working
environment.
Process overview
Calcium carbonate and kaolin, found in
quarries all over the world, are among
the most widely used minerals. After
a number of treatment steps they are
used not only as pigments in paint and
paper products, but also in ceramics
and cosmetics. The typical production
method involves mechanical processes
such as crushing, screening and washing,
followed by classification and dewatering.
The drier the product is after dewatering,
the more energy can be saved in the
final drying step of the calcining process.
Product requirements can be very
specific, which creates a need for a suit-
able process for tailor-made production.
The final particle characteristics are
often critical for specific applications,
making it imperative to obtain a well-
defined particle size distribution or
specific purity.
 Mining Crushing Screening Milling Flotation Classification
and washing

Calcium Carbonate ore

Ground Calcium Carbonate

Coarse product
(GCC) Production
Dewatering Fine
product

MINING / BENEFICIATION EXTRACTION & CONCENTRATION

MINING / BENEFICIATION
Product Fine GrindingLeaching / DigestionThickening EXTRACTION & CONCENTRATION
Water Solid-Liquid Separation

Leaching / Digestion Solid-Liquid Separation Pregnant Liquor

Pregnant Liquor
4
Screening /Washing 4 Precipitation Precipitates /Concent
Surface Mining
Screening /Washing Precipitation Precipitates /Concent
2
Surface Mining
Tailings
MINING / BENEFICIATION
2

Flotation Tailings

Flotation
Crushing Grind Thickening
Leaching
Crushing Fines Rejects / Slimes Grind 6
Thickening
MINING / BENEFICIATION Limestone Concentrate
6

Calcium carbonate
Fines Rejects / Slimes
the number of particles smaller than two
CaCO3
Concentrate
Leaching / Digestion Solid-Liquid Se
microns. This makes the classification Tailings

production
He
Underground Mining
3

at
Tailings

step very important, as it can be the

1
MINING / BENEFICIATION Screening /Washing

ed
Underground Mining
ed

Calcium carbonate is readily available

3
1
Surface Mining The lime 5
Ca r bo nat

Coarse Reject Tailings Pond / Dam driving force behindLeaching quality differentiations
/ Digestion Solid-Liquid Separation
4
in quarries around the world. It is minedCoarse Reject cycle for
5
2
Tailings Pond / Dam
Screening /Washing based on particle
Pond / Dam size and distribution.
high-calcium
Tailings
as Surface
limestone Miningand can be ground to MINING / BENEFICIATION
The degritting
Tailings Pond / Dam
process before the
the right2 particle size. This produces lime
Screening /Washing PURIFICATION AND METAL RECOVERYLeaching / Digestion
4
Solid-Liquid Separation Flo
Slaked lime Quicklime classification step is important if small
GCC (Ground Calcium Carbonate)
Surface Mining
viaCRUD Crushing
Anode Slimes
PURIFICATION AND METAL RECOVERY
Grind Pre
2
a mechanical process in which the CRUD Ca(OH) 8 2 Slimes
Anode
CaO amounts of sand are present.
9
Flotation 4 Tailings
8 Fines Rejects / Slimes
9

mineral is washed by aSurface

large volume
Crushing
Screening /Washing e d
W ater ad d Grind Flotation

of water. 2
Mining
Crushing
Advantages Grind
for all
Fines Rejects / Slimes
Solvent Extraction Electrowinning Cathode
Fines Rejects / Slimes
processes and requirementsConcentrate Tailings

PCC (Precipitated Calcium Carbonate)

Underground Mining Kaolin, one of the principal ingredients
Solvent Extraction Electrowinning Cathode
A decanter offers a Flotation number of benefits, Concentrate

3
calcium carbonate production of ceramic goods, is often called "china
is anotherConcentrate 1 Crushing regardless
Grind of which calcium carbonate
Tailings
Tailings

method. The limestone

Underground Mining
Concentrate Underground Mining
goes through clay". Fines Rejects / Slimes
3
production method is used or whether Concentrate
1 3
1
the same primary mechanical crushing Coarse Reject classification
Tailings orPond
dewatering
/ Dam is required.
Leaching Impurity Removal Drying 5

process, but is then heated to 1000°C

Leaching in The kaolin production
Impurity Removal process has
Coarse Reject Tailings Pond / Dam
Decanter processThickening
parameters
Tailings such
(Reduction, Precipitation,
Cementation, Crystallization)
Filtration
Drying
12
Underground Mining Filtration

GCC process, as bowl speed, pond level settings

(Reduction, Precipitation,
Coarse Reject Tailings Pond / Dam3
a calcination tower. 1 strong similarities with the Thickening
Cementation, Crystallization)
11
12
Tailings Pond / Dam
and differential speed can be used to
Waste / Residue 11

as it includes both classification Waste / Residue

and 10 5
Tailings
Kaolin production dewatering steps in which a decanter
Coarse Reject Tailings Pond / Dam
10 classify the product and particle sizes Calcining PU
PURIFICATION AND METAL RECOVERY
Kaolin is a general name for minerals centrifuge can be used. deviating from a certain diameter can TailingsCalcining Pond / Dam
CRUD CRUD Anode Slimesbe excluded. Anode Slimes PURIFICATION AND METAL REC
such as kaolinite and halloysite, which 8 9
8 9
are mainly used in paper filling and coating, Kaolin is often described as primary or PURIFICATION AND METAL RECOVERY
CRUD Anode Slimes
as well as plastics, rubber and paint. secondary
8
kaolin deposits, which9 define
CRUD Anode Slimes
8 9

Solvent Extraction Electrowinning Cathode

Solvent Extraction Electrowinning Cathode

Solvent Extraction Electrowinning Cathode

Concentrate Solvent Extraction Electrowinning Cathode

Kaolin Production Concentrate

Concentrate
Leaching Impurity Removal
(Reduction, Precipitation,
Concentrate Cementation, Crystallization) Thickening

11

Mining Crushing Blunging

Leaching Degritting
Impurity Removal
Leaching Classification Waste /Magnetic
Impurity Removal Residue Separation Flotation/
(Reduction, Precipitation,
10 Cementation, Crystallization)
Selective Flocculation
Thickening

Leaching Impurity Removal Fine product 11

(Reduction, Precipitation,
Waste / Residue
Cementation, Crystallization) T
10
Waste / Residue

10
Grit Kaolin Waste / Residue
Dewatering
10

Coarse product
Water

Solid fraction
 Mining Crushing Calcination Lime slaking Lime tank Carbonation Dewatering

Calcium Carbonate ore

Fuel and air Water CO2

Solid Water
fraction

Precipitated
Calcium Carbonate
(PCC) Production Packaging Fine grinding Drying
MINING / BENEFICIATION EXTRACTION & CONCENTRATION
MINING / BENEFICIATION EXTRACTION & CONCENTRATION
Leaching / Digestion Solid-Liquid Separation
Leaching / Digestion Solid-Liquid Separation
Pregnant Liquor
Pregnant Liquor

4
4
Screening /Washing Precipitation Precipitates /Concent
Surface Mining Screening /Washing Precipitation Precipitates /Concent
Surface Mining
2
2
Tailings
Tailings
Flotation
Flotation
Crushing Grind Thickening
Crushing Grind Thickening
Fines Rejects / Slimes 6
Fines Rejects / Slimes 6

Kaolin production, like calcium carbonate the drying process, which is often an separation
Concentrate
Concentrate means we can provide you with
production, requires a final dewatering energy-intensive process. Tailings
Tailings
an optimized design for your application.
Underground Mining

in order to minimize the cost for final

Underground Mining 3
1 3
1

drying of the product. Consequently, Besides a unique bowl geometry and 5

Efficient
Tailings Pondprotection
5
Coarse Reject Tailings Pond / Dam

the process benefits are similar to those

Coarse Reject
MINING / BENEFICIATION
/ Dam
an inlet zone to ensure gentle accele-
and high reliability
Tailings Pond / Dam

of decanter installations in calcium ration Tailings

of the slurry, we can offerLeaching
Pond / Dam
higher / Digestion Solid-Li

PURIFICATIONgrade materials
RECOVERY to protect the bowl and
carbonate applications. With more than 100 years of experience, AND METAL
PURIFICATION AND METAL RECOVERY
CRUD
CRUD
Alfa Laval brings you cleaner and more
Anode Slimes
Anode Slimes
conveyor. We can also offer economical 4
8 9
Screening /Washing
The product can be dewatered to a Surface Miningefficient solid-liquid separation. Our accu-
8 9
options for less aggressive, less erosive
higher dryness, minimizing the cost in
2
mulated expertise in industrial minerals slurries if this is a priority.
Solvent Extraction Electrowinning Cathode Flotation
Solvent Extraction Electrowinning
Crushing
No matter what the Grind
Cathode solution, all the critical
Key benefits: parts
Fines Rejects / Slimes
we provide are made of wear and
Concentrate corrosion-resistant material. There are Concentrate
• Concentrate
A solid fraction with low water content means lower drying costs
also options to include tiles that provide
• High flexibility – decanters can be applied in classification and dewatering Tailings
Underground
Leaching Mining Impurity Removal extra conveyor protection, or cleaning- Drying
• Lower power consumption Leaching than competing separation technologies such
Impurity Removal 3 Filtration
(Reduction, Precipitation, Drying
1
in-place (CIP) programs
Thickening
especially
Filtration
(Reduction, Precipitation,
Cementation, Crystallization)
12

as plate-and-frame filters Thickening Cementation, Crystallization)

11 12

adapted to the specific application. 11

• Unmatched separation efficiency facilitated by our special Waste / Coarse

Residue Reject
Waste / Residue
Tailings Pond / Dam
10

deep-pond technology 10
Ta
Calcining
• Small installation space – the largest capacity per installed area Calcining

• Continuous, automatic operation instead of batch operation PURIFICATION AND METAL

• Enclosed process means a greatly improved working environment.
CRUD Anode Slimes
8 9

Solvent Extraction Electrowinning Cathode

Concentrate

Leaching Impurity Removal

(Reduction, Precipitation,
Dewatering Drying and Packaging Cementation, Crystallization)

Calcination
Waste / Residue

10

Water

Solid fraction

Samples from a dewatering test on calcium carbonate. The inlet slurry (left) is separated into the solids
fraction (middle) and liquid fraction (right) in an Alfa Laval decanter centrifuge. Parameters such as
Drying Packaging bowl speed, pond level setting and differential speed can be changed in the decanter to meet targets
for solid-fraction dryness, particle size and separation efficiency.
Alfa Laval's decanter centrifuges are the perfect choice for treating
calcium carbonate, kaolin and other non-metallic minerals slurries.

High torque –  Automatic control in nearly 100 countries is a source of

low power consumption
Separation is often performed at high
solid loads and the minerals are very
dense. The backdrive system must
produce a high torque as well as a
high differential speed to scroll out
the dry solids and keep the liquid clean
– or, in a classification application, to
maintain efficient and exact separation.
Alfa Laval’s gearbox provides both the
required torque and scrolling rate, while
also ensuring the lowest possible power
consumption.
The 2Touch control system automatically
adjusts operation of the decanter accor-
ding to changing conditions, such as
variable flow rates and solids concentra-
tion. This guarantees a very dry solids
fraction, accurate classification, stable
operation and minimum wear and tear.
Maintenance and service
Wherever you are, support from Alfa
Laval is never far away. Our worldwide
network of sales companies, service
organisation and field service engineers
are ready to provide assistance, rapid
support and ongoing optimization.
Our close cooperation with customers
valuable feedback for our research and
development team, giving us an edge
in the development of market-leading
technology.
Design based on experience
Our decanters are designed based on
experience, knowledge and testing in
laboratory and field environments to
optimize your specific processes, setting
a framework for scaling up to meet your
exact requirements and specifications.
Alfa Laval has a wide range of test
equipment and resources available to
suit the vast range of applications in
the mining and mineral industry.

Selected references

Alfa Laval has full-scale references worldwide for different

applications and has also carried out extensive testing and
laboratory analysis on numerous types of slurry.
Country Decanter Year Application
India P2-300 2011 Calcium carbonate
India P2-405 2015 Kaolin
France P2-500 2009 Calcium carbonate
Malaysia P2-405 2016 Kaolin

At MS Sawa Clay & Minerals in Rajasthan, northern India,

five Alfa Laval decanters are installed in parallel to handle the
classification process, separating two-micron particles from
coarser material. The customer is very happy with the separation
efficiency, and thanks to good communication during the entire
engineering of the project, Alfa Laval’s design recommendations
were adopted to achieve the highest possible process efficiency.

PEP00245EN 1611 Alfa Laval reserves the right to change specifications without prior notification.

How to contact Alfa Laval

Up-to-date Alfa Laval contact details for all countries are
always available on our website at www.alfalaval.com.