High Efficiency Kaolin Ultrafine Grinding Mill: 5TPH Production Line Solution

Introduction

The kaolin industry demands increasingly sophisticated processing solutions to meet the stringent quality requirements of high-end applications such as paper coating, ceramics, paints, and advanced polymers. Achieving consistent, high-purity ultrafine kaolin powder (typically D97 ≤ 5μm or 2500 mesh) with high production efficiency and low operational cost is a significant technical challenge. This article presents a comprehensive 5-ton-per-hour (TPH) production line solution designed specifically for high-value kaolin processing, focusing on equipment selection, process flow, and technological advantages.

Challenges in Ultrafine Kaolin Processing

Processing kaolin to ultrafine specifications involves several critical challenges: maintaining precise particle size distribution, preventing contamination from grinding media, managing high energy consumption, ensuring system stability for continuous operation, and meeting stringent environmental standards for dust and noise. Traditional ball mills or Raymond mills often fall short in terms of energy efficiency, fineness control, or product purity for the most demanding applications.

Core Equipment Recommendation: SCM Ultrafine Mill

For the heart of a 5TPH ultrafine kaolin grinding line, the selection of the main mill is paramount. Our SCM Series Ultrafine Mill stands out as the optimal solution, particularly the SCM1680 model. Engineered for high-capacity, precision grinding, it is perfectly suited for producing 325-2500 mesh kaolin powder.

Why the SCM1680 is Ideal for a 5TPH Kaolin Line

• Perfect Capacity Match: With a processing capacity range of 5.0-25 TPH, the SCM1680 operates comfortably within its optimal efficiency zone at a 5 TPH output, ensuring stable performance and longevity.
• Superior Fineness & Purity: Its advanced vertical turbine classifier enables precise particle size切割, achieving a final product of D97 ≤ 5μm (2500 mesh). The design ensures no coarse powder mixing, resulting in exceptionally uniform and high-purity kaolin powder.
• Remarkable Energy Efficiency Compared to jet mills, the SCM1680 offers double the capacity while reducing energy consumption by approximately 30%. Its intelligent control system provides automatic feedback on product fineness, optimizing power usage in real-time.
• Durability & Low Maintenance: The grinding rollers and ring are made from special wear-resistant materials, extending service life several times over conventional parts. The innovative bearing-less screw design in the grinding chamber enhances operational stability and reduces failure points.
• Environmental Compliance: Integrated pulse dust collection exceeds international standards, ensuring dust emissions are minimal. The mill’s soundproof chamber design keeps operational noise below 75dB, creating a better working environment.

Complete 5TPH Production Line Configuration

A successful grinding line involves more than just the main mill. A synergistic system ensures smooth operation from raw material to packaged product.

1. Raw Material Handling & Pre-Crushing

Kaolin clay (≤50mm) is fed via a vibrating feeder to a primary crusher, such as a jaw crusher or our Hammer Mill (PC4012-90). The Hammer Mill efficiently reduces the feedstock to ≤20mm, which is the optimal feed size for the SCM1680. Its high manganese steel liners and stable operation make it a reliable choice for preliminary size reduction.

2. Grinding & Classification System

The pre-crushed kaolin is elevated into the SCM1680 Ultrafine Mill’s feed hopper. The core grinding process begins here:

Working Principle: The main motor (315kW) drives the multi-layer grinding ring to rotate. Material is centrifugally dispersed into the grinding track and is subjected to rolling, pressing, and grinding between the rollers and rings. The ground powder is carried by the airflow to the integrated classifier. The vertical turbine classifier performs precise particle size separation; qualified fine powder proceeds, while oversized particles are rejected back to the grinding chamber for further milling.

3. Product Collection & Dust Removal

The fine kaolin powder that passes the classifier enters a high-efficiency cyclone collector for primary separation. Subsequently, the residual fine powder in the airflow is captured by a pulse-jet bag filter, achieving a collection efficiency of over 99.9%. This two-stage collection system guarantees high product yield and a clean workshop.

4. Packaging & Automation

The collected powder can be conveyed to silos and then to automatic packing machines. A central PLC control system monitors and regulates the entire production line, from feed rate and grinding parameters to fan speed and bag filter pulse cleaning, ensuring fully automated, stable, and efficient operation.

Technical Advantages of the Complete Solution

• High Integrated Efficiency: The line is designed for seamless integration, minimizing pressure loss and energy waste between components.
• Exceptional Product Quality: The combination of the SCM mill’s precision grinding and classification produces kaolin powder with narrow particle size distribution, high whiteness, and low contamination.
• Low Operational Cost: The high energy efficiency of the SCM1680, combined with durable components that reduce wear part replacement frequency, significantly lowers cost per ton.
• Scalability & Flexibility: The line design can be adapted. For projects requiring coarser kaolin powder (e.g., 30-325 mesh) at higher capacities, our MTW Series Trapezium Mill (e.g., MTW215G model) presents an excellent alternative. The MTW series offers robust construction, high throughput (up to 45 TPH), and features like curved air ducts and cone gear drive for enhanced efficiency and reliability in medium-fine grinding applications.
• Green Production: The entire system operates under negative pressure, with advanced dust collection ensuring emissions are well below national standards. The low-noise design of the main equipment contributes to environmental protection.

Conclusion

Establishing a 5TPH high-efficiency ultrafine kaolin production line requires careful planning and selection of state-of-the-art equipment. The solution centered on our SCM1680 Ultrafine Mill provides a technically advanced, economically viable, and environmentally responsible answer to this challenge. Its proven ability to deliver consistent, high-quality ultrafine powder with outstanding operational efficiency makes it the cornerstone of a modern kaolin processing plant. For investors and operators aiming to capture value in the high-end kaolin market, this integrated production line solution represents a strategic investment in quality, productivity, and sustainable operation.