The Production Process of Calcium Carbonate Powder in an Artificial Stone Factory
Introduction
The production of artificial stone, such as quartz surfaces and engineered marble, relies heavily on high-quality calcium carbonate powder as a key filler material. This powder not only enhances the structural integrity and durability of the final product but also improves its aesthetic appeal. The process of producing calcium carbonate powder involves several critical stages, each requiring precision and efficiency to ensure the desired particle size distribution, purity, and consistency. This article delves into the detailed production process, highlighting the importance of advanced grinding technology and recommending our company’s flagship products for optimal performance.
Raw Material Selection and Preparation
The first step in producing calcium carbonate powder is the selection of high-purity limestone or marble as the raw material. The quality of the raw material directly impacts the final product’s properties, including brightness, chemical composition, and particle morphology. Once selected, the raw material undergoes primary crushing to reduce its size to manageable chunks, typically below 50mm. This is often achieved using jaw crushers or hammer mills, which ensure uniform feed size for subsequent grinding stages.
Primary and Secondary Crushing
After initial crushing, the material is further reduced in size through secondary crushing processes. This step is crucial for achieving a consistent feed size for the grinding mills, which directly affects grinding efficiency and product quality. Secondary crushers, such as impact crushers or cone crushers, are employed to produce particles with a size range of 0-20mm. At this stage, impurities like clay, silica, and iron compounds are removed through washing and drying processes to ensure the purity of the calcium carbonate powder.
Grinding: The Heart of the Process
Grinding is the most critical phase in calcium carbonate powder production, as it determines the fineness, particle size distribution, and overall quality of the powder. The choice of grinding equipment is paramount, and our company’s SCM Series Ultrafine Mill is highly recommended for this application. With an output fineness ranging from 325 to 2500 mesh (D97 ≤ 5μm) and a processing capacity of 0.5 to 25 tons per hour, the SCM mill excels in producing ultra-fine calcium carbonate powder with exceptional uniformity and low energy consumption. Its intelligent control system automatically adjusts grinding parameters to maintain consistent product quality, while the vertical turbine classifier ensures precise particle size cut-off without coarse powder contamination.
For larger-scale production requiring coarser powders, our MTW Series Trapezium Mill is an excellent choice. It handles input sizes up to 50mm and produces powders with fineness between 30 and 325 mesh, making it ideal for pre-grinding or producing fillers for artificial stone with specific granular requirements. The MTW mill features anti-wear shovel blades, an optimized curved air duct, and integrated cone gear transmission, which collectively enhance efficiency, reduce maintenance costs, and ensure stable operation.
Classification and Collection
Following grinding, the powdered material undergoes classification to separate particles based on size. Air classifiers or cyclone separators are commonly used to achieve this, ensuring that only particles within the desired size range proceed to the next stage. The SCM and MTW mills incorporate advanced classification systems, such as the vertical turbine classifier in the SCM mill, which provides high precision and efficiency. After classification, the fine powder is collected using baghouse filters or pulse-jet dust collectors, which not only ensure high collection efficiency but also meet stringent environmental standards by minimizing dust emissions.
Surface Treatment and Modification
In some cases, calcium carbonate powder undergoes surface treatment to improve its compatibility with polymer resins used in artificial stone production. This involves coating the powder particles with stearic acid or other coupling agents, which enhance dispersion, reduce viscosity, and improve the mechanical properties of the final composite. The treatment is typically carried out in high-speed mixers or coating machines, where the powder is uniformly coated under controlled temperature and mixing conditions.
Quality Control and Packaging
Rigorous quality control is essential throughout the production process. Key parameters such as particle size distribution, brightness, chemical purity, and moisture content are continuously monitored using laser particle analyzers, spectrophotometers, and other advanced instruments. Once the powder meets the required specifications, it is packaged in bulk bags or smaller bags for storage and transportation. Proper packaging ensures that the powder remains free from contamination and moisture, preserving its quality until it is used in artificial stone manufacturing.
Conclusion
The production of calcium carbonate powder for artificial stone is a complex process that demands advanced technology, precise control, and high-quality equipment. Our company’s SCM Series Ultrafine Mill and MTW Series Trapezium Mill are designed to meet these challenges, offering unparalleled efficiency, durability, and environmental performance. By integrating these machines into your production line, you can achieve consistent, high-quality calcium carbonate powder that enhances the properties of your artificial stone products. For more information on our products and how they can benefit your operations, please contact our technical team.
