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Published byDangelo Parmley Modified over 9 years ago
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KAOLIN NOT JUST FOR INDIGESTION…. Sue Border
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COMMERCIAL KAOLIN White (white firing) non-swelling clay - Also called “China Clay” White (white firing) non-swelling clay - Also called “China Clay” Dominantly kaolinite Dominantly kaolinite World Production 30mtpa (US$3b) Export markets 9mtpa
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USES OF KAOLIN v Papermaking Pigment/Filler/Coating v Pigment in paint/inks High v Plastics/Rubber Value v Ceramics oMineral FillerLow Value Products oSource of Al2O3 oRefractories
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Commercial Economics PREMIUM GRADE CRITERIA A high priced Kaolin has : v Superior Brightness v Superior Whiteness v Desired particle size v High opacity (good hiding power) v Chemical purity v Low viscosity (for paper markets) v Other properties - abrasivity, conductivity, etc
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Pigment markets - Brightness Competitors Pigment Price per tonne (A$) v TiO2$3500 - $6000 v CaCO3 $350 - $500 v Kaolin $200 - $1200 Kaolin gives good performance for the price
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Markets - Paper Demand v Paper demand increases with GDP v Asian paper production to overtake USA by 2010* Asia imports Kaolin from: GeorgiaBrazilUK * Source: Pulp and Paper Magazine
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TASMANIA NEW ZEALAND USA EUROPE AND MIDDLE EAST INDONESIA THAILAND MALAYSIA AUSTRALIA JAPAN KOREA TAIWAN PROJECTLOCATION C ANADA West Coast CHINA
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KAOLIN FORMATION v Economic deposits mainly weathering related v Associated with laterite and bauxite v Formed in wet/dry tropical climate v Over 1500m rain pa v Leaching process
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LATERITIC WEATHERING BAUXITE IRONSTONE MOTTLED PALLID BEDROCK Leaching of cations --- Highest water --- Lowest water
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MORE EFFECTIVE LEACHING v More water flow (fresh water & permeability) v More time v More bugs v Acid groundwater (oxidising organics) § Parent is only important if time is short or leaching is slow.
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REMOVAL OF IRON v Ferrous leached more easily than ferric. v Least iron just below lowest water table v But leaching is slow below the water table v Organic grey kaolins formed here.
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DIAGENESIS OF KAOLIN Feldspars & clays kaolinite Kaolinite increases in grain size The perfect kaolin recipe - Formed below water table then raised above it
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SEDIMENTARY KAOLINS? v Cannot separate kaolinite from other clays by sedimentation. v All commercial kaolins are formed in situ (Pickering & Hurst 1997) v Ball clays? (70% disordered kaolin).
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SKARDON RIVER KAOLIN - discovery…. Andrew White in 1985 19 holes 2 in lease Target of “Bulimba” kaolin found; Older weathering kaolin noted. Samples to CSIRO
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SKARDON RIVER KAOLIN - exploration history pre SRK v 1986 - Drilled 93 holes - geology only v 1987 - 1990 Bulk sampling & testwork v 1993 - 188 RC holes - geology & ‘clay’ v 1994 - 10 DD holes v 1994 - 97 - Testing selected drill samples v 1997 - 207 RC holes - poor control
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MISTAKES….. oNo initial raw values oDid not relate metallurgy to geology oPoor technical knowledge at board level oMoving goal posts oRolls Royce plant oMajor cost over-runs oNo coordination of consultants/contractors
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GEOLOGICAL HISTORY….. Cretaceous - Marine Shale
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Uplift and Weathering... Rolling Downs Formation Claystone
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Tertiary Sheet Fluvials Bulimba Formation
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Weathering to bauxite
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Fluvial Channel Develops Namaleta Creek Floodplain
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Further Weathering…... Fluvial K3 Claystone
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Claystone Mining
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Conchoidal claystone
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Fluvial in exploration pit
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ML and Drilling Wet Plant DRILLHOLES AND OUTLINE OF FLUVIAL CHANNEL Green – RC holes Black – AKL grade control holes
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RESOURCES Purple – inferred claystone Grey – measured claystone Blue – inferred fluvial
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Resource Summary In 000s tMeasuredIndicatedInferred Claystone6409205,200 Meas + Indclaystone1560 Fluvial7284,270 Total 100 years at 75,000tpa.
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Skardon Kaolin Properties ClaystoneK3Fluvial Grit content (+ 45 ) 3%56%55% -45 psd70% -1 75% -1 80% -1 Brightness, -5 ISO 656070 Hydrous prod’t ISO 70 +80 +85 Calcined bright -ness ISO 90 – 91.58391
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Hydrous KaolinsHydrous Kaolins Plant capacity 75,000 tpa Wide range of industrial applications Represents the bulk of world supply Target of paint & rubber markets Skardon Product Range Calcined Kaolins Calcined Kaolins Plant capacity 75,000 tpa Higher performance Better brightness, opacity Competes with TiO2 Premium price Limited number of producers Paint, rubber, paper
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Stage 1 Processing: Wet Plant Kaolin Ore Blunger Degritting Centrifuge Decanter Centrifuge Disc-nozzle Centrifuge High Gradient Magnet Separator Membrane Filter Pipeline to Dry Plant Sand Tailings Dam Delaminating Mill, Leaching circuit
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Stage 2 Processing: Dry Plant Pipeline from Wet Plant Spray Dryer Pulveriser Calcining Kiln Pulveriser CALCINEDKAOLIN HYDROUSKAOLIN
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MAJOR WORLD DEPOSITS Georgia, USA Amazon, Brazil Cornwall, UK ………. the odd one out Hercynian granite 280mA Debate weathering vs hydrothermal Coarse grained well crystallised kaolin Very limited available resources Product yield 15-20%
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Georgia - Geology Cretaceous and Tertiary bedded kaolins Exposed just south of Fall Line Cap bentonite Cretaceous 60% -2micron Tertiary 85% -2micron
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Georgia - Economics ADVANTAGES v Two types of kaolin v Expertise v Reputation v Transport for E USA & Europe DISADVANTAGES vOlder updated plants vMine locations vHigh stripping ratios vTransport to Asia
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Amazon Geology Under bauxite exposed on slopes. Rio Jari – Pliocene, very fine grained 75% -2 micron. 36m thick deposit. Rio Capim – also Tertiary. Coarser than Jari. Thinner and some grit.
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Amazon Economics ADVANTAGES Fine Kaolin Modern plant DISADVANTAGES vPipeline distance vTransport to Asia
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Summary of the Skardon River Kaolin Project Long mine life Growing international demand Premium products Exceedingly low CAPEX entry price Best logistics for Asia Marketing and distribution agreements Technical Management Expertise
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That’s it folks!
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