Description of the CaCO₃ manufacturing process at Dhansri Minerals, incorporating washing and purification steps based* not shown in this typical flow chart:
1. Calcium Carbonate Extraction:
The process begins by extracting limestone, the raw material rich in calcium carbonate, from a quarry.
2. Crushing and Grinding:
The extracted limestone undergoes crushing in multiple stages (primary, secondary, and potentially tertiary crushing) to progressively reduce its size.
After crushing, the limestone is further pulverized into a fine powder using a ball mill or roller mill.
3. Washing (Optional):
Depending on the desired purity level and limestone quality, the crushed limestone may undergo a washing stage.
This washing step involves suspending the limestone powder in water and using separation techniques (like hydro cyclones) to remove impurities like clay or silica.
4. Screening and Classification:
The crushed and ground limestone powder (washed or unwashed) is then passed through screens to achieve the desired particle size distribution according to customer requirements.
5. Flotation (Optional):
In some cases, an additional purification step called flotation might be employed to further enhance the CaCO₃ content.
This process utilizes differences in surface properties between CaCO₃ and impurities, separating them using air bubbles and water.
6. Quality Testing and Sampling:
Throughout the process, samples are extracted for laboratory testing to ensure the CaCO₃ powder meets the required quality standards. This includes testing for both chemical composition and particle size distribution.
7. Drying:
After washing or flotation (if applicable), the CaCO₃ slurry needs to be dried to remove excess moisture. This can be achieved through various methods like rotary dryers or spray dryers.
8. Packaging and Distribution:
The finished CaCO₃ powder is then packaged in various options such as bulk bags, paper bags, or jumbo bags depending on customer needs.
Finally, the packaged CaCO₃ is distributed to customers across various industries.
Note: The presence or absence of washing and purification steps (like flotation) may depend on the specific raw material quality and desired end product characteristics. Dhansri Minerals' actual process involve additional steps or variations not shown here.
