At Shikhar Microns, we've perfected the calcite powder manufacturing process using advanced ball mill and vertical roller machine technology. Our 27+ years of experience in Rajasthan, India has enabled us to develop efficient processes that deliver high-quality calcite powder for various industrial applications.
Understanding Calcite Powder
Calcite powder is a natural calcium carbonate (CaCO₃) mineral that is widely used in paints, plastics, paper, rubber, and construction industries. It's known for its high brightness, low oil absorption, and excellent whiteness properties, making it ideal for various industrial applications.
Key Properties of Calcite
- Chemical Formula: CaCO₃
- Hardness: 3 on Mohs scale
- Specific Gravity: 2.7
- Brightness: 95%+
- Applications: Paints, plastics, paper, rubber, construction
Our Manufacturing Process Overview
Our calcite powder manufacturing process involves several critical stages, each designed to ensure optimal quality and consistency. We use state-of-the-art ball mill and vertical roller machine technology to achieve the desired particle size distribution and quality standards.
Stage 1: Raw Material Selection and Preparation
The process begins with careful selection of high-quality calcite deposits from our Rajasthan mines:
- Quality Assessment: Testing raw materials for chemical composition and physical properties
- Grade Selection: Choosing deposits with optimal CaCO₃ content (typically 98%+)
- Size Preparation: Initial crushing to prepare materials for grinding
- Moisture Control: Ensuring optimal moisture content for processing
Stage 2: Primary Crushing and Size Reduction
Raw calcite rocks undergo primary crushing to reduce size and prepare for grinding:
- Jaw Crushers: Initial size reduction to 6-8 inches
- Cone Crushers: Secondary crushing to 1-2 inches
- Impact Crushers: Fine crushing for specific applications
- Size Classification: Screening to separate different particle sizes
Ball Mill Processing Technology
Our ball mill technology is the cornerstone of our calcite powder manufacturing process. This equipment ensures consistent particle size distribution and optimal quality control.
Ball Mill Specifications and Operation
Ball Mill Features
- High-efficiency grinding
- Precise particle size control
- Low energy consumption
- Continuous operation capability
Processing Parameters
- Grinding media: Steel balls
- Rotation speed: Optimized
- Feed size: 1-2 inches
- Output: 200-400 mesh
Ball Mill Process Flow
- Material Loading: Pre-crushed calcite is loaded into the ball mill
- Grinding Process: Steel balls crush and grind the material
- Size Reduction: Continuous grinding until desired particle size
- Discharge: Ground material is discharged for further processing
- Quality Check: Particle size analysis and quality verification
Vertical Roller Machine Technology
Our vertical roller machine provides fine grinding capabilities for producing ultra-fine calcite powder with superior quality and consistency.
Vertical Roller Machine Specifications
| Parameter | Specification | Application |
|---|---|---|
| Grinding Table Diameter | 1000-1500 mm | Fine grinding operations |
| Roller Number | 3-4 rollers | Uniform grinding pressure |
| Feed Size | 15-25 mm | Pre-ground material input |
| Output Size | 400-1500 mesh | Ultra-fine applications |
| Capacity | 2-25 TPH | Production flexibility |
Vertical Roller Machine Process Flow
- Material Feeding: Pre-ground material from ball mill is fed into vertical roller machine
- Grinding Chamber: Material enters the grinding chamber with rotating rollers
- Fine Grinding: Rollers apply pressure to achieve ultra-fine particle sizes
- Air Classification: Air flow separates particles by size
- Collection: Fine particles are collected in cyclone separators
- Quality Control: Final particle size verification and quality testing
Quality Control and Testing
Our comprehensive quality control system ensures every batch of calcite powder meets our high standards:
Chemical Analysis
- CaCO₃ content ≥ 98%
- Moisture content ≤ 0.5%
- pH value: 8.0-9.5
- Impurity levels controlled
Physical Properties
- Particle size distribution
- Brightness ≥ 95%
- Oil absorption ≤ 25 g/100g
- Bulk density testing
Particle Size Distribution
Our ball mill and vertical roller machine combination allows us to produce calcite powder in various particle sizes:
| Mesh Size | Particle Size (Microns) | Equipment Used | Applications |
|---|---|---|---|
| 200 | 74 | Ball Mill | Construction materials, coarse fillers |
| 300 | 50 | Ball Mill | Standard industrial applications |
| 400 | 38 | Ball Mill + Vertical Roller | Paints, plastics, rubber |
| 600 | 20 | Vertical Roller Machine | Fine applications, coatings |
| 800 | 15 | Vertical Roller Machine | Ultra-fine applications |
| 1000 | 12 | Vertical Roller Machine | Premium coatings, specialty products |
Environmental Considerations
Our calcite powder manufacturing process prioritizes environmental responsibility:
- Dust Control: Advanced filtration systems minimize airborne particles
- Water Conservation: Closed-loop water systems reduce consumption
- Energy Efficiency: Optimized ball mill and vertical roller machine operations
- Waste Reduction: Recycling and reuse of by-products
- Emission Control: Advanced air pollution control systems
Applications of Our Calcite Powder
Our calcite powder finds applications across various industries:
Paint Industry
High brightness, low oil absorption
Plastic Industry
Enhanced properties and cost efficiency
Paper Industry
Improved brightness and opacity
Why Choose Shikhar Microns?
As a leading calcite powder manufacturer in Rajasthan, India, we offer:
- 27+ Years Experience: Proven expertise in mineral processing
- Advanced Technology: State-of-the-art ball mill and vertical roller machine
- Quality Assurance: Comprehensive testing and quality control
- Custom Solutions: Tailored products for specific applications
- Reliable Supply: Consistent quality and timely delivery
- Competitive Pricing: Cost-effective solutions for all applications
Key Takeaways
- Our ball mill provides efficient coarse to medium grinding (200-400 mesh)
- Vertical roller machine delivers ultra-fine grinding (400-1500 mesh)
- Combined technology ensures optimal particle size distribution
- Comprehensive quality control maintains consistent product quality
- Environmental responsibility integrated throughout the process