Calcium Carbonate Crushing Process: A Comprehensive Guide
Calcium carbonate (CaCO₃) is a widely used mineral in industries such as construction, agriculture, pharmaceuticals, and manufacturing. To meet diverse industrial requirements, raw calcium carbonate must undergo a crushing process to achieve the desired particle size. Below is a detailed overview of the calcium carbonate crushing process.
1. Raw Material Preparation
Calcium carbonate is sourced from natural deposits like limestone, marble, or chalk. The raw material is first extracted through mining or quarrying. Impurities such as clay, silica, and iron oxides are removed via washing and sorting to ensure high purity before crushing.
2. Primary Crushing
Large chunks of calcium carbonate are fed into a jaw crusher or gyratory crusher for initial size reduction. These machines break down the material into smaller pieces (typically 50–150 mm) using compressive force.
3. Secondary Crushing
The coarsely crushed material is further processed in a cone crusher or impact crusher, reducing it to particles of about 10–30 mm. This stage ensures uniformity and prepares the material for fine grinding.
4. Grinding (Tertiary Crushing)
For ultra-fine applications (e.g., paints, plastics, or paper coatings), specialized grinding mills are used:
– Ball Mill: Wet or dry grinding to produce fine powders (10–100 microns).
– Raymond Mill: Achieves medium-fine particles (50–500 mesh).
– Ultrafine Mill: Produces micron-sized particles (<10 microns) using high-pressure rollers or air classification.
5. Classification & Separation
Crushed/ground calcium carbonate is classified by particle size using:
– Vibrating Screens: Separate coarse and fine particles.
– Air Classifiers: For ultrafine powder separation based on aerodynamic properties.
Impurities are removed via magnetic separators or flotation processes if needed..jpg)
6. Drying & Packaging
If wet grinding is employed, the slurry is dried in rotary dryers or spray dryers. The final product is packed in bags, bulk containers, or silos for transport and industrial use..jpg)
Key Equipment Used:
– Jaw Crusher / Gyratory Crusher (Primary)
– Cone Crusher / Impact Crusher (Secondary)
– Ball Mill / Raymond Mill / Ultrafine Grinding Mill (T