Kaolin - Ballclay - Other Clays and Shale
Kaolin - Ballclay - Other Clays and Shale
Kaolin - Ballclay - Other Clays and Shale
Indian Minerals
Yearbook 2013
(Part- III : Mineral Reviews)
52nd Edition
(ADVANCE RELEASE)
GOVERNMENT OF INDIA
MINISTRY OF MINES
INDIAN BUREAU OF MINES
January, 2015
29-1
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
29-2
Table –1 : Reserves/Resources of China Clay as on 1.4.2010
(By Grades/States)
(In '000 tonnes)
By States
Andhra Pradesh 2524 339 2205 5068 683 1490 1147 126 691 61883 3088 69108 74176
Assam - - - - - 131 - 392 - 3520 - 4043 4043
Bihar - - - - - - - 104 39 1296 - 1439 1439
Chhattisgarh 834 - 344 1178 480 765 1076 - - 11512 - 13833 15011
Delhi - - - - - - - 857 630 3802 - 5289 5289
Goa - - - - - - 16 - - - - 16 16
Gujarat 34290 240 6232 40762 4654 856 24135 - 878 40904 - 71427 112189
Haryana - - - - 2367 789 3377 13 34 5485 - 12065 12065
Jammu & Kashmir - - - - - - - - - 28122 - 28122 28122
Jharkhand 8554 325 8731 17610 209 2031 1565 1936 7363 149957 18019 181080 198690
Karnataka 943 835 280 2058 819 738 3390 220360 443 24685 6030 256465 258523
Kerala 3352 792 - 4144 2447 463 2985 43930 20439 569226 20200 659690 663834
Madhya Pradesh - - - - 942 - 61 - 415 11741 - 13159 13159
Maharashtra - - - - 418 256 856 11 184 5523 - 7248 7248
Manipur - - - - - - - 2520 - - - 2520 2520
Meghalaya - - - - - - - 1410 6266 76032 5167 88875 88875
Odisha 2376 715 811 3902 - 1252 2476 223 35393 236421 1259 277024 280926
Puduchery - - - - - - - - - 2940 - 2940 2940
Rajasthan 70012 7603 22497 100112 11524 14008 29483 1260 4067 271314 749 332405 432517
Tamil Nadu - - - - - - - - 327 56570 - 56897 56897
Uttar Pradesh - - - - - - - 11600 3447 10018 - 25065 25065
West Bengal 1232 185 906 2323 - 202 703 38 332236 80335 5826 419340 421663
Table – 2 : Details of Exploration Activities for Kaolin and other Clays, 2012-13
China Clay
DMG
Kerala Aravanchal - - 02 41.5 - Object of exploration was to
Kannur area assess the resource for the
development of clay based
industries. The average
thickness of variegated clay was
found out to be about 9 m.
Resources were not estimated.
29-4
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
Location of mine
Name & address of producer Location of mine
State District Name & address of producer
State District
Vinodbhai P. Solanki, Gujarat Kachchh
Sevansheri, Baladiya,
Bhuj-370 427, Distt. Kachchh
Gujarat. Shree Ram Minechem International, Gujarat Kachchh
G.I.D.C Area, Madhapar,
EICL Limited, Kerala Thiruvanantha-
TC -79/4, Veli, puram Bhuj- 370 020,
Thiruvananthapuram-695 021, Distt. Kachchh,
Kerala.
Gujarat.
H.D. Enterprises Pvt. Ltd, Gujarat Kachchh
101, H.D. House, J.K. White Cement Works, Rajasthan Chittorgarh
Pooja Complex 'A',
Station Road, PO- Gotan-342 902
Bhuj - 370 001, Distt. Nagaur,
Distt. Kachchh,
Gujarat. Rajasthan.
29-5
Table – 5 : Production of Kaolin, 2011-12 and 2012-13 (P)
(By Sectors/States/Districts/Grades)
(Qty. in tonnes; value in `’000)
2011-12 2012-13(P)
Public sector 5 16664 2500 10331 33168 26995 35668 5 4594 689 8739 37923 13333 38612
Private sector 100(4) 2983997 515889 65803 100811 3049800 616700 126(7) 3565385 683724 100212 268832 3665597 952556
Andhra Pradesh 11 75115 11775 - - 75115 11775 8 50236 8370 - - 50236 8370
Adilabad 1# - - - - - - - - - - - - -
East Godavari 6 11116 2163 - - 11116 2163 5 5716 1143 - - 5716 1143
Chhattisgarh 1# - - - - - - - - - - - - -
Rajnandgaon 1# - - - - - - - - - - - - -
Gujarat 35(1) 1482871 231866 34633 46499 1517504 278365 50(2) 1956020 317414 33929 46241 1989949 363655
Kachchh 24(1) 1427378 221284 - - 1427378 221284 37(2) 1870791 299221 - - 1870791 299221
Mahesana 4 36570 6948 16413 23326 52983 30274 4 42763 8773 15208 22171 57971 30944
Sabarkantha 5 18923 3634 18220 23173 37143 26807 5 17267 3590 18721 24070 35988 27660
Jharkhand 9(1) 96869 11456 25543 49754 122412 61210 6(1) 53121 5154 13114 26215 66235 31369
Sahebganj 3(1) 91269 5016 18073 37682 109342 42698 3(1) 52621 4579 12879 25648 65500 30227
Singhbhum (West) 6 5600 6440 7470 12072 13070 18512 3 500 575 235 567 735 1142
(Contd.)
Table - 5 : (Concld.)
2011-12 2012-13(P)
Madhya Pradesh 2 6950 621 - - 6950 621 2 11200 672 - - 11200 672
Katni 2 6950 621 - - 6950 621 2 11200 672 - - 11200 672
Satna - - - - - - - 1# - - - - - -
Rajasthan 18(2) 512145 104587 - - 512145 104587 31(3) 544586 148892 47568 187090 592154 335982
29-7
Bhilwara 6 179970 39037 - - 179970 39037 7(1) 158408 36102 - - 158408 36102
Bikaner (1) 11655 2564 - - 11655 2564 (1) 39569 13092 - - 39569 13092
Bundi 1 1514 176 - - 1514 176 1 3515 541 - - 3515 541
Chittorgarh 7 251095 47052 - - 251095 47052 9 283385 83622 - - 283385 83622
Jaipur 1 63951 15348 - - 63951 15348 1 - - 47568 187090 47568 187090
Karauli - - - - - - - 1 2847 475 - - 2847 475
Nagaur 1(1) 3960 410 - - 3960 410 9(1) 47115 12336 - - 47115 12336
Pali - - - - - - - 2 8337 2438 - - 8337 2438
Sikar 1# - - - - - - - - - - - -
Udaipur 1# - - - - - - 1 1410 286 - - 1410 286
West Bengal 11 86521 32691 5627 4558 92148 37249 13 90006 43888 5601 9287 95607 53175
Bankura 2 5315 625 - - 5315 625 3 5465 941 - - 5465 941
Birbhum 9 81206 32066 5627 4558 86833 36624 10 84541 42947 5601 9287 90142 52234
29-8
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
MINING, PROCESSING & Kannur district, Kerala; 20 Microns Ltd, Mamuara, Bhuj
district Kachchh, Gujarat (80,500 tpy capacity; a new
MARKETING plant of 33,600 tpy is also installed); Amrapali China
China clay deposits worked in India are mostly of Clay Washing Plant, Nadapa, Bhuj, district Kachchh,
pocket-type. Opencast manual mining is followed in Gujarat; Mokdumnagar China Clay Processing Plant
most kaolin mines. The most common practice is to dig of West Bengal Projects Ltd, Mohammad Bazar,
trial pits for locating clay pockets or beds which are Birbhum district, West Bengal and Hindalco's
gradually enlarged into pits of various dimensions. Beneficiation Plant at Bagru Plateau in Lohardaga
China clay is often soft and easily extracted with no district, Jharkhand. EICL has capacity to produce
blasting required. Clay and overburden are quarried in 240,000 tpy paper coating and filler grades of processed
benches. In few mines, bulldozers and excavators are china clay (hydrous), besides 60,000 tpy of calcined
used to remove the overburden which is then clays. Popular Minerals are reported to be developing
transported through trucks/tractors/trailers. its mine and plant in Chittorgarh, Rajasthan. Ashapura
Crude china clay is normally processed outside is also establishing new production unit in
the leasehold area. Almost, all the china clay user Thiruvananthapuram, Kerala with a 180,000 tpa kaolin
industries except cement, insecticide and refractory units capacity of various grades - air floated, lumps, hydrous
consume processed china clay. The natural china clay and hydrous calcined kaolin reserves with 96%
is processed in the country mostly by conventional kaolinite content. Ashapura International is planning
method of levigation/washing. In addition, hi-tech to set up a kaolin powder making plant at Bhuj in
processes, such as, Mozeley hydrocyclone separator, Gujarat. The investment & capacity is not disclosed by
high-intensity magnetic separator, bleaching (chemical the company. The new facility will be company's second
decolourisation), spray drying and calcination are in facility after the one operational in Kerala, and make
practice. There is a need to use more sophisticated Ashapura one of the largest producer of kaolin in Asia.
processing techniques like ultra froth-flotation, cryo- Ashapura has already acquired new mines reserves of
filter, etc. about 2.5 to 3.0 million tonnes in Kerala to meet high
demand for kaolin.
The recovery percentage of processed china clay
from raw china clay ranges from as low as 14% to as Processed kaolin is presently marketed
high as 56%, depending upon the quality of china clay under various trade names mostly in levigated
available in different states. Large number of levigation and spray dried forms. A small quantity of
plants are installed in the country mostly in Kerala, crude kaolin is also marketed. The various trade names
Gujarat, Jharkhand, West Bengal and Rajasthan. Kerala under which the levigated kaolin is marketed are
has become a hub for India's processed kaolin Highest brightness calcined clays for coated paper,
production. The important plants in the country are excellent partial replacement for TiO 2 . Zeta-
English Indian Clays Ltd (EICL) (240,000 tpy capacity), balanced kaolin, highest brigntness calcined clays
Veli, Thiruvananthapuram, Kerala; Kerala Clays and for architectural decorative and industrial
Ceramic Products Ltd, (10,000 tpy capacity) Payangadi, coatings/inks. High brightness finer hydrous clays
29-9
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
for all kinds of acqueous paints, excellent The Bureau of Indian Standards (BIS)
functional clays for all paints formulations. has prescribed specifications for china clay to be
Calcined lumps for refractory grade materials non- used in different industries. They are IS:505-1995
calcined lumps for refractories. Highly reactive (Third Revision, Reaffirmed 2011) for paper
pozzolan, Meta kaolin for RMC and cement coating and filler for paper, rubber, textile
application; kaolin for Agrochemicals, Rubber & industries, IS:1463-1983 (Third Revision,
Plastics, soaps & detergents, Fibre glass & Reaffirmed 2000) for cosmetics and IS:7589-1974
ceramics. Improved processing techniques could (Reaffirmed 2011) for Explosive & Pyrotechnic
further the prospects of Indian kaolin in the Industry. BIS has revised the specifications for
international markets. Uma group of kaolin located china clay for Ceramic Industry to IS:2840-2002
in Kachchh district, Gujarat engaged in mining, (Second Revision, Reaffirmed 2008) and for
processing & trading of china clay. It possess paint industry to IS:68-2006. The whiteness,
mining area in Dagara & Mamuara. Koat particle size, plasticity, contents of alumina, iron
manufacturing company is engaged in processing and titanium are some important factors which
of hydrous kaolin, calcined kaolin & metakaolin, control the specifications of china clay for
having plant of capacity 1000 mtpm at Kachchh, different end-uses. China clay for ceramic and
Gujarat. Hydrous Kaolin, Vadodara manufacturers refractory applications is analysed for grit,
Levigated/Water Washed/Deaminated/spray dried
brightness, green and dry strength, fixed colour,
kaolin products available from 75% to 84%(ISO)
iron and alumina contents. For filler and extender
brightness. Particle size 2 Micron-49% to 93%
applications, it must meet very rigid
(packing options available - 25 kg/50 kg/500 kg
specifications, such as, particle size, colour,
jumbo bags). China clay powder manufacturers:
brightness and viscosity (Table - 9). Production
Shree Umia Sales Corpn. in GIDC Ahmedabad are
exporters, suppliers Indian china clay powder, ball of kaolin from south-west England is now around
clay. 1 m tpa, just one third of totals seen in 1988. The
dramatic decrease in kaolin production is due to a
USES AND SPECIFICATIONS combination of factors, one of which has been
China clay (kaolin) is used in a number the replacement of kaolin as a filler with
of industries in both crude and processed forms. precipitated calcium carbonate (PCC) and ground
The major use for crude china clay in India is calcium carbonate (GCC). Some 87% of the paper
in the Cement Industry, whereas Ceramic Industry market used kaolin in 1980,but by 2010, 65% of
accounts for consumption of a major share of the market was using GCC due to a switch by paper
processed form of china clay. Besides ceramics, makers from an acid-based processing route to an
processed china clay finds use in other industries alkali-based route for production.
in the country, such as sealants, paper coatings,
as extender in fibre glass, paint and as a filler for CONSUMPTION
paper, rubber, plastic, cosmetics, pharmaceuticals The main consuming industry for raw
and textiles. Crude china clay also finds use in china clay is the china clay processing/refining
Insecticide and Refractory Industries. Other plants. The china clay processed by these
uses of china clay are in ink, ultramarine, synthetic plants in turn is consumed by various industries
zeolite, catalyst, water filter candles, soaps & except cement, refractory and pesticide
detergents and explosives & pyrotechnic industries. The data on raw china clay
industries. Some of the areas where use of consumption by various china clay processing
china clay is gaining importance are in the plants are not readily available. However, the
manufacture of plastic film, video and audio tapes consumption of china clay by various industries
where clays are used as anti-blocking agents, and is given in Table-10.
in the field of biotechnology, where ceramics are
widely in use for its light weight & high strength Consumption of china clay decreased slightly
properties. EICL has been producing Metakaolin to 1,489 thousand tonnes in 2012-13, from
for the concrete industry for over a decade and 1,490 thousand tonnes in 2011-12. Cement
now we have been exporting regularly to the UAE, Industry accounted for 45% consumption
Kuwait and Germany for the durability of concrete followed by ceramic (42%), the major consumer of
by lime fixation and arresting of deterioration of raw china clay. Pesticide, paint, refractory, paper,
concrete by weathering. Himacem has high cosmetic, rubber, abrasive, asbestos products,
chemical resistance which makes the product chemical, dry cell batteries, textile, electrical,
suitable for construction of high span bridges, electrode and glass industries together accounted
under-water structures and chemical plants. for the remaining 13%.
29-10
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
Table – 9 : Specifications of China Clay Required in Different Industries
Filler in
Paper paper,
Sl. Characteristics coating rubber, Cosmetics Explosives
No. Grade I textile
Grade II
* As agreed.
@ To pass test for iron and carbonate as well.
29-11
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
29-12
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
Table – 13 : Imports of Kaolin h i g h b i n d i n g p o w e r, t e n s i l e s t r e n g t h a n d
(By Countries) shrinkage. It is utilised generally after mixing
with non-plastic clay to impart the desired
2011-12 2012-13 plasticity in pottery, porcelain and refractory
Country
Qty Value Qty Value materials. It also helps in the preparation of glaze,
(t) (`'000) (t) (`'000) enamels and for imparting a dense vitrified body.
All Countries 73647 1078287 87865 1095336
29-13
Table – 14 : Reserves/Resources of Ball Clay as on 1.4.2010
(By Grades/States)
(In tonnes)
By Grades
Ceramic/Pottery 12252380 350832 4059390 16662602 3225279 3818040 11158607 268486 2279330 36989941 57739683 74402285
29-14
By States
Andhra Pradesh 6017412 - 1288720 7306132 1821233 2806267 9512513 - 2279330 27555824 43975167 51281299
Rajasthan 6275408 350832 2845470 9471710 4301217 1100691 2875062 18676 - 14045369 22341015 31812725
29-15
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
Table – 18 : Mine-head Stocks of Ball Clay Table – 19 : Consumption of Ball clay 2010-11
2012-13(P) to 2012-13(P)
(By States) (By Industries)
(In tonnes) (In tonnes)
State At the beginning At the end Industry 2010-11 2011-12 (R) 2012-13(P)
of the year of the year
All Industries 589500 579600 585000
India 671202 668005
Abrasive 100(3) 100(3) 100(3)
Andhra Pradesh 136446 138656 (e)
Ceramic 576000(222) 565000(222) 565200(222)
Gujarat 931 -
Refractory 13400(26) 14500(28) 19700(30)
Rajasthan 526770 518517
29-16
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
29-17
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
Table – 23 : Production of Clay (Others), 2010-11 to 2012-13
(By States)
(Qty in tonnes; value in `’000)
Figures in parentheses indicate number of Associated mines of Clay (Others) with ball clay, dolomite, kaolin,fire clay
laterite,limestone, ochre & steatite.
* Production of associated mineral or labour reported.
29-18
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
Upto 5000 21(20) 29(20) 49389 66384 3.48 3.34 3.48 3.34
5001 to 10000 3(1) 3(3) 28320 50261 2.00 2.53 5.48 5.87
10001 to 20000 5(1) 7(2) 83590 137802 5.90 6.93 11.38 12.80
20001 to 30000 (1) 1(2) 28240 69665 1.99 3.51 13.37 16.31
30001 & above 6(5) 11(10) 1228145 1663024 86.63 83.69 100.00 100.00
Figures in parentheses indicate number of Associated mines of Clay (Others) with Laterite, Lime Stone, Steatite &
Ochre.
Chhattisgarh 1843 -
29-19
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
All Countries 16811 126294 22049 178899 All Countries 13013 144418 14637 194203
Saudi Arabia 1272 10828 6611 35104 USA 2169 59727 2200 72548
Kenya 1630 14719 2655 31593 Ukraine 8000 39776 7997 55210
Bangladesh 5111 18285 3739 29483 China 1336 11551 3124 30721
UAE 1184 9572 1112 8447 Germany 273 6914 122 5592
Other countries 2863 33355 2482 28329 Other countries 324 6098 248 2572
29-20
Table – 29 : Reserves/Resources of Shale as on 1.4.2010
(By Grades/States)
(In '000 tonnes)
All India : Total 14,992 76 263 15,331 - - 245 - - 252 83 580 15,911
29-21
By Grade
By State
Location of mine
Name and address of producer
State District
29-22
KAOLIN, BALL CLAY, OTHER CLAYS AND SHALE
Table – 32 : Production of Shale, 2011-12 & 2012-13
(By Sectors/States/Districts)
(Qty in tonnes; value in `'000)
2011-12 2012-13(P)
State/District
No. of mines Quantity Value No. of mines Quantity Value
29-23