Optimization of Grinding Parameters for the Mechanochemical Activation of Kaolin with the Addition of Trass

Abstract

At present, to achieve further reductions in CO2 emissions in the cement industry, it is essential to improve the efficiency of grinding processes and reduce the energy demand. This study examined the effects of various grinding parameters (addition of trass, ball to powder mass ratio (BPR), material of grinding bodies and jars, rotational speed, and mill type) to minimize the energy consumption of the mechanochemical activation of kaolinite. X-ray diffraction, Fourier transform infrared spectroscopy, inductively coupled plasma optical emission spectroscopy, scanning electron microscopy, and specific surface area measurements were used to examine the influence of grinding parameters. It was found that the addition of as little as 25% (mass percent) trass reduced the specific energy demand for the complete amorphization of kaolinite by 56%. The application of steel grinding bodies (instead of ZrO2 ones) had a slight influence on the amorphization kinetics of kaolinite, but it could mechanochemically activate 30% more samples at the same BPR and specific energy demand. The use of the four-pot milling instead of the one-pot could considerably decrease the specific energy demand of the complete and incomplete (α = 0.9) amorphization of kaolinite. Overall, a 94% reduction was achieved in specific energy demand with steel grinding material, 14:1 BPR, four-pot milling, and the incomplete amorphization of kaolinite.