Characterization and processing of kaolin from southern Brazil for potential strategic application in the porcelain stoneware tiles manufacturing

The ceramic industry in the productive hub of Santa Catarina needs some raw materials with specific characteristics such as kaolin to manufacture its products. This clay mineral with a naturally variable chemical composition in relation to its geolocation (in extraction area composed by rock and combined with sediment materials), attributes significant increases in transport costs due to its distance from the main productive areas in southern Brazil. Thus, as a strategic alternative, the improvement of kaolin with a high quartz content (69.9%) from the northern region of the state of Santa Catarina (∼400 km from ceramic hub in the south of the state), more precisely from the municipality of Garuva, was sought. Unit processing operations by classifying this mineral for suitability for use in industry, resulted in an increase in the concentration of kaolinite. The results indicated that the proposed method reduced the amount of quartz and consequently increased the kaolinite content, resulting in an aluminum oxide content of approximately 28.20%, a value higher than the normal natural content of ∼19%.