Ball Clay

Ball clay is an extremely rare mineral found in very few places around the world. Its name dates back to the early methods of mining when specialized hand tools were used to extract the clay in rough cube shapes of about 30 cm. As the corners were knocked through handling and storage these cubes became rounded and ‘ball’ shaped. It also is sometimes referred to as plastic clay.
Ball clays are sedimentary in origin. Ancient rivers and streams washed kaolinite (formed from decomposed granite) from its parent rock. As the streams flowed from upland area they mixed with other clay minerals, sands, gravels and vegetation before settling in low-lying basins to form overlaying seams of ball clay. Ball clays usually contain three dominant minerals: from 20-80% kaolinite, 10-25% mica, and 6-65% quartz. In addition, there are other 'accessory' minerals and some carbonaceous material (derived from ancient plants) present. The wide variation both in mineral composition and in the size of the clay particles results in different characteristics for individual clay seams within a deposit.
Ball clay is extracted using mechanical equipment, of which the most popular are hydraulic "back-hoe" excavators, that work as "benches" cut into the quarry to access the seams of clay. Individual raw clay selections are blended carefully according to pre-determined recipes to provide a product with a consistent and predictable range of characteristics and behavior. The first stage in processing then is to shred (or ‘kibble’) the blended clay into smaller, more regular lumps about the size of a golf ball. Much blended clay is sold in this shredded form. Further processing through drying and grinding yields powdered plastic clays and ceramics manufacturers (particularly in the sanitaryware sector) also have benefited from the development of refined ball clays which offer improved performance and reduced manufacturing process costs. Refined clays are available in ‘noodled’ and slurried form. Ball clays also are sold in a partially dried form, which consist of golf ball size materials that are not powdered. Internationally, deposits of high quality ball clay are much rarer than those of kaolin.