A process for producing high grade metakaolin directly from kaolinzed sands ore body. In one embodiment, a source of kaolin ore is reduced in the size to a size distribution of between −2 inches and 10 mesh. The ore is then dried in a dryer at a temperature of not greater than 180° C. to a moisture content of not greater than 0.5% by weight to liberate kaolin and calcined at a temperature ...
