Abstract: A method of preparing a mineral ore may include crushing the mineral ore via a crusher apparatus to form crushed mineral ore. The method may further include depositing the crushed mineral ore into a media mill and adding water and dispersant into the media mill to form a slurry of the crushed mineral ore. The method may further include operating the media mill to grind the crushed mineral ore to form a slurry of ground mineral ore, and separating media of the media mill from the slurry of the ground mineral ore. The mineral ore may include at least one of bauxite and kaolin. For example, the mineral ore may include at least one of crude bauxite and crude kaolin, and crushing the mineral ore may include crushing the at least one of crude bauxite and crude kaolin. The method may be used to prepare a feed for use in ceramic proppants.

Abstract: A proppant may include particles including a sintered ceramic composition, wherein the particles have a particle size distribution such that less than 25 wt. % of the particles have a particle size less than 100 mesh, and wherein the particles have a particle size distribution such that less than 1 wt % of the particles have a particle size greater than 60 mesh. The particles may have a sphericity ranging from 0.4 to 0.9. A proppant may include particles including a sintered ceramic composition, wherein the proppant has a conductivity of at least 1.5 times the conductivity of 100 mesh sand. A method of treating a subterranean area around a well bore may include providing a fracturing fluid including such proppants, and injecting the fracturing fluid into the subterranean area around the well bore.

Abstract: A method for obtaining rare earth element compositions may include providing a dispersed aqueous suspension of a particulate material including at least one rare earth element compound and kaolinite. The method may further include adding to the suspension a selective flocculation polymer that facilitates separation of at least a portion of the at least one rare earth element compound from the kaolinite by flocculating the kaolinite and allowing particles of the rare earth element compound to be or remain deflocculated. The method may also include allowing the suspension containing the polymer to separate in a selective flocculation separator into layers including a flocculated product layer and a deflocculated layer containing the portion of the at least one rare earth element compound. The method may further include extracting each of the separated layers from the separator. The rare earth element compound may include La2O3, CeO2, Nd2O3, or Y2O3.

Abstract: A mineral composition and related methods may include a mineral treated with a styrene-based polymer. The mineral treated with a styrene-based polymer may be used for a coating on a paper product having a first Cobb value that is less than a second Cobb value of the paper product with the coating devoid of the mineral composition.

Abstract: A method of making a sintered ceramic proppant may include providing a ceramic precursor material comprising kaolin clay, 0.2%-2% by weight alkali silicate, and not more than 0.05% by weight polymeric anionic dispersant. The method may further include pelletizing the ceramic precursor and sintering the ceramic precursor pellets for form a sintered ceramic proppant having a specific gravity ranging from 2.40 to 2.57.

Abstract: A method of making a sintered ceramic proppant may include providing a kaolin clay. The kaolin clay may include an Al2O3 content no greater than about 46% by weight, and a K2O content no greater than 0.1% by weight. The kaolin clay may have a particle size distribution such that greater than 70% of the particles have an equivalent spherical diameter of less than 0.5 microns as measured by Sedigraph, and a shape factor less than about 18. The method may further include blunging the kaolin clay, agglomerating the kaolin clay, and sintering the agglomerated kaolin clay to produce a sintered ceramic proppant. The kaolin clay may have an A-bob Hercules viscosity of at least about 3,300 rpm at 18 kilodyne-cm and 70% solids.

Abstract: A method for calibrating an apparatus for measuring shape factor is provided, wherein the method comprises determining aspect ratios for each of a plurality of kaolin samples and measuring the shape factors of each of the plurality of kaolin samples using the apparatus, wherein each of the kaolin samples includes potassium oxide in an amount less than about 0.1% by weight of each of the kaolin samples. The method further includes calibrating the apparatus based on a correlation between the aspect ratios and the shape factors.

Abstract: A method of making a sintered ceramic proppant may include providing a kaolin clay. The kaolin clay may include an Al2O3 content no greater than about 46% by weight, and a K2O content no greater than 0.1% by weight. The kaolin clay may have a particle size distribution such that greater than 70% of the particles have an equivalent spherical diameter of less than 0.5 microns as measured by Sedigraph, and a shape factor less than about 18. The method may further include blunging the kaolin clay, agglomerating the kaolin clay, and sintering the agglomerated kaolin clay to produce a sintered ceramic proppant. The kaolin clay may have an A-bob Hercules viscosity of at least about 3,300 rpm at 18 kilodyne-cm and 70% solids.

Abstract: A mineral composition and related methods may include a mineral treated with a styrene-based polymer. The mineral treated with a styrene-based polymer may be used for a coating on a paper product having a first Cobb value that is less than a second Cobb value of the paper product with the coating devoid of the mineral composition.

Abstract: A method for obtaining rare earth element compositions may include providing a dispersed aqueous suspension of a particulate material including at least one rare earth element compound and kaolinite. The method may further include adding to the suspension a selective flocculation polymer that facilitates separation of at least a portion of the at least one rare earth element compound from the kaolinite by flocculating the kaolinite and allowing particles of the rare earth element compound to be or remain deflocculated. The method may also include allowing the suspension containing the polymer to separate in a selective flocculation separator into layers including a flocculated product layer and a deflocculated layer containing the portion of the at least one rare earth element compound. The method may further include extracting each of the separated layers from the separator. The rare earth element compound may include La2O3, CeO2, Nd2O3, or Y2O3.

Abstract: Disclosed herein are stabilized kaolin slurries comprising a kaolin comprising no more than about 80% by weight of particles having an equivalent spherical diameter of less than 2 microns and at least one stabilizer, wherein the stabilized kaolin slurry has a 28-day pour test result of at least about 80% poured. Also disclosed are methods of making such stabilized kaolin slurries.

Abstract: A method of treating a kaolin particulate material to improve one or more of its properties by removal of impurity particles therein which includes: producing a dispersed aqueous suspension of a kaolin particulate material containing at least 0.1% by weight, based on the dry weight of the kaolin particulate material of separable particulate impurity; diluting said dispersed aqueous suspension by adding a diluent thereto; adding a selective flocculation polymer to the diluted suspension; allowing the suspension containing the polymer to separate in a selective flocculation separator into layers comprising a flocculated product layer and a deflocculated impurity layer containing the separable impurity; and extracting the separated layers from the separator, wherein at least a portion of said deflocculated impurity layer is recirculated for use as at least a portion of the aforementioned diluent.

Abstract: Disclosed herein are kaolin compositions, such as beneficiated fine sedimentary kaolin compositions. The beneficiated fine sedimentary kaolins may be obtained from the upper bed of the Rio Capim Kaolin deposit. The compositions may have at least one property chosen from a low iron content and low Hinckley crystallinity index, such as Fe2O3 in an amount less than about 0.8% by weight relative to the total weight of the solids content and wherein the Hinckley crystallinity index of the kaolin is less than about 0.5. Also disclosed are products obtained therefrom, such as paint and paper coating compositions.

Abstract: Disclosed herein are granulated kaolin compositions exhibiting at least one of improved material handling properties, low dusting during transit, easy make-down into mineral-water slurries, and requiring less energy to produce than spray dried kaolin products. The granulated kaolin compositions may, in one embodiment, be characterized by a moisture content ranging from about 12% to about 23% by weight relative to the total weight of the composition. In another embodiment, the granulated kaolin compositions may have an average granule size of greater than about 10 mesh. Also disclosed herein are granulated kaolin compositions having a moisture content ranging from about 12% to about 23% by weight relative to the total weight of the composition, wherein the composition is friable when subjected to a shear force.

Abstract: A method for calibrating an apparatus for measuring shape factor is provided, wherein the method comprises determining aspect ratios for each of a plurality of kaolin samples and measuring the shape factors of each of the plurality of kaolin samples using the apparatus, wherein each of the kaolin samples includes potassium oxide in an amount less than about 0.1% by weight of each of the kaolin samples. The method further includes calibrating the apparatus based on a correlation between the aspect ratios and the shape factors.

Abstract: Disclosed herein are kaolin compositions, such as beneficiated fine sedimentary kaolin compositions. The beneficiated fine sedimentary kaolins may be obtained from the upper bed of the Rio Capim Kaolin deposit. The compositions may have at least one property chosen from a low iron content and low Hinckley crystallinity index, such as Fe2O3 in an amount less than about 0.8% by weight relative to the total weight of the solids content and wherein the Hinckley crystallinity index of the kaolin is less than about 0.5. Also disclosed are products obtained therefrom, such as paint and paper coating compositions.

Abstract: Disclosed herein are kaolin compositions, such as beneficiated fine sedimentary kaolin compositions. The beneficiated fine sedimentary kaolins may be obtained from the upper bed of the Rio Capim Kaolin deposit. The compositions may have at least one property chosen from a low iron content and low Hinckley crystallinity index, such as Fe2O3 in an amount less than about 0.8% by weight relative to the total weight of the solids content and wherein the Hinckley crystallinity index of the kaolin is less than about 0.5. Also disclosed are products obtained therefrom, such as paint and paper coating compositions.

Abstract: Disclosed herein is a method of calcining particulate material, such as kaolin. The method comprises providing a feed mixture comprising a particulate material, such as hydrous kaolin, wherein at least a portion of the particulate feed is coated with a liquid fuel. The method further comprises heating the particulate feed mixture to calcine the particulate feed and burn the liquid fuel to form a calcined product. The liquid fuel coating can act as a secondary, indirect heat source for calcining. The overall calcining temperatures and/or times can be reduced as a result of adding the liquid fuel.

Abstract: Disclosed herein are stabilized kaolin slurries comprising a kaolin comprising no more than about 80% by weight of particles having an equivalent spherical diameter of less than 2 microns and at least one stabilizer, wherein the stabilized kaolin slurry has a 28-day pour test result of at least about 80% poured. Also disclosed are methods of making such stabilized kaolin slurries.

Abstract: The present invention relates to a kaolin composition having improved physical properties, for example, for use in the production of paper products. The composition can comprise kaolin having a shape factor of at least about 20. The kaolin can have a particle size distribution such that at least about 94% by weight of the kaolin can have an esd of less than about 2 ?m and/or at least about 80% by weight of the kaolin can have an esd of less than 1 ?m. The amount of the kaolin having an esd of less than about 0.25 ?m can range from about 25% to about 60% by weight. The Hercules viscosity of the kaolin product is less than 4000 rpm at 18 dynes at 63% solids and less than 1500 rpm at 18 dynes at 69% solids when measured using the “A” bob. The present invention also relates to an improved method for making the kaolin product from sedimentary kaolin.