Abstract: A particulate product comprising kaolin produced from a method wherein the kaolin of a feed suspension is such that not more than 30% by weight has a particle size less than 2 ?m and not more than 30% by weight has a particle size greater than 10 ?m, wherein the kaolin of a product suspension produced is such that not more than 10% by weight has a particle size greater than 10 ?m and not more than 10% by weight has a particle size less than 0.25 ?m, and wherein the particulate product comprises kaolin produced from a fine fraction suspension.

Abstract: Disclosed herein are methods for removing discoloring impurities, such as carbon impurities, particularly graphite, from kaolin clay to enhance the brightness of the kaolin clays. The methods include reverse flotation processes. Also disclosed herein are high brightness kaolin products, and the uses thereof.

Abstract: Disclosed are methods of making calcined kaolin having a high mullite content involving heating to certain temperatures. Also disclosed are systems for making the calcined kaolin having a high mullite content and polymer composites containing the calcined kaolin having a high mullite content. The present calcined kaolin having a high mullite content is particularly useful in making polymer composites. The polymer composites may be used in electrical cable.

Abstract: A pulling roll for glass manufacture comprised of a high-temperature millboard material. The millboard comprises aluminosilicate refractory fiber, silicate, mica, and kaolin clay. A method of manufacturing a pulling roll is disclosed, together with a roll produced by the methods disclosed herein. The method comprises forming a pulling roll and densifying at least a portion of the pulling roll by exposing to the pulling roll to high temperatures.

Abstract: Disclosed are pigment mixtures containing at least two components, where component A contains bismuth oxychloride (BiOCl) or boron nitride (BN) and component B contains synthetic flakes treated with at least one metal soap or mineral flakes treated with at least one metal soap and to the use thereof especially in cosmetic formulations.

Abstract: A basecoat including a pigment blend, the pigment blend including at least a calcined clay and a hyper-platy clay, the hyper-platy clay having a shape factor of at least about 40:1.

Abstract: A heated mixture comprising dehydroxylated kaolin and a high refractive index pigment is disclosed. When the dehydroxylated kaolin is metakaolin, the heated mixture has a GE brightness greater than 86% and a Hunter yellowness index of less than about 11. When the dehydroxylated kaolin is fully calcined kaolin, the heated mixture has a GE brightness greater than 89%. The heated mixture is advantageously used in decorative paper. Also disclosed are methods of using and making the decorative paper, and decorative laminates containing the decorative paper.

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.

Abstract: Spherical and rod-shaped proppants and anti-flowback agents made from sillimanite minerals possess high strength and high conductivity. The sillimanite minerals may be selected from the group consisting of kyanite, sillimanite, and andalusite and may be used alone or in combination with other materials, such as bauxite, kaolin, meta-kaolin, pure or technical grade alumina (about 98%-99.9% alumina by weight), alumina-containing slag, zirconia, silica, iron, alkali elements (such as calcium, magnesium, and sodium), and virtually any other mineral containing alumina. The starting material may optionally be milled to achieve better compacity and crush resistance in the final proppant or anti-flowback agent. A fracturing fluid may comprise the rods or spheres alone, or in combination with each other or other proppants or anti-flowback agents of different shapes.

Abstract: A clay plaster formulation and application. The clay plaster is a mixture of various clays, and aggregate. This plaster is both functional and decorative and is for use on new and existing construction.

Abstract: The disclosed invention relates to a blended hydrous kaolin clay product comprising a platy coarse kaolin clay and a fine, hydrous kaolin clay. The blended kaolin clay product is suitable for use as a raw material component in the formation of cordierite products.

Abstract: The invention relates to interspersed clay, comprising clay and a seaweed extract used as an interspacing component, particularly an ulva extract. The invention also relates to a method for the preparation thereof and to foodstuffs and nanocomposites comprising said interspersed clay.

Abstract: A coating composition for paper and other substrates, particularly mechanical papers such as lightweight coated (LWC) paper, comprises an aqueous suspension of a particulate pigment together with a binder, wherein the particulate pigment comprises: (a) a first component which is a precipitated calcium carbonate consisting predominantly of aragonitic or rhombohedral particle shapes or of aragonitic and rhombohedral particle shapes in a weight ratio of between around 40:60 and about 60:40 (e.g.

Abstract: The present invention relates to a composition comprising calcined kaolin having a narrow particle size distribution. The composition can have many uses, such as fillers or extenders in paint, plastics, polymers, papermaking, and coating compositions. More generally, the inventive products may be used wherever calcined kaolins are used.

Abstract: The present disclosure relates to a coating composition for use in producing a coating on paper and other substrates comprising an aqueous suspension of a particulate pigment together with a binder, wherein the particulate pigment comprises a mixture of: a first pigment component comprising particulate ground calcium carbonate (GCC) having a particle size distribution (psd) steepness factor ranging from about 30 to about 45; and a second pigment component comprising particulate precipitated calcium carbonate (PCC) having a psd steepness factor ranging from about 55 to about 75. The particulate pigment may optionally further include a particulate kaolin clay.

Abstract: An improved composite material, and method of manufacture thereof, comprising varying amounts tungsten powder, or metal/alloy powder of similar density, and clay or silicone is disclosed. The improved composite material may be useful as a replacement for lead and lead-based composites where similar densities are required but the use of lead is undesirable. The disclosed composite material permits a large variety of tungsten powder particle sizes to be utilized and results in improved ductility over known tungsten powder composites.

Abstract: Disclosed herein is a kaolin composition having nanosize dimensions. At least about 75% of the kaolin particles by weight have an equivalent spherical diameter (esd) of less than about 0.25 ?m. The kaolin can also have a particle size distribution wherein at least about 99% of the particles by weight have an esd of less than about 2 ?m, and/or wherein at least about 98% of the particles by weight have an esd of less than about 1 ?m, and/or wherein at least about 97% of the particles by weight have an esd of less than about 0.5 ?m. The kaolin can have a mean diameter ranging from about 0.075 ?m to about 0.2 ?m, and a shape factor of about 30 or less.

Abstract: A two step method for preparing a filler composition, the filler composition useful to prepare a nanocomposite polymer. The first step is to disperse a water dispersible filler material in a liquid comprising water to form a dispersion. The second step is to replace at least a portion of the water of the liquid with an organic solvent to form the filler composition, the water concentration of the liquid of the filler composition being less than six percent by weight, the average size of at least one dimension of the filler material being less than two hundred nanometers upon examination by transmission electron microscopy of a representative freeze dried sample of the dispersion of the first step.

Abstract: Disclosed herein are a method of reductively bleaching a mineral slurry comprising adding in the mineral slurry an effective amount of a formamidine sulfinic acid (FAS) and an effective amount of a borohydride to reductively bleach the mineral slurry, compositions comprising a mineral slurry, a FAS, and a borohydride, and final products comprising a mineral obtained by the method disclosed herein.

Abstract: A ball clay powder having a moisture content of less than 5% and at least about 25% of indigenous silica, said powder comprising a blend of at least two natural ball clays, wherein one of the ball clays is naturally silica rich and has at least about 40% indigenous silica.

Abstract: 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 of not greater than 875° C. to produce metakaolin.

Abstract: The present invention relates to coarse calcined kaolin slurries having a high solids content. The invention also relates to methods of making such slurries. The resulting slurries can have a solids content of at least about 58% by weight wherein at least about 40% by weight of the calcined kaolin particles has a particle size of at least about 1 ?m. The slurries can be stabilized where the solids show little settling from suspension. The slurries have many uses, including fillers or extenders in paint and coating compositions for paper or paper board. More generally, the inventive products may be used wherever calcined kaolins are used. The present invention also related to coarse calcined kaolin slurries having a multimodal particle size distribution and a high solids content.

Abstract: An ultra-fine powder formed from a naturally occurring mineral or rock material and having a controlled or “engineered” particle size distribution (PSD) to match the infrared spectra with a maximum particle size in the range of 14-17 microns measured as either D99, or preferably D95, and a minimum particle size D5 in the range of 4-7 microns. Preferably the maximum particle size is about 15 microns, the minimum particle size is about 5 microns and the D50 particle size is about 8-10 microns with the moisture content of the particle size “engineered” powder being less than about 0.20 percent by weight and preferably about 0.05 to 0.08 percent by weight of the powder. This specially “engineered” ultra-fine powder is used to reduce the thermicity of thermal film to a value less than about 20%.

Abstract: A pigment product for use in a coating composition to provide a gloss coating on paper, the pigment product comprising a processed particulate kaolin having a particle size distribution such that at least about 80% by weight of the particles have an equivalent spherical diameter less than about 2 p,m and in the range of from about 10% to about 20% by weight of the particles have an equivalent spherical diameter less than about 0.25 wm, the particles have a shape factor in the range of from about 20 to about 36 and the particles have a particle steepness in the range of about greater than about 35, more preferably in the range of about 35 to about 40, and wherein the kaolin is derived from a secondary kaolin source.

Abstract: The invention concerns a new synthetic mineral matter containing carbonate, the decomposition of which reduces the rate of fossil fuel carbon dioxide emission. It also concerns its manufacture in batches, or in a batch-continuous manner, or in a continuous manner, together with its uses in the pharmaceutical field, the field of human or animal foodstuffs, or again the papermaking field with, notably, manufacture of paper, filler or coating, or again every other paper surface treatment, together with the fields of water-based or non-water-based paints, together with the field of plastics, such as that of breathable polyethylene films, or again the field of printing inks.

Abstract: A binder mix containing a hydraulic binding agent and an admixture mixed therewith, a process for preparing a hydraulically hardened binder mass, a calcinated kaolin product and a process for preparing the same. A paste-like composition is formed from the hydraulically hardening binding agent, a pozzolanically reacting admixture and water, which, when so desired, contains stone aggregate or similar filler, the paste-like composition is worked and the worked composition is allowed to harden to form the binder mass. The admixture comprises spherical, porous metakaolin agglomerates, the size of which is 2-200 microns and which have an open pore structure. The invention can be used to improve the manufacturing methods of cast concrete products and shorten the manufacturing times, and to provide concrete with better mechanical and chemical properties, as well as improve the fire and frost resistance of concrete.

Abstract: A method for dispersing a pigment in a solvent comprises mixing the pigment in a nanoscale with clay in a layered or platelet form and mixing the resultant mixture with the solvent. The method is based on geometric inhomogeneity and mutually exclusive aggregation. The layered or platelet clay having a high aspect ratio is provided to hinder aggregation of the pigment nanoparticles. The pigment nanoparticles can be stably dispersed in a matrix containing an organic solvent and water without aggregation again.

Abstract: Disclosed herein is ultra-low residue, high solids, wet “cake” kaolin and ultra-low residue, high solids, wet “cake” calcined kaolin products, produced by use of wet screening/non-drying product isolation, which are useful in the manufacture of top size-sensitive applications.

Abstract: Disclosed are methods of processing kaolin to produce two distinct grades of kaolin in a simultaneous manner. The methods involve processing kaolin by degritting a kaolin crude; subjecting the degritted kaolin crude to flotation to provide a kaolin having reduced titania content; ozonating the kaolin having reduced titania content; centrifuging the kaolin to provide a coarse stream and fine stream; refining the coarse stream into a coarse engineered kaolin pigment; and refining the fine stream into a fine glossing kaolin pigment. Also disclosed are systems for the automated processing of kaolin to produce two distinct grades of kaolin with real time feedback.

Abstract: The present invention relates to tinted optical lenses and to methods of manufacturing tinted optical lens. This invention relates to a method for tinting optical lenses using an ink receptor film. The method of the invention allows a good transfer of the color to the substrate which represents the support of lens, a good final coloration of the substrate with good color homogeneity. The invention relate also to a method of tinting optical lenses, using the said ink receptor film which is applied onto a primer layer coating the substrate of the lens. The ink receptor material comprises an inorganic filler and an water-based emulsion. Preferably the ink receptor material also comprises a water-soluble polymer, a modified cationic polymer and a carrier able to accelerate the absorption of the ink into the substrate.

Abstract: A clay plaster formulation and application. The clay plaster is a mixture of various clays, and aggregate. This plaster is both functional and decorative and is for use on new and existing construction.

Abstract: Disclosed are methods of processing kaolin to produce ultrafine hydrous kaolin. The methods involve processing gray crude kaolin by subjecting the kaolin crude to flotation and then centrifuging the kaolin to provide a fine stream that is subject to refinement. Also disclosed are systems for the automated processing of gray crude kaolin to produce the ultrafine hydrous kaolin and paint compositions that contain the ultrafine hydrous kaolin.

Abstract: Disclosed herein are inorgano-neutralized calcined kaolin comprising calcined kaolin treated with at least one basic inorganic compound, a composition comprising the inorgano-neutralized calcined, and use of the inorgano-neutralized calcined kaolin in silicone rubber formulation. Further disclosed herein are a method of making the inorgano-neutralized calcined kaolin and a method of making a silicone rubber formulation comprising the inorgano-neutralized calcined kaolin.

Abstract: The invention relates to suspensions, to the production of said suspensions, and to the use thereof for accelerating the setting and hardening of cement and mixtures containing the same. According to the invention, said suspensions consist of aluminium sulphate in a quantity of more than 8 wt. % as Al2O3, preferably between 10 and 12 wt. %, and of suspended bentonite in a quantity of between 1 and 7 wt. %. Said suspensions can especially be used as economical and ecological alternatives in the field of wet spraying. The inventive suspensions are free of COD and alkali.

Abstract: In an alkali activated hydraulic binder containing slags and aluminium silicates slag, in particular furnace slag in amounts from ?20% (w/w), aluminium silicates different from furnace slag such as for example flue-ash and natural aluminium silicates, such as for example basalt, clays, marl, andesite or zeolite, in amounts from 5 to 75% (w/w) and an alkali activator in an amount, which corresponds to a Na2O equivalent defined as (Na2O+0.658 K2O) (ASTM C 150) between 0.7 and 4% (w/w), respectively related to the entire mixture are present in the mixture as constitutive components.

Abstract: There is provided a method of producing a kaolin particulate material suitable for use as an improved super-calendered filler. This method includes: (a) preparing an aqueous feed suspension of kaolin; (b) treating the kaolin of the feed suspension by attrition grinding in a vessel using grinding media granules; (c) delivering an aqueous suspension of the kaolin ground in (b) to a particle size classifier and separating the kaolin of the suspension into a coarse fraction and a fine fraction; (d) returning an aqueous suspension of the coarse fraction produced in (c) to the grinding vessel to be further attrition ground; and (e) extracting an aqueous suspension of the fine fraction produced in (c) as a product suspension. Advantageously, the kaolin of the feed suspension in (a) is such that not more than 30% by weight has a particle size less than 2 ?m and not more than 30% by weight has a particle size greater than 10 ?m.

Abstract: A swellable layer silicate is described based on smectite or sepiolite/palygorskite for use in media containing di- or polyvalent cations that reduce swellability, characterized by a swelling volume of about 5 to 50 mL, measured by addition of 2 g layer silicate (air-dried) to 100 mL water, and by a fineness of maximum 5 wt. % >40 ?m and maximum 20% >20 ?m, as dry sieve residue.

Abstract: The present invention relates to a particulate kaolin suitable for use as a filler material in compositions for making uncoated paper, the kaolin having a mean particle size ranging from 0.7 ?m to 3 ?m and a shape factor of at least 60. The invention also relates to compositions comprising a particulate kaolin, and methods for making uncoated paper sheets.

Abstract: Disclosed herein is a method of heat-treating 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 an additive/liquid fuel mixture comprising at least one additive dispersed in liquid fuel. The method further comprises heating the particulate feed to heat treat, e.g., calcine, the particulate feed and burn the liquid fuel to form a heat-treated product. The liquid fuel coating can act as a secondary, indirect heat source for heat treating.

Abstract: Pigment suitable for use in coating compositions for inkjet recording media. Surfaces of an inorganic particulate are interacted with a water-soluble polyvalent metal salt in an aqueous medium. The treated particle surfaces have a significant cationic surface charge imparted to them. The salt is a salt of a metal of Group II or Group III of the Periodic Table. Inkjet recording media treated with a coating composition containing the above pigment provide high density, fast-drying, and non-feathering ink images with suitable water fastness, while the coating compositions also offer cost advantages and improved rheology at higher pigment levels over coatings based on silica pigments.

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: The present invention provides high brightness kaolins exhibiting a Brightness (GE) of at least about 90.0. The hydrous kaolin pigments of the present invention may also have, inter alia, a steepness index (d30/d70×100) of at least about 39 and/or a titania concentration less than or equal to about 0.40% by weight of the pigment on a dry basis. (062) The hydrous kaolin pigment is produced by a process comprising: a) forming an aqueous suspension of a hydrous kaolin clay; b) forming a primary product by subjecting the suspension to classification or a combination of classification and griding; c), separating the kaolin from impurities by selective flocculation; and d) defining the separated kaolin. (063) The hydrous kaolins of the present invention allow coated papers to be produced at high brightness while maintaining acidic conditions on a paper machine. The invention pigmets exhibit brightness levels unexpectedly higher, e.g., about 2 to about 2.

Abstract: Disclosed are methods of processing Chinese kaolin involving providing Chinese kaolin having a desired powder size, delaminating the Chinese kaolin, pulverizing the delaminated Chinese kaolin at least two times, and heating the at least twice pulverized Chinese kaolin. Also disclosed are systems for automated processing of Chinese kaolin containing a pulverizer for pulverizing Chinese kaolin, a tester for testing and generating data of at least one parameter of the Chinese kaolin or at least one parameter of the pulverizer, a controller, operatively coupled to the pulverizer and the tester, for controlling operation of the pulverizer based on data received from the tester.

Abstract: A clay slurry is described using smectite clay, water, and a defined phosphonate additive that is hydrolytically stable over time. The viscosity of the clay slurry remains pourable and relatively unchanged over time compared to prior art slurries. The slurry is useful to provide rheological control to paints and coatings and is particularly useful as an anti-bleed additive for concrete.

Abstract: The present invention provides a high solids mineral slurry having long term stability and a method for producing the same. Specifically, the present invention provides a talc slurry having a solids content of up to 65% and a stability against sedimentation for up to 100 days. The talc slurry of the present invention comprises a phyllosilicate mineral, a chelating agent and multivalent ions, wherein the slurry has a pH of between about 10.2 and about 11.8.

Abstract: The present invention relates to a hydrous kaolin product having improved optical properties, for example, when used in the production of paper products. The present invention comprises an improved barrier coating for paper and a method of making the coated paper. The present invention also comprises an improved method from making filled and coated paper products. The present invention uses a composition comprising kaolin having a shape factor of at least about 70:1, such as at least about 80:1 or at least about 100:1.

Abstract: The present invention relates to a hydrous kaolin product having improved optical properties, for example, when used in the production of paper products. The present invention comprises an improved barrier coating for paper and a method of making the coated paper. The present invention also comprises an improved method from making filled and coated paper products. The present invention uses a composition comprising kaolin having a shape factor of at least about 70:1, such as at least about 80:1 or at least about 100:1.

Abstract: Pigment suitable for use in coating compositions for inkjet recording media. Surfaces of an inorganic particulate are interacted with a water-soluble polyvalent metal salt in an aqueous medium. The treated particle surfaces have a significant cationic surface charge imparted to them. The salt is a salt of a metal of Group II or Group III of the Periodic Table. Inkjet recording media treated with a coating composition containing the above pigment provide high density, fast-drying, and non-feathering ink images with suitable water fastness, while the coating compositions also offer cost advantages and improved rheology at higher pigment levels over coatings based on silica pigments.

Abstract: New methods of producing narrower particle size distribution precipitated silica and/or silicate materials are provided. Such a method permits a significant reduction in manufacturing costs through the utilization of more efficient drying/evaporation components, in essence, in one potentially preferred embodiment, production of such silica and/or silicate materials followed directly by a hydraulic chamber press filtering step combined with vacuum dewatering subsequently leading to the needed resultant particle comminution. The resultant precipitated silicas and/or silicates produced thereby exhibit greater density prior to comminution and thus greater propensity for more uniform milling than previously utilized and prevalent spray/flash drying apparatuses.

Abstract: The present invention provides an improved method of beneficiating and dewatering kaolin clays. The product of the improved process is a brightened, dewatered kaolin, suitable for use in pigments and paper coating compositions. The improved beneficiation process provides refined kaolin for pigments and other purposes of the same or better quality as prior art processes, but with the use of fewer steps and materials, at significant cost and environmental savings.