Abstract: Described herein are spunlaid fibers including at least one polymeric resin and at least one filler having an average particle size of less than or equal to about 5 microns and/or having a top cut of less than about 15 microns. The at least one filler may be present in an amount of less than about 40% by weight, relative to the total weight of the spunlaid fibers. Also described herein is a method for producing spunlaid fibers including adding calcium carbonate to at least one polymeric resin and extruding the resulting mixture. Further described herein are nonwoven fabrics including such spunlaid fibers, and methods for producing them.

Abstract: A heterogeneous composition for use as rock dust is disclosed. The heterogeneous composition includes a fine, wet ground inorganic particulate material treated with at least one fatty acid, a salt thereof, or an ester thereof, and a coarse, untreated, dry ground inorganic particulate material. Also disclosed is a heterogeneous composition including coal dust and mine rock dust including a fine, wet ground inorganic particulate material treated with at least one fatty acid, a salt thereof, or an ester thereof, and a coarse, untreated, dry ground inorganic particulate material. The amount of mine rock dust may be sufficient to render the coal dust explosively inert. The fine, treated, wet ground inorganic particulate material may be calcium carbonate. The coarse, untreated inorganic particulate material may be calcium carbonate. The fatty acid may be stearic acid.

Abstract: A coating composition may include kaolin having a shape factor less than about 70 and calcium carbonate, wherein less than about 90% by weight and greater than about 60% by weight of particles of the calcium carbonate have an equivalent spherical diameter (esd) less than 2 microns. The coating composition may include a thickener present in an amount ranging from about 0.1% to about 0.9% by active dry weight of the composition. A coating composition may include kaolin having a shape factor less than about 70 and calcium carbonate having a mean particle size (d50) of at least about 2.4 microns and a steepness factor of at least about 30. The coating composition may be a paper basecoat composition or a paperboard basecoat composition. A paper or paperboard product may include the coating composition on at least one surface of the paper product or paperboard product.

Abstract: Disclosed herein are monofilament fibers comprising at least one polymeric resin and at least one coated filler, wherein the at least one coated filler has an average particle size of less than or equal to about 3 microns and/or has a top cut of less than or equal to about 10 microns, and wherein the at least one coated filler is present in an amount of less than or equal to about 50% by weight, relative to the total weight of the monofilament fibers. Also disclosed herein are methods for producing monofilament fibers comprising adding ground calcium carbonate to at least one polymeric resin and extruding the resulting mixture.

Abstract: A composition for use as rock dust is disclosed. The composition may include a ground inorganic particulate material treated with at least one fatty acid, a salt thereof, or an ester thereof. Also disclosed is a composition including coal dust and mine rock dust, which may include a ground inorganic particulate material treated with at least one fatty acid, a salt thereof, or an ester thereof. The amount of mine rock dust may be sufficient to render the coal dust explosively inert. The composition may also include an untreated inorganic particulate material. The treated inorganic particulate material may be calcium carbonate. The untreated inorganic particulate material may be calcium carbonate. The fatty acid may be stearic acid.

Abstract: A method for treating calcium carbonate includes combining calcium carbonate with an amount of stearic acid and an amount of water to form a mixture, the amount of water being at least about 0.1% by weight relative to the total weight. The method further includes blending the mixture to form a stearic acid-treated calcium carbonate composition.

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: Described herein are spunlaid fibers including at least one polymeric resin and at least one filler having an average particle size of less than or equal to about 5 microns and/or having a top cut of less than about 15 microns. The at least one filler may be present in an amount of less than about 40% by weight, relative to the total weight of the spunlaid fibers. Also described herein is a method for producing spunlaid fibers including adding calcium carbonate to at least one polymeric resin and extruding the resulting mixture. Further described herein are nonwoven fabrics including such spunlaid fibers, and methods for producing them.

Abstract: A method for treating calcium carbonate includes combining calcium carbonate with an amount of stearic acid and an amount of water to form a mixture, the amount of water being at least about 0.1% by weight relative to the total weight. The method further includes blending the mixture to form a stearic acid-treated calcium carbonate composition.

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 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 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 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: A method for treating calcium carbonate includes combining calcium carbonate with an amount of stearic acid and an amount of water to form a mixture, the amount of water being at least about 0.1% by weight relative to the total weight. The method further includes blending the mixture to form a stearic acid-treated calcium carbonate composition.

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: 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: The Rio Capim Kaolin deposit contains a lower bed of soft kaolin clay that averages 10 meters thick, and an upper bed of “hard” kaolin (“RCC hard kaolin”) that may be as thick as 6 to 8 meters. Due to their high impurity content fine particle size, cementetious nature, and high degree of particle aggregation, hard kaolins are difficult to process. Disclosed herein are compositions comprising kaolin having a particle size distribution such that at least about 90% of the kaolin has a particle size of less than 1 micron and a GE brightness of at least about 91, where the kaolin may be derived from a crude kaolin having a Fe2O3 content of at least about 1.0% by weight, and optionally comprises titania in an amount of at least about 1.5% by weight. Also disclosed herein are methods of refining the hard kaolins, such as RCC hard kaolins, by dispersing the kaolin with at least one anionic organic dispersant and at least one inorganic dispersant.