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 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: 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: Coarse platey, high brightness kaolin products and methods for making the same, including combining a coarse kaolin fraction and a fine kaolin fraction, where each coarse or fine kaolin fraction may be produced by processing one or more crude kaolin samples through different stages of the methods of the present invention, by blending of one or more crude kaolin samples so processed, or as a by-product of a coarse or fine kaolin product.

Abstract: The present invention provides several methods for improving the high and low shear rheology of a substantially grit-free and substantially dispersed particulate slurry using a rotor-stator type mill. The methods are applicable to slurries including a natural mineral, suspensions including a natural mineral, and suspensions including synthetic minerals. The methods of the present invention selectively include performance of one or more of the processes of beneficiation, re-milling, dewatering and re-dispersion, and drying, performed in any one of several sequences as disclosed or suggested herein.

Abstract: High brightness kaolin pigments and methods of making high brightness kaolin pigments are provided. Both delaminated and nondelaminated clays are provided having typical brightness of 87 or higher. The pigments have high brightness and good opacity, providing an optimum pigment for paper coating and paper filler. Also provided are blended high brightness kaolins having increased opacity properties.

Abstract: Provided is a method of making improved brightness kaolin clay from an aqueous kaolin clay slurry in which the primary active dispersant is a weak dispersant, at least including the steps of adding to the kaolin clay an effective magnet enhancer reagent wherein the magnet enhancer reagent comprises an aqueous solution of one or more magnetic oxides and one or more surface active agents; conditioning the kaolin clay; and performing high gradient magnetic separation on the conditioned kaolin clay to produce an improved brightness kaolin clay. The method is also applied to decreasing iron- and/or titania-containing impurities in a clay.

Abstract: A process for producing a high brightness, high solids kaolin clay aqueous slurry. An aqueous low solids suspension of crude kaolin clay is degritted, and subjected to a particle size classification. The aqueous suspension of the fine particle fraction is acidified to a pH of 5.0 or lower to produce an acid flocculated suspension which is treated with a bleaching agent to reduce ferric ion impurities to ferrous ion impurities. A ferrous ion chelating agent is added to the bleached acid flocculated suspension after which an alkaline agent is added to raise the pH to a level greater than 5.0 to form a dispersed aqueous suspension of the beneficiated kaolin. The dispersed suspension is then subjected to membrane filtration to partially dewater same, and additional water is thermally evaporated from the partially dewatered dispersed kaolin suspension to produce the high solids product suspension.

Abstract: A method for increasing the bulk density and decreasing the time of wetting with water of a substantially anhydrous kaolin clay powder, comprising dry milling said powder in a media mill wherein the media is at least +5 mesh, and using work inputs of from about 5 to about 40 HP-hrs/ton of dry clay. The process enables improved handling characteristics for the treated clay with respect to bulk material handling systems.

Abstract: A method for increasing the bulk density and decreasing the time of wetting with water of a substantially anhydrous kaolin clay powder, comprising dry ball-milling said powder using work inputs of from about 5 to about 40 HP-hrs/ton of dry clay. The milling may be effected by grinding the clay with ceramic balls of less than 5 inches diameter. The process enables improved handling characteristics for the treated clay with respect to bulk material handling systems.

Abstract: A method for increasing the bulk density and decreasing the time of wetting with water of a substantially anhydrous kaolin clay powder, comprising dry ball-milling the said powder using work inputs of from about 5 to about 40 HP-hrs/ton of dry clay, followed by pulverization in a high energy impact mill and classification to eliminate undesirable larger particles. The ball-milling may be effected by grinding the clay with ceramic balls of less than 5 inches diameter. The process enables improved handling characteristics for the treated clay with respect to bulk material handling systems.

Abstract: Aliphatic complex phosphate esters or salts thereof, of a non-ionic surface active compound, are utilized together with aliphatic fatty acids as collector agents during flotation for removing titanium-based impurities from kaolin clays in a froth flotation process.