Abstract: An anion intercalated hydrotalcite filler material for polymer and paper systems. The filler material is formed by a method which includes reacting an activated magnesia with an aqueous solution of aluminate, anion, such as bromide, chloride, sulfate, borate and combinations thereof and hydroxyl ions. The method can be carried out at atmospheric pressure to form hydrotalcite in high purity and high yield. In a preferred embodiment of the invention, the aluminate solution is formed from sodium aluminate, sodium bromide and sodium hydroxide and the aqueous solution is substantially carbonate free. Other anion intercalated hydrotalcites can also be produced by the method of the present invention.

Abstract: A method for producing an anion intercalated hydrotalcite without first forming hydrotalcite and then having to activate the hydrotalcite prior to substituting anions in the hydrotalcite structure. The method includes reacting an activated magnesia with an aqueous solution of aluminate, anion, such as bromide, chloride, sulfate, borate and combinations thereof and hydroxyl ions. The method can be carried out at atmospheric pressure to form hydrotalcite in high purity and high yield. In a preferred embodiment of the invention, the aluminate solution is formed from sodium aluminate, sodium bromide and sodium hydroxide and the aqueous solution is substantially carbonate free. Other anion intercalated hydrotalcites can also be produced by the method of the present invention.

Abstract: A filler material for use in a polymer or paper system. The filler material is formed by heating hydrotalcite to less than approximately 600.degree. C. to remove most of the carbonate and water of hydration; submersing the hydrotalcite in a NaBr solution for 1-24 hours in a nitrogen atmosphere to form a bromide intercalated hydrotalcite; and adding the bromide intercalated hydrotalcite as a 25-65 wt % filler in a polymer system selected from the group of polypropylene, polybutylene terephtalate, nylon, and acrylonitrile-butadiene-styrene.

Abstract: A composite and a process for forming it are provided, said process comprising providing a substrate bearing crystalline and preferably single crystal filaments as growths on the substrate and forming a solid matrix encompassing the filaments. The composites are useful for aircraft, boat and auto skins and structural members.

Abstract: A process for preparing a stabilized high cristobalite from a gel comprising ultramicroscopic particles of SiO.sub.2, Na.sub.2 O, and Al.sub.2 O.sub.3 where the ratio of moles of Na.sub.2 O to Al.sub.2 O.sub.3 is from about 0.95 to about 1.1, and the molar ratio of SiO.sub.2 to Al.sub.2 O.sub.3 is between about 10 and about 40. After the gel is formed, it is heated at 800-1400.degree. C. for a time sufficient to form stabilized high cristobalite.

Abstract: A process is disclosed for purifying gibbsitic alumina-rich ore of high silica content including admixing the ore with an aqueous digestion solution high in silica concentration. In one aspect the digestion is performed with high alumina and soda concentration at low temperature, e.g., such as by atmospheric digestion.

Abstract: Disclosed is a process for producing purified alumina from high-silica bauxite including separating alumina-rich ore containing high-silica content into a coarse fraction and a fines fraction; digesting the fines fraction in a sodium aluminate solution at low temperatures; digesting the coarse fraction in a sodium aluminate solution at higher temperatures under pressure; and precipitating out alumina from the digest solutions after the combined liquors are desilicated during clarification.

Abstract: A method for making spherical binderless pellets using a rotating drum mixer whereby at least a portion of the particles comprising the pellets is comprised of coking coal particles.