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: 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: 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: 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: Paper coating pigments comprising a product obtained by the controlled mechanical delamination of kaolin particles. The pigments provide improved opacification, brightness, printing properties and gloss compared to conventional delaminated kaolin pigments. The pigment of the invention is particularly useful for coating light weight printed paper and provides a unique combination of high opacity, brightness and gloss not available when using other kaolin pigments. The novel pigment is specifically designed to replace plastic pigments and (or) titanium dioxide in coating formulations while maintaining or improving desired paper properties.

Abstract: This invention relates to paper filling pigments comprising novel mechanically delaminated kaolin particles having controlled narrow particle size distribution and shape. The pigments provide improved opacification compared to conventional and engineered kaolin particles in fine paper making.

Abstract: Novel titania-calcined kaolin composite pigments wherein structuring and adhesion of titania and calcined kaolin particles is achieved by use of a cationic polyelectrolyte. Methods for compositing titania and calcined kaolin pigments which feature the presence of at least one polyanionic dispersant (such as sodium polyacrylate, sodium silicate, sodium condensed phosphate or mixtures thereof) in the pigment slurry into which cationic polyelectrolyte is introduced and the use of strongly alkaline pH (e.g., above 9).

Abstract: A heat stabilized slurry of bulked kaolin pigment is prepared by mixing a small but effective amount of a water-soluble cationic material such as a cationic polyelectrolyte flocculant with a kaolin clay pigment in the presence of water. The resultant bulked clay product is dispersed to form a high solids clay-water slurry useful in making aqueous coating colors suitable for manufacturing lightweight coated publication papers or the pigment can be used as a filler for paper webs. Slurries having stable viscosity during storage at elevated temperature and improved resistance to the formation of sediment are prepared by using as the dispersant a combination of an anionic lignosulfonate and an anionic naphthalene sulfonate formaldehyde complex in combination with a polyacrylate salt.

Abstract: A method for preparing a heat stable aqueous slurry of a bulking pigment suitable for use in coating or filling paper which comprises preparing a fluid aqueous suspension of particles of kaolin clay, adding thereto a water-soluble cationic polyelectrolyte, the amount of said cationic polyelectrolyte being sufficient to substantially thicken and flocculate said fluid suspension, acidifying the resulting flocculate clay suspension, bleaching the clay in said suspension with a hydrosulfite salt, filtering said acidified suspension to recover bulked clay, washing the filtered clay and adding minimal amounts of a sodium polyacrylate and a nonionic surfactant to the recovered bulked clay to provide a fluid suspension of bulked clay.

Abstract: A highly bulked kaolin pigment is prepared by mixing a small but effective amount of a water-soluble cationic polyelectrolyte flocculant with a kaolin clay pigment in the presence of water to prepare a bulked clay pigment product. Upon dewatering, the resultant polyelectrolyte treated clay product can be dispersed to form high solids clay-water slurries useful in making aqueous coating colors suitable for manufacturing coating lightweight publication papers or the pigment can be used as a filler for paper webs.