Abstract: A method for preparing nano silica and nano calcium carbonate using rice hull ash and flue gas. The method includes: 1) adding rice hull ash to a sodium hydroxide solution, to yield a first mixed solution; stirring and heating the first mixed solution; then filtering the first mixed solution to yield a first filtrate; 2) adding the first filtrate to a reaction still, and diluting the first filtrate; adding polyethylene glycol as a dispersant to the reaction solution; introducing flue gas to the reaction solution; filtering the reaction mixture to yield a first filter cake and a second filtrate; washing the first filter cake to a neural pH, slurrying and drying the first filter cake to yield nano silica; and 3) mixing the second filtrate and a washing solution collected from 2); adding a calcium hydroxide solution to the reaction still, to yield nano calcium carbonate.

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: The invention is concerned with a material which shows low absorption for UV radiation having a wavelength below 250 nm, low birefringence, high chemical resistance and high radiation resistance and which is therefore particularly usable for making optical components for microlithography. According to the invention the material consists of synthetically produced quartz crystallites which form a polycrystalline structure and have a mean grain size in the range between 500 nm and 30 ?m. The method according to the invention for making a blank from the material comprises providing granules consisting of synthetically produced quartz crystals having a mean grain size in the range between 500 nm and 30 ?m, and sintering the granules to obtain a blank of polycrystalline quartz.

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 invention concerns a conditioned composition comprising at least a liquid absorbed on a support containing a precipitated silica, said silica being in the form of substantially spherical beads and having: a mean pellet size greater than 150 ?m; a filling density in compact state(DRT) greater than 0.29; an oversize rate for a grid with mesh aperture size of 75 ?m of at least 92% by weight. The invention also concerns the use of such a silica as a support for liquid.

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: Silanised, structurally modified silicas, characterised by groups fixed on the surface, the groups being alkylsilyl (SiCnH2n+1, with n=2-18). They are produced in that pyrogenically produced silicas are treated with the silanising agent and structurally modified. They are used to improve scratch resistance in lacquers.

Abstract: Metal oxide particle agglomerates prepared by adding an aluminum phosphate agglomerating agent with mixing to an aqueous dispersion of metal oxide nanoparticles to form an aqueous homogeneous dispersion of nanoparticles and agglomerating agent and then adjusting the pH of the dispersion with mixing to about 3.5 to about 6.5 to produce the particle agglomerates and use of the particle agglomerates to prepare ink receptive coatings, as catalysts, as reinforcing fillers, as polishing abrasives and as flattening agents.

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: The inventive method for producing refractory high-strength spherical granules consists in separately presintering kaolin and bauxite in a rotational furnace, jointly sintering said components in order to produce a charging material, granulating, drying and screening said charging material, sintering said granules in the rotational furnace and screening the sintered granules. Said sintered kaoline is produced by sintering at a temperature ranging from 1400 to 1500 DEG C so far as a water absorption of 5% is attained for kaoline containing 40-45 mass % and a free quartz in a quantity equal to or greater than 60 mass %. The Al2O3:SiO2 ratio in the charging material is equal to 1:1 at the following charging material component ratio: 36-67 mass % sintered kaolin and the rest being sintered bauxite.

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: An aggregate turf filler for use with the turf of athletic fields and landscaped areas which comprise crushed silica sand particles (SiO2) which are substantially round in shape and are sized to be between 12 and 40 mesh. An acrylic based sealer covering the outer surface of each of the silica sand particles. Finally, providing that the silica sand particles have a smooth outer surface, possess an angle of repose of less than 30°, repel water, resist compacting, present no damaging sharp edges when incorporated with the turf and are environmentally safe.

Abstract: A composite pigment is provided with the composite pigment including a dense inorganic material and silica. The pigment composition is characterized by a CTAB surface area of greater than about 20 m2/g; a BET surface area of greater than about 15 m2/g; and a density of greater than about 2.5 g/cm3.

Abstract: Amorphous inorganic particles as a dental material includes silica and inorganic oxide(s) other than silica and has high x-ray impermeability. The inorganic particles as a dental material includes silica with the content in the range from 70 to 98 weight % and oxide(s) of one or more elements selected from the group of Zr, Ti, La, Ba, Sr, Hf, Y, Zn, AL, and B, wherein 5 to 70 weight % of the silica is originated from an acidic silicic acid solution and 30 to 95 weight % of the silica is originated from a sol of silica. The inorganic particles as a dental material have an average particle diameter in the range from 1 to 10 ?m, specific surface area in the range from 50 to 350 m2/g, pore volume in the range from 0.05 to 0.5 ml/g, amorphous crystallinity as observed by x-ray diffraction, and the refractive index in the range from 1.47 to 1.60.

Abstract: Calcined kaolin clay having a high bulk density, improved wet out and slurry incorporation times is produced by using pressure to compact the clay. Other properties of the compacted clay are improved or equivalent to the non-compacted starting calcined clay material.

Abstract: Calcined kaolin clay having a high bulk density, improved wet out and slurry incorporation times is produced by using pressure to compact the clay. Other properties of the compacted clay are improved or equivalent to the non-compacted starting calcined clay material.

Abstract: A manufactured granular substrate composition suitable for use as a carrier for active chemical agents. The composition includes one or more mineral components having a bulk density greater than about 70 pounds per cubic foot. The composition also contains about one or more light weight additives and one or more water soluble binders. The resulting manufactured granular substrate has a bulk density of less than about 55 pounds per cubic foot with a size guide number of about 75 to about 300.

Abstract: Aggregated mineral pigments (such as kaolin clay pigments) having a high surface area and useful in coating and filling compositions for ink jet printing media are manufactured by dry grinding an unground mineral composition starting material and then optionally acid treating the ground material.

Abstract: A pigment product suitable for use in a coating composition to provide a gloss coating on paper, the pigment product comprising a processed particulate kaolin produced from a naturally platy kaolin clay having a particle size distribution such that about 50% to 60% by weight of the particles have an esd less than 2 &mgr;m and less than 25% by weight of the particles have an esd less than 0.25 &mgr;m and a shape factor of at least 15. This platy clay can be blended with b-fraction clay component. In processing, the crude kaolin is ground to a shape factor greater than 50 to produce even greater “platy” clay. The pigment product has a particle size distribution such that at least 80% by weight of the particles have an esd less than 2 &mgr;m and greater than 12% and less than 35% by weight of the particles have an esd less than 0.25 &mgr;m and whose surface area is greater than 12 m2/g when measured by the BET method.

Abstract: Aggregated mineral pigments (such as kaolin clay pigments) having a high surface area and useful in coating and filling compositions for ink jet printing media are manufactured by dry grinding an unground mineral composition starting material and then optionally acid treating the ground material.

Abstract: Systems and methods of making and using fine particle materials in pigment blends and for using the aforementioned pigment blends in paint, coating, or coloring compositions are provided. This invention further provides systems and methods of enhancing the visual appearance of a variety of substrates by introducing a paint, coating, or coloring composition to the substrate. The fine particle materials of the present invention have a substantially random geometric shape, a particle size less than about 100 microns, and help provide both functional and visual enhancing properties to compositions and substrates containing these fine particle materials.

Abstract: Colored pigments having one or more desired parameters and/or properties are described. These parameters and/or properties include: a) a particles size of from about 10 nm to about 300 nm; b) an accusizer number of less than 1010 particles/ml of dispersion at 15% solids which are greater than 0.5 micron; c) a filterability such that when in a liquid medium, 100 ml having 10% solids of the colored pigment filters through a 3 micron nylon absolute filter; d) a colored pigment purity of greater than about 80%, based on extractable material; and/or e) a stability such that the above-described properties do not change by more than 50% at 25 degrees C. for at least one week. Colored pigments having at least one organic group and having one or more of the above-described characteristics is also described as well as a process for preparing surface-modified colored pigments.

Abstract: Aggregated mineral pigments (such as kaolin clay pigments) having a high surface area and useful in coating compositions for ink jet printing media are manufactured by dry grinding an unground mineral composition starting material and then optionally acid treating the ground material.

Abstract: The present invention relates to an integrated additive composition which contains anti-blocking agents and at least one organic component and is characterized in that the organic component(s) is (are) localized in a concentration of 5 to 65 wt.-%, relative to the total weight of the composition, in the pores of the anti-blocking agent, the volume of the organic component(s) not being greater, however, than the pore volume of the anti-blocking agent. The invention also describes processes for the preparation of this integrated additive composition and its use in polyolefin films and in injection molding.

Abstract: A filler material comprising a fibrous material and one or more forms of surface-modifying particles for use in dental composites and dental restorations. The surface-modifying particles are bonded to the fibrous material to increase the surface area of the fibrous material and improve the bonding properties of the fibrous material to enable it to better bond to a resin matrix material in a dental composite. In accordance with the present invention, the fibrous material possesses a lower melting temperature than the surface-modifying particles. The surface-modifying particles and the fibrous material are heated to a temperature below the softening temperature of the fibrous material but at a temperature and time sufficient to soften the surface of the fibrous material in order to bond the surface-modifying particles thereto.

Abstract: Flux calcined kaolin clay especially useful as a pigment for low sheen paints is obtained by mixing hydrous kaolin with an aqueous solution of alkaline flux, spray drying, pulverizing, calcining and repulverizing.

Abstract: The invention relates to an aggregated silica gel which has been produced from silica gel particles having a particle size of 1 to 20.mu., a surface of 200 to 1000 m.sup.2 /g and a specific pore volume of 0.4 to 2.5 ml/g and a binding agent selected from synthetic or natural phyllosilicate, pyrogenic silicon dioxide and organic polymers soluble in water or dispersible in water. Aggregation takes place by spray-drying a suspension having 1 to 25% solids. The product is suitable as a matting agent for coatings, as an antiblocking agent for polymer films and as a beer clarifying agent.

Abstract: The present invention provides compositions, and method for making same, comprising large particle size, calcined kaolin clays that, when used in paint formulations, provide paints having low sheen and good weathering resistance. Compositions of the invention include a composition comprising the pigment produced by a process comprising calcining a feed comprising kaolin having a median equivalent spherical diameter (e.s.d.) as measured on a Sedigraph 5100 of greater than about 2.0 microns and having .ltoreq. about 15% less than 0.5 micron.

Abstract: A process for preparing a molding sand for a green sand mold is provided. The process comprises the step of drying under a reduced pressure of 0 to 0.3 atm for 0.5 to 30 seconds a green molding sand obtained by kneading silica sand, clay, and water, to dry the clay superficial part and to retain in a moist state the clay deeper part on the silica sand core part in each particle of the molding sand. The molding sand prepared by this process has enhanced flowability. Furthermore, the sand mold prepared from the molding sand has sufficient strength.

Abstract: Granules based on silicon dioxide and having the properties:Average particle size: 10 to 120 .mu.mBET surface area: 40 to 400 m.sup.2 /gPore volume: 0.5 to 2.5 ml/gPore size distribution: less than 5% of the total pore volume exists of pores with a diameter<5 nm, remainder are meso- and macroporespH value: 3.6 to 8.5Tapped density: 220 to 700 g/lThey are prepared by dispersing silicon dioxide in water, spray drying, and optionally heating and/or silanizing. The granules can be used as catalyst supports.

Abstract: A finely divided inorganic filler material is a sintered composite which consists of larger macro-filler particles of glass and of smaller micro-filler particles of glass or ceramics partially covering the macro-filler particle and firmly connected to it by sintering. Plastic materials reinforced with the filler are distinguished by improved abrasion resistance.

Abstract: A structured composite pigment composed of TiO.sub.2, calcined clay and polyaluminum chloride (PAC). A novel process is disclosed for producing an aggregated composite premium pigment having superior optical, physical and dispersion characteristics for papermaking applications. The aggregated pigment is produced by chemically aggregating a mixture containing TiO.sub.2 and calcined clay with polyaluminum chloride of a basicity of 10-85% in alkaline conditions of pH 8.5-10.5.

Abstract: A fluidized bed reactor is supplied with fuel, oxygen-containing gas, and kaolinite, which contains water of crystallization. At least 80% by weight of the kaolinite have particle sizes in the range from 0.1 to 3 mm. A fluidized bed at temperatures in the range from 850.degree. to 950.degree. C. is formed in the fluidized bed reactor. A meta-kaolin white pigment which contains water of crystallization not in excess of 2% by weight is withdrawn from the fluidized bed reactor.

Abstract: An opacifying kaolin pigment with improved porosity, light scattering ability (opacity), gloss, and ink receptivity over that of the starting pigment is manufactured by a process which comprises the steps of treating an aqueous solution of kaolin with a phosphate compound, using the endogenous aluminum leached from kaolin and/or adding a soluble aluminum compound and increasing the pH of the mixture.

Abstract: A process for conditioning diaryldiketopyrrolo[3,4-c]pyrrole pigments (DPP) and for preparing solid solutions having a DPP component are disclosed. The inventive processes involve dissolving the DPP in aqueous, basic DMSO, alone, or in mixture with additional components in the case of a solid solution, and then precipitating the conditioned pigment or pigment solid solution by methods known in the art.

Abstract: Pigments for use in paper are comprised of structured aggregate clays which are reaction products of kaolin clays and colloidal silicas. Silica modified clays of low treatment level can under certain high-shear mixing conditions be attritioned back to their starting clay particle size consequently yielding silica coated clay particles that provide unique properties. Also provided are structured aggregate clay products produced by the reaction of kaolin clay, colloidal silicas and spacer particles such as titanium dioxide, which products have improved porosity and light scattering characteristics. Also provided are clay slurry products which comprise mixtures of the reaction product of kaolin clay and colloidal silica, and optionally titanium dioxide, blended with other clay products.

Abstract: Inorganic oxide pigments (ceramics) are prepared by mixing the starting materials in the presence of water and in the presence or absence of assistants, drying and subsequent calcining in a rotary furnace by processing the starting materials in the presence of water into a pumpable suspension having particle sizes of 50%<10 .mu.m and 100%<50 .mu.m, dewatering the suspension by spray drying it to leave porous granules, and calcining those granules>97% from 20 to 800 .mu.m in size.

Abstract: A detergent additive for commercial detergents (softener agents) that contain fabric softeners is described. This additive is based on agglomerates of a smectic laminar silicate coated with divided particles. This detergent additive is characterized in that the agglomerates are at least partially coated with particles of a cation exchanger that will pass through a screen with a mesh of about 45 .mu.m and have an average particle size of less than about 10 .mu.m, where the amount of cation exchanger particles is about 2 to 30 wt % (based on the dry weight of the uncoated agglomerates). This detergent additive may be used in the conventional detergent formulations.

Abstract: A process for producing micropellets of lightweight aggregate having a substantially spheroidal configuration which includes continuously mixing ceramic clay and liquid in a high speed rotating pin mixer to encapsulate substantially all other non-volatile inorganic solid materials present in micropellets having a diameter not exceeding about six mesh. The spheroidal micropellets are then fired at a temperature of at least 2,000.degree. F. to oxidize all volatile organic compounds present. The light-weight aggregate of micropellets can advantageously-be used to replace sand in a cement or concrete matrix, as a well as for numerous other uses.

Abstract: Calcined kaolin clay is pelletized in a pelletizer by a process wherein the calcined clay has ammonia added to it, suitably in relatively small amounts such as less than 1% by weight. The pelletized clay is preferably coated with a binder to improve its flowability.

Abstract: Solid form additive systems which are dispersible in aqueous media are disclosed, as are methods for preparing such additive systems. The additive systems are dry, free-flowing particulate materials that contain at least one additive component, at least one tackifying agent, and at least one surfactant.

Abstract: Colorant clusters comprising an aggregation of a plurality of grains of sol-derived material and colorant. The clusters are particularly useful as pigments in liquid compositions, e.g., paints and inks, for forming coatings that are retroreflective immediately upon drying. Also, a process for preparing such colorant clusters comprising admixing colorant in a binder sol to yield a pigment sol and then removing liquid medium from the pigment sol to yield the clusters. Also, a coating composition comprising retroreflective elements, a vehicle, and the aforementioned colorant clusters. After application of the composition to a substrate, the resultant coating is immediately retroreflective upon drying.

Abstract: Method for the recovery of solvent from a solvent-based wash liquid containing non-hazardous waste resulting from an equipment cleaning operation. The wash solution typically averaging approximately 90 percent solvent and 10 percent resin, pigments and other dissolved or suspended solids is continuously tumbled in a tumbler/evaporator vessel together with a highly porous, adsorbent extender in granulated form, while maintaining temperatures sufficient to evaporate the solvent and prevent the solid matter from sticking together after processing. The extender is a substantially inert, material and may be selected from diatomaceous earth, powdered calcium silicate, powdered glass (100 mesh), oak sawdust (100 mesh), cedar sawdust (100 mesh), bentonite, charcoal (100 mesh) and ground corn cobs. The amount of extender introduced into the vessel is of the order of 5 to 20 percent by weight of the wash solution. The system may employ jacketed ribbon, double cone or rotating helix blenders.

Abstract: The rheology of an aqueous slurry of a calcined kaolin clay powder is significantly improved by spray drying a slurry of the calcined kaolin clay powder, recovering the spray-dried material, and forming an aqueous slurry from said spray-dried material.

Abstract: A low-abrasion calcined kaolin opacifying pigment composed of particles in the size range of about 70 to 84% by weight finer than 2 microns and having a color defined by Hunter Trisitimulus values of "L" within the range of 92 to 94, "a" within the range of .sup.+ 1.0 to .sup.+ 2.2 and "b" within the range of .sup.+6.4 to .sup.+ 7.5. The pigment is produced by novel wet processing including high solids degritting of a high iron, high titania content Tertiary kaolin without conventional fractionation, bleaching and dewatering to isolate a fine particle size fraction, followed by spray drying, pulverization, calcination and repulverization.

Abstract: A method for forming a hydrothermally aggregated kaolin clay pigment, comprising preparing an aqueous slurry of particulate kaolin clay and sodium aluminate, having a total solids concentration of from about 2 to 25% by weight, the weight ratio between kaolin and aluminate being greater than 1; and hydrothermally treating the slurry in a closed system to form aggregates of adherent kaolin platelets.

Abstract: A structured kaolinitic pigment having improved physical and optical characteristics when incorporated as a filler in paper. The pigment is also useful in paper coating applications. The pigment consists of porous aggregates of kaolin particles which are chemically bonded together. The pigment may be produced by chemically reacting a particulate kaolin with a metal chloride, such as silicon tetrachloride. The process is conducted under conditions such that the kaolinite structure is not impaired.

Abstract: The present invention offers a mould additive for continuous casting of steel characterized by having a fully spherical shape in which average particle size is in the range of 100 to 800 .mu.m.