Abstract: An improved process for producing a aggregated kaolin pigment having desired physical and optical characteristics when used as a coating, filler or pigment in paper. The aggregated pigment is produced by mixing an aqueous slurry of a fine particle kaolin with a previously hydrolyzed organic silicon compound, such as hydrolyzed tetraethoxysilane, and then spray drying the mixture to form a dry, chemically aggregated kaolin pigment.

Abstract: A process for producing a high solids aqueous slurry of a beneficiated kaolin. An impure crude kaolin clay is initially subjected to wet processing including a size classification step, to recover a beneficiated fine particle size kaolin fraction which is formed into a dilute aqueous slurry of deflocculated kaolin particles. The dilute slurry is filtered by flowing it generally parallel to and in contact with the surface of a microporous barrier while maintaining a pressure drop across the barrier in a direction transverse to the slurry flow. A gel permeation layer is thereby formed of kaolin overlying the surface of the microporous barrier. The gel permeation layer and underlaying surface are substantially impervious to the passage of clay solids while being pervious to the passage of water molecules, ions and dissolved salts; whereby water molecules, ions and dissolved salts are caused to pass through the barrier, thereby increasing the concentration of the solids in the kaolin slurry.

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 chemical process is described for removing ferric iron present in submarginal quantities in concentrates of kaolin, quartz, titanium minerals, ceramic minerals for glass, paper and electronics use and other materials of industrial interest by which ferric iron is reduced to ferrous iron using acid solutions, possibly in the presence of low concentrations of sugars containing 5 or more carbon atoms.

Abstract: Sodium Aluminosilicates (SAMS) are produced by silicate/clay reactions under hydrothermal conditions, the SAMS being characterized by low oil absorption values and high total pore volumes. The SAMS products are useful as coating pigments for paper, paper fillers and paint pigments.

Abstract: Paper coating pigments comprising mechanically delaminated kaolin particles. The pigments possess the opacification, smoothness and printability advantages of conventional delaminated kaolin pigments but have desirably low viscosity and gloss not characteristic of conventional delaminated kaolin pigments.

Abstract: High performance synthetic sodium aluminosilicate compositions, and the method of making the same by the hydrothermal reaction of certain delaminated kaolin clays with select sodium silicate reagents, result in enhanced performance flatting agents for paint systems and anti-block agents for plastic film applications.

Abstract: A method for forming a hydrothermally aggregated kaolin clay pigment, comprising: preparing an aqueous slurry of a particulate kaolin clay, sodium silicate, and finely divided calcium carbonate, having a total solids concentration of from about 10 to 20% by weight; the non-aqueous components including 60 to 80 parts per hundred by weight of said kaolin and from 10 to 20 pph by weight each of said sodium silicate and said calcium carbonate; and hydrothermally treating said slurry in a closed system to form aggregates of adherent kaolin platelets.

Abstract: A method of producing a high opacifying kaolin pigment by separating from one or more iron-stained titania-containing crude kaolins having a titania content of from about 1 to 2 weight percent, one or more titania-enriched kaolin fractions which contain the titania in an amount of above 2 weight percent; subjecting the fraction(s) to media grinding; dewatering and drying the media ground fraction(s); blending the fraction(s) with a fine particle size unground kaolin having a titania content less than 2%, in proportions to provide a calciner feed having at least 2% titania; and calcining the feed at a temperature in the range of 1500.degree. to 2200.degree. F.

Abstract: A method for producing a low abrasion calcined kaolin pigment which comprises forming an aqueous pulp of crude kaolin dispersing the pulp by adding thereto sufficient water-soluble organic cationic dispersant to impart a positive zeta potential to said particles and, preferably, an acidic pH to said pulp, removing coarse particles from said dispersed pulp and fractionating the dispersed pulp to separate a fine particle size fraction of mineral particles from coarser particles. The fine particle size fraction is dried, pulverized, calcined and repulverized.

Abstract: The present invention is directed to an improved purging of a liquid drain system for a liquid separator used in a moisture laden process vacuum system wherein the liquid separated from the flow stream by the separator is collected in an accumulator which in turn is periodically pressure purged to quickly remove the liquid contents of the accumulator while such accumulator is out of fluid communication with the liquid separator so that the vacuum process need not be interrupted. A pressure responsive drain valve is connected between the separator and the accumulator. The pressure used to purge the accumulator also activates the normally opened drain valve to inhibit the fluid flow between the separator and the accumulator. A pressure responsive drain is connected to the accumulator and opens in response to the increased pressure used to purge the accumulator and close the normally opened drain valve.

Abstract: A method of producing a high opacity paper filler pigment which comprises subjecting an iron-stained titania-containing kaolin to beneficiation by froth flotation or high intensity magnetic separation; recovering the froth or magnet rejects, dewatering and drying the rejects to produce a kaolin enriched in titania, and calcining the same at a temperature in the range of about 1500.degree. to about 2200.degree. F.

Abstract: A method is provided for reducing the abrasiveness of calcined clay, e.g., kaolin clay. The method comprises intermixing the clay prior to calcination with a finely-divided silica, preferably in the form of colloidal or fumed silica, in an amount sufficient to reduce the abrasiveness of the calcined product.

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 high bulking kaolin pigment is provided which exhibits improved opacifying efficiency as a paper filler. The kaolin pigment comprises an uncalcined clay composition consisting essentially of kaolin particles which have not only been treated with an amine, but also upon which aluminum hydroxide has been precipitated, and, of which less than about 20% by weight have a particle size less than 0.3 microns in equivalent spherical dimeter. Further, a method is provided for producing the pigment from a hydrated kaolin clay having a brightness of at least about 89. The selected starting clay is dispersed in water and subjected as a slurry to delamination, defining, surface treatment with an amine and aluminum sulfate, and leaching. The treated kaolin slurry is subsequently rinsed and filtered to a produce a filter cake which is redispersed to yield a commercial paper filler.

Abstract: Kaolin clay treated with 0.5 to 1.5 wt. % of aluminum chlorohydrate or a double hydroxide of aluminum and magnesium are an effective pitch adsorption agent for use in paper making processes.

Abstract: Organophilic clays useful for modifying the rheological properties of organic fluids are made from a smectite type clay, a quaternary ammonium compound and an organosilane.

Abstract: Organophilic clays useful for modifying the rheological properties of organic fluids are made from a smectite type clay, a quaternary ammonium compound and a zirconium-aluminum organic complex.

Abstract: There is disclosed a method for improving the rheological properties of a clay mineral which, when dispersed with water, either releases into solution or retains on its surface multivalent cations, which method includes the step of treating the clay mineral in aqueous suspension with an aluminosiliceous material having a cation exchange capacity of at least 50 meq/100 g, said aluminosiliceous material being employed in an amount sufficient to react with a significant proportion of the exchangeable cations in the clay mineral. Also disclosed is an aqueous suspension of a clay mineral, a method for preparing a paper coating composition and a method for improving the rheological properties of a clay mineral.

Abstract: A method of delaminating a phyllosilicate is disclosed wherein the phyllosilicate is heated in the presence of a reactive vapor phase, preferably a hydrogen-containing atmosphere. The delaminated phyllosilicate is less than 1000.ANG. thick, and is stabilized against moisture pickup. The formation of either a layer of a transition metal, or an organic reactive site, on the phyllosilicate surface is also disclosed.

Abstract: A process for production of useful materials including a product of similar composition to nepheline involves contacting a slurry of red mud with sulphur dioxide to dissolve components of the red mud that are soluble in sulphurous acid, removing residual undissolved solids by filtration, and recovering a filtrate containing soda, alumina and silica values, removing free water from the filtrate to produce a crystallized residue, and calcining the crystallized residue.

Abstract: There is disclosed a delaminated phyllosilicate particle of less than 1000 .ANG. thickness and having a coating of a transition metal on its surface, the metal being selected from the transition elements and groups 3a, 4a, 5a and 6a of the Periodic Table. Also disclosed is a method of producing such particle by an ion exchange treatment coupled with a reactive vapor phase/thermal treatment. A ceramic-metal composite composed of such metal coated particles compressed in a solid body is also disclosed.

Abstract: An organoclay is prepared by mixing a quaternary ammonium compound with an aqueous suspension of a smectite clay in proportions such that there are present from 75 to 110 milliequivalents of quaternary ammonium cation per 100 g of dry smectite clay, thereafter subjecting the smectite clay/quaternary ammonium compound/water mixture to high shear mixing for a time sufficient to dissipate in the mixture at least 100 KJ of energy per kg. of dry solids in the mixture; and then dewatering the product thus obtained.

Abstract: An organoclay which is readily dispersible in an organic liquid composition, is prepared by suspending a smectite clay in water to form a fluid suspension; treating the suspension with a solution of an inorganic salt, the cation of which preferably has a valency of at least two, the concentration of the salt being such as to flocculate the smectite clay substantially completely; mixing the suspension of the flocculated smectite clay with a quaternary ammonium compound, at least one of the four alkyl groups of which has from 10 to 24 carbon atoms; and dewatering the resultant product.

Abstract: An organo-clay is prepared by mixing a quaternary ammonium compound with an aqueous suspension of a smectite clay; thereafter subjecting the smectite clay/quaternary ammonium compound/water mixture to high shear mixing for a time sufficient to dissipate in the mixture at least 100 KJ of energy per kg. of dry solids in the mixture; and then dewatering the product thus obtained.

Abstract: An aluminosilicate ceramic product or article and a method of forming the article from as-mined ore. The product is useful as a proppant in gas and oil well fracturing. The ratio, on a calcined basis, of alumina to silica is between approximately 2.2 to 4.0. The amount of iron in the product is controlled as a function of the alumina to silica ratio so as to produce products having less than ten percent (10%) crush loss when subjected to a force of 10,000 psi.

Abstract: Novel pigments useful as primary extenders in exterior grade latex formulations are described. The pigments are composed of particles of calcined clay, substantially all the particles of which are finer than about 44 microns and having an average particle size, equivalent spherical diameter, within the range of about 3 to 10 microns, most preferably within the range of about 4 to 8 microns. The novel pigments are further characterized by having a significantly lower oil absorption value (ASTM) than conventional, calcined clay pigments. Exterior grade paint formulations containing such pigments can be formulated below the critical pigment volume concentration without substantially reducing opacity or chalking resistance.

Abstract: Raw bentonite is beneficiated by treating a substantially iron oxide-free bentonite, as an aqueous suspension, with an alkali at a temperature of at least 60.degree. C.; washing the alkali treated bentonite at least once with water; and then subjecting a suspension of the alkali-treated and washed bentonite to shearing, attrition and impact forces in a homogenizer of the type wherein the suspension is forced in the form of a film through a thin, hard-surfaced gap under a pressure of at least 1.7 MPa, and at high velocity. The suspension of bentonite thus obtained can then be dried to a product which has a good white color and is more resistent to bacteriological growth.

Abstract: An anhydrous white kaolin clay pigment is disclosed, which consists of porous aggregates of kaolin clay platelets. The pigment exhibits exceptionally high light-scattering ability when incorporated as a filler in paper. The aggregates have an average specific gravity in the range of 0.5 to 0.6, and a size distribution such that not more than 5% by weight thereof are of greater than 10 microns ESD, at least 75% are of less than 2 microns ESD, and not more than 15% are of less than 1 micron ESD. The pigment has a Valley abrasion value below 30 mg, and preferably below 20 mg, and a GE brightness of at least 93. The mean size of the internal pores in the aggregates is less than 0.55 microns and preferably is less than 0.5 microns. This low mean pore size is deemed instrumental in producing the aforementioned high scattering ability. A method for producing the said pigment is also disclosed and claimed.

Abstract: A method of upgrading crude sodium bentonite to improve its fluid loss properties, comprises subjecting the bentonite to shearing forces that are sufficient to increase the methylene blue uptake by the bentonite, and then drying and pulverizing the bentonite. The shearing forces are applied to the bentonite by extruding the bentonite while it has a moisture content between about 20 and 40 wt. %.

Abstract: A process for the continuous production, by extrusion, of a partly finished clay product comprising a pair of parallel strips joined in back-to-back relation by a plurality of longitudinally extending walls in the form of frangible bridges which, when the partly finished clay product has been cut into blanks and fired to harden it, can be broken to separate the blanks into two ceramic tiles. The process comprises the steps of feeding a base material to a first screw extruder having two screw conveyors in series separated by a degassing chamber, and feeding a second, differently colored, material to the degassing chamber, preferably through a second screw extruder. Downstream of the degassing chamber the screw conveyor imparts a rotary mixing motion to the two-colored clays to swirl these and then the mixture is pressed through a die plate of suitable shape, which also cuts the extruded strip to expose a face having a wood grain effect.