Abstract: A method for producing a clinker substitute for use in cement production includes predrying clay with an iron content >1.5 wt-% in a form of iron oxides and a kaolinite content <40 wt-% to a moisture <10 wt-%. The clay is comminuted to a grain size <2 mm. The clay is calcined by thermal treatment in a furnace at a temperature of 600 to 1000° C. The clay is thermally treated under reducing conditions at a temperature of 600 to 1000° C. so as to form a reduction product. The reduction product is intermediately cooled to a temperature <300° C. and finally cooled.

Abstract: A process for heat treatment of fine-grained mineral solids includes passing fine-grained mineral solids through a flash reactor so as to contact the fine-grained mineral solids with hot gases in the flash reactor at a temperature of 450 to 1500° C. so as to obtain hot solids. The hot solids arc passed through a residence time reactor at a temperature of 500 to 890° C. The hot solids are withdrawn from the residence time reactor after a residence time of 1 to 600 minutes. A waste gas of the residence time reactor is recirculated to at least one of the flash reactor and a preheating stage.

Abstract: A binder mix containing a hydraulic binding agent and an admixture mixed therewith, a process for preparing a hydraulically hardened binder mass, a calcinated kaolin product and a process for preparing the same. A paste-like composition is formed from the hydraulically hardening binding agent, a pozzolanically reacting admixture and water, which, when so desired, contains stone aggregate or similar filler, the paste-like composition is worked and the worked composition is allowed to harden to form the binder mass. The admixture comprises spherical, porous metakaolin agglomerates, the size of which is 2-200 microns and which have an open pore structure. The invention can be used to improve the manufacturing methods of cast concrete products and shorten the manufacturing times, and to provide concrete with better mechanical and chemical properties, as well as improve the fire and frost resistance of concrete.

Abstract: To provide a catalyst for production of a polyester, a process for producing a polyester using the catalyst and a titanium-containing polyethylene terephthalate having excellent characteristics. A catalyst for production of a polyester, characterized by comprising at least (1) a Group 4A compound (hereinafter referred to as compound (1)), (2) a compound of at least one element selected from the group consisting of magnesium, calcium and zinc (hereinafter referred to as compound (2)) and an oxygen-containing organic solvent. A process for producing a polyester using this catalyst. A titanium-containing polyethylene terephthalate, having characteristics represented by the following (A), (B) and (C): (A) titanium K absorption edge: the peak intensity ratio R defined by R=A/B exceeds 0.

Abstract: A brick additive and methods for using the brick additive are disclosed. The additive may include an internal porosity. The internal porosity may display an intra-granular internal porosity in which at least some of the pores are interconnected via an open network of pore spaces. In some embodiments, the additive is capable of maintaining its internal porosity after undergoing thermal modification via calcination, for example. In addition, brick additives of the present invention may display a large surface area.

Abstract: The present invention involves the use of fired clay, in particular flint clay, as a filler particulate and substitute for standard polymeric particulate commonly used in solid surface products. As well, it is also a substitute for ground stone as used in engineered stone products.

Abstract: A process of making ceramic spheroids by firing clay spheroids comprising by weight percent: FeO (3.22-5.21), Fe3O4 (3.40-5.11), SiO2 (52.49-59.42), CaO (1.99-7.96), MgO (2.81-4.69), Al2O3 (12.05-17.65), TlO2 (0.58-0.71), MnO (0.07-0.19), Na2O (0.47-0.86), K2O (1.70-2.37), P2O3 (0.13-0.19), S (0.03-0.29), CO2 (0.90-8.23), Organic C (0.22-1.04), H2O+ (4.14-7.28), H2O− (2.12-5.48) in contact with a particulate parting agent selected from aluminum oxide, magnesium oxide, and their precursors at a sufficiently high temperature and for a sufficiently long time to form a shell. Preferably, the clay spheroids are obtained from a deposit located at Hallock in Kittson County Minn., U.S.A.

Abstract: Porous calcined clay sports field conditioners exhibit excellent playability while also displaying excellent drainage, freedom from compaction, and moisture retention under hot, dry conditions. The conditioners are non-hydrating granulates of narrow particle size distribution and are preferably of a red to brown coloration.

Abstract: A method of heat treating kaolin particles which includes the steps of establishing in a furnace a heating zone suitable to calcine the particles and passing the particles rapidly through the heating zone whereby the particles are flash calcined in the heating zone, wherein the furnace is of the kind in which a toroidal fluid flow heating zone is established and the particles are heated in the said heating zone to a temperature of at least 800° C. but not greater than 1100° C. by application to the particles of a temperature increase rate greater than 103 Celsius degrees per second to give a rapid blistering of the particles caused by rapid dehydroxylation of the kaolin and wherein the particles have a residence time of less than 1 second in the said toroidal fluid flow heating zones.

Abstract: The activated kaolin powder compound is prepared from naturally-existing kaolin (hereinafter “natural kaolin”). The activated kaolin powder compound is prepared by heating natural kaolin to 480° C. within at most one hour, calcinating the heated natural kaolin at high temperature by heating in the range of 800˜950° C. over at least 15 minutes, quenching the calcinated kaolin with water or air, and pulverizing the quenched activated kaolin to give powder having particle sizes of 2 &mgr;m or less, wherein the natural kaolin is primarily composed of halloysite (Al2O3.2SiO2.4H2O). The activated kaolin powder compound is employed in an amount of about 5 to 15% by weight of cement for preparing mortar or cement. The cement composition containing the activated kaolin powder compound can provide a mortar or concrete having excellent properties in compressive strength, flexural strength and water permeability.

Abstract: Composition whereby ceramic manufactured articles, obtained by moulding a conventional ceramic mixture without added TiO2., are colored from yellow to orange, said composition consisting of an aqueous solution of inorganic compounds or organic complexes of titanium and chromium combined with antimony or tungsten or mixtures thereof, in quantities corresponding to 2 to 6% by wt. Ti, 3 to 12% Sb (or 4 to 14% tungsten) and 0.2 to 2.5% chromium.

Abstract: An improved process for transforming clays that cannot be utilized in commercial pigment production to low-viscosity pigment for commercial application is described whereby a treated clay is produced having a reduced viscosity as compared to the initial clay when compared at equivalent solids content. The process comprises the steps of: drying the clay; mixing the dried clay with an aqueous solution of an alkali metal salt wherein the alkali metal salt is selected from the group consisting of lithium, potassium, rubidium and cesium salts; extruding the material obtained from alkali metal salt treatment; heat-treating the extruded material and high-shear blunging of the heat-treated material. Typically, a high viscosity clay that has been treated with this five-step procedure will exhibit a viscosity that is about 10% to about 20% of the viscosity of the starting clay.

Abstract: A method of producing a porous inorganic particulate material which comprises treating a particulate aluminosilicate material with a leaching agent which chemically reacts with or solubilizes aluminum and thereby leaches aluminum from the aluminosilicate material, wherein the particulate aluminosilicate material is a particulate hydrous aluminosilicate material which has been flash calcined.

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: Materials, such as kaolin clays, which are discolored by the presence of goethite mineral impurities are first heated to convert the goethite to hematite and then treated to remove the hematite, whereby the color and brightness of the product are improved over the starting material.

Abstract: A method of making a hydraulic material which contains metakaolinite and calcium hydroxide from a kaolin-containing compound. The method is performed in a fluidized bed installation having a freeboard under conditions such that the amount of calcium oxide formed is minimized. Preferably, the method is performed at a fluidized bed temperature of 780.degree. C. and a freeboard temperature of no more than 780.degree. C. By minimizing the amount of calcium hydroxide formed, the use of an additional installation for converting calcium oxide to calcium hydroxide is avoided. The starting material is typically waste paper and other residues from recycling of waste paper for reuse in the paper industry. The product may be used to form concrete having a high compression strength.

Abstract: Substantially crystalline kaolin clays having varying morphological properties are produced by the hydrothermal treatment, in an acidic environment, of substantially amorphous calcined kaolin clay.

Abstract: The present invention relates to a mineral eluting material for drinking water with granite as raw material and manufacturing method thereof and a structural body of mineral eluting material. The mineral eluting material includes granite crushed to sizes of 0.075.about.0.145 mm, submerged in 3.about.10% glucose solution for 24 hours, baked at 380.degree..about.400.degree. C. for 12.about.24 hours, and cooled at room temperature in a tightly sealed vessel. The structural body according to the present invention is manufactured by piling up granular granite and silver activated charcoal in 2-10 layers respectively and alternately in a cylindrical column. Water having passed the structural body according to the present invention comprising granular granite contains no impurities and abounds in minerals.

Abstract: A whiteware ceramic composition is provided comprising a filler, 4 to 10% by weight of a flux having a median particle size of below 6 microns, a prefired ceramic material milled separately from the other components, and raw clay constituting from 5 to 20% by weight of the composition. Fired whiteware made by firing the composition of the invention is also disclosed.

Abstract: An improvement is disclosed applicable to the method for producing a calcined kaolin by the steps of wet beneficiating a crude kaolin to form a slurry of the beneficiated kaolin; dewatering the slurry to form a substantially dry calciner feed; and calcining the feed at a temperature of at least 1450.degree. F. by passing a stream of hot gases through a calciner in which the kaolin feed is resident, whereby an exhaust stream of hot gases is generated which entrains quantities of partially calcined and hydrous kaolin pigment fines. The improvement, enabling useful application of the kaolin pigment fines, comprises recovering the kaolin pigment fines from the exhaust stream for use in papermaking. The fines can be recovered at a wet scrubber, and after being partially dewatered, shipped directly as a product slurry to the paper maker.

Abstract: An object of the present invention is to shorten the working time for high pressure slip casting. There is provided a composition for high pressure casting slip including a first starting powder forming a frame of a mold body and second starting powder forming the frame of the mold body and acting as a plastic agent, wherein the first and second starting powders are uniformly mixed in a dry condition. "Slip" of a minimum water content is easily prepared by the composition to effect optimal fluidity of the slip so that the water is removed from the slip in a short time during a casting process.

Abstract: A method for brightening kaolin contaminated with organic matter by decarboxylation treatment of an aqueous kaolin slurry. The decarboxylation is carried out by contacting the clay slurry with selected oxidizing agent in a pressurized reaction vessel at a temperature of 175.degree.-500.degree. C. without dehydroxylation (calcination) of the kaolin. Oxidizing agents include oxygen, ozone, hydrogen peroxide, and hypochlorite.

Abstract: There is disclosed a process for preparing a filler composition suitable for incorporation in a polyester film-forming material, which process comprises the following steps:(a) calcining a crude kaolin clay under conditions such that the calcined product comprises particles consisting of aggregates of fine kaolin platelets;(b) suspending the calcined clay product from step (a) in water containing a dispersing agent for the calcined clay, so as to form a suspension containing from 40% to 70% by weight of dry calcined clay;(c) subjecting the suspension formed in step (b) to comminution by attrition grinding with a particulate grinding medium for a time sufficient to reduce the average diameter of the aggregate particles to within the range from 0.3 .mu.m to 0.9 .mu.m, and to ensure that the calcined clay is substantially free of particles having an equivalent spherical diameter larger than 5 .mu.

Abstract: A method for producing calcined kaolin pigments of high opacifying properties and low abrasion. A kaolin crude is selected having a G.E. brightness in the range of 70 to 80, a titania content of 2.0 to 3.0% by weight, less than 2% iron expressed as Fe.sub.2 O.sub.3, and a particle size distribution such that at least 88% by weight of the particles of said crude are of less than 2 .mu.m E.S.D.. The crude is blunged with water, and the resultant slurry degritted to form an aqueous slurry having at least 65% by weight solids. The slurry is centrifuged and a fraction recovered having over 65% solids, and in which at least 92% by weight of the particles are of less than 2 .mu.m. The recovered fraction is dried to less than 1% moisture, and pulverized to break up agglomerates. The pulverized fraction is then calcined by heating same to 1450.degree. to 1600.degree. F. after which the calcined kaolin is milled to yield a product having a G.E. brightness of 79 to 81 and an Einleiner abrasion of not mere than 2.

Abstract: A method for preparing a calcined kaolin clay powder having good high shear rheology in high solids aqueous slurries. A kaolin clay powder of fine particle size is calcined at a sufficient temperature and for a sufficient period to destroy the crystallinity thereof; and the calcined product is dry milled in a media mill, using a work input of from 100 to 160 hp-hr/ton of dry clay.

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: An improvement is disclosed applicable to systems where a mineral ore, such as a crude kaolin is introduced into a high shear, high energy mixing device with a suspending fluid and dispersing agents added to the same mixing device at controlled rates to produce a suspension with a solid content not more than 72% by weight. The process is applicable to systems where inorganic materials are suspended in a slurry, using water as the suspending fluid, in the presence of a dispersing agent, as for example in the processing of kaolin clay where the crude clay is formed into an aqueous suspension for the purpose of removing impurities and further processing. Heat is applied to the fluids in or before entering the mixing zone of the mixer, in sufficient quantity to raise the temperature of the suspension by at least 10.degree. C. This lowers the flow resistance of fluids in the mixing zone.

Abstract: Thioxotropic Fuller's earth clay minerals which are structurally double silica chains linked together through oxygen to form double-ribbed sheets held by aluminum and/or magnesium in octahedral coordination in an amphibole chain are vacuum dried and admixed with a stabilizing fluid, e.g., silicone fluid, to result in new, low moisture content thixotropic agents. The mineral products thus produced are superior thixotropes when compounded in plastics such as plastisols, adhesive sealants, coatings and other organic binder systems which are heat set or heat cured or moisture cured, and compliance coatings.The methods involve reducing the moisture content of Fuller's earth clay, e.g., attapulgite, by (1) heating it under vacuum at an elevated temperature, preferably between 100.degree. C. and 300.degree. C., or (2) heating it at an elevated temperature, preferably between 100.degree. C. and 350.degree. C.

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: In a method of preparing a treated clay product, clay is heated such that kalinite in the clay is converted to metakaolin, substantially no mullite being formed. The treated product may be combined with raw ball clay and/or china clay to provide compositions suitable for use in manufacturing china articles. The casting compositions enable the casting step to be accelerated and are particularly suitable for use in pressurized casting methods.

Abstract: The bulk handling characteristics of a calcined kaolin clay powder, including the bulk density and flowability, are significantly improved by forming an aqueous slurry of the calcined kaolin clay powder and spray drying the slurry.

Abstract: An admixture for cement compositions is prepared by calcining at 630.degree. to 870.degree. C. at least one substance selected from the group consisting of natural kaolin, halloysite and synthetic kaolin, effecting classification so that amorphous portions of alumina/silica having a mixing ratio of 0.5 to 1.3 form main components, with all particles having diameters up to 8 .mu.m and an average diameter of 0.5 to 2 .mu.m, and a specific gravity ranging from 2.45 to 2.55. This admixture is used to produce a cement composition such as mortar or concrete, which realizes excellent fluidity to promote workability, and a high strength structure.

Abstract: A method of treating a water-swellable clay after the clay has been mined and dried. After the common initial drying of the clay to a moisture content of 12% or less, the clay is re-wetted to a moisture content of more than 12% by weight, preferably at least about 15% or more, based on the dry weight of the clay, then redried to a moisture content of 12% by weight or less, based on the dry weight of the clay.

Abstract: Conventional presintering and reaction presintering processes for the production of ceramic powders yield products exhibiting an undesired primary particle size distribution along with localized distribution of impurities, which give rise to the formulation of undesired duplex structures during final sintering.In order to avoid formation of undesired duplex structures within sintered ceramic parts a process and a device for producing ceramic powders based on single- or multi-phase metal oxides (including SiO.sub.2 - compounds), exhibiting a narrow particle size distribution, i.e. with a maximum deviation of the primary crystal size (REM) of +/- 0.75 .mu.m, preferentially less than +/- 0.25 .mu.m, within an average particle size of 0.05 up to 10.0 .mu.m, is conceived. The raw feed material exhibits a specific surface area of 0.05 up to 500 m.sup.2 /g (BET), preferentially 5.0 up to 50 m.sup.

Abstract: A method for producing an attapulgite clay which retains its thixotropic properties, but does not release gases upon being compounded and cured in organic binder systems, such as plastisol, and the resultant low moisture thixotrope. The method involves (1) reducing the moisture content of the attapulgite by heating it under vacuum at an elevated temperature, preferably between 100.degree. C. and 300.degree. C., or (2) reducing the moisture content of the attapulgite by heating it at an elevated temperature, preferably between 100.degree. C. and 350.degree. C., and adding a silicone fluid, to preserve its thixotropic properties.

Abstract: A novel ceramic material affording a ceramic molded bodies having a high toughness and a high tensile strength is disclosed which comprises a smectite clay mineral having at least a portion of ion-exchangeable cations thereof ion-exchanged with bismuth ions. The ceramic material is prepared by treating a smectite clay mineral with an aqueous solution containing bismuth ions to ion-exchange at least a portion of ion-exchangeable cations thereof with bismuth ions.

Abstract: A method for producing an attapulgite clay which retains its thixotropic properties, but does not release gases upon being compounded and cured in organic binder systems, such as plastisol. The method involves reducing the moisture content of the attapulgite by heating it under vacuum at an elevated temperature, preferably between 100.degree. C. and 300.degree. C., to preserve its thixotropic properties.

Abstract: An improvement is disclosed applicable to the production of calcined and hydrous kaolins in particulate form. A process and system are disclosed in which the calciner is integrated with a filtration process and a preceding spray dryer by passing the dust-laden calciner hot off-gases to the spray dryer to achieve savings in energy. Waste heat from the calciner, and concomitantly dustlike clay particles carried in the off-gas, are thereby passed to the dryer and subsequently treated and their values recovered.

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: 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: The invention relates to a structured kaolinitic pigment having improved physical and optical characteristics when incorporated as a filler or coating pigment in paper. 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, and with urea or an organic amine. The process is conducted under conditions such that the kaolinite structure is not altered.

Abstract: A coated paper of improved optical and printing qualities, coated with a structured kaolinitic pigment. 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 for preparing the structured pigment is conducted under conditions such that the kaolinite structure is not impaired.

Abstract: A process is described in which a structured aggregated kaolin pigment is prepared by mixing substantially dry kaolin in particulate form with an aqueous alkali metal silicate to deposit on the surface of the kaolin particles a substantially molecular level of said silicate without formation of silica gel, drying the treated kaolin without calcination and exposing it to an acidic gas. The product is useful as a pigment in the coating or filling of paper.

Abstract: The invention relates to an aggregated kaolinitic pigment having improved physical and optical characteristics when incorporated as a filler or coating pigment in paper. The pigment may be produced by treating a particulate kaolin with an alkaline earth metal carbonate or hydroxide or alkali metal carbonate, and urea or an organic amine. The pigment consists of porous aggregates of kaolin particles.

Abstract: There is disclosed a natural phyllosilicate and, in solid solution therewith, at least one additional silicate or spinel phase such as beta-quartz, beta-spodumene, biotite, donathite, magnetite and Ca.sub.2 MgFe.sub.2 O.sub.6. There is also disclosed a method of producing such solid solution by introducing a phyllosilicate into a salt bath to effect an ion exchange between the salt of the bath and the phyllosilicate and subjecting the ion-exchanged phyllosilicate to a thermal treatment to develop a new phase which forms a solid solution.

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 improvement is disclosed applicable to the production of calcined, anhydrous kaolins in particulate form. A process and system are disclosed in which the calciner is integrated with a preceding spray drier by cycling the dust-laden calciner hot off-gases to the spray drier to achieve savings in energy. Waste heat from the calciner, and concomitantly dust-like clay particles carried in the off-gas, are thereby passed to the drier and their values recovered.

Abstract: A beneficiated kaolin clay slurry is concentrated from a solids content of about 50% to 60% by weight to a solids content of at least 65% by weight by evaporating water therefrom by passing the aqueous clay slurry through one or more non-contact evaporated heat exchangers. The kaolin clay slurry is passed in indirect heat exchange relationship with a heating vapor, with the heating vapor comprising water vapor previously evaporated from the aqueous clay slurry.

Abstract: A filled elastomer composition comprises a natural or synthetic rubber and, as a filler, a substantially dehydroxylated clay which contains at least 60% by weight of particles smaller than 2 microns equivalent spherical diameter, has a specific gravity not greater than 2.4 and a spherical surface area of at least 10 m.sup.2 g.sup.-1 and which has been treated with a substituted silane. The substantially dehydroxylated clay can be obtained by "shock" calcining a kaolinitic clay.

Abstract: A method is disclosed for separating titaniferous and ferruginous discolorants from a crude kaolin clay. A dispersed aqueous slurry of the clay is formed containing a deflocculant and a fatty acid collecting agent, and the slurry is conditioned to coat the discolorants with the collecting agent to thereby render the discolorants hydrophobic. A system of sub-micron sized magnetic ferrite seeding particles, the surfaces of which have been rendered hydrophobic, is thereupon added to the slurry. The seeded slurry is mixed to coalesce the hydrophobic-surfaced discolorants with the hydrophobic-surfaced seeding particles, and the slurry is then subjected to a froth flotation, which removes substantial quantities of the discolorants and seeding partices coalesced therewith, and also removes excess seeding particles and excess collecting agent.