Imerys Pigments, Inc.

Imerys Usa, Inc.

Ecc International Limited

Imerys Oilfields Minerals, Inc.

Jun Yuan

Michael J. Garska

Robert J. Pruett

Philip J. E. Jones

David O. Cummings

Bomi M. Bilimoria

Robin Wesley

Robert J Pruett

Michael J Garska

David O Cummings

William L Garforth

Anthony V Lyons

Bomi M Bilimoria

Ismail Yildirim

J Philip E Jones

Christopher R L Golley

Steven M Fortier

Daniel John Panfil

Paula R Alves

Michael Burgess

Christopher Nutbeem

Rajan R Iyer

William H Pope

Donald Allen Anschutz

Harry Vincent Brown, Jr

Roger W Wygant

Dona L Archer

Ernest Gay

Jondahl Davis

Ismail Yildirum

Johnny W Larimore

H Vince Brown

Paul M Meizanis

William Limousin

H Vincent Brown

Larry C Powell

Mikel Dean Smith

Jim Richardson

Jose Messias

Vince H Brown

Sayre Mender

Philip J Jones

Philip JE Jones

Juan Yuan

Philip J E Jones

A method for obtaining rare earth element compositions may include providing a dispersed aqueous suspension of a particulate material including at least one rare earth element compound and kaolinite. The method may further include adding to the suspension a selective flocculation polymer that facilitates separation of at least a portion of the at least one rare earth element compound from the kaolinite by flocculating the kaolinite and allowing particles of the rare earth element compound to be or remain deflocculated. The method may also include allowing the suspension containing the polymer to separate in a selective flocculation separator into layers including a flocculated product layer and a deflocculated layer containing the portion of the at least one rare earth element compound. The method may further include extracting each of the separated layers from the separator. The rare earth element compound may include LaO, CeO, NdO, or YO.

Rare earth element compositions obtained from particulate material comprising kaolin and methods for obtaining such compositions

A mineral composition and related methods may include a mineral treated with a styrene-based polymer. The mineral treated with a styrene-based polymer may be used for a coating on a paper product having a first Cobb value that is less than a second Cobb value of the paper product with the coating devoid of the mineral composition.

Compositions comprising kaolin treated with a styrene-based polymer and related methods

A method of making a sintered ceramic proppant may include providing a kaolin clay. The kaolin clay may include an AlOcontent no greater than about 46% by weight, and a KO content no greater than 0.1% by weight. The kaolin clay may have a particle size distribution such that greater than 70% of the particles have an equivalent spherical diameter of less than 0.5 microns as measured by Sedigraph, and a shape factor less than about 18. The method may further include blunging the kaolin clay, agglomerating the kaolin clay, and sintering the agglomerated kaolin clay to produce a sintered ceramic proppant. The kaolin clay may have an A-bob Hercules viscosity of at least about 3,300 rpm at 18 kilodyne-cm and 70% solids.

Proppants and anti-flowback additives including kaolin clay

Disclosed herein are stabilized kaolin slurries comprising a kaolin comprising no more than about 80% by weight of particles having an equivalent spherical diameter of less than 2 microns and at least one stabilizer, wherein the stabilized kaolin slurry has a 28-day pour test result of at least about 80% poured. Also disclosed are methods of making such stabilized kaolin slurries.

Stabilized kaolin slurry and methods for improving kaolin slurry stability

A method of treating a kaolin particulate material to improve one or more of its properties by removal of impurity particles therein which includes: producing a dispersed aqueous suspension of a kaolin particulate material containing at least 0.1% by weight, based on the dry weight of the kaolin particulate material of separable particulate impurity; diluting said dispersed aqueous suspension by adding a diluent thereto; adding a selective flocculation polymer to the diluted suspension; allowing the suspension containing the polymer to separate in a selective flocculation separator into layers comprising a flocculated product layer and a deflocculated impurity layer containing the separable impurity; and extracting the separated layers from the separator, wherein at least a portion of said deflocculated impurity layer is recirculated for use as at least a portion of the aforementioned diluent.

Method of treating an aqueous suspension of kaolin

Disclosed herein are methods for removing discoloring impurities, such as carbon impurities, particularly graphite, from kaolin clay to enhance the brightness of the kaolin clays. The methods include reverse flotation processes. Also disclosed herein are high brightness kaolin products, and the uses thereof.

Methods for purifying kaolin clays using reverse flotation, high brightness kaolin products, and uses thereof

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 FeOin 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.

Compositions comprising fine sedimentary kaolin and methods for preparing same

Disclosed herein are granulated kaolin compositions exhibiting at least one of improved material handling properties, low dusting during transit, easy make-down into mineral-water slurries, and requiring less energy to produce than spray dried kaolin products. The granulated kaolin compositions may, in one embodiment, be characterized by a moisture content ranging from about 12% to about 23% by weight relative to the total weight of the composition. In another embodiment, the granulated kaolin compositions may have an average granule size of greater than about 10 mesh. Also disclosed herein are granulated kaolin compositions having a moisture content ranging from about 12% to about 23% by weight relative to the total weight of the composition, wherein the composition is friable when subjected to a shear force. Further disclosed herein is a method for producing granulated kaolin compositions comprising mixing at least one kaolin slurry with at least one predispersed spray dried kaolin and agglomerating the resulting mixture. Still further disclosed herein is a system for producing granulated kaolin compositions comprising a first zone for mixing at least one kaolin slurry with at least one predispersed spray dried kaolin and a second zone for agglomerating the resulting mixture.

Granulated kaolin compositions and processes for their production

Disclosed herein is a method of calcining particulate material, such as kaolin. The method comprises providing a feed mixture comprising a particulate material, such as hydrous kaolin, wherein at least a portion of the particulate feed is coated with a liquid fuel. The method further comprises heating the particulate feed mixture to calcine the particulate feed and burn the liquid fuel to form a calcined product. The liquid fuel coating can act as a secondary, indirect heat source for calcining. The overall calcining temperatures and/or times can be reduced as a result of adding the liquid fuel.

Methods of calcining particulate material

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 &#x3bc;m and/or at least about 80% by weight of the kaolin can have an esd of less than 1 &#x3bc;m. The amount of the kaolin having an esd of less than about 0.25 &#x3bc;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.

Fine platy kaolin composition

The Rio Capim Kaolin deposit contains a lower bed of soft kaolin clay that averages 10 meters thick, and an upper bed of 'hard' kaolin ('RCC hard kaolin') that may be as thick as 6 to 8 meters. Due to their high impurity content fine particle size, cementetious nature, and high degree of particle aggregation, hard kaolins are difficult to process. Disclosed herein are compositions comprising kaolin having a particle size distribution such that at least about 90% of the kaolin has a particle size of less than 1 micron and a GE brightness of at least about 91, where the kaolin may be derived from a crude kaolin having a FeOcontent of at least about 1.0% by weight, and optionally comprises titania in an amount of at least about 1.5% by weight. Also disclosed herein are methods of refining the hard kaolins, such as RCC hard kaolins, by dispersing the kaolin with at least one anionic organic dispersant and at least one inorganic dispersant. Also disclosed are compositions comprising an aqueous kaolin slurry comprising the hard kaolin, such as an RCC hard kaolin, at least one anionic organic dispersant, and at least one inorganic dispersant. Also disclosed are products containing the refined kaolin, such as paints, paper coatings, and plastics.

Method for separating mixture of finely divided minerals

Disclosed herein is a kaolin composition having nanosize dimensions. At least about 75% of the kaolin particles by weight have an equivalent spherical diameter (esd) of less than about 0.25 &#x3bc;m. The kaolin can also have a particle size distribution wherein at least about 99% of the particles by weight have an esd of less than about 2 &#x3bc;m, and/or wherein at least about 98% of the particles by weight have an esd of less than about 1 &#x3bc;m, and/or wherein at least about 97% of the particles by weight have an esd of less than about 0.5 &#x3bc;m. The kaolin can have a mean diameter ranging from about 0.075 &#x3bc;m to about 0.2 &#x3bc;m, and a shape factor of about 30 or less.

Compositions comprising kaolin having nanosize dimensions

Disclosed herein are a method of reductively bleaching a mineral slurry comprising adding in the mineral slurry an effective amount of a formamidine sulfinic acid (FAS) and an effective amount of a borohydride to reductively bleach the mineral slurry, compositions comprising a mineral slurry, a FAS, and a borohydride, and final products comprising a mineral obtained by the method disclosed herein.

Effective reductive bleaching of mineral slurries

The present invention relates to a hydrous kaolin product having improved optical properties, for example, when used in the production of paper products. The present invention comprises an improved barrier coating for paper and a method of making the coated paper. The present invention also comprises an improved method from making filled and coated paper products. The present invention uses a composition comprising kaolin having a shape factor of at least about 70:1, such as at least about 80:1 or at least about 100:1.

Hyperplaty clays and their use in paper coating and filling, methods for making same, and paper products having improved brightness

Growing community of inventors

Milledgeville, GA, United States of America

Robert J Pruett