US4030941A
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Method for reducing the viscosity and for refining kaolin clays
Assignee: JM Huber Corp
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Filing: 1976-10-12
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Granted: 1977-06-21
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Expires: 1996-10-12
Abstract
Abstract A method for reducing the viscosity and for refining crude kaolin clays is disclosed. The inherent viscosities or crude kaolin clay ores, particularly those having acceptable optical and purity properties for use in preparing paper coating pigments, but normally rejected because of their high inherent viscosities, are significantly reduced by contacting an aqueous slurry of the crude clay with an inorganic polymeric complex having the general formula [AI(OH).sub.y A.sub.3.sub.-y ].sub.x wherein x = 6 to 24, y = 1.0 to 2.75 and A is selected from the group consisting of Cl - , (SO 4 = ) 0 .5 and NO 3 - . In a preferred embodiment the above treated clay is also subjected to a high shear mixing action or kneading prior to further conventional processing procedures, such as fractionation, leaching, etc. The treatment of the clay with the above polymer complex and high shear mixing or kneading have a synergistic effect in providing a refined clay product having significantly lower viscosity when dispersed or slurried. The refined products produced in accordance with the method thus have particular use as paper coating pigments.
Inventors
- 👤 Albert C. Kunkle
- 👤 Carl E. Kollmar, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 13:36
CPC Classifications
D; D21; D21H; D21H19/00; D21H19/36; D21H19/38; D21H19/40; C; C04; C04B; C04B33/00; C04B33/02; C04B33/13; C04B33/18; C09; C09C; C09C1/00; C09C1/40; C09C1/42; C01; C01P; C01P2004/00; C01P2004/60; C01P2004/61; C01P2006/00; C01P2006/22; C01P2006/60
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
71 words
A method for reducing the viscosity of crude kaolin clay ores for producing clay pigments comprising contacting a clay/water slurry of said crude kaolin clay with an inorganic polymer complex having the general formula: [Al(OH).sub.y A.sub.3-y ].sub.x wherein x = 6 to 24, y = 1.0 to 2.75 and A is selected from the group consisting of Cl - , (SO 4 = ) 0 .5 and NO 3 - .
Claim 2
Independent Claim
71 words
A method for reducing the viscosity of crude kaolin clay ores for producing clay pigments comprising contacting a clay/water slurry of said crude kaolin clay with an inorganic polymer complex having the general formula: [Al(OH).sub.y A.sub.3-y ].sub.x wherein x = 6 to 24, y = 1.0 to 2.75 and A is selected from the group consisting of Cl - , (SO 4 = ) 0 .5 and NO 3 - .
Claim 3
Dependent Claim
81 words
The method of claim 1, wherein the inorganic polymeric complex is formed in situ in the crude kaolin clay/water slurry by the addition thereto of a compound selected from the group consisting of AlCl 3 , Al 2 (SO 4 ) 3 , Al(NO 3 ) 3 , their various hydrated forms and mixtures thereof, and a compound selected from the group consisting of NaOH, NH 4 OH, KOH and mixtures thereof in respective amounts for producing the inorganic polymeric complex.
Claim 4
Dependent Claim
23 words
The method of claim 1, including subjecting the crude kaolin clay/water slurry contacted with the inorganic polymeric complex to shear before further processing.
Claim 5
Dependent Claim
34 words
The method of claim 1, wherein the crude kaolin clay/water slurry is subjected to a high shear mixing action or kneading following the contacting with the inorganic polymeric complex and before further processing thereof.
Claim 6
Dependent Claim
35 words
The method of claim 1, wherein the inorganic polymeric complex is present in an amount of from about 0.1 to below about 3.0% per ton of crude clay, based upon the weight of dry clay.
Claim 7
Dependent Claim
24 words
The method of claim 1, wherein the crude kaolin clay has an initial clay/water viscosity of at least 300 centipoises Brookfield at 70% solids.
Claim 8
Dependent Claim
26 words
The method of claim 1, wherein the contacting is carried out at about room temperature for a time period of about 10 to about 15 minutes.
Claim 9
Independent Claim
63 words
A method for reducing the viscosity of crude kaolin clay ores comprising contacting a crude clay/water slurry of said kaolin clay ore with an inorganic polymeric complex having the general formula: [Al(OH).sub.2.25 A.sub..75 ].sub.x wherein x = 6 to 24 and A is selected from the group consisting of Cl - , (SO 4 = ) 0 .5 and NO 3 - .
Claim 10
Independent Claim
63 words
A method for reducing the viscosity of crude kaolin clay ores comprising contacting a crude clay/water slurry of said kaolin clay ore with an inorganic polymeric complex having the general formula: [Al(OH).sub.2.25 A.sub..75 ].sub.x wherein x = 6 to 24 and A is selected from the group consisting of Cl - , (SO 4 = ) 0 .5 and NO 3 - .
Claim 11
Independent Claim
45 words
A method for reducing the viscosity of crude kaolin clays, said method comprising the steps of contacting a crude kaolin clay/water slurry with a polymeric complex having the general formula: [Al(OH).sub.y Cl.sub.3-y ].sub.y wherein x = 6 to 24 and y = 1.0 to 2.75.
Claim 12
Independent Claim
45 words
A method for reducing the viscosity of crude kaolin clays, said method comprising the steps of contacting a crude kaolin clay/water slurry with a polymeric complex having the general formula: [Al(OH).sub.y Cl.sub.3-y ].sub.y wherein x = 6 to 24 and y = 1.0 to 2.75.
Claim 13
Dependent Claim
55 words
The method of claim 9, wherein said polymeric complex is formed in situ in the crude kaolin clay/water slurry by the addition of aluminum trichloride and sodium hydroxide to the slurry in accordance with the equation xAlCl.sub.3 + xyNaOH→[Al(OH).sub.y Cl.sub.3-y ].sub.x + xyNaCl wherein x = 6 to 24 and y = 1.0 to 2.75.
Claim 14
Dependent Claim
30 words
The method of claim 9, wherein said clay/water slurry is subjected to a high shear mixing action or kneading following contacting with said polymeric complex and before further processing thereof.
Claim 15
Dependent Claim
24 words
The method of claim 9, wherein the crude kaolin clay has an initial clay/water viscosity of at least 300 centipoises Brookfield at 70% solids.
Claim 16
Dependent Claim
85 words
The method of claim 9, wherein said polymer complex is formed in situ in said kaolin clay/water slurry by the addition of aluminum trichloride and sodium hydroxide thereto in accordance with the equation: xAlCl.sub.3 + 2.25x NaOH→[Al(OH).sub.2.25 Cl.sub..75 ].sub.6-24 + 2.25x NaCl said aluminum trichloride and sodium hydroxide being added in amounts to produce the polymeric complex in the clay/water slurry in an amount within the range of from about 0.25% to about 1.5% per ton of clay, based upon the weight of dry clay.
Claim 17
Dependent Claim
29 words
The method of claim 13, including subjecting the crude kaolin clay/water slurry contacted with the polymer complex to a high shear mixing action or kneading before further processing thereof.
Claim 18
Dependent Claim
27 words
The method of claim 14, wherein the kaolin clay/water slurry is contacted with the polymeric complex for about 10 to about 15 minutes at about room temperature.
Claim 19
Dependent Claim
24 words
The method of claim 13, wherein the crude kaolin clay has an initial clay/water viscosity of at least 300 centipoises Brookfield at 70% solids.
Claim 20
Independent Claim
160 words
A method for refining crude kaolin clay ores having a wide initial crude clay/water viscosity range, said method comprising the steps of: forming a slurry of crude kaolin clay in water having a solids content of from about 10 to about 40% by weight; degritting the crude clay/water slurry; contacting the crude clay/water slurry with an inorganic polymeric complex having the formula [Al(OH).sub.y A.sub.3-y ].sub.x wherein x = 6 to 24, y = 1.0 to 2.75, and A is selected from the group consisting of Cl - , (SO 4 = ) 0 .5 and NO 3 - ; subjecting the crude clay/water slurry to a high shear mixing action or kneading; fractionating the crude clay/water slurry to form coarse and fine fractions of said clay; leaching the fine fraction of the classified clay/water slurry; filtering the leached clay/water slurry; concentrating the resulting filter cake to a desired clay solids; and recovering the clay as a finished clay pigment product.
Claim 21
Independent Claim
160 words
A method for refining crude kaolin clay ores having a wide initial crude clay/water viscosity range, said method comprising the steps of: forming a slurry of crude kaolin clay in water having a solids content of from about 10 to about 40% by weight; degritting the crude clay/water slurry; contacting the crude clay/water slurry with an inorganic polymeric complex having the formula [Al(OH).sub.y A.sub.3-y ].sub.x wherein x = 6 to 24, y = 1.0 to 2.75, and A is selected from the group consisting of Cl - , (SO 4 = ) 0 .5 and NO 3 - ; subjecting the crude clay/water slurry to a high shear mixing action or kneading; fractionating the crude clay/water slurry to form coarse and fine fractions of said clay; leaching the fine fraction of the classified clay/water slurry; filtering the leached clay/water slurry; concentrating the resulting filter cake to a desired clay solids; and recovering the clay as a finished clay pigment product.
Claim 22
Dependent Claim
24 words
The method of claim 17, wherein the crude kaolin clay has an initial clay/water viscosity of at least 300 centipoises Brookfield at 70% solids.
Claim 23
Dependent Claim
45 words
The method of claim 17, wherein the inorganic polymeric complex has the formula: [AL(OH).sub.2.25 A.sub..75 ].sub.x wherein x = 6 to 24 and A is selected from the group consisting of Cl - , (SO 4 = ) 0 .5 and NO 3 - .
Claim 24
Dependent Claim
80 words
The method of claim 17, wherein the inorganic polymeric complex is formed in situ in the crude kaolin clay/water slurry by the addition thereto of a compound selected from the group consisting of AlCl 3 , Al 2 (SO 4 ) 3 , Al(NO 3 ) 3 , their various hydrated forms and mixtures thereof, and a compound selected from the group consisting of NaOH, NH 4 OH, KOH and mixtures thereof, in respective amounts to produce the polymeric complex.
Claim 25
Dependent Claim
44 words
The method of claim 20, wherein the respective compounds are added in respective amounts to produce the inorganic polymeric complex in situ in an amount of from about 0.1% to below about 3.0% per ton of clay, based upon the weight of dry clay.
Claim 26
Dependent Claim
22 words
The process of claim 17, wherein the inorganic polymeric complex has the formula: [Al(OH).sub.2.75 Cl.sub..75 ].sub.x wherein x = 6 to 24.
Claim 27
Dependent Claim
78 words
The method of claim 22, wherein the polymeric complex is formed in situ by addition to the clay/water slurry aluminum trichloride and sodium hydroxide in accordance with the equation: xAlCl.sub.3 + 2.25x NaOH [Al(OH).sub.2.25 Cl.sub..75 ].sub.6-24 + 2.25x NaCl the aluminum trichloride and sodium hydroxide being added in respective amounts to produce the polymer complex in situ in an amount of from about 0.25% to about 1.5% per ton of clay, based upon the weight of dry clay.
Claim 28
Dependent Claim
27 words
The process of claim 17, wherein the clay/water slurry is contacted with the inorganic polymeric complex at about room temperature for about 10 to about 15 minutes.
Claim 29
Dependent Claim
37 words
The process of claim 17, wherein the clay/water slurry contacted with the inorganic polymeric complex is concentrated and then subjected to a high shear mixing action or kneading at the rate of about 37 hp-hr/ton of clay.
Claim 30
Dependent Claim
24 words
The process of claim 25, wherein the crude kaolin clay has an initial clay/water viscosity of at least 300 centipoises Brookfield at 70% solids.
Claim 31
Dependent Claim
25 words
The process of claim 26, wherein the initially formed slurry of crude kaolin clay in water has a solids content of about 20% by weight.
References Cited (Backward Citations)
US3510330A
Cited
US3510331A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-06-20 | 1980-12-20 | 1981-06-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-06-20 | 1984-12-20 | 1985-06-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-06-20 | 1988-12-20 | 1989-06-21 | $7700.00 | Window Closed / Lapsed |