US4419228A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for producing high brightness clays utilizing magnetic beneficiation and calcining
Assignee: ECC America Inc
•
Filing: 1982-08-06
•
Granted: 1983-12-06
•
Expires: 2002-08-06
Abstract
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. The floatation-beneficiated slurry is then subjected to a magnetic separation by passing the slurry through a porous ferromagnetic matrix positioned in a magnetic field, having an intensity of at least 0.5 kilogauss, to remove further quantities of the discolorants and seeding particles associated therewith, and to remove seeding particles unassociated with said discolorants. The product from said magnetic separation may then be calcined at a temperature of at least 1500 DEG F. to yield an exceptionally high brightness, low abrasion product.
Inventors
- 👤 Jerry A. Cook
- 👤 Gary L. Cobb
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 12:31
CPC Classifications
B; B03; B03B; B03B9/00; B03B1/00; B03B1/04; B03C; B03C1/00; B03C1/002; B03D; B03D1/00; B03D1/001; B03D1/004; B03D1/008; B03D1/02; B03D2201/00; B03D2201/02; B03D2203/00; B03D2203/02; B03D2203/04
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
180 words
A method for producing a low-abrasion, high brightness calcined clay from a crude kaolin clay containing titaniferous and iron-containing discolorants, comprising the steps of: forming a dispersed aqueous slurry of said clay, containing a deflocculant, and a fatty acid collecting agent; and conditioning said slurry to coat said discolorants with said collecting agent, to thereby render same hydrophobic; adding to said slurry a system of sub-micron sized magnetic ferrite seeding particles, the surfaces of which have been rendered hydrophobic; mixing said seeded slurry to coalesce said hydrophobic surfaced discolorants with said hydrophobic-surfaced seeding particles; subjecting said seeded slurry to a froth flotation to remove substantial quantities of said discolorants and seeding particles coalesced therewith, and to remove excess seeding particles and coalesced seeding particles, and to remove excess of the fatty acid collecting agent; subjecting the flotation-beneficiated clay slurry to a magnetic separation to remove further quantities of the discolorants and seeding particles associated therewith, and to remove seeding particles unassociated with said discolorants; and calcining the product from said magnetic separation, at a temperature of at least 1500° F.
Claim 2
Independent Claim
180 words
A method for producing a low-abrasion, high brightness calcined clay from a crude kaolin clay containing titaniferous and iron-containing discolorants, comprising the steps of: forming a dispersed aqueous slurry of said clay, containing a deflocculant, and a fatty acid collecting agent; and conditioning said slurry to coat said discolorants with said collecting agent, to thereby render same hydrophobic; adding to said slurry a system of sub-micron sized magnetic ferrite seeding particles, the surfaces of which have been rendered hydrophobic; mixing said seeded slurry to coalesce said hydrophobic surfaced discolorants with said hydrophobic-surfaced seeding particles; subjecting said seeded slurry to a froth flotation to remove substantial quantities of said discolorants and seeding particles coalesced therewith, and to remove excess seeding particles and coalesced seeding particles, and to remove excess of the fatty acid collecting agent; subjecting the flotation-beneficiated clay slurry to a magnetic separation to remove further quantities of the discolorants and seeding particles associated therewith, and to remove seeding particles unassociated with said discolorants; and calcining the product from said magnetic separation, at a temperature of at least 1500° F.
Claim 3
Dependent Claim
29 words
A method in accordance with claim 1, wherein the clay subjected to said calcining has been classified to at least 94% by weight thereof less than 1 micron E.S.D.
Claim 4
Dependent Claim
29 words
A method in accordance with claim 2, wherein said clay has been classified to said greater than 94% less than 1 micron fraction, prior to said magnetic separation step.
Claim 5
Dependent Claim
20 words
A method in accordance with claim 2, wherein said calcining step is conducted at temperatures not greater than 2000° F.
Claim 6
Dependent Claim
24 words
A method in accordance with claim 2, wherein the product from said magnetic separation, is subjected to a reductive bleaching step prior to calcination.
Claim 7
Dependent Claim
34 words
A method in accordance with claim 5, wherein said bleached kaolin clay product is flocced, filtered, redispersed, and milled prior to calcining; and wherein the calcined product is subjected to a further pulverizing step.
Claim 8
Dependent Claim
17 words
A method in accordance with claim 6, wherein said pulverizing is effected in a high-energy impact mill.
Claim 9
Independent Claim
17 words
A method in accordance with claims 1, 2, or 7, wherein said collecting agent comprises oleic acid.
Claim 10
Independent Claim
38 words
A method in accordance with claims 1, 2, or 7, wherein said magnetic separation is effected by passing said slurry through a porous ferromagnetic matrix positioned in a magnetic field having an intensity of at least 0.5 kilogauss.
Claim 11
Independent Claim
35 words
A method in accordance with claims 1, 2, or 7 wherein said slurry is seeded with at least 0.2 lbs. Fe 3 O 4 molar equivalent of said magnetic ferrite per ton of dry clay.
Claim 12
Independent Claim
17 words
A method in accordance with claims 1, 2, or 7 wherein said magnetic ferrite comprises ferrosoferric oxide.
Claim 13
Dependent Claim
41 words
A method in accordance with claim 1, wherein said seeding system comprises magnetic ferrite particles in an aqueous phase, together with a fatty acid containing from 10 to 15 carbon atoms, said acid rendering said ferrite particles hydrophobis and size-stabilizing same.
Claim 14
Dependent Claim
14 words
A method in accordance with claim 12, wherein said fatty acid comprises dodecanoic acid.
Claim 15
Dependent Claim
14 words
A method in accordance with claim 12, wherein said magnetic ferrite comprises ferrosoferric oxide.
Claim 16
Dependent Claim
38 words
A method in accordance with claim 12, wherein said magnetic ferrite seeding system includes at least 0.003 lbs. of dodecanoic acid molar equivalent of fatty acid per lb. of magnetic ferrite expressed as Fe 3 O 4 .
Claim 17
Dependent Claim
23 words
A method in accordance with claim 1, where said seeding system comprises magnetic ferrite particles in an organic phase containing a fatty acid.
Claim 18
Dependent Claim
21 words
A method in accordance with claim 16, wherein said fatty acid is oleic acid, and wherein said organic liquid is kerosene.
Claim 19
Dependent Claim
29 words
A method in accordance with claim 16, wherein at least sufficient of said organic liquid is present to produce a fluid mixture of said ferrite particles and organic liquid.
Claim 20
Dependent Claim
24 words
A method in accordance with claim 16, wherein at least sufficient fatty acid is present to render the surfaces of said ferrite particles hydrophobic.
Claim 21
Dependent Claim
14 words
A method in accordance with claim 16, wherein said magnetic ferrite comprises ferrosoferric oxide.
Claim 22
Dependent Claim
29 words
A method in accordance with claim 1, wherein said seeding system comprises magnetic ferrite particles in a stable emulsion of water and an organic liquid containing a fatty acid.
Claim 23
Dependent Claim
20 words
A method in accordance with claim 21, wherein said organic liquid comprises kerosene and said fatty acid comprises oleic acid.
Claim 24
Dependent Claim
25 words
A method in accordance with claim 21, wherein at least sufficient of said organic liquid is present to produce a stable emulsion at ambient temperature.
Claim 25
Dependent Claim
24 words
A method in accordance with claim 21, wherein at least sufficient fatty acid is present to render the surfaces of said ferrite particles hydrophobic.
Claim 26
Dependent Claim
14 words
A method in accordance with claim 21, wherein said magnetic ferrite comprises ferrosoferric oxide.
References Cited (Backward Citations)
US3806449A
Cited
US3856523A
Cited
US3961971A
Cited
US3974067A
Cited
US4087004A
Cited
US4125460A
Cited
US4299807A
Cited
US4343694A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-12-05 | 1987-06-06 | 1987-12-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-12-05 | 1991-06-06 | 1991-12-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-12-05 | 1995-06-06 | 1995-12-06 | $7700.00 | Window Closed / Lapsed |