Disclosed are methods of processing kaolin to produce two distinct grades of kaolin in a simultaneous manner. The methods involve processing kaolin by degritting a kaolin crude; subjecting the degritted kaolin crude to flotation to provide a kaolin having reduced titania content; ozonating the kaoli
Disclosed are methods of processing kaolin to produce two distinct grades of kaolin in a simultaneous manner. The methods involve processing kaolin by degritting a kaolin crude; subjecting the degritted kaolin crude to flotation to provide a kaolin having reduced titania content; ozonating the kaolin having reduced titania content; centrifuging the kaolin to provide a coarse stream and fine stream; refining the coarse stream into a coarse engineered kaolin pigment; and refining the fine stream into a fine glossing kaolin pigment. Also disclosed are systems for the automated processing of kaolin to produce two distinct grades of kaolin with real time feedback.
대표청구항▼
What is claimed is: 1. A method of processing kaolin, comprising sequentially: providing a kaolin crude comprising higher amount of gray kaolin and a lower amount of white kaolin; degritting the kaolin crude; subject the degritted kaolin crude to flotation to provide a kaolin having reduced titania
What is claimed is: 1. A method of processing kaolin, comprising sequentially: providing a kaolin crude comprising higher amount of gray kaolin and a lower amount of white kaolin; degritting the kaolin crude; subject the degritted kaolin crude to flotation to provide a kaolin having reduced titania content; ozonating the kaolin having reduced titania content; centrifuging the kaolin at high speeds to provide a coarse stream and fine stream, the course stream comprising kaolin wherein at least about 70% by weight has a size of 2 microns or less, the fine stream comprising kaolin wherein at least about 80% by weight has a size of 1 micron or less; refining the coarse stream into a coarse engineered kaolin pigment, wherein the coarse engineered kaolin pigment has a surface area from about 15 to about 19 m 2/g and about 0.75% by weight or less of titania; and refining the fine stream into a fine glossing kaolin pigment; with the proviso that the method does not comprise fractioning the kaolin. 2. The method of claim 1, wherein centrifuging at high speeds involves using at "g" forces from about 2,000 to about 10,000. 3. The method of claim 1, wherein the kaolin crude comprises at least about 70% of gray kaolin and less than about 30% of white kaolin. 4. The method of claim 1, wherein flotation reduces the titania content of the kaolin to less than about 1% by weight. 5. The method of claim 1, wherein ozonating comprises contacting from about 0.1 to about 20 pounds of ozone per ton of kaolin. 6. The method of claim 1, further comprising centrifuging the kaolin at low speeds before flotation or after centrifuging the kaolin at high speeds. 7. The method of claim 6, wherein centrifuging at low speeds involves using "g" forces from about 200 to about 2,000. 8. The method of claim 1, wherein refining the fine stream comprises at least two of delamination, bleaching, filtering, and spray drying. 9. The method of claim 1, wherein refining the fine stream comprises at least two of delamination, bleaching, filtering, and drying. 10. A method of processing kaolin, comprising sequentially: providing a kaolin crude comprising at least about 60% of gray kaolin and less than about 40% of white kaolin; degritting the kaolin crude; subjecting the degritted kaolin crude to flotation to provide a kaolin having reduced titania content; ozonating the kaolin having reduced titania content; centrifuging the kaolin at high speeds to provide a coarse stream and find stream, the coarse stream comprising kaolin wherein at least about 80% by weight has a size of 2 microns or less, the fine stream comprising kaolin wherein at least about 80% by weight has a size of 1 micron or less; and bleaching, filtering, and spray drying the coarse stream to provide a coarse engineered kaolin pigment, wherein the coarse engineered kaolin pigment has a surface area from about 15 to about 19 m2/g and about 0.75% by weight or less of titania; with the proviso that the method does not comprise fractioning the kaolin. 11. The method of claim 10, further comprising combining the fine stream with a white kaolin to provide a kaolin pigment having a brightness of at least about 90. 12. The method of claim 10, wherein degritting the kaolin crude comprises passing the kaolin crude through at 325 mesh sieve or smaller. 13. The method of claim 10, wherein flotation comprises one of froth flotation, ultraflotation, and TREP flotation. 14. The method of claim 10, further comprising refining the fine stream into a line glossing kaolin pigment. 15. The method of claim 1, wherein flotation is conducted using a solids contents from about 10% to about 50%, a pH from about 5 to about 11, and at a temperature from about 10�� C. to about 90�� C. 16. The method of claim 10, wherein flotation is conducted using a solids content from about 20% to about 40%, a pH from about 6 to about 10, and at a temperature from about 20�� C. to about 60�� C. 17. The method of claim 10, wherein flotation reduces the titania content of the kaolin to less than about 0.7% by weight and iron oxide to less than about 1.25% by weight. 18. The method of claim 1, wherein the coarse engineered kaolin pigment has at least about 96% by weight of the particles having a size of 5 microns or less, at least about 90% by weight of the particles having a size of 2 microns or less, at least about 25% by weight of the particles having a size of 0.3 microns or less, a surface area from about 15 to about 19 m 2/g, about 0.75% by weight or less of titania, about 1.25% by weight or less of iron oxide, and a brightness of about 87.5 or more; and the fine glossing kaolin pigment has at least about 90% by weight of the particles having a size of 1 micron or less, at least about 97% by weight of the particles having a size of 2 microns or less, at least about 98% by weight of the particles having a size of 5 microns or less, from about 65% to about 80% of the particles having a size of 0.3 microns or less, a surface area from about 22 to about 29 m2/g, about 0.5% by weight or less of titania, about 1.25% by weight or less of iron oxide, brightness of about 90 or more, and high shear viscosity of about 15 dynes/4400 rpm or less at 70% solids. 19. The method of claim 10, wherein the coarse engineered kaolin pigment has at least about 97% by weight of the particles having a size of 5 microns or less, at least about 95% by weight of the particles having a size of 2 microns or less, from about 26% to about 33% by weight of the particles having a size of 0.3 microns or less, a surface area from about 16 to about 19 m2/g, about 0.5% by weight or less of titania, about 1% by weight or less of iron oxide, and a brightness of about 89 or more; and the fine glossing kaolin pigment has at least about 95% by weight of the particles having a size of 1 micron or less, at least about 99% by weight of the particles having a size of 2 microns or less, at least about 99.9% by weight of the particles having a size of 5 microns or less, from about 70% to about 75% of the particles having a size of 0.3 microns or less, a surface area from about 23 to about 28 m/g, about 0.4% by weight or less of titania, about 1% by weight or less of iron oxide, brightness of about 91 or more, and high shear viscosity of about 10 dynes/4400 rpm or less at 70% solids.
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