EP2900864A1 - Verfahren und vorrichtung zur herstellung einer materialkomponente, materialkomponente und deren verwendung, streckmittelpigmentprodukt und endprodukt - Google Patents

Verfahren und vorrichtung zur herstellung einer materialkomponente, materialkomponente und deren verwendung, streckmittelpigmentprodukt und endprodukt

Info

Publication number
EP2900864A1
EP2900864A1 EP13841588.0A EP13841588A EP2900864A1 EP 2900864 A1 EP2900864 A1 EP 2900864A1 EP 13841588 A EP13841588 A EP 13841588A EP 2900864 A1 EP2900864 A1 EP 2900864A1
Authority
EP
European Patent Office
Prior art keywords
ash
particle size
material component
extender pigment
grinding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13841588.0A
Other languages
English (en)
French (fr)
Other versions
EP2900864A4 (de
Inventor
Taru PÄIVÄLÄINEN
Teuvo LEPPÄNEN
Matti Ristolainen
Meri Ventola
Nina PYKÄLÄINEN
Folke ÖRSÅ
Heiko Hilbert
Matti Lindeman
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
UPM Kymmene Oy
Original Assignee
UPM Kymmene Oy
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by UPM Kymmene Oy filed Critical UPM Kymmene Oy
Publication of EP2900864A1 publication Critical patent/EP2900864A1/de
Publication of EP2900864A4 publication Critical patent/EP2900864A4/de
Withdrawn legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D11/00Inks
    • C09D11/02Printing inks
    • C09D11/03Printing inks characterised by features other than the chemical nature of the binder
    • C09D11/037Printing inks characterised by features other than the chemical nature of the binder characterised by the pigment
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40Additives
    • C09D7/60Additives non-macromolecular
    • C09D7/61Additives non-macromolecular inorganic
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/01Waste products, e.g. sludge
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63Inorganic compounds
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63Inorganic compounds
    • D21H17/64Alkaline compounds
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63Inorganic compounds
    • D21H17/67Water-insoluble compounds, e.g. fillers, pigments
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23JREMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J1/00Removing ash, clinker, or slag from combustion chambers
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/18Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20Oxides; Hydroxides
    • C08K3/22Oxides; Hydroxides of metals
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/18Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24Acids; Salts thereof
    • C08K3/26Carbonates; Bicarbonates

Definitions

  • the invention relates to a method for manu ⁇ facturing a material component. Further, the invention relates to a material component, an extender pigment product and a final product. Further, the invention relates to a use of the material component. Further, the invention relates to an apparatus for manufacturing a material component.
  • the objective of the invention is to disclose a new method for treating ash or ash type material to form a new type material component which can be uti ⁇ lized. Further, the objective of the invention is to disclose a new method for utilizing ash as a raw mate ⁇ rial .
  • the method for manufacturing a material com- ponent from boiler ash according to the present invention is characterized by what is presented in claim 4.
  • the apparatus such as also process, contain ⁇ ing different devices for manufacturing a material component according to the present invention is char- acterized by what is presented in claim 18.
  • the material component according to the pre ⁇ sent invention is characterized by what is presented in claim 27.
  • the final product according to the present invention is characterized by what is presented in claim 30.
  • the method for manufacturing an extender pig ⁇ ment according to the present invention is characterized by what is presented in claim 31.
  • the extender pigment according to the present invention is characterized by what is presented in claim 41.
  • the use of the extender pigment according to the present invention is characterized by what is pre ⁇ sented in claim 42.
  • the extender pigment product according to the present invention is characterized by what is present ⁇ ed in claim 44.
  • the final product according to the present invention is characterized by what is presented in claim 45.
  • Fig. 1 is a flow chart illustration of a method according to one embodiment of the present in ⁇ vention
  • Fig. 2 is a flow chart illustration of a method according to another embodiment of the present invention.
  • Fig. 3 is a flow chart illustration of a method according to another embodiment of the present invention.
  • Fig. 4 is a flow chart illustration of a method according to another embodiment of the present invention.
  • Fig. 5 is a flow chart illustration of a waste paper treatment
  • Fig. 6 is a flow chart illustration of a method according to one embodiment of the present in ⁇ vention
  • Fig. 7 is a flow chart illustration of a method according to another embodiment of the present invention.
  • Fig. 8 is a flow chart illustration of a method according to another embodiment of the present invention.
  • Fig. 9 is a flow chart illustration of a method according to another embodiment of the present invention .
  • a mate ⁇ rial component 4, 24 is formed from ash 1, 21.
  • the material component 4, 24 can be formed from ash 1,21 which can contain one or more ash component.
  • the ash and ash component can con ⁇ tain any ash and/or ash type raw material.
  • the ash can be coming from paper industry, paper mill, pulp mill, saw mill, plywood mill, waste paper treatment, dein- king process, waste water treatment, gasification and/or other suitable mill or process.
  • the ash can be coming from boiler or lime kiln or gasification.
  • the ash can be formed by incineration or combustion using any technique in any boiler.
  • the ash can be produced in different incineration temperatures.
  • the ash can be formed by using any suitable lime kiln technique in any lime kiln.
  • the ash can be formed by using any suitable gasification technique in any gasification.
  • the ash is selected from the group containing boiler ash, lime kiln ash, residue from the gasification, such as char, and their combinations.
  • the ash may include 0 - 100 % by weight boiler ash, 0 - 100 % by weight lime kiln ash and/or 0 - 100 % by weight residue from the gasification.
  • the ash includes boiler ash.
  • the ash is boiler ash.
  • the boiler ash can be formed in any boiler.
  • the boiler ash contains fly ash and/or bottom ash.
  • the boiler ash contains 0 - 100 % by weight fly ash and/or 0 - 100 % by weight bottom ash.
  • the boiler ash is formed from a sludge which contains reject or rejects from a waste paper treatment, such as from a deinking pro ⁇ cess, recycled fiber production, a paper mill and/or a waste water treatment plant.
  • the boiler ash can be formed from any sludge by incineration or combustion in any boiler.
  • the sludge contains rejects, such as sludges, rejects and residues, from a waste paper treatment, such as from a deinking process, re ⁇ cycled fiber production, a paper mill and/or a waste water treatment plant.
  • the sludge contains at least rejects, such as sludges, rejects and residues, from a waste paper treatment, e.g.
  • RCF sludge recycled fiber sludge
  • deinking sludge and/or coarse screening rejects and/or possibly drum rejects A typical waste paper treatment process is presented in figure 5.
  • the sludge may include rejects, such as sludges, rejects and residues, from a paper mill.
  • the sludge may include rejects, such as sludges, from a waste water treatment plant, e.g. pri- mary sludge and/or biosludge.
  • the sludge may include rejects, such as sludges, rejects and resi ⁇ dues, from any paper and board industry process.
  • the sludge may also include sludges and rejects from other processes.
  • RCF sludge means any RCF reject or any combination of different RCF rejects from recycled fiber plant, e.g. wood based recycled fibre production.
  • deinking sludge means any sludge and reject which is separated in a deinking step from the recovered paper, board or related fiber based products.
  • the deinking sludge may include coarse screening rejects and/or biosludge.
  • the sludge may include minerals used in paper coating, filler and printing inks, and fibers, fines, sticky materials like starch, latex and adhesive, and other inorganic components and/or small amount of other com ⁇ ponents, preferably other reject components.
  • the sludge is high solid sludge in which dry solid content can be about 50 - 70 %.
  • the sludge can be dewatered to form the high solid sludge.
  • the sludge may be treated in the dewatering, for example by means of a gravita ⁇ tion table and/or disc filter and/or screw press or the like before the method of the present invention.
  • the sludge can also be dried to higher, even 99 % con sistency prior to incineration.
  • the mate ⁇ rial that is combusted can consist solely of the inor- ganic fraction separated from the deinking sludge.
  • additional fuels such as bark, wood, waste wood, adhesive laminate waste, adhesive material, re ⁇ lease material, green liquor dregs, wood-based, fiber- based or plastic-based composite material, bags, ener- gy waste, peat, oil for instance and/or any raw mate ⁇ rial which produces ash, can be mixed with the sludges and other residues listed here in order to enhance the incineration .
  • the ash is formed from bark, wood, waste wood, adhesive laminate waste, adhe ⁇ sive material, release material, green liquor dregs, wood-based, fiber-based or plastic-based composite ma ⁇ terial, bags, energy waste, peat, oil for instance and/or any raw material which produces ash.
  • the ash is formed in any boiler.
  • the method comprises reduc ⁇ ing particle size of the ash (1,21) in at least one stage.
  • the particle size reduction can be carried out such as presented in this context.
  • the method comprises neu ⁇ tralizing the ash (1,21) .
  • the neutralizing can be made such as presented in this context.
  • a material component 4 is formed from boiler ash 1, wherein method comprises: reducing 2 particle size of the boiler ash 1 in at least one reduction stage and neutralizing 3 the boil ⁇ er ash in a liquid composition in a neutralizing stage in order to form the material component.
  • the boiler ash such as defined above is used as a raw material.
  • the boiler ash 1 contains one or more ash component.
  • the boiler ash can be formed by incineration or combustion using any technique in any boiler.
  • the boiler ash can be produced in different incineration temperatures.
  • the boiler ash or its component is formed from a sludge such as defined above.
  • the boiler ash 1 is fed to the apparatus.
  • the apparatus includes a feeding device for feeding the boiler ash 1 to the apparatus.
  • a technical effect of the present invention is that the boiler ash with high alkalinity, abrasive- ness and inappropriate particle size distribution can be utilized in a material component thanks to the treatment containing particle size reduction and neu ⁇ tralization of the boiler ash.
  • a technical effect of the invention is that different boiler ash can be utilized to form a new product.
  • An additional technical effect of the inven ⁇ tion is that different rejects for example from a waste paper treatment and/or a paper mill and/or waste water treatment plant can be utilized in the incinera ⁇ tion in order to produce the ash that is being uti- lized in the end products, e.g. in the ink composi ⁇ tions. Then environmental load decreases.
  • particle size reduction 2 means any reduction of the material particle size, e.g. by mechanically.
  • the particle size reduction may be selected from the group of pulverization, grinding, crushing, cutting, chopping, shearing, compressing, breaking up of a material, e.g. by braying or rubbing or by air, by sound wave or by ultrasound, to a de ⁇ sired particle size or other suitable grinding method or their combinations.
  • the particle size reduction it is important to produce ultrafine particles.
  • the particle size reduction can be carried out by means of any suitable method.
  • the particle size reduction can be carried out in one stage or in more than one stage.
  • the particle size re ⁇ duction stage 2 comprises a grinding device.
  • the particle size reduction can be made in two stages so that the boiler ash is pre-ground by first de ⁇ vice to produce fine particles and then is ground by second device to produce ultrafine particles.
  • the parti ⁇ cle size reduction containing more than one stage can comprise different devices. It is important that ul ⁇ trafine particles are produced in at least the finish particle size reduction stage.
  • the particle size reduction 2 can be carried out by any suitable grinding method and devices, e.g. by dry grinding, such as by fluidized bed jet mill or dry agitating ball mill, or by wet grinding, such as by ball mill or pearl mill, or by any kind of other grinder, e.g. by abrasion resistant grinder, that can produce ultrafine particles.
  • the grinding method can be select- ed from the group consisting of crushing-based grind ⁇ ing, attrition-based grinding, abrasion-based grind ⁇ ing, cutting-based grinding, blasting-based grinding, explosion-based grinding, wet grinding, dry grinding, grinding under pressure, other suitable grinding meth- od and their combinations.
  • the grinding device used for grinding is selected from the group consisting of impact mill, air jet mill, sand mill, bead mill, pearl mill, ball mill, vibration mill, screw mill, extrusion device, other suitable de- vice and their combinations.
  • the grinding additives can be used.
  • classifiers can be used for obtaining a narrower particle size distribution after the particle size reduction stage. Any classifiers known per se may be used.
  • the neutralizing 3 is made by C0 2 . Either pure C0 2 or recovered waste C0 2 can be uti ⁇ lized.
  • the neutralizing 3 is made by an acid. Any suitable acid known per se, e.g. HC1, car- boxylic acid or lipid such as fatty acid, e.g stearic acid, oleic acid, myristic acid or caprylic acid or any other fatty acid or mixture of them, can be used in the neutralizing.
  • the lipid is originated from side flows of the wood- or fiber processing indus- try.
  • the fatty acid or fatty acid con ⁇ taining compound is originated from side flows of the wood- or fiber processing industry.
  • the apparatus comprises at least one device for feeding acid or C0 2 into the boiler ash 1 before or during the neu- tralizing stage 3.
  • the boiler ash 1 is mixed with a liquid 5 to form a liquid composition before the neu ⁇ tralizing 3, before grinding 2 and neutralizing 3 or during the neutralizing 3.
  • the neutralizing is made in the liquid composition so that the ground boiler ash has been mixed with a liquid to form a liquid composition, and a liquid composition containing boiler ash is neutralized. If the wet grinding is used in the particle size reduction, so then the boiler ash is mixed with a liquid before the particle size reduc ⁇ tion.
  • the apparatus comprises at least one device for mixing the liquid 5 and the boiler ash 1 before or during the neutralizing stage 3.
  • the liquid is selected from the group water, acid, ink, paint or colour vehicle or one or several components of vehicles, and their combi ⁇ nations.
  • Vehicle is either ink, paint or color vehicle which can comprise several substances like water, var ⁇ nish, oils and the like, and their different combina- tions.
  • the liquid is selected from the group water, acid, solvent, varnish, oils, fatty ac ⁇ ids and their combinations.
  • Varnish can include mineral oil, tall oil, vegetable oil or their fractions, e.g. distillates, or their combination.
  • oils or their fractions or distillates can be originated from industrial side streams.
  • the boiler ash is mixed with acid and varnish to form a neutralized material component.
  • the liquid composition in ⁇ cludes 10 - 50 w-%, preferably 10 - 20 w-%, more prefer ⁇ able 12 - 18 w-%, boiler ash.
  • the neutraliz- ing 3 is carried out at 10 - 20 % concentration of the boiler ash.
  • the particle size of the boiler ash is reduced 2 and after that the boiler ash is neutralized 3. In one embodiment the particle size of the boiler ash is reduced 2 at two stages and after that the boiler ash is neutralized 3.
  • the boiler ash is neutral ⁇ ized 3 and after that the particle size of the boiler ash is reduced 2.
  • the boiler ash is neutral ⁇ ized in connection with the particle size reduction of the boiler ash, preferably at the same time and/or at the same process stage.
  • the particle size of the boiler ash is reduced 2 in at least two stages and the boiler ash is neutralized 3 between two particle size reduction stages.
  • the first stage may be a dry-treating stage, i.e. a dry grinding stage
  • the second stage may be a wet-treating stage, i.e. a wet grinding stage.
  • the first stage may be a dry-treating stage, i.e. a dry grinding stage
  • the second stage may be a dry-treating stage, i.e. a dry grinding stage.
  • the first stage may be a wet- treating stage, i.e. a wet grinding stage
  • the second stage may be a dry-treating stage, i.e. a dry grinding stage.
  • the first stage may be a wet-treating stage, i.e. a wet grinding stage
  • the second stage may be a wet-treating stage, i.e. a wet grinding stage.
  • the neutralizing is made by
  • the neutralizing is made by an acid, wherein the boiler ash, the particle size of which is reduced or not reduced, is mixed with the acid and neutralized.
  • the acid acts as a liquid in the liquid composition during the neutralizing. If the particle size of the boiler ash is not reduced before the neutralization so the particle size reduction is made after the neutralization.
  • the particle size re ⁇ duction can also be made both before and after the neutralization .
  • the boiler ash is first mixed with varnish and the particle size reduction is carried out for the ash-based mixture, and then the neutralization is carried out after the particle size reduction of said ash-based mixture.
  • the particle size reduction and the neutralization is made at the same stage.
  • pH of the material component 4 is at neutral level, prefer ⁇ ably about 6 - 8, more preferable about 6 - 7.5, after the neutralizing 3.
  • pH has to be about 6 - 7 for example in printing inks.
  • the material component 4 is in the form of slurry, dispersion, solution or the like.
  • the material component may be dry compo ⁇ nent, e.g. in the form of fine pulver or powder.
  • the material component has particle size which is in the size range of the ultrafine parti- cles.
  • the particle size reduction is carried out so that the mean particle size of the ma ⁇ terial component is under 10 ym, preferably between 0.1 - 8 ⁇ and more preferable between 0.1 - 5 ym, af ⁇ ter the particle size reduction and the neutraliza- tion.
  • the mean particle size of the material component is under 5 ym, preferably between 0.1 - 4 ym, more preferable between 0.1 - 3 ym and most preferable between 0.1 - 2 ym, after the particle size reduction and before the neutralization.
  • the mean particle size of the material com ⁇ ponent is measured by the Coulter-device. Alternative ⁇ ly, the mean particle size can be measured by any oth ⁇ er suitable device or method.
  • the apparatus comprises at least one drying device 6, preferably for drying the ma ⁇ terial component.
  • the material component 4 e.g. material component slurry 8 is dried after the combination of the particle size reduction 2 and neu- tralization 3.
  • the material compo ⁇ nent is dried at temperatures between 90 - 120 ° C, preferably between 100 - 110 ° C, in order to form a dry cake.
  • the dried material component is then ground again into fine pulver.
  • the boiler ash 1 is dried after the neutralization 3 and before the particle size reduction 2 when the boiler ash is first neutralized 3 and after that the particle size of the boiler ash is reduced 2.
  • dry grinding can be used in the particle size reduction.
  • wet grinding can be used in the particle size re ⁇ duction. If the wet grinding is used so then the mate- rial component is preferably dried again after the particle size reduction and after that preferably re- ground .
  • the drying can be carried out by any suitable method or device.
  • the drying can be made by means of drying device selected from the group: indirect dryer, direct dryer, paddle dryer, flash dryer, fluidized bed dryer, cyclone dryer, air dryer, air grinder, rotor mill, centrifugal mill, air turbulence mill, air tur- bulence dryer and other suitable dryers and other suitable mills, and their combinations.
  • the drying is carried out by such air dryer or air grinder in which particles can be separated one from the oth ⁇ er.
  • drying devices are possible. It is im- portant that drying temperature is selected so that the boiler ash or material component is not damaged.
  • the dried material compo ⁇ nent can be re-ground, preferably after the drying.
  • the material component is re-ground in order to form fine pulver or powder.
  • the ap ⁇ paratus comprises at least one re-grinding device, pref ⁇ erably for re-grinding the material component.
  • the re- grinding can be made by any grinding device known per se.
  • re-grinding can be made by some method or device presented previously in this applica ⁇ tion, in connection with particle size reduction.
  • a drying device can also act as a grinder.
  • a grinder can act as a drying device.
  • the drying and re- grinding may be made by the same device at one process step. The grinding additives may be used in the grind ⁇ ing .
  • classifiers can be used for obtaining a narrower particle size distribution after the re-grinding stage. Any classifiers known per se may be used. In one embodiment the drying and re-grinding can be made once or more than once.
  • the material component has particle size which is in the size range of the ultrafine parti- cles after the drying and re-grinding.
  • the mean particle size of the material component is under 10 ⁇ , preferably between 0.1 - 8 ym and more preferable between 0.1 - 5 ⁇ , after the drying and re- grinding .
  • the boiler ash or the mate ⁇ rial component is treated, e.g. surface-treated.
  • the treatment may be selected from the group containing dispersing, hydrogenation, acidifying, making the material component or its surface into hydrophobic, mix- ing of the material component or boiler ash with other agents, blackening of the material component and their combinations.
  • the dispersing of the material component and making the material component into hydrophobic are carried out at the same stage.
  • the material component e.g. its surface
  • the material component is treated so that the material com ⁇ ponent, e.g. its surface, becomes hydrophobic.
  • This treatment can be made by means any method known per se and/or by means of any suitable agents, e.g. lipid, fatty acid, carboxylic acid, dispergation agents, hy ⁇ drophobic agents or any other suitable agents.
  • the material component is treated with fat ⁇ ty acids.
  • the material component be ⁇ comes hydrophobic during the neutralization. If the neutralization is carried out by lipid, fatty acid or carboxylic acid then the surface of the material com ⁇ ponent can be turned into hydrophobic during the neu ⁇ tralization.
  • the boiler ash is treated with fatty acids.
  • a material component 4 is formed from boiler ash 1 so that particle size of the boiler ash is reduced by dry grinding 2, the boiler ash 1 is mixed with a liquid 5 to form a liquid composition and the boiler ash is neutralized 3 in a liquid compo ⁇ sition.
  • the material component 4 is dried 6 and re-grinded 12 after the dry grinding and the neutralization.
  • the material component 4 is turned into hydrophobic after the dry grinding and the neutralization.
  • the material component 4 is dried 6 and re-grinded 12 af ⁇ ter the dry grinding, neutralization and turning into hydrophobic.
  • the material component 4 is dried 6 and re-grinded 12 after the dry grinding and the neutralization, and after that the material component is turned into hydrophobic.
  • a material component 4 is formed from boiler ash 1 so that the boiler ash 1 is mixed with a liquid 5 to form a liquid composition, particle size of the boiler ash is reduced by wet grind ⁇ ing 2 and the boiler ash is neutralized 3.
  • the material component 4 is dried 6 and re- grinded 12 after the wet grinding and the neutraliza ⁇ tion.
  • the material component 4 is turned into hydrophobic after the wet grinding and the neutralization.
  • the material compo ⁇ nent 4 is dried 6 and re-grinded 12 after the wet grinding, neutralization and turning into hydrophobic.
  • the material component 4 is dried 6 and re-grinded 12 after the wet grinding and the neu ⁇ tralization, and after that the material component is turned into hydrophobic.
  • a material component 4 is formed from boiler ash 1 so that the boiler ash 1 is mixed with a liquid 5 to form a liquid composition, the boiler ash is neutralized 3 and particle size of the boiler ash is reduced by wet grinding 2.
  • the material component 4 is dried 6 and re- grinded 12 after the neutralization and the wet grind ⁇ ing.
  • the material component 4 is turned into hydrophobic after the neutralization and the wet grinding.
  • the material com ⁇ ponent 4 is dried 6 and re-grinded 12 after the neu ⁇ tralization and wet grinding, and after that the mate- rial component 4 is turned into hydrophobic.
  • a material component 4 is formed from boiler ash 1 so that the boiler ash 1 is mixed with a liquid 5 to form a liquid composition, the boiler ash is neutralized 3, dried 6 and particle size of the dried boiler ash is reduced by grinding 2. In one embodiment the material component 4 is turned into hydrophobic after the neutralization, drying and grinding .
  • a material component 4 is formed from boiler ash 1 so that the boiler ash 1 is mixed with a liquid 5 to form a liquid composition, and after that the boiler ash is neutralized 3, turned in ⁇ to hydrophobic and particle size of the boiler ash is reduced by wet grinding 2 at the same process stage.
  • the material component 4 is dried 6 and re-grinded 12 after the neutralization, turning into hydrophobic and wet grinding.
  • a material component is formed from boiler ash so that particle size of the boiler ash is reduced by dry grinding in the first grinding stage, the boiler ash is mixed with a liquid to form a liquid composition, particle size of the boiler ash is reduced by wet grinding in the second grinding stage and the boiler ash is neutralized in a liquid composition.
  • the material component is dried and re-grinded after the grinding stages and the neutralization.
  • the material component is turned into hydrophobic after the grinding stages and the neutralization.
  • the material component is dried and re- grinded after the grinding stages, neutralization and turning into hydrophobic.
  • the mate- rial component is dried and re-grinded after the grinding stages and the neutralization, and after that the material component is turned into hydrophobic.
  • a material component is formed from boiler ash so that particle size of the boiler ash is reduced by dry grinding in the first grinding stage, the boiler ash is mixed with a liquid to form a liquid composition, the boiler ash is neutralized in a liquid composition and particle size of the boiler ash is reduced by wet grinding in the sec ⁇ ond grinding stage.
  • the material component is dried and re-grinded after the grinding stages and the neutralization.
  • the material component is turned into hydrophobic after the grinding stages and the neutralization.
  • the material component is dried and re- grinded after the grinding stages, neutralization and turning into hydrophobic.
  • the mate ⁇ rial component is dried and re-grinded after the grinding stages and the neutralization, and after that the material component is turned into hydrophobic.
  • the material component can be utilized as such.
  • a mixture can be formed contain ⁇ ing the material component and at least one other com- ponent, e.g. varnish, carbon black, fatty acids, pig ⁇ ments separated directly from deinking sludge, fresh extender pigments and/or pitch oil and tar oil and their derivates that can be originated from industrial side streams.
  • carbon black, varnish, pigments separated directly from deinking sludge and/or pitch oil is added into the material component to form a mixture and later a recycling based product.
  • the mixture includes the material component and varnish.
  • the mixture includes the material component and carbon black.
  • the mixture includes the material component, carbon black and varnish.
  • the mix- ture includes the material component and the pitch oil.
  • the mixture includes the mate ⁇ rial component and the pigments separated directly from deinking sludge.
  • the mixture includes the material component, carbon black and the pigments separated directly from deinking sludge.
  • the mixture is utilized as such or in final products.
  • the material component may be in the form of wet slurry, dry powder, dried and ground material, such as fine pulver or powder, or the like.
  • the mixture may be in the form of wet slurry, dry powder, dried and ground material, such as fine pulver or powder, or the like.
  • the material component or the mixture can include one or more material component formed according to the method of the invention.
  • the material component formed only by grinding is mixed with carbon black, varnish, pigments separated directly from deinking sludge and/or pitch oil to form a mixture.
  • the apparatus comprises at least one second mixing stage 9 for forming a composi ⁇ tion from the material component or the mixture which is in the form of wet slurry, dry powder, dried and ground material, such as fine pulver or powder, or the like.
  • the composition is re- ground by wet-grinding after the mixing.
  • Said composition can be e.g. in the form of dispersion, slurry, solution or the like.
  • the dispersing can be carried out by any suitable way, e.g. by mill, such as by three roll mill.
  • the material component or the mixture or the composition is mixed with other ink compounds to form an ink composition or a printing ink composition.
  • Said ink composition can be in the form of dispersion, slurry, solution or the like. It is important in the printing that pH of the printing ink composition is neutral or slightly acidic. Therefore it is important to form a neutral or slightly acidic composition for the printing.
  • carbon black is added into the material component or the mixture or the composi ⁇ tion.
  • carbon black is in the form of carbon black flush.
  • the carbon black is side product in energy or bioenergy production.
  • the carbon black is added into the material component to form a mixture, and the mixture is used in manufacturing a product.
  • the carbon black and the material component is combined in flush to form an ink raw material, paint material or any other colour material.
  • the carbon black is mixed with the boiler ash.
  • the carbon black and the boiler ash are ground at same time, and then the neutralization is carried out after the grinding. If the carbon black and the boiler ash are ground at same time so pigment particles of the boiler ash or the material component may act as a grinding aid. Then the forming of carbon black agglomerates can be reduced. Further, more even print quality can be achieved in the printing. It is preferable to produce a flush which contains both carbon black as a colour pigment and boiler ash based material component as an extender in same flush.
  • the carbon black and var- nish is mixed with the boiler ash. In one embodiment the carbon black and the boiler ash and varnish are ground at same time, and then the neutralization is carried out after or during the grinding.
  • the pigments separated di- rectly from deinking sludge is mixed with the boiler ash. In one embodiment this composition combination are ground at same time, and then the neutralization is carried out after or during the grinding. In one embodiment the carbon black and pigments separated di ⁇ rectly from deinking sludge is mixed with the boiler ash. In one embodiment this composition combination are ground at same time, and then the neutralization is carried out after or during the grinding. In one embodiment the carbon black and pigments separated di ⁇ rectly from deinking sludge and varnish is mixed with the boiler ash. In one embodiment this composition combination are ground at same time, and then the neu ⁇ tralization is carried out after or during the grinding .
  • the pitch oil is mixed with the boiler ash.
  • the boiler ash and pitch oil are ground at same time, and then the neu ⁇ tralization is carried out after or during the grinding .
  • a material component can be used as a bio-based pigment agent, e.g. a colorant, as a filler and/or an extender in different purposes and in different final products.
  • the final product includes the material component, preferably 1 to 100 w-%.
  • the material component can be used in papers, composites, coating colors, printing inks, paints and other suitable products.
  • each product includes also other compo ⁇ nents.
  • the extender composition includes both the material component as extender and fresh extenders.
  • the material component can be used in connection with cyan, magenta and black colours and/or spot colours in final product applica ⁇ tions.
  • black inks it may also include pigments sep ⁇ arated directly from deinking sludge that have been ground after or during the separation of the pigments or together with boiler ash according to this invention.
  • Extenders are used as additional pigments in printing inks.
  • Normally fresh fillers e.g. calcium carbonate or clay, which are ground to small enough particle size are used as extenders.
  • the material com- ponent formed from the boiler ash can offer a cheaper and more ecological alternative to the fresh filler based extender pigments.
  • the material component used as extender has been treated so that it is hydropho- bic. In one embodiment the material component used as extender in the printing ink has been treated so that it is hydrophobic.
  • the end product obtained from this process can, in addition to printing ink extender embodiments, be used also as fine filler in paper embod ⁇ iments or as an extender in coating colors and paints. If acid is used for the neutralization stage, its presence in the final printing ink can improve the emulsifiability of the printing ink and thus render the size distribution of the ink drops more uniform which results more even print quality.
  • a material component is formed from boiler ash so that the particle size of the boiler ash is reduced in at least one stage.
  • the neutralization of the boiler ash is carried out in connection with the particle size re ⁇ duction of the boiler ash, preferably at the same time.
  • the neutralization is made by means of the liquid in connection with the particle size reduction of the boiler ash, e.g. in wet- grinding.
  • the neutralization is not made but the particle size of the boiler ash is re ⁇ Jerusalem, e.g. by grinding, such as by dry-grinding and/or by wet-grinding, in one or more steps, without the neutralization.
  • the particle size reduction can be carried out by any method or device disclosed in this application.
  • the formed material component is used as an extender, e.g. in printing inks.
  • the printing ink composition with neutral properties is obtained from the material component which has been reduced in at least one stage but not neutralized at separate neutralization stage.
  • a neutral mixture or composition is formed from the ma ⁇ terial component in connection with the mixing with other components.
  • the process according to the invention can be a continuous and/or batch process.
  • different boiler ashes can be utilized as secondary raw material for new high value products. Further, different sludges and rejects can be utilized via the forming boiler ash.
  • the present invention provides products with good quality.
  • the method of the present invention offers a possibility to prepare the products from the boiler ash cost-effectively.
  • the present invention provides an industrially applicable, simple and affordable way of treating boiler ash and making the products from boiler ash.
  • a technical effect of the present invention is that boiler ash can be turned into material compo- nent product through particle size reduction and neu ⁇ tralization, and then costs can be saved.
  • An additional technical effect is that the material component of the present invention can replace fresh extenders and fillers and turn waste into product. Further, when the material component of the present invention is used in the printing ink compositions then even print quality is obtained.
  • the method according to the present invention is suitable for use in the manufacture of the differ- ent products from different boiler ashes and sludges that are first incinerated.
  • the present invention brings both economical and ecological benefits.
  • the material component is ecological.
  • the material compo ⁇ nent preserves environment on one hand by reducing landfilling of deinking rejects and on the other hand by replacing fresh filler based extenders with second- ary raw material based extenders. Furthermore, if waste C0 2 is utilized in the neutralization step, the product actually adsorbs this greenhouse gas and thus prevents it from entering the atmosphere.
  • the material component is the extender pigment 24, preferably for printing ink.
  • the extender pigment is formed from ash 21.
  • the extender pigment 24 can be formed from ash 21 such as defined above.
  • the extender 24 can be formed from ash 21 which can be any ash and/or ash type raw material, such as defined above.
  • the ash may include any ash and/or ash component and/or ash type component, for example combustion residue or gasifica ⁇ tion residue or char.
  • the ash can include one or more components.
  • the extender pigment can be formed from one or more ashes or ash components.
  • the extender pigment 24 is in the form of slurry, dis- persion, solution, flush, paste or the like.
  • the extender pigment may be dry component, e.g. in the form of fine pulver or powder.
  • the extender pig ⁇ ment can be used in any final product. In one embodi ⁇ ment the extender pigment is used in the printing ink compositions.
  • the extender pigment product 26 can be formed from the extender pigment 24.
  • the ex ⁇ tender pigment product includes the extender pigment.
  • the extender pigment product may include also other components, e.g. oil, such as mineral oil, tall oil or vegetable oil, fatty acid, additives, varnish, other printing ink component or components, other oil based component or components from refinery, paint or colour vehicle or one or several components of vehicles and/or their combinations.
  • the extender pig ⁇ ment product includes 1 - 100 % by weight extender pigment.
  • the extender pigment prod ⁇ uct is extender pigment.
  • the extender pigment product is in the form of slurry, dispersion, solution, flush, paste, fine pulver or powder or the like.
  • the extender pigment product is selected from the group containing extender varnish, extender base or the like.
  • the ash is selected from the group containing boiler ash, lime kiln ash, residue from the gasification, such as char, and their combinations.
  • a technical effect of the present invention is that the ash with high alkalinity, abrasiveness and inappropriate particle size distribution can be uti ⁇ lized in an extender pigment thanks to the treatment of the present invention.
  • a technical effect of the invention is that different ashes can be utilized to form a new product.
  • An additional technical effect of the invention is that different rejects for example from a waste paper treatment and/or a paper mill and/or waste water treatment plant can be utilized in the incineration in order to produce the ash that is being utilized in the end products, e.g. in the ink compositions. Then envi ⁇ ronmental load decreases.
  • the particle size of the ash is reduced.
  • the ash is treated by reduc ⁇ ing particle size of the ash in at least one stage.
  • the ash is treated by grinding.
  • the ash is ground.
  • the ash is ground as such.
  • the ash is ground in a separate grinding step.
  • the ash is ground during other process step, such as during mixing.
  • particle size reduction 22 means any reduction of the material particle size, e.g. by mechanically.
  • the particle size reduction may be selected from the group of pulverization, grinding, crushing, cutting, chopping, shearing, compressing, breaking up of a material, e.g.
  • the particle size reduction it is important to produce ultrafine particles.
  • abrasiveness of the ash can be reduced during the particle size reduction, such as during the grinding.
  • the particle size reduction can be carried out by means of any suitable method.
  • the parti- cle size reduction can be carried out in one stage or in more than one stage.
  • the particle size reduction stage 22 comprises a grinding device.
  • the particle size reduction can be made in two stages so that the ash is pre-ground by first device to produce fine particles and then is ground by second device to produce ultrafine particles.
  • the particle size reduction containing more than one stage can comprise different devices. It is important that ultrafine parti ⁇ cles are produced in at least the finish particle size reduction stage.
  • the particle size reduction 22 can be carried out by any suitable grinding method and devices, e.g. by dry grinding, such as by fluidized bed jet mill or dry agitating media mill, or by wet grinding, such as by ball mill or pearl mill, or ultra-fine grinding or by any kind of other grinder, e.g. by abrasion resistant grinder, that can produce ultrafine particles, or by their combination.
  • ultra-fine dry grinding is used.
  • the grinding method can be selected from the group consisting of crushing-based grinding, attrition-based grinding, abrasion-based grinding, cutting-based grinding, blasting-based grinding, ex- plosion-based grinding, wet grinding, dry grinding, grinding under pressure, other suitable grinding method and their combinations.
  • the parti ⁇ cle size reduction is carried out by three roll mill treating, such as three roll mill grinding.
  • the grinding device used for grinding is se ⁇ lected from the group consisting of impact mill, air jet mill, sand mill, bead mill, pearl mill, dry agitated pearl mill, ball mill, vibration mill, screw mill, three roll mill, extrusion device, other suita ⁇ ble device and their combinations.
  • the grinding additives can be used.
  • classifiers can be used for obtaining a narrower particle size distribution after the particle size reduction stage. Any classifiers known per se may be used.
  • classifiers can be used for separating a coarse ash fraction from a fine ash frac- tion after the particle size reduction stage, such as after the grinding.
  • the particle size of the coarse ash fraction is again reduced, and after that said fraction is mixed together with the fine ash fraction and is utilized in the process.
  • classifiers can be used for separating a coarse ash fraction from a fine ash fraction before the the parti ⁇ cle size reduction stage, such as before the grinding. The fine ash fraction is used as such and the particle size of the coarse ash fraction is reduced by grinding.
  • the extender pigment has particle size which is in the size range of the ultrafine parti ⁇ cles.
  • the particle size reduction is carried out so that the mean particle size of the ex ⁇ tender pigment is under 100 ym, more preferably under 50 ym.
  • the mean particle size of the extender pigment is measured by the Coulter-device. Alternatively, the mean particle size can be measured by any other suitable device or method.
  • the ash is mixed with first component 28 in the first mixing step 23 and ground.
  • the first component may be selected from the group contain ⁇ ing oil, such as mineral oil, tall oil or vegetable oil, fatty acid, additives, grinding additive, other printing ink component or components, other oil based component or components from refinery and/or their combinations.
  • the extender pigment prod ⁇ uct is formed by mixing ash with first component in the first mixing step and grinding the formed mixture.
  • the ash is treated by mixing with second component 31 in the second mixing step 25 in order to form an extender pigment 4 or extender pigment product 26.
  • the second component may be selected from the group containing oil, such as mineral oil, tall oil or vegetable oil, fatty acid, additives, varnish, other printing ink component or components, other oil based component or components from refinery, paint or colour vehicle or one or several components of vehicles and/or their combinations.
  • Vehicle is either ink, paint or col ⁇ or vehicle which can comprise several substances like water, varnish, oils and the like, and their different combinations.
  • Varnish can include mineral oil, tall oil, vegetable oil or their fractions, e.g. distillates, or their combination.
  • oils or their fractions or distillates can be originated from industrial side streams.
  • the ash is mixed with acid and varnish to form a neutralized extender pigment or extender pigment product.
  • the extender pigment prod ⁇ uct is formed in the second mixing step.
  • the second mixing is a man- ufacturing step of the printing ink composition.
  • the particle size of the ash is reduced in connection with the second mixing, prefer- ably with the strong mixing, during the mixing.
  • the ash may be used as such as extender pigment, e.g. in print ⁇ ing ink, without treating in a separate particle size reduction step.
  • the particle size of the ash may be reduced, for example by grinding, before or after the mixing step.
  • the ash is treated by neu ⁇ tralizing and/hydrophobizing .
  • the ash is treated by neu- tralizing the ash.
  • the neutralizing may be made in connection with the particle size reduction or the mixing, or at a separate neutralizing stage.
  • the ash is neutralized in a liquid composi ⁇ tion at a neutralizing stage.
  • the neutralizing is made during the mixing of the ash with the other component or components.
  • the neutralizing is made during the mixing of the ash with fatty acid or fatty acids.
  • the neutralization is car- ried out after the particle size reduction of ash. In one embodiment the neutralization is carried out be ⁇ fore the particle size reduction of ash. In one embod ⁇ iment the neutralization is carried out at the same time than the particle size reduction of ash.
  • the neutralizing is made with an acid.
  • Any suitable acid known per se e.g. fatty ac ⁇ ids such as stearic acid, oleic acid, myristic acid or caprylic acid or any other fatty acid or mixture of them, can be used in the neutralizing.
  • the fatty acid or fatty acid containing compound is originated from side flows of the wood- or fiber pro ⁇ cessing industry.
  • the ash is hydrophobized.
  • the hydrophobizing the ash is treated so that the ex- tender pigment becomes hydrophobic.
  • the hydrophobizing may be made in connection with the particle size re ⁇ duction or the mixing, or at a separate hydrophobizing stage.
  • the hydrophobizing is made during the mixing of the ash with the other component or components.
  • the hydrophobizing is made during the mixing of the ash by means of fatty acid or fatty acids .
  • the hydrophobizing is carried out after the particle size reduction of the ash. In one embodiment the hydrophobizing is carried out before the particle size reduction of the ash. In one embodiment the hydrophobizing is carried out at the same time with the particle size reduction of the ash. In one embodiment the hydrophobizing is carried out after the particle size reduction of the ash and dur ⁇ ing mixing the ash with other components.
  • the hydrophobizing is car ⁇ ried out so that the ash is mixed with one or more printing ink components and/or fatty acids during the first mixing step 23 and after that the formed mixture is grinded.
  • the ash is treated with fat ⁇ ty acid or fatty acids.
  • Fatty acids can be used for hy ⁇ drophobizing and/or neutralizing the surface of the ash wherein dispersibility of the ash improves with oils and other printing ink components.
  • the ash is neutralized with fatty acids.
  • em ⁇ bodiment pH of the ash is adjusted with fatty acids.
  • the ash is hydrophobized with fatty ac ⁇ ids.
  • Fatty acid may be in a solid form or fatty acid may be in a liquid form.
  • the printing ink is manufactured so that the proportion of extender pigment to fatty acids is between 1000:1 and 1:300.
  • the ash or the extender pigment is surface-treated.
  • the treatment may be se ⁇ lected from the group containing dispersing, hydro- genation, acidifying, making the extender pigment or its surface into hydrophobic, mixing of the extender pigment or ash with other agents, blackening of the extender pigment and their combinations .
  • the dispersing of the extender pigment and mak- ing the extender pigment into hydrophobic are carried out at the same stage.
  • the extender pigment e.g. its surface
  • the extender pigment is treated so that the extender pigment, e.g. its surface, becomes hydrophobic.
  • This treatment can be made by means of any method known per se and/or by means of any suitable agents, e.g. fatty acid, car- boxylic acid, dispersing agents, hydrophobizing agents or any other suitable agents.
  • the extender pigment becomes hydrophobic during the neu- tralization. If the neutralization is carried out by carboxylic acid then the surface of the extender pig ⁇ ment can be turned into hydrophobic during the neu ⁇ tralization .
  • a final product 27 containing an extender pigment or an extender pigment product is formed.
  • the final product is selected from the group containing printing ink composition, paint, e.g. lime wash or silicate paint, grinding paste, polishing wax and composites.
  • the extender pigment or the extender pigment product is used as bulk pigment or filler pigment in paints.
  • the extender pigment or the extender pigment product is used as a component in lime wash to produce colour without other pigments or together with other pig- ments.
  • the extender pigment or the extender pigment product with suitable particle size is used in grinding pastes or polishing waxes.
  • the extender pigment or the extender pigment product is used as an extender in the final product.
  • the extender pigment is mixed with other printing ink components.
  • the extender pigment obtained by the method of the invention may be used as a component in a final product, e.g. in a printing ink composition.
  • the extender pigment is used as an extender pigment product.
  • the extender pig ⁇ ment can be utilized as such in the final product.
  • carbon black, varnish, fatty acid, and/or other additive are added into the extender pig ⁇ ment to form the extender pigment product, and the ex- tender pigment product is used as a component in a fi ⁇ nal product.
  • the extender pigment product contains 1 - 100 % by weight the extender pigment ob ⁇ tained by the method of the invention.
  • the final product contains 1
  • the extender pigment or the extender pigment product can include one or more ex ⁇ tender pigment formed according to the method of the invention .
  • At least one conventional extender which is known per se, is added into the ex- tender pigment to form the extender pigment product.
  • the conventional extender may be formed from virginal or fresh raw material or recy ⁇ cling raw material.
  • the extender pigment product contains the conventional extender 1 - 100 %.
  • the extender pigment is mixed with carbon black, varnish, pigments separated directly from deinking sludge and/or pitch oil to form the extender pigment product.
  • carbon black, varnish, fatty acid and/or other additive are added into the extender pigment in order to form the extender pigment product which may be in the form of flush, paste or extender varnish, and the formed product is used, preferably as an extender, in a printing ink composition.
  • the extender pigment prod ⁇ uct can be formed containing the extender pigment and at least one other component, e.g. varnish, carbon black, pigments separated directly from deinking sludge according to patent application FI20125993, ma ⁇ terial component produced according to this present application, fresh extender pigments and/or pitch oil and tar oil and their derivates that can be originated from industrial side streams.
  • varnish, carbon black, pigments separated directly from dein ⁇ king sludge according to patent application FI20125993 or material component produced according to this pre- sent application and/or pitch oil is added into the ex ⁇ tender pigment to form the extender pigment product and later a recycling based final product.
  • the extender pigment product includes the extend ⁇ er pigment and varnish. In one embodiment the extender pigment product includes the extender pigment and car ⁇ bon black. In one embodiment the extender pigment product includes the extender pigment, carbon black and varnish. In one embodiment the extender pigment product includes the extender pigment and the pitch oil. In one embodiment the extender pigment product includes the extender pigment and the pigments sepa ⁇ rated directly from deinking sludge. In one embodiment the extender pigment product includes the extender pigment and pigments separated directly from deinking sludge according to patent application FI20125993 and/or material component produced according to this present application.
  • the extender pigment product includes the extender pigment, carbon black and the pigments separated directly from dein- king sludge according to patent application FI20125993 and/or material component produced according to this present application.
  • the extender pigment product is utilized as such or in final products.
  • the extender pigment prod ⁇ uct may be in the form of oil based slurry or dry pow ⁇ der.
  • the extender pigment product is in the form of dry powder.
  • the ex ⁇ tender pigment product consists of the extender pig ⁇ ment and it is in the form of dry powder.
  • the extender pigment product includes the ex ⁇ tender pigment containing ash, and the extender pig- ment product is in the form of dry powder.
  • the extender pigment product includes the ex ⁇ tender pigment containing ash and fatty acids, and the extender pigment product is in the form of dry powder.
  • the extender pigment product con- tains the extender pigment and oil, e.g. mineral oil, tall oil, vegetable oil or the like.
  • the extender pigment contains ash.
  • the extender pigment contains ash and fatty acids .
  • the extender pigment product is in the form of flush or paste containing the extender pigment and oil.
  • the extender pigment or the extender pigment product is post-ground, e.g. by wet- grinding, and/or dispersed after the mixing.
  • the dis- persing can be carried out by any suitable way, e.g. by mill, such as by three roll mill.
  • the extender pigment is formed for printing ink from ash.
  • the ash can be treated or used as such in order to form the extender pig- ment.
  • the extender pigment is used, preferably as an extender, in a printing ink composition. If the ash is used as such so then the ash is mixed with other printing ink components to form printing ink composition. Preferably, the particle size of the ash is reduced during the mixing. Then the extender pigment, and also extender pigment product, is formed during the printing ink mixing. In one embodiment the extender pigment or the extender pigment product is mixed with other ink compounds to form an ink composition or a printing ink composition. Said ink composition can be in the form of dispersion, slurry, solution, flush, paste or the like .
  • fatty acid is added into the extender pigment or the extender pigment product.
  • Fatty acids can be used for hydrophobizing and/or neu- tralizing the extender pigment.
  • fatty ac ⁇ ids which are present for example in printing ink composition are able to hydrophobize and/or neutralize the extender pigment.
  • the extender pigment which has been mixed with printing ink components to form printing ink composition may be ground in the printing ink composition.
  • carbon black is added into the extender pigment or the extender pigment product.
  • carbon black is in the form of carbon black flush.
  • the carbon black is side product in energy or bioenergy production.
  • the carbon black is added into the extender pigment to form the extender pigment product, and the extender pigment product is used in manufacturing a final product. In one embodiment the carbon black and the extender pigment is combined in flush to form an ink raw material, paint material or any other colour material.
  • the carbon black is mixed with the ash.
  • the carbon black and the ash are treated at same time. If the carbon black and the ash are ground at same time so pigment parti ⁇ cles of the ash may act as a grinding aid. Then the forming of carbon black agglomerates can be reduced. Further, more even print quality can be achieved in the printing. It is preferable to produce a flush which contains both carbon black as a colour pigment and ash based extender pigment as an extender in same flush .
  • the carbon black and var ⁇ nish is mixed with the ash.
  • the car- bon black and the ash and varnish are treated, e.g. ground, at same time.
  • the pigments separated di ⁇ rectly from deinking sludge according to patent appli ⁇ cation FI20125993 and/or material component produced according to this present application is mixed with the ash.
  • this composition combina ⁇ tion is treated, e.g ground, at same time.
  • the carbon black and pigments separated di ⁇ rectly from deinking sludge according to patent appli- cation FI20125993 and/or material component produced according to this present application is mixed with the ash.
  • this composition combina ⁇ tion is treated, e.g. ground, at same time.
  • the carbon black and pigments separated di- rectly from deinking sludge according to patent appli ⁇ cation FI20125993 and/or material component produced according to this present application and varnish is mixed with the ash.
  • this composition combination is treated, e.g. ground, at same time.
  • the pitch oil is mixed with the ash. In one embodiment the ash and pitch oil are treated, e.g ground at same time.
  • an extender pigment can be used as a bio-based pigment agent, e.g. a colorant, as a filler and/or as an extender in different purposes and in different final products.
  • the ex ⁇ tender pigment can be used in papers, composites, coating colors, printing inks, paints and other suita ⁇ ble products.
  • each final product includes also other components.
  • the extender pigment product includes both the extender pigment of the invention and fresh extenders.
  • the ex- tender pigment can be used in connection with cyan, magenta and black colours and/or spot colours in final product applications. In black inks it may also in ⁇ clude pigments separated directly from deinking sludge that have been ground after or during the separation of the pigments or together with ash according to this invention .
  • Extenders may be used as additional pigments in printing inks.
  • Normally fresh fillers e.g. calcium carbonate or clay, which are ground to small enough particle size are used as extenders.
  • the extender pig ⁇ ment formed from the ash can offer a cheaper and more ecological alternative to the fresh filler based ex ⁇ tender pigments.
  • the extender pigment has been treated so that it is hydrophobic.
  • the extender pigment used as extender in the printing ink has been treated so that it is hydropho ⁇ bic .
  • fatty acid is used for the neutralizing and/or hydrophobizing, its presence in the final printing ink can improve the emulsifiability and dis- persibility of the printing ink. Furthermore, the hy- drophobized ash stays in the printing ink better com- pared to conventional extender without transferring to fountain solution.
  • an extender pigment 24 is formed from ash 21 so that the particle size of the ash is reduced in at least one stage 22.
  • the neutralization of the ash is carried out in connection with the particle size reduction 22 of the ash, preferably at the same time.
  • the neutralization is made by means of suitable liquid in connection with the particle size reduction of the ash, e.g. in wet-grinding.
  • the neu ⁇ tralization is not made but the particle size of the ash is reduced, e.g. by grinding, such as by dry- grinding and/or by wet-grinding, in one or more steps, without the neutralization.
  • the particle size reduc ⁇ tion can be carried out by any method or device dis ⁇ closed in this application.
  • the formed extender pig- ment or extender pigment product is used as an extend ⁇ er, e.g. in printing inks.
  • the printing ink composition with neutral properties is obtained from the extender pigment of which particle size has been reduced in at least one stage but the extender pigment has not been neutralized at separate neutralization stage.
  • a neutral mix ⁇ ture or composition is formed from the extender pig ⁇ ment in connection with the mixing with other components .
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed with printing ink components 30, e.g. by means of three roll mill, in a printing ink mixing step 29.
  • the ash 21 is used as such as the extender pigment.
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed in the second mixing step 25 with other components by a strong mixing in a suitable device, e.g. in three roll mill. Simultaneously the particle size of the ash is reduced.
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed in the second mixing step 25 with other components containg fatty acids by a strong mixing in a suitable device, e.g. in three roll mill. Simultaneously the particle size of the ash is reduced and the ash is neutralized and turned into hydrophobic thanks to fatty acids.
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed in the second mixing step 5 with fatty acids by a strong mix ⁇ ing in a suitable device, e.g. in three roll mill, and after that they are mixed with printing ink components 30 in the printing ink mixing step 29. Simultaneously the particle size of the ash is reduced and the ash is neutralized and turned into hydrophobic thanks to fat ⁇ ty acids .
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed in the second mixing step 25 with fatty acids and mineral oil by a strong mixing in a suitable device, e.g. in three roll mill, and after that they are mixed with printing ink components 30 in the printing ink mixing step 29. Simultaneously the particle size of the ash is reduced and the ash is neutralized and turned into hydrophobic thanks to fatty acids .
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed in the second mixing step 25 with mineral oil by a strong mixing in a suitable device, e.g. in three roll mill, and after that they are mixed with printing ink compo ⁇ nents 30 in the printing ink mixing step 29. Simulta- neously the particle size of the ash is reduced.
  • an extender pigment 24 is formed from ash 21 so that the ash is ground in the grinding step 22. After the grinding 22 the extender pigment 24 is mixed with printing ink components 30 in the printing ink mixing step 29. In one embodiment an extender pigment 24 is formed from ash 21 so that the ash is ground by ultra-fine dry-grinding 22.
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed with printing ink components in the first mixing step 23 and after that they are ground in the grinding step 22.
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed with min- eral oil in the first mixing step 23 and after that they are ground in the grinding step 22.
  • the formed mixture is mixed with printing ink components 30 in the printing ink mixing step 29.
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed with addi- tives in the first mixing step 23 and after that they are ground in the grinding step 22.
  • the formed mixture is mixed with printing ink components 30 in the print ⁇ ing ink mixing step 29.
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed with fatty acids in the first mixing step 23 and after that they are ground in the grinding step 22.
  • dry-grinding preferably ultra-fine dry-grinding, is used.
  • the formed mixture is mixed with printing ink components 30 and/or oil in the printing ink mixing step 29.
  • the extender pigment is neutralized and turned into hydrophobic thanks to fat ⁇ ty acids .
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed with fatty acids and mineral oil in the first mixing step 23 and after that they are ground in the grinding step 22.
  • the formed mixture is mixed with printing ink compo ⁇ nents 30 in the printing ink mixing step 29. Simulta- neously the the extender pigment is neutralized and turned into hydrophobic thanks to fatty acids.
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed with fatty acids 28 in the first mixing step 23 and after that the mixture including ash and fatty acids is ground in the grinding step 22. After the grinding 22 the extender pigment 24 is mixed with printing ink components 30 in the printing ink mixing step 29. Simulta ⁇ neously the extender pigment is neutralized and turned into hydrophobic thanks to fatty acids.
  • an extender pigment 24 is formed from ash 21 so that the ash is mixed with fatty acids 28 in the first mixing step 23 and after that the mixture including ash and fatty acids is ground in the grinding step 22.
  • the extender pigment is mixed with mineral oil 31 in the second mixing step 25 in order to form an extender pigment product 26.
  • the extender pigment product 26 is mixed with printing ink components 30 in the print ⁇ ing ink mixing step 29. Simultaneously the extender pigment product is neutralized and turned into hydro- phobic thanks to fatty acids.
  • the process according to the invention can be a continuous and/or batch process.
  • different ashes can be utilized as secondary raw material for new high value products. Further, different sludges and rejects can be utilized via the forming ash.
  • the present in ⁇ vention provides products with good quality.
  • the meth ⁇ od of the present invention offers a possibility to prepare the products from the ash cost-effectively.
  • the present invention provides an industrially appli ⁇ cable, simple and affordable way of treating ash and making the products from ash.
  • the ash can be utilized economically and ecologically.
  • a technical effect of the present invention is that ash can be turned into extender pigment prod ⁇ uct, and then costs can be saved.
  • An additional tech ⁇ nical effect is that the extender pigment of the pre ⁇ sent invention can replace fresh extenders and fillers and turn waste into product.
  • the method according to the present invention is suitable for use in the manufacture of the differ ⁇ ent products from different ashes and sludges that are first incinerated.
  • the present invention brings both economical and ecological benefits.
  • the extender pig- ment is ecological.
  • the extender pigment preserves en ⁇ vironment on one hand by reducing landfilling of dein- king rejects, lime kiln ash and gasification rejects and on the other hand by replacing fresh filler based extenders with secondary raw material based extenders.
  • a material component is formed from a boiler ash 1 originated from incineration of a sludge comprising deinking sludge.
  • the boiler ash 1 is fed to the apparatus, and the boiler ash is treated so that particle size of the boiler ash is reduced by dry grinding in a particle size reduction stage 2 and the boiler ash 1 is neu ⁇ tralized in a neutralizing stage 3 to form a material component 4.
  • a liquid 5 is added into the boiler ash before the neutralizing stage 3.
  • a material component is formed from a boiler ash 1 originated from incineration of a sludge comprising deinking sludge.
  • the boiler ash 1 is fed to the apparatus, and the boiler ash is treated so that the boiler ash 1 is neutralized in a neutralizing stage 3 and particle size of the boiler ash is reduced by wet grinding in a particle size reduction stage 2 to form a material component 4.
  • a liquid 5 is added into the boiler ash before the neutralizing stage 3.
  • Example 3 In these tests a material component was formed separately from two boiler ashes, ash A and ash B, originated from deinking sludge. This process is shown in figure 3.
  • the ash, ash A or ash B, 1 was first ground in a grinding stage 2 with a fluidized bed opposed jet mill, and then mixed with water 5 to form a liquid composition with about 15 % concentration and neutral- ized in a neutralizing stage 3 by introducing C0 2 to the ash slurry until pH of the slurry remained at about 7. Grinding pressure was about 10 bar and clas ⁇ sifier speed was about 22 000 rpm. After the neutral ⁇ izing stage 3, an excess of water 7 was removed 16 from material component slurry 8 to provide dry con ⁇ tent of the material component over 20 %.
  • the specific surface area of the material components were 38.94 m 2 /g (ash B) and 62.9 m 2 /g (ash A) .
  • the mean particle sizes of the material components measured by Coulter- device were 5.66 ym (ash B) and 4.323 ym (ash A) .
  • the neutralized material component 4 was mixed with other printing ink compounds 10 in a mixing stage 9 to form a printing ink composition 11.
  • Laboratory scale printing experiments were carried out with the Prtifbau device. Even print quality was obtained with both A and B ash based extenders. ISO brightnesses of the produced extenders were surpris ⁇ ingly high, 74.8 % and 82.4 %.
  • Example 4 In the tests it was observed that good and even print quality was obtained with the material com ⁇ ponent containing printing ink. Further, it was observed that the material component can be used as the extender in connection with black inks, cyan inks and/or magenta inks thanks to good optical properties. Further, it was observed that the material component has high specific surface area.
  • the ashes 1 was first ground in a dry grind ⁇ ing stage 2 with an ultrafine grinder by means of typ ⁇ ical grinding additive and then mixed with water 5 to form a liquid composition with about 15 % concentra ⁇ tion, and neutralized in a neutralizing stage 3 by in ⁇ troducing C0 2 to the ash slurry until pH of the slurry remained at about 7.
  • the neutralized material compo ⁇ nent 8 was dried in a drying stage 6 at temperature about 105 °C to form a dry cake.
  • the cake 13 was re- ground in a re-grinding stage 12 to form pulverized material component 14 which was mixed with other printing ink compounds 10 in a mixing stage 9 to form a printing ink composition 11.
  • Laboratory scale print- ing experiments were carried out with the Prtifbau de ⁇ vice .
  • the specific surface area of the material components were 33.53 m 2 /g (ash B) and between 33.56 - 69.01 m 2 /g (ash A) .
  • the mean particle size of the ma- terial components measured by Coulter-device were 3.648 ym (ash B) and between 4.211 - 4.461 ym (ash A) .
  • a particle size and dispersibility are im ⁇ portant for the material component formed in the pro ⁇ cess according to the invention.
  • the mate ⁇ rial component of the invention is used to replace ex ⁇ pensive pigments and extenders.
  • an extender pigment 24 is formed from a boiler ash 21 originated from incineration of a sludge comprising deinking sludge.
  • the ash 21 is used as such as the ex ⁇ tender pigment.
  • the ash 21 is fed to a printing ink mixing step 29 in which the ash is mixed with printing ink components 30 by means of three roll mill. During the printing ink mixing the ash is grinded by the three roll mill wherein an extender pigment is formed.
  • the printing ink components may contain fatty acids.
  • a final product 27 including printing ink components and extender pigment is formed in the printing ink mixing 29.
  • an extender pigment 24 is formed from a boiler ash 21 originated from incineration of a sludge comprising deinking sludge.
  • the ash is ground in the grinding step 22 which may be ultra-fine dry-grinding.
  • the extender pigment 24 is mixed with with printing ink components 30 in the printing ink mixing step 29.
  • the printing ink components may con- tain fatty acids.
  • a final product 27 including print ⁇ ing ink components and extender pigment is formed in the printing ink mixing 29.
  • an extender pigment 24 can be used as an extender pigment product 26 before the printing ink mixing 29.
  • an extender pigment 24 is formed from a boiler ash 21 originated from incineration of a sludge comprising deinking sludge.
  • the ash is mixed with fatty acids 28 in the first mixing step 23 and after that the mixture including ash and fatty acids is ground in the grind ⁇ ing step 22 which may be ultra-fine dry-grinding in order to form the hydrophobic extender pigment 24.
  • the extender pigment is in the form of hydrophobic powder.
  • the extender pigment 24 is mixed with with printing ink components 30 in the printing ink mixing step 29.
  • the printing ink components may contain additional fatty acids.
  • a final product 27 in ⁇ cluding printing ink components and extender pigment is formed in the printing ink mixing 29.
  • an extender pigment 24 can be used as an extender pigment product 26 before the printing ink mixing 29.
  • an extender pigment 24 is formed from a boiler ash 21 originated from incineration of a sludge comprising deinking sludge.
  • the ash is mixed with fatty acids 28 in the first mixing step 23 and after that the mixture including ash and fatty acids is ground in the grind ⁇ ing step 22 which may be ultra-fine dry-grinding in order to form the hydrophobic extender pigment 24.
  • the extender pigment is mixed with mineral oil 31 in the second mixing step 25 in order to form an extender pigment product 26.
  • the extender pigment product 26 may be in the form of flush or paste.
  • the extender pigment product has good flow properties and viscosity properties.
  • the extender pigment product 26 is mixed with with print ⁇ ing ink components 30 in the printing ink mixing step 29.
  • the printing ink components may contain additional fatty acids.
  • a final product 27 including printing ink components and extender pigment product is formed in the printing ink mixing 29.
  • an extender pigment product 26 can be utilized separately.
  • the ash was mixed with about 1 % of fatty acid.
  • the mixture was dry-ground with a ball mill.
  • a hydrophobic powder was obtained that was mixed with mineral oil. Even with 60 % ash consistency, an ash-oil paste with good flow and viscosity properties was obtained.
  • an extender pigment was formed from a boiler ash originated from incineration of a sludge comprising deinking sludge.
  • the ash was ground with a dry agitating media mill to 1.824 ym mean particle size (Coulter) . 1 % of grinding additive was used in the dry grinding. In- stead of fresh extender pigments the ground ash powder was mixed with other printing ink compounds and the laboratory printing experiments were carried out with the Prtifbau device. The laboratory results indicate that most of the ground ash stays in the printing ink without transferring to the fountain solution. Furthermore, even print quality was obtained with the printing ink containing the ground ash as extender pigment . In the tests it was observed that the extend ⁇ er pigment of the invention can be used to replace ex- pensive fresh raw material based and/or conventional pigments and extenders.
  • the material components according to the pre- sent invention are suitable in different embodiments to be used in different products.
  • the method according to the present invention is suitable in different em ⁇ bodiments to be used for manufacturing the most dif ⁇ ferent kinds of material components.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Inorganic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Processing Of Solid Wastes (AREA)
EP13841588.0A 2012-09-25 2013-09-25 Verfahren und vorrichtung zur herstellung einer materialkomponente, materialkomponente und deren verwendung, streckmittelpigmentprodukt und endprodukt Withdrawn EP2900864A4 (de)

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FI20125992 2012-09-25
FI20135599 2013-05-30
PCT/FI2013/050934 WO2014049206A1 (en) 2012-09-25 2013-09-25 Method and apparatus for manufacturing a material component, a material component and its use, an extender pigment product and a final product

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WO1996032354A1 (en) * 1995-04-11 1996-10-17 Ecc International Ltd. Treatment of solid-containing material derived from effluent
JP2001011337A (ja) * 1999-06-29 2001-01-16 Oji Paper Co Ltd 焼却灰を原料とした白色顔料の製造方法
JP2002030231A (ja) * 2000-07-17 2002-01-31 Oji Paper Co Ltd 焼却灰を原料とする白色顔料及びその製造方法並びにその製造装置
JP3819706B2 (ja) * 2000-11-29 2006-09-13 大王製紙株式会社 白色顔料の製造方法
JP2002356629A (ja) * 2001-05-30 2002-12-13 Nippon Kakoh Seishi Kk 顔料塗工古紙の脱墨スラッジを原料とする白色顔料の製造方法
JP2004176208A (ja) * 2002-11-27 2004-06-24 Nippon Paper Industries Co Ltd 塗工紙製造工程の排水処理汚泥からの填料の製造方法およびこれを充填した紙
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