Classifications

• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP 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
  • D21H3/00—Paper or cardboard prepared by adding substances to the pulp or to the formed web on the paper-making machine and by applying substances to finished paper or cardboard (on the paper-making machine), also when the intention is to impregnate at least a part of the paper body
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP 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
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/03—Non-macromolecular organic compounds
  • D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
  • D21H17/14—Carboxylic acids; Derivatives thereof
  • D21H17/15—Polycarboxylic acids, e.g. maleic acid
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP 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
  • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
  • D21H11/16—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only modified by a particular after-treatment
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP 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
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/63—Inorganic compounds
  • D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
  • D21H17/675—Oxides, hydroxides or carbonates
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP 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
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/63—Inorganic compounds
  • D21H17/70—Inorganic compounds forming new compounds in situ, e.g. within the pulp or paper, by chemical reaction with other substances added separately
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP 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
  • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
  • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
  • D21H23/04—Addition to the pulp; After-treatment of added substances in the pulp

Definitions

• the present invention relates to a filler-fiber composite, a process for its production, the use of such in the manufacture of paper or paperboard products and to paper produced therefrom. More particularly the invention relates to a filler-fiber composite in which the morphology and particle size of the mineral filler are established prior to the development of the bond to the fiber. Even more particularly, the present invention relates to a PCC filler-fiber composite, wherein the desired optical and physical properties of the paper produced therefrom are realized.
• an object of the present invention is to produce a filler-fiber composite. Another object of the present invention is to provide a method for producing a filler-fiber composite. While another object of the present invention is to produce a filler-fiber composite that maintains physical properties such as tensile strength, breaking length and internal bond strength. Still a further object of the present invention is to produce a filler-fiber composite that maintains optical properties such as ISO opacity and pigment scatter. While still a further object of the present invention is to provide a filler-fiber composite that is particularly useful in paper and paperboard products.
• U.S. Pat. No. 6,156,118 teaches mixing a calcium carbonate filler with noil fibers in a size of P50 or finer.
• U.S. Pat. No. 5,223,090 teaches a method for loading cellulosic fiber using high shear mixing of crumb pulp during carbon dioxide reaction.
• U.S. Pat. No. 5,665,205 teaches a method for combining a fiber pulp slurry and an alkaline salt slurry in the contact zone of a reactor and immediately contacting the slurry with carbon dioxide and mixing so as to precipitate filler onto secondary pulp fibers.
• U.S. Pat. No. 5,679,220 teaches a continuous process for in-situ deposition of fillers in papermaking fibers in a flow stream in which shear is applied to the gaseous phase to complete the conversion of calcium hydroxide to calcium carbonate immediately.
• U.S. Pat. No. 5,122,230 teaches process for modifying hydrophilic fibers with a substantially water insoluble inorganic substance in-situ precipitation.
• U.S. Pat. No. 5,733,461 teaches a method for recovery and use of fines present in a waste water stream produced in a paper manufacturing process.
• U.S. Pat. No. 5,731,080 teaches in-situ precipitation wherein the majority of a calcium carbonate trap the microfiber by reliable and non-reliable mechanical bonding without binders or retention aids.
• U.S. Pat. No. 5,928,470 teaches method of making metal oxide or metal hydroxide-modified cellulosic pulp.
• U.S. Pat. No. 6,235,150 teaches a method of producing a pulp fiber lumen loaded with calcium carbonate having a particle size of 0.4 microns to 1.5 microns.
• the present invention relates to a filler-fiber composite including feeding slake containing seed to a first stage reactor, reacting the slake containing seed in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry, reacting the first partially converted calcium hydroxide calcium carbonate slurry in a second stage reactor in the presence of carbon dioxide to produce a second partially converted calcium hydroxide calcium carbonate slurry and reacting the second partially converted calcium hydroxide calcium carbonate slurry in a third stage reactor in the presence of carbon dioxide and fibers to produce a filler-fiber composite.
• the present invention relates to a filler-fiber composite including feeding slake containing seed to a first stage reactor, reacting the slake containing seed in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry and reacting the first partially converted calcium carbonate slurry in a second stage reactor in the presence of carbon dioxide and fibers to produce a filler-fiber composite.
• the present invention relates to a filler-fiber composite including feeding slake containing citric acid to a first stage reactor, reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry, reacting the first partially converted calcium hydroxide calcium carbonate slurry in a second stage reactor in the presence of carbon dioxide to produce a second partially converted calcium hydroxide calcium carbonate slurry, and reacting the second partially converted calcium hydroxide calcium carbonate slurry in a third stage reactor in the presence of carbon dioxide and fibers to produce a filler-fiber composite.
• the present invention relates to a filler-fiber composite Including feeding slake containing citric acid to a first stage reactor, reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry, taking a first portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibers and reacting such in a second stage reactor in the presence of carbon dioxide to produce a calcium carbonate ⁇ fiber composite to serve as a heel and taking a second portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibers and surfactant and reacting in the presence of CO 2 to produce a second partially converted Ca(OH) 2 /CaCO 3 /fiber material and reacting the second partially converted Ca(OH) 2 /CaCO 3 /fiber material in the presence of CO 2 in a third stage reactor to produce a filler-fiber composite.
• the present invention relates to a filler-fiber composite including feeding slake containing citric acid to a first stage reactor, reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a first partially converted calcium hydroxide calcium carbonate slurry, taking a first portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibers and reacting such in a second stage reactor in the presence of carbon dioxide to produce a calcium carbonate/fiber composite to serve as a heel and taking a second portion of the partially converted calcium hydroxide calcium carbonate slurry adding fibers and polyacrylamide and reacting in the presence of CO 2 to produce a second partially converted Ca(OH) 2 /CaCO 3 /fiber material and reacting the second partially converted Ca(OH) 2 /CaCO 3 /fiber material in the presence of CO 2 in a third stage reactor to produce a filler-fiber composite.
• the present invention relates to a filler-fiber composite including feeding slake containing citric acid to a first stage reactor, reacting the slake containing citric acid in the first stage reactor in the presence of carbon dioxide to produce a CaCO 3 heel and adding slake containing sodium carbonate to the heel material of the first stage reactor in the presence of CO 2 to produce a partially converted calcium hydroxide calcium carbonate slurry and reacting the partially converted calcium hydroxide calcium carbonate slurry in a second stage reactor in the presence of carbon dioxide and fibers to produce a filler-fiber composite.
• Fiber as used in the present invention is defined as fiber produced by refining (any pulp refiner known in the pulp processing industry) cellulose and/or mechanical pulp fiber.
• the fibers are typically 0.1 to 2 microns in thickness and 10 to 400 microns in length and are additionally prepared according to U.S. Pat. No. 6,251,222, which is by this reference incorporated herein.
• the first step in this process involves making a high reactive Ca(OH) 2 milk-of-lime slake and screening it at ⁇ 325 mesh. This slake is then added to an agitated reactor, brought to a desired reaction temperature, 0.1 percent citric acid is added to the slake to inhibit aragonite formation, and reacted with CO 2 gas. The reaction proceeds 10 percent to 40 percent of the way through at which point the reaction is stopped. This produces a partially converted Ca(OH) 2 /CaCO 3 slurry (approximately 20 percent solids by weight) which is then fed into a reaction vessel at a rate that matches CO 2 gassing to maintain a given conductivity (ionic saturation) to produce a scalenohedral crystal.
• the product made once stabilization is achieved (approximately 95 percent converted) is then mixed with diluted fibers (approximately 1.5 percent concentration) and water. This mixture is then reacted with CO 2 gas to endpoint pH 7.0.
• the product manufactured using this method can contain from about 0.2 percent to about 99.8 percent scalenohedral PCC with respect to fibers at 3 percent to 5 percent total solids.
• the product has a specific surface area from about 5 meters squared per gram to about 11 meters squared per gram; product solids from about 3 percent to about 5 percent and a PCC content from about 0.2 percent to about 99.8 percent, and is predominantly scalenohedral in morphology.
• the first step in this process involves making a high reactive Ca (OH) 2 milk-of-lime slake and screened at ⁇ 325 mesh.
• the concentration of this slake is approximately 15 percent by weight.
• This slake is then added to an agitated reactor, brought to a desired reaction temperature, from about 0.05 percent to about 0.04 percent additive is added to direct morphology and size, and reacted with CO 2 gas.
• the reaction proceeds 10 percent to 40 percent of the way through at which point the reaction is stopped.
• This produces a partially converted Ca (OH) 2 /CaCO 3 slurry which is then fed into a reaction vessel at a rate that matches CO 2 gassing to maintain a given conductivity (ionic saturation) to produce an acicular, aragonitic crystal.
• the reaction continues until process stabilization is achieved.
• the product made once stabilization is achieved (approximately 95 percent calcium carbonate) is mixed with diluted fibers (approximately 1.5 percent concentration) and water.
• the calcium carbonate and fibers are then reacted with CO 2 gas to an endpoint of pH 7.0.
• the product manufactured using this method contains from about 0.2 percent to about 99.8 percent aragonitic PCC with respect to the fibers at about 3 percent to about 5 percent total solids.
• the product has a specific surface area of about 5 meters squared per gram to about 8 meters squared per gram; product solids from about 3 percent to about 5 percent by weight and a PCC content from about 0.2 percent to about 99.8 percent with respect to fibers and has a predominantly aragonitic morphology.
• the first step in this process involves making a high reactive Ca (OH) 2 milk-of-lime slake which is screened at ⁇ 325 mesh and has a concentration of approximately 20 percent by weight. 0.1 percent citric acid is added to inhibit aragonite formation. A portion of this slake is added to an agitated reactor, brought to a desired reaction temperature and carbonated with CO 2 gas. The reaction proceeds to conductivity minimum producing a “heel”.
• a “heel” is defined as a fully converted calcium carbonate crystal with average particle size typically in the range of about 1 micron to about 2.5 micron with any crystal morphology. Sodium carbonate is added to the remainder of the slake not used in the manufacture of the “heel” material.
• This slake and CO 2 is added to the “heel” material at a CO 2 gassing rate to maintain a given conductivity (ionic saturation) to produce a rhombohedral crystal.
• the reaction is continued until process stabilization is achieved.
• this product (approximately 90 percent to 95 percent converted) is mixed with diluted fibers (approximately 1.5 percent concentration) and water. Additional CO 2 is added to an endpoint of pH 7.0.
• the product manufactured using this method contains from about 0.2 percent to about 99.8 percent rhombohedral PCC with respect to fibers and is about 3 percent to about 5 percent total solids.
• the product has a specific surface area from about 5 meters squared per gram to about 8 meters squared per gram; product solids from about 3 percent to about 5 percent; and PCC content from about 0.2 percent to about 99.8 percent and has a predominantly rhombohedral morphology:
• a “seed” is defined as a fully converted aragonitic crystal that has been endpointed and milled to a high specific surface area (i.e. greater than 30 meters squared per gram and typically a particle size of 0.1 to 0.4 microns).
• the 2.3:1 Ca(OH) 2 /CaCO 3 slurry was transferred to an agitated 20-liter storage vessel. Transferred 2 liters of the 2.3:1 Ca(OH) 2 /CaCO 3 slurry to a first 4-liter agitated, double jacketed stainless steel reaction vessel with agitation set at 1250rpm and the temperature was brought to 52 degrees Celsius. Began addition of 20 percent CO 2 gas in air (1.00 standard liter minute CO 2 /3.99 standard liter minute air) to the first 4-liter reaction vessel and the reaction was continued until a pH of 7.0 was achieved producing a 100 percent CaCO 3 slurry. The temperature of the 100 percent CaCO 3 slurry of the first 4-liter reaction vessel was brought to 63 degrees Celsius.
• control fiber of the present invention was refined at the Empire State Paper Research Institute (ESPRI) using an Escher-Wyss (conical) refiner to an 80° SR (freeness). Measured by a fiber quality analyzer (using arithmatic means) the control fiber measured 200-400 microns
• the morphology controlled filler-fiber composite showed equivalent or greater physical properties (i.e. tensil strength, breaking length, and internal bond strength) as compared with the control filler-fiber.
• TABLE 4 ISO Opacity Optical Properties Filler Loading Scalenohedral Aragonitic Rhombohedral Control Levels Filler-fiber Filler-fiber Filler-fiber Filler-fiber 20 89.20 88.20 87.38 88.18 25 89.93 89.15 88.78 89.55 30 90.95 90.40 89.68 90.83
• the morphology controlled filler-fiber composite showed equivalent optical properties (i.e. ISO Opacity and Pigment Scatter) as compared with the control filler-fiber.

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• Chemical & Material Sciences (AREA)
• Inorganic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Paper (AREA)
• Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)

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Applications Claiming Priority (1)

Publications (1)

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Cited By (15)

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Citations (4)

Family Cites Families (9)

• 2002
  • 2002-12-09 US US10/314,584 patent/US20040108081A1/en not_active Abandoned
• 2003
  • 2003-12-03 RU RU2005121567/04A patent/RU2005121567A/ru not_active Application Discontinuation
  • 2003-12-03 CA CA002509514A patent/CA2509514A1/en not_active Abandoned
  • 2003-12-03 EP EP03790217A patent/EP1576236A1/en not_active Withdrawn
  • 2003-12-03 JP JP2004559205A patent/JP2006509118A/ja not_active Withdrawn
  • 2003-12-03 AU AU2003293225A patent/AU2003293225A1/en not_active Abandoned
  • 2003-12-03 WO PCT/US2003/038218 patent/WO2004053229A1/en not_active Application Discontinuation
  • 2003-12-03 CN CNA200380105511XA patent/CN1723314A/zh active Pending
  • 2003-12-03 BR BR0316926-0A patent/BR0316926A/pt not_active IP Right Cessation
  • 2003-12-04 CL CL200302529A patent/CL2003002529A1/es unknown
  • 2003-12-05 AR ARP030104509A patent/AR042328A1/es not_active Application Discontinuation
  • 2003-12-05 UY UY28107A patent/UY28107A1/es not_active Application Discontinuation
  • 2003-12-06 KR KR1020030088374A patent/KR20040050051A/ko not_active Application Discontinuation
  • 2003-12-09 TW TW092134687A patent/TW200500534A/zh unknown
• 2005
  • 2005-06-27 NO NO20053138A patent/NO20053138L/no not_active Application Discontinuation

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