US20060106118A1 - Grinding method - Google Patents

Grinding method Download PDF

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Publication number
US20060106118A1
US20060106118A1 US10/523,105 US52310505A US2006106118A1 US 20060106118 A1 US20060106118 A1 US 20060106118A1 US 52310505 A US52310505 A US 52310505A US 2006106118 A1 US2006106118 A1 US 2006106118A1
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Prior art keywords
inorganic particulate
particulate material
aqueous suspension
dispersant
grinding
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US10/523,105
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English (en)
Inventor
John Husband
Nigel Jarvis
Charles Payton
David Skuse
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Imerys Minerals Ltd
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Imerys Minerals Ltd
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Application filed by Imerys Minerals Ltd filed Critical Imerys Minerals Ltd
Assigned to IMERYS MINERALS LIMITED reassignment IMERYS MINERALS LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JARVIS, NIGEL V., HUSBAND, JOHN CLAUDE, PAYTON, CHARLES DESMOND, SKUSE, DAVID ROBERT
Publication of US20060106118A1 publication Critical patent/US20060106118A1/en
Priority to US12/728,917 priority Critical patent/US7938346B2/en
Abandoned legal-status Critical Current

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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
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    • C04B35/6261—Milling
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    • C01F11/00—Compounds of calcium, strontium, or barium
    • C01F11/18—Carbonates
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    • C09C3/00—Treatment in general of inorganic materials, other than fibrous fillers, to enhance their pigmenting or filling properties
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    • C09C3/00—Treatment in general of inorganic materials, other than fibrous fillers, to enhance their pigmenting or filling properties
    • C09C3/04—Physical treatment, e.g. grinding, treatment with ultrasonic vibrations
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    • C08K3/346—Clay

Definitions

  • This invention relates to a method of grinding an aqueous suspension of an inorganic particulate material and to products obtained thereby.
  • Aqueous suspensions containing inorganic particulate material for example an alkaline earth metal (e.g. calcium) carbonate or kaolin, are used widely in a number of applications. These include, for example, the production of pigment or filler containing compositions which may be used in paper manufacture or paper coating, and the production of filled compositions for paints, plastics and the like.
  • alkaline earth metal e.g. calcium
  • the inorganic particulate material typically has a known particle size distribution (psd), dictated by the intended end use in ways which are well known in the art.
  • psd particle size distribution
  • the required psd is obtained by a method which includes grinding the inorganic particulate material in an aqueous suspension.
  • the suspension may contain a high (e.g. above about 50% by weight) or low (e.g. below about 50% by weight) content of the inorganic particulate solids.
  • aqueous suspension has a high solids content
  • a dispersing or deflocculating agent dispersant
  • High solids grinding typically produces a relatively high proportion of ultra-fine particles (e.g. having an equivalent spherical diameter smaller than about 0.25 ⁇ m.
  • ultra-fine particles e.g. having an equivalent spherical diameter smaller than about 0.25 ⁇ m.
  • a dispersant can be avoided. This enables the suspension to be dewatered cost-effectively, but problems can be encountered when mixing dispersant into the suspension later.
  • a “steep” psd refers to a steepness factor greater than about 35, more particularly above about 40, steepness factor being defined as the ratio of the d 30 equivalent spherical diameter (at which 30% by weight of the particles are finer) to the d 70 equivalent spherical diameter (at which 70% by weight of the particles are finer), multiplied by 100.
  • the present invention aims to go at least some way towards overcoming the above problems, or at least to provide an acceptable alternative method of grinding an aqueous suspension of an inorganic particulate material.
  • the present invention is based on the finding that the problems referred to above can be alleviated by performing the grinding of an inorganic particulate material in an aqueous suspension which includes a very small amount of a dispersant.
  • a method of grinding an inorganic particulate material in an aqueous suspension wherein the said aqueous suspension includes a sub-effective amount of a dispersant for the inorganic particulate material.
  • the term “sub-effective” means that the dispersant is present in a finite amount, but that amount is not sufficient to give rise to deflocculation of the particulate inorganic material, so that the flocculation characteristics of the suspension are substantially the same as would be found in the complete absence of any dispersant.
  • Such an amount of the dispersant may typically be up to about 0.25% by weight, based on the weight of dry inorganic particulate, for example up to about 0.15% by weight, e.g. up to about 0.1% by weight.
  • a method of grinding an aqueous suspension of a particulate inorganic material to obtain a particulate inorganic material of reduced particle size and increased steepness wherein the grinding is carried out in the presence in the aqueous suspension of a sub-effective amount of a dispersant for the inorganic particulate material.
  • the method may, for example, be used in the grinding of an inorganic particulate material at a low solids level in the suspension, e.g. the amount of the inorganic particulate solids being less than about 50% by weight, based on the total weight of the suspension.
  • the method preferably further comprises grinding the inorganic particulate material under grinding conditions such as to raise the steepness of the inorganic particulate material to a steepness factor above about 35, more particularly above about 40, for example above about 45.
  • the method preferably further comprises dewatering the aqueous suspension to raise the solids content thereof, more preferably to a content of inorganic particulate material above about 50% by weight, based on the total weight of the suspension.
  • an aqueous suspension of a ground particulate inorganic material comprising a sub-effective amount of a dispersant for the inorganic particulate material.
  • the aqueous suspension may suitably be prepared by a grinding method according to the first or second aspect of the present invention.
  • the particulate inorganic material suitably has a steepness factor above about 35, more particularly above about 40, for example above about 45.
  • the dispersant is suitably present in the aqueous suspension in an amount up to about 0.25% by weight, based on the weight of dry inorganic particulate, for example up to about 0.15% by weight, e.g. up to about 0.1% by weight.
  • the aqueous suspension may be at a high or low solids content.
  • an aqueous suspension of a ground inorganic particulate material comprising a dispersant-effective amount of a dispersant for the inorganic particulate material, when prepared by a method according to the first or second aspect of the present invention and which includes the addition, after grinding, of an amount of a dispersant to the aqueous suspension.
  • a dry ground inorganic particulate material comprising an amount of a dispersant for the inorganic particulate material, the material being the dry residue of an aqueous suspension according to the third or fourth aspect of the present invention.
  • the inorganic particulate material may, for example, be an alkaline earth metal carbonate such as calcium carbonate, a hydrous kandite clay such as kaolin or ball clay, an anhydrous (calcined) kandite clay such as metakaolin or fully calcined kaolin, wollanstonite, bauxite, talc, mica, titanium dioxide, silicon dioxide or carbon.
  • the preferred inorganic particulate material for use in the present invention is calcium carbonate.
  • the particle size distribution (psd) of the inorganic particulate material after grinding is suitably such that at least about 80% by weight of the calcium carbonate particles have an equivalent spherical diameter less than 2 ⁇ m, at least about 50% by weight of the particles have an equivalent spherical diameter less than 1 ⁇ m, at least about 20% by weight of the particles have an equivalent spherical diameter less than 0.5 ⁇ m, and less than about 20% by weight of the particles have an equivalent spherical diameter less than 0.25 ⁇ m.
  • the particles may suitably have an equivalent spherical diameter less than 2 ⁇ m, at least about 70% by weight of the particles may have an equivalent spherical diameter less than 1 ⁇ m, at least about 30% by weight of the particles may have an equivalent spherical diameter less than 0.5 ⁇ m, and less than about 15% by weight of the particles may have an equivalent spherical diameter less than 0.25 ⁇ m.
  • the particles may suitably be calcium carbonate.
  • the mean (average) equivalent particle diameter (d 50 value) of the particulate calcium carbonate after grinding may suitably be in the range about 0.4 to about 1.2 ⁇ m, for example in the range about 0.4 to about 1.0 ⁇ m.
  • the mean (average) equivalent particle diameter (d 50 value) and other particle size properties referred to herein for the inorganic particulate materials are as measured by sedimentation of the particulate material in a fully dispersed condition in an aqueous medium using a Micromeritics Sedigraph 5100 unit.
  • the mean equivalent particle size d 50 is the value determined in this way of the particle esd at which there are 50% by weight of the particles which have an equivalent spherical diameter less than that d 50 value.
  • the dispersant is a chemical additive capable, at a sufficient amount greater than the amount to be used in the present invention, of acting on the particles of the inorganic material to prevent or effectively restrict flocculation or agglomeration of the particles to a desired extent, according to the normal processing requirements.
  • the dispersant is not effective in this way, although it serves the useful and unexpected result of assisting to alleviate the problems noted in relation to the prior art, particularly one or more of: reduction in discoloration of the particulate material; improvement of introduction of dispersants in effective amounts at the high solids stages; improvement of comparability of the particulate material in mixtures with other particulate materials including conventional dispersants such as polyacrylates.
  • the dispersant may, for example, be selected from conventional dispersant materials commonly used in the processing and grinding of inorganic particulate materials. Such dispersants will be well recognised by those skilled in this art. They are generally water-soluble salts capable of supplying anionic species which in their effective amounts can adsorb on the surface of the inorganic particles and thereby inhibit aggregation of the particles.
  • the unsolvated salts suitably include alkali metal cations such as sodium. Solvation may in some cases be assisted by making the aqueous suspension slightly alkaline.
  • suitable dispersants include: water soluble condensed phosphates, e.g.
  • polymetaphosphate salts [general form of the sodium salts: (NaPO 3 ) x ] such as tetrasodium metaphosphate or so-called “sodium hexametaphosphate” (Graham's salt); water-soluble salts of polysilicic acids; polyelectrolytes; salts of homopolymers or copolymers of acrylic acid or methacrylic acid, or salts of polymers of other derivatives of acrylic acid, suitably having a weight average molecular mass of less than about 20,000.
  • Sodium hexametaphosphate and sodium polyacrylate the latter suitably having a weight average molecular mass in the range of about 1,500 to about 10,000, are especially preferred.
  • the method of the present invention is preferably carried out on an aqueous suspension which comprises up to 35% by weight of the inorganic particulate material, typically of the order of 20-30% by weight.
  • the amount of dispersant used in the method is preferably less than about 0.25% by weight, more preferably less than 0.15% by weight, typically less than about 0.1% by weight, based on the weight of dry inorganic particulate.
  • the precise amounts may be varied easily by those skilled in the art, to achieve the effect provided by the present invention.
  • the aqueous suspension may suitably be prepared by conventional mixing techniques, and may suitably include optional additional components, as will be well appreciated and understood by those skilled in this art.
  • the grinding is suitably performed in conventional manner.
  • the grinding may be an attrition grinding process in the presence of a particulate grinding medium, or may be an autogenous grinding process, i.e. one in the absence of a grinding medium.
  • the particulate grinding medium when present, may be of a natural or a synthetic material.
  • the grinding medium may, for example, comprise balls, beads or pellets of any hard mineral, ceramic or metallic material; such materials may include, for example, alumina, zirconia, zirconium, silicate, aluminium silicate or the mullite-rich material which is produced by quening kaolinitic clay at a temperature in the range of from about 1300° C. to about 1800° C.
  • particles of natural sand of a suitable particle size may be used.
  • the type of and particle size of grinding medium to be selected for use in the invention may be dependent on the properties, such as, e.g. the particle size of, and the chemical composition of, the feed suspension of inorganic material to be, ground.
  • the particulate grinding medium comprises particles having an average diameter in the range of from about 0.1 mm to about 6.0 mm and, more preferably in the range, of from about 0.2 mm to about 4.0 mm.
  • the grinding medium (or media) may be present in an amount of from about 40% to about 70% by volume of the charge; and, more preferably in an amount from about 50% to about 60% by volume of the charge.
  • the grinding may be carried out in one or more stages.
  • the feed suspension may be partially ground in a first attrition grinder, the suspension of partially ground inorganic particulate material then being fed to a second attrition grinder for further grinding, after which the suspension of ground material may be fed to one or more subsequent attrition grinders.
  • the grinding process may, for example, be conducted at a relatively low temperature, e.g. below about 30° C. Lower temperatures are believed to assist in preventing or restricting discoloration of white inorganic particulates resulting from iron-based corrosion products entering the aqueous suspension.
  • the suspension may be dewatered to a high solids suspension, and any grinding medium removed. Thereafter the ground product may be dried.
  • a high solids suspension formed by said dewatering may suitably have a solids level of the order of 70% by weight, and be formed using a dispersing agent, such as one of the dispersing agents mentioned above.
  • the dispersing agent used may or may not be the same as that used in the grinding step.
  • the dispersing agent used at the post-grinding stage will be required to restrict flocculation of the particulate inorganic material in the high solids suspension, and must therefore be present in a dispersant-effective amount, typically at least about 0.3% by weight of dry inorganic particulate, more preferably at least about 0.4% by weight, for example at least about 0.5% by weight.
  • the very small amount of dispersant used in accordance with the present invention is sufficient to “pre-coat” the inorganic particulate material, allowing more even distribution of the larger amounts of dispersant added later to make a high solids slurry.
  • the small amounts of dispersant used serve as a corrosion inhibitor during the grinding process.
  • the ground particulate material obtained using the method of the present invention may be used in a wide variety of applications, as will be readily apparent to one of ordinary skill in this art.
  • the inorganic particulate material is present as a coating or filler, or as part of a coating or filler composition.
  • the applications include, for example, the preparation of: paper (which term includes within its scope all forms of paper, card, board, cardboard and the like, including without limitation printing paper and writing paper); polymers and rubbers, e.g. plastics (which may be in the form of a film); paints; sealants and mastics; ceramics; as well as compositions which are subsequently processed to obtain any of the above.
  • FIG. 3 shows the permeability of the slurries obtained using the dispersants of the experiment of Example 2, under low pressure piston press dewatering.
  • Ground calcium carbonate was prepared by laboratory slurry sandgrinding at 250 kWh/t at low solids (25 weight-%) from a coarse calcium carbonate feed.
  • Three batches of sandground material were prepared containing, respectively, dispersant at 0.1%, 0.2% and 0.3% by weight of dry calcium carbonate. The three batches were then dewatered by low pressure piston pressing at 250 psi, to obtain a cake. The permeability and resistance of the cake was measured during pressing in each case, using the test methods described below.
  • Samples 1, 3 and 5 showed the least structure formation, suggesting that a dose of 0.5% partially neutralised dispersant at the makedown stage is optimum;
  • the method was essentially that described above for Example 1, but using different dispersants, as shown in FIGS. 1 to 3 of the drawings, and with a total dose of added dispersant equal to 0.6%.
  • Samples of two ground calcium carbonates A and B were used, having respective psd as follows: A—99% by weight less than 2 ⁇ m, 90% by weight less than 1 ⁇ m, 70% by weight less than 0.5 ⁇ m, 35% by weight less than 0.25 ⁇ m; B—95% by weight less than 2 ⁇ m, 75% by weight less than 1 ⁇ m, 40% by weight less than 0.5 ⁇ m, 15% by weight less than 0.25 ⁇ m. Each carbonate sample was split into two portions and each portion was diluted to provide about 30 and 20 wt % solids suspensions (slurries) of carbonates A and B.

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US20080141905A1 (en) * 2006-12-15 2008-06-19 Volker Juergens Method for the Surface Treatment of Solid Particles, Particularly Titanium Dioxide Pigment Particles
US20080286183A1 (en) * 2006-11-06 2008-11-20 Radway Jerrold E Control of combustion system emissions
US20110105670A1 (en) * 2008-07-07 2011-05-05 Patrick Gane Procedure for manufacture of aqueous suspensions of calcium carbonate and suspensions obtained, and their uses
US20120090517A1 (en) * 2005-11-05 2012-04-19 Radway Jerrold E Control of combustion system emissions
US20130174994A1 (en) * 2010-05-28 2013-07-11 Matthias Buri Process for manufacturing high solids suspensions of mineral materials
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US20060003117A1 (en) * 2004-06-14 2006-01-05 Specialty Minerals (Michigan) Inc. Ink jet recording paper
EP2194103A1 (de) * 2008-12-04 2010-06-09 Omya Development Ag Verfahren zur Herstellung von Calciumcarbonatmaterialien mit einer Teilchenoberfläche mit verbesserten Adsorptionseigenschaften
WO2012092986A1 (en) * 2011-01-07 2012-07-12 Omya Development Ag Process for water based mineral material slurry surface whitening
KR20200022534A (ko) * 2013-03-12 2020-03-03 쓰리엠 이노베이티브 프로퍼티즈 컴파니 접합된 연마 용품
EP2871159A1 (de) 2013-11-08 2015-05-13 Omya International AG Verfahren zur Verbesserung der Partikelgrößenverteilung eines calciumcarbonathaltigen Materials
CN103923494B (zh) * 2014-03-26 2016-03-30 江西广源化工有限责任公司 灯箱广告膜专用超细水合硅酸镁粉的制备方法
EP2966129B1 (de) 2014-07-11 2018-10-31 Omya International AG Trocknungsverfahren
GB201505320D0 (en) * 2015-03-27 2015-05-13 Imerys Minerals Ltd Mineral slurries
GB201520217D0 (en) * 2015-11-17 2015-12-30 Imerys Minerals Ltd Mineral dispersion
CN105506638B (zh) * 2015-12-21 2018-07-06 黄志华 一种金相分析用抛光液及其制备方法、使用方法
CN109972446B (zh) * 2019-03-08 2021-09-21 华南理工大学 一种适用于高速打印的白板纸及其制备方法
CN109972453B (zh) * 2019-03-08 2021-08-06 华南理工大学 一种适用于高速打印的涂布卡纸及其制备方法

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US20120090517A1 (en) * 2005-11-05 2012-04-19 Radway Jerrold E Control of combustion system emissions
US8807055B2 (en) * 2005-11-05 2014-08-19 Clearchem Development, Llc Control of combustion system emissions
US20150136003A1 (en) * 2005-11-05 2015-05-21 Clearchem Development, Llc Control of combustion system emissions
US9278311B2 (en) * 2005-11-05 2016-03-08 Enerchem Incorporated Control of combustion system emissions
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US20130174994A1 (en) * 2010-05-28 2013-07-11 Matthias Buri Process for manufacturing high solids suspensions of mineral materials
US8721838B2 (en) * 2010-05-28 2014-05-13 Omya International Ag Process for manufacturing high solids suspensions of mineral materials
US9243121B2 (en) 2010-05-28 2016-01-26 Omya International Ag Process for manufacturing high solids suspensions of mineral materials

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DK1546268T3 (da) 2007-05-14
ES2277107T3 (es) 2007-07-01
JP2005539124A (ja) 2005-12-22
EP1546268B1 (de) 2007-01-03
CN1681895A (zh) 2005-10-12
AU2003269130A1 (en) 2004-04-08

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