Kaoline

Acid refractory materials include fireclays, flint clays, china clays (kaolins), silica, flint, chalcedony, ganister and titanium dioxide. 

Inequality Re > H corresponds to the other case, when only a part of a penetrant is extracted by a developer and can form crack s indication. Such a situation can take place when one use kaolin powder as the developer. We measured experimentally the values Rj for some kaolin powders. For the developer s layer of kaolin powder, applied on tested surface. Re = 8 - 20 pm depending on powder s quality. 

One more obvious example illustrates strong influence of particle s sedimentation upon the sensitivity threshold. Assume that we have to ensure the detection of the cracks with the depth 10 > 2 mm in the case when the same product family indicated above is applied and h = 20 pm. The calculation using formula (1) shows that in the absence of sedimentation only the cracks with the width H > 2 pm could be detected. But when the effect of sedimentation results in the reduction of the value of developer layer thickness from h = 20 pm to h = 8 pm, then the cracks of substantially smaller width H > 0,17 pm can be revealed at the same length lo = 2 mm. Therefore we can state that due to the sedimentation of developer s particles the sensitivity threshold has changed being 12 times smaller. Similar results were obtained using formula (2) for larger particles of the developers such as kaolin powder. 

Very finely divided minerals may be difficult to purify by flotation since the particles may a ere to larger, undesired minerals—or vice versa, the fines may be an impurity to be removed. The latter is the case with Ii02 (anatase) impurity in kaolin clay [87]. In carrier flotation, a coarser, separable mineral is added that will selectively pick up the fines [88,89]. The added mineral may be in the form of a floe (ferric hydroxide), and the process is called adsorbing colloid flotation [90]. The fines may be aggregated to reduce their loss, as in the addition of oil to agglomerate coal fines [91]. 

Aluminium is not found free but its compounds are so widespread that it is the most abundant metal in the earth s crust. Aluminosilicates such as clay, kaolin (or china clay), mica and feldspar are well known and widely distributed. The oxide. AI2O3. occurs (anhydrous) as corundum and emery, and (hydrated) as bauxite. Cryolite. Na,AlF. (sodium hexafluoroaluminate). is found extensively in Greenland. 

Fig. 16. Two-hquid flotation flow sheet (39). The original ROM is kaolin (white clay) that contains 11% impurity in the form of mica, anatase, and siUca. Treatment produces high purity kaolin and a Ti02-rich fraction. A, Kaolin stockpile D, dispersant (sodium siUcate plus alkah) W, water K, kerosene C, collector (sodium oleate) RK, recycled kerosene S, screen M, inline mixer SPR, separator CFG, centrifuge P, product and T, to waste.

C or higher for the kaolin-based products to 1425°C and above for the zirconium-containing materials. At temperatures above 1000°C these ceramic fibers tend to devitrify and partially crystallize. Specially prepared ceramic fibers are used to protect space vehicles on re-entry and can withstand temperatures above 1250°C (see Ablative materials Refractory fibers). 

A process has been developed by J. M. Huber Co. to treat kaolin clay pigments using a hydrothermal process (see Clays) (25). The products, called synthetic alkah metal aluminosihcates (SAMS), have superior pigmentary quahties for paper (qv) coating. 

Flake Mica. Flake mica is mined from weathered and hard rock pegmatites, granodiorite, and schist and gneiss by conventional open-pit methods. In soft, residual material, dozers, shovels, scrapers, and front-end loaders are used to mine the ore. Often kaolin, quartz, and feldspar are recovered along with the mica (see also Clays Silicon compounds). 

Sodium sihcate (41°Bh, 1 3.22 ratio Na20 Si02) is added in the milling operation to disperse the slime, mosdy kaolin. Dispersion also aids the grinding process. The rod mill serves to grind the ore to 0.833 mm (—20 mesh) or to the point where mica, quart2, feldspar, and iron minerals are Hberated. Cyclones, or rake, hydrauhc, or other types of classifiers, are used after grinding to produce coarse and fine mica fractions that are treated separately. 

The slime, consisting of kaolin, fine quart2, and feldspar, is sometimes used as is after being dewatered. This material may be used in the manufacture of light-colored brick or may be further processed to produce a high grade ceramic kaolin used in the manufacture of dinnerware, electrical porcelain, or sanitary-ware (see Ceramics). Floes of kaolin may be sold in bulk from the drier or pulveri2ed and sold in a powdered form. 

The main by-products of mica processiag plants are kaolin, quart2, and feldspar. Some plants produce all of these products for sale. 

Glass-grade siUca can be produced from most mica operations with additional beneficiation of the quart2. Ceramic-grade kaolin can be produced from some mica flotation plants by selective mining and additional processiag of the clay slime removed prior to mica flotation (see Clays). 

Cl y Conversion. The starting material for this process is kaolin, which usually must be dehydroxylated to y /i7-kaolin by air calcination. At 500—600°C, yW /t -kaohn forms, followed by a mulliti2ed kaolin at 1000—1050°C. 

The 2eohtes are prepared as essentially bindedess preformed particles. The kaolin is shaped in the desired form of the finished product and is converted in situ in the pellet by treatment with suitable alkaU hydroxide solutions. Preformed pellets of 2eohte A are prepared by this method. These pellets may be converted by ion exchange to other forms such as molecular sieve Type 5A (1). ZeoHtes of higher Si02/Al202 ratios, eg, 2eohte Y, can be obtained by the same method, when sodium metasiUcate is incorporated in the preshaped pellets, or when acid-leached metakaolin is used. 

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