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Transcript of ACC Europe Training Dec 06 v3
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Btgenbach Belgium
December 2006An Introduction To
Australian China Clays
AUSTRALIANCHINACLAYSLIMITED
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Company Profile
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ACC- Company Structure
Minerals Corporation
Limited
Swan River Kaolin
Limited
Australian ChinaClays Limited
ACC EuropeSkardon River Kaolin
Limited
Kiss International
Trading
Other BusinessDevelopments
100%
96.6% 100% 100% 100%
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AUSTRALIAN CHINA CLAYS LIMITEDORGANISATION CHART
Board of Directors
Exec. Chairman: C.V. Alexander
Non Exec. Directors: A. EnglishG. BirchP. Lush
Company Secretary: R. Lo
Chief Executive Officer
C. V. Alexander
Kaolin Business
DevelopmentJames Marsh
Paper Andrew Pleeth
Polymers James MarshCeramics Neil MifflinPaint Philip SambellsChina William WangEurope Alain Heck
Technical Manager
Dr Sanjib Banerjee
Kaolin Operations
Steve Downard
Cairns Office
Financial ControllerDavid Hockey
Group GeologyExploration &Environment
Sue Border (Consultant)
Swan River Kaolin Project
Steve Downard
China Projects
William Wang
Group FinancialController
Robert Lo
Logistics
Derek Bicknell
Managing Director
Andrew Pleeth
Plant Superintendent
Garry Donaldson
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Australian China Clays Marketing TeamJames Marsh Andrew PleethMarketing Manager Polymers Managing Director - Paper
Phil Sambells Alain HeckBusiness Manager Coatings Business Manager - Europe
Neil Mifflin William Wang
Business Manager
Ceramics Business Manager - China
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Locations
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Australian China Clays Limited (ACCs) operations, projects, exploration interest and
business investments are based within Australia, as well as an Agency in PR China
Fully Operational Plant
Pilot Plant
Exploration Interests
Business Investments
Other Locations :
Calcined KaolinAgencyAgreement (China)
Key;
SkardonRiverKaolinMine
SwanRiver
KaolinProject
Operations & Interests
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World class high-grade resource over 100 years mine life
fluvial deposit has the finest particle size of premium quality kaolin
known worldwide
Easy to mine ore body
overburden stripping ratio initially less than 3:1, compared to Georgia
current ratios of over 9:1
Fully commissioned hi-tech stainless steel plant 175k tpacapacity
Focus on global sale to paint, ceramics, rubber and paperindustries
Skardon River
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TASMANIA NEW ZEALAND
USA
EUROPE
ANDMIDDLEEAST
INDONESIA
THAILAND
MALAYSIA
AUSTRALIA
JAPANKOREA
TAIWAN
PROJECT
LOCATION
CANADAWest Coast
CHINA
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Defined kaolin resource of 41m tonnes
Pilot plant to supply paper mills in 2006
Full scale plant of 200,000 tonnes - completion 2007/8.
Swan River Kaolin
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China
China Calcined Kaolin Agency agreement
Commenced 2004
100% owned
Exclusive 5 yr export agency agreement
Strategic extension to product range
Increasing importance of PR China market
JV agreement reached
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The Skardon River Production Process
Geology & Mining
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Section Through the Deposit
Rolling Downs
Fluvial K3K3
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Skardon River Kaolin-Kaolin Mining
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Claystone Stockpile
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The Production Process
The Wet Plant
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Kaolin Ore
Blunger
Degritting Centrifuge
Decanter Centrifuge
Disc-nozzle Centrifuge
High Gradient Magnet Separator
Membrane Filter
Pipeline to Dry Plant
Sand
Tailings Dam
Stage 1 Processing: Wet Plant
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Windows Based Control System.
This Automation Allows For An Efficient And
Controlled Processing Environment
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Loading up the front end of the wet plant with kaolin ore
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Blunger
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Screens
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Degritting Centrifuges
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Decanter Centrifuge
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Disc Nozzle Centrifuge
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Superconducting Magnet
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Ultra Filtration System
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The Production Process
The Dry Plant
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Pipeline from Wet Plant
Spray DryerPulveriser
Calcining Kiln
Pulveriser
CALCINED
KAOLIN
HYDROUS
KAOLIN
Stage 2 Processing: Dry Plant
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Access Road Connecting Wet & Dry Plant
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Dry Plant At Skardon River Kaolin
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Base Of Spray Drier
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Rotary Kiln
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Bagging & Warehouse Overlooking The Skardon River
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3.4 The Pilot Plant at Skardon River Kaolin -
contains scaled down versions of all the unit processes
Feed Hopper
Mobile Tanks
Carpco Magnet
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The Pilot Plant at Skardon River Kaolin -
contains scaled down versions of all the unit processes
Centrifuges &
Spray DrierRotary Kiln
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Shipping Skardon River Kaolin
To The World
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Break Bulk Shipments By Sea
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Loose Bulk
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Shipping By Road
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Shipping By Container Load
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The Swan River Pilot Plant
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The Chinese Calcined Kaolin Production Process
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Packaging
Hydrous GradesBulk ShreddedTypically for Ceramic applications
Blends available
Big Bags5001000Kg
25Kg paper bags
Calcined Grades
Big Bags500Kg to 1000Kg
20Kg & 25kg paper bags
Silane Treated GradesBig bags500Kg to 1000Kg
25Kg paper bags
Melt processable bags and special weights available
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Hydrous Kaolins
Wide range of industrial
applications
Represents the bulk of world
supply
Targeting paint, polymers,
ceramics, paper and ink
markets.
Calcined Kaolins
Higher performance
Better brightness, opacity
Extends TiO2
Premium price
Limited number of producers
Targeting paint, polymers,
paper, inks.
ACC Product Streams
ACC P d t d N l t S t
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ACC Products and Nomenclature System
MicrobriteTrade name for all non ceramic hydrous and calcined kaolins
KerabriteTrade name for all ceramic grade hydrous and calcined kaolins
MetabriteTrade name for low temperature calcined kaolin (Metakaolin)
Skardon Hydrous Grades
First Letter = ore body origin (C=Claystone, F=Fluvial, R=Rolling Downs)
Second Letter = product type (H=Hydrous, C=Calcined, M= Metakaolin, R=Raw Ore)
Number = weight percent less than 2um (80 = 80wt% < 2um)
Hydrous Grades
Microbrite CH80 Kerabrite CH35
Microbrite CH98 Kerabrite CH80
Microbrite FH95 Kerabrite CH98
Microbrite FH100 Kerabrite RH
Microbrite FH100BP Kerabrite CR, FR, RRMicrobrite CH40SR**In this case the 40 = Surface Area/m2g, and SR = Synthetic Replacement
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ACC Products and Nomenclature SystemChinese Calcined Grades
Microbrite C75/95 C1
Microbrite C80/95 C1
Microbrite C70/90 C2
Microbrite C75/91 C2
Microbrite C80/92 C2
C = Calcined
First two digits = %
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ACC Products and Nomenclature System
Surface Treated Calcined Grades
Multibrite 1VS (Medium particle size with vinyl silane)Multibrite 2VS (Fine particle size with vinyl silane)
Multibrite 3VS (High brightness, low iron with vinyl silane)
Multibrite 1AS (Medium particle size with amino silane)
Multibrite 2AS (Fine particle size with amino silane)Multibrite 3AS (High brightness, low iron with amino silane)
Special silanes and hydrous grades available on request.
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Kaolin - The Mineral
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KaolinNaturally Occurring Hydrous Aluminium Silicate
Also known as China Clay
Al2O3.2SiO2.2H2O. Plate like hexagonal flat shape.
Specific Gravity 2.6.
Refractive Index 1.56.
Based on the crystalline mineral Kaolinite.
Inert and insoluble in water.
Skardon River Kaolins are amongst the finest in the world.
In particle size
In quality
CHINA CLAY (KAOLIN)
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CHINA CLAY (KAOLIN)Al2O3 2SiO2 2H2O
Main Constituent: Kaolinite
Minor: Mica, Quartz, Feldspar
Aspect Ratio: 8/1 - 100/1
Average: 20/1
Specific Gravity: 2.6
Refractive Index: 1.56
MOH Hardness: 2.5
Surface Chemistry: Edges - Positive; Faces - Negative :
Covered with SiOH monolayer, OH groups,Al3+ Si4+ Lewis Acid Sites
pH: 4 - 5; Inert to Acids and Alkalis
OH
HO
OH
OHOH
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Micrograph of Kaolin
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Micrograph of Kaolin
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Primary Kaolins & Secondary Kaolins
Primary kaolins
Found where they were formed
Usually large amounts of impurities (quartz (silica) & mica)
Typically much Coarser than secondary kaolinsTypically higher brightness than secondary kaolinsAn example of primary kaolins is found in Cornwall, England. For every tonne of
kaolin mined there are 89 tonnes of waste causing significant environmental
problems.
Secondary kaolins
Formed in the same way as Primary Kaolins
Washed and deposited away from where they were formed
Low impurities - typically 90% of the deposit is saleableVery fine particle sizeLower brightnessAn example is the Skardon River deposit where purity is up to 93%
Reactivation of
prehistoric fault lines
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Movement of the
plates of the Earths
crust cause the rock
far below ground to
melt.
This molten rock
bubles up and formsgranite domes (called
plutons) which are
still below the ground
surface.
Over several million
years the rocks
overlying the hard
plutons were
weathered away
exposing the granite.
In the sub tropical
climate some of the
feldspathic minerals
in the granite were
naturally altered to
kaolinite.
The continuous
weathering washed
the kaolin from the
granite along with
other minerals from
the upland regions.
prehistoric fault lines
led the ground to sink
in places forming
basins and shallow
inland seas.
Streams from the
uplands emptied into thebasins and seas forming
short lived lakes and
river systems.
Heavier sands and
gravels settled from the
water first forming the
layers over marine
shales, eventually
forming what would
become todays kaolindeposits.
The fine clay
particles remained in
suspension in the
water until a
chemical reaction,
making the water
acidic causing the
clay particles toclump together and
form sedimentary
layers.
The upland areas
were heavily forestedby prehistoric
specimens. When
they died these were
washed downstream
and became part of
the mass of
vegetation and other
material forming
what would
eventually become
todays coal deposits.
A li Chi Cl H d G d f E
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Australian China Clays Hydrous Grades for Europe
Higher value Australian grades:
Microbrite FH95
Microbrite FH100 & FH100BP Microbrite CH40SR
Advantages/BenefitsAustralian grades
Extremely fine particle size
Low yellowness
Low crystalline silica
Neutral pH
Chinese grades:
Microbrite HC1
High brightness/ultrafine grade planned early 2007
Advantages/BenefitsChinese grade
o Medium/coarse particle size
o Good brightness
o Cost effective
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Calcined Kaolin
Anhydrous Aluminium Silicate
Al2O3.2SiO2 Irregular, hard, shape made up of many hexagonal platelets
Specific gravity 2.6
Refractive Index 1.56
Inert and insoluble in water
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Micrograph of Calcined Kaolin
What is Calcined Kaolin?
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What is Calcined Kaolin?
Calcined kaolin is formed when kaolin is heated to above 980CIt has an amorphous structure with some hydroxyl (-OH) groups at the surface
If heated above 1200C hard, abrasive mullite is formed
Hydrous Kaolin Calcined Kaolin
Wh t i C l i d K li ?
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What is Calcined Kaolin?Differential Thermal AnalysisFor Kaolin Calcination
Exotherm
Endotherm
Metakaolin
Fully Calcined(Amorphous)
Loss of Crystallinity: 950 - 1050C
Dehydroxylation: 450 - 750C
Mullite Formation
A t li Chi Cl
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Australian China Clays
Calcined Kaolin Grades for Europe
Chinese calcined kaolins:
Metabrite CMC Microbrite C70/90 C2 Microbrite C75/91 C2 (Pharmaceutical rubber) Microbrite C80/92 C2
Microbrite C75/95 C1 Microbrite C80/95 C1
Advantages/Benefits
Incredibly pure feed material
Extremely consistent feed material
Highly efficient calcination
Highest brightness products commercially available
Very low coarse particle content
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Highest performance kaolin products
High price must be justified by significant performance improvements
Essential where stress and moisture resistance at high temperatures is requirede.g. High voltage electric cables
Essential where physical performance at high temperature is requirede.g. Automotive engine components
Surface Modified KaolinsMultibrite Range
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Major Uses of Kaolin
Papermaking Pigment/Filler/Coating
Pigment in paint/inks
Polymers in Rubber/Plastics/Adhesives
Pharmaceuticals/Cosmetics
Ceramics (Pottery)
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Applications For Kaolin In Paints
Phil SambellsBusiness Development ManagerPaints
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What Is Paint ?
Traditionally the term paint described a pigmented liquidcoating and was used to distinguish it from a clear varnish.
Today the word applies to a wide variety of materials used for
coating purposes and the terms paint & surface coatings
have become almost synonymous.
A pigmented liquid coating, which when applied to a substrate
and allowed to dry forms a surface coating which provides a
desired function..
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Protection of a vulnerable substrateeg from air or water.
Decoration.
A purposeeg non refletive paint on military aircraft.
Informationroad marking, signs.
Desired functions imparted by a paint
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The Constituents Of Paint
Pigment.
Resin.
A volotile component or solvent.
(Additives).
h i i ill b
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The exact composition will be
dependant upon many factors, eg :-
The Substrate.
The method of application.
The service environment.
The desired role of the coating.
Price
O h i di hi h b i i
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Other ingredients which can be present in a paint.
Extenders.
Dispersants.
Thickeners & rheological additives.
Coalescing solvents.
Antifoams Biocides.
Catalysts.
pH modifiers
Anti-skinning agents Re-odorants
UV absorbers
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Paint Types
Decorative Paints (Architectural Coatings)
Industrial Paints
Production
50%
50%
Use of
Extenders
85%
15%
D ti P i t
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Decorative Paints
Water Based Gloss.
Semi Gloss.
Matt (Flat) Interior.Matt (Flat) Exterior
Solvent Based Gloss
Semi Gloss
Primers
Undercoats
% of extender used
05
515
1550515
05
515
515
1550
Industrial Paints
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Industrial Paints
Protective CoatingsPrimers
Undercoats
Topcoats
Auto RefinishPrimerColour Coat
Clear Coat
Coil CoatingsWhite Goods
Cladding
Auto OEMED Primer
Surfacer
Colour Coat
Clear Coat
General IndustrialWood
Metal
Powder Coatings
Indicates potentials for SRK Materials
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Common extenders used in Paints
Hydrous Kaolin.
Calcined Kaolin.
Calcium Carbonate.
Talc.
Mica.
Barium sulphate.
Silica
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This presentation concentrates on
the use of
Kaolins & Calcined Kaolins
as extenders in paints
Specifically kaolins from
Australian China Clays
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What is an extender ?
Minerals.Which are :-
Usually supplied as a powder.
Insoluble in the liquid paint.
Have a refractive index below 1.7
Extends / Supplements the prime pigments.
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All extenders will ..
Reduce gloss of the dry paint
Reduce the overall paint formulation cost.
Bulk out the paint volume.
Kaolins from Australian China Clays
can do much more.
d d C l i d li
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Hydrous and Calcined Kaolins
From Australian China Clays can help to enhance
Opacity, (Hiding Power).
The Mechanical properties of the dry paint film.
Improve mudcrack resistance
Improve scrub resistance
The Weathering resistance.
Improve corrosion resistance
Improve resistance to chalking
They can also help to
Modify the rheology of the liquid paint.
Pi & E d
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Pigments
TiO2 Rutile
White
Refractive index of 2.7
Expensive ~US$ 2.6 per Kg
Pigments & Extenders
Extenders
Hydrous & Calcined Kaolins
Colour from Grey to White
Refractive index 1.56
Relatively cheap ~US$ 0.20.8
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The refractive index of a substance equates to -
= speed of light in a vacuum
speed of light in a substance
The greater the difference in refractive index between twosubstances the greater the degree of refraction.
eg. The different refractive indicies between air & water is
illustrated when a straight object which is partly immersedin water and viewed at an angle appears to be bent.
Laws of Physics
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The greater the number of transitions between differingrefractive indicies the more the light is bent and scattered.
eg A pane glass appears transparent. But if that pane of glass
is then ground into a powder it appears white. This is because
the light is being refracted on numerous occasions betweenthe glass particles and trapped air.
Similarly bubbles of air in water when brought together forms
a foam. Again a white appearance is obtained due to therepeated difference in refractive index.
Employing physics to create opacity
The effect on Opacity by TiO2 & Extender Particles below the
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The effect on Opacity by TiO2 & Extender Particles below the
Critical Pigment Volume Concentration (CPVC)
substrate
Light meterLight meter
TiO2Particles
= 2.7
Resin / Latex
= 1.5
Extender
Particles
= 1.56
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Because the refractive index of the resin (1.5) and the
extender (1.51.7) are similar, the light easily passes
through the paint film to the substrate and back out giving
this paint low opacity.
The difference in the refractive index between the resin and
TiO2 (2.7) is however greater and this difference gives the
paint its opacity.
Pigment Volume concentration (PVC)
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Pigment Volume concentration (PVC)
Defined as the percentage of pigment in a paint i.e.
PVC = Pigment & Extender Volume X 100
Pigment, Extender + Binder Volume
Critical Pigment Volume Concentration (CPVC)
The CPVC is the region when the close packed pigment &
extender particles have just enough binder to fill the voids in
between themselves. On further increase in PVC, beyond the
CPVC, there is not enough binder to satisfy all the pigment &
extender requirement. We then have a paint which has air voids
within. This results in an increase in opacity.
Effect of PVC on Opacity (Hiding Power)
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0 100
PropertyInc
reases
C
PVC
Region Dry Hiding
TiO2
Extender
Effect of PVC on Opacity (Hiding Power)
Gloss region
Matt (Flat)
Region
% PVC
The Effect of PVC on Scrub & Mud Cracking Resistance
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% PVC0 100
PropertyIncreases Scrub Resistance
Mud Cracking Resistance CPVC
Region
g
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Microbrite FH95
Is an ultrafine hydrous kaolin from Skardon River Kaolin with
high brightness.
It can be used in water based emulsions as an excellent
extender, with the ability topartially replace TiO2 in gloss &semi gloss emulsion paints.
Supplied as a spray dried powder for convenient handling it is
also very easily dispersed.
Finer & well dispersed extender particles offer improved utilization ofexpensive pigments & hence can reduce formulation costs by partial
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substrate
Light meterLight meter
Coarse
extenderTiO2
ParticlesMicrobrite FH95
Particles
replacement of these pigments. With coarse extenders the expensive
pigment tends to form together in pockets leaving large areas (windows)
where no pigment is employed and hence gives poor opacity.
Latex / binder
Hydrous Kaolin
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Hydrous Kaolin
Calcined Kaolin
Hard & Irregular shape
Calcium Carbonate
Air Voids
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Microbrite C70/90 C2Is a high quality Calcined Kaolin from Australian China Clays.
With 70% passing 2 microns and a 90 ISO brightness.
It is an excellent extender for Matt Emulsion Paints
giving good opacity and excellent mechanical properties.
Microbrite C80/95 C1Is a high quality ultrafine Calcined Kaolin from Australian China Clays.
With 80% passing 2 microns and a 95 ISO brightness.
Used in formulations where opacity is the main requirement.
In a paint above the CPVC the calcined kaolin offers improved
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substrate
In a paint above the CPVC the calcined kaolin offers improved
opacity (hiding power) over coarse blocky extenders due to the
trapped air increasing the changes in refractive indecies.
Light meterLight meter
It also offers improved scrub resistance as the calcined kaolin is
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substrate
It also offers improved scrub resistance as the calcined kaolin is
harder and its irregular shape means it is stuck firmly into the paint
surface. The Calcium Carbonate is easily removed (Chalking).
Calcium Carbonate is easily dissolved in acid conditions making
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substrate
Ca c u Ca bo ate s eas y d sso ved ac d co d t o s a g
the paint defective. One form of calcium carbonate is chalk, hence
the term chalking. This is where white powder is easily rubbed off
and is commonly seen in cheap poor quality paints where a highlevel of calcium carbonate has been used. Calcined kaolins are
inert and unaffected by harsh chemicals.
Mudcracking is another factor which blocky extenders are prone
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substrate
Coarse
extenderTiO2
ParticlesMicrobrite FH95
Particles
to. Propagation of cracks where a platey extenders are employed
is more tortuous and therefore thicker paint films can be applied
before cracking happens.
Latex / binder
At Skardon River Kaolin we have the ability to carry out arange of paint testing.
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range of paint testing.
Microbrite FH95 - Printing Inks
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g
Microbrite FH95 is an ultrafine spray dried kaolin suitable for
water based printing inks.
Microbrite FH95 is also used as a filler in Cold Set (Solvent
based) inks where good milling (dispersion) is employed.
Microbrite FH95 has been approved by some of the worlds
leading ink producers.
ACC sell 2000 tonnes of Microbrite FH95 into China per year
for printing ink applications.
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Applications For Kaolin In
Polymers
History of Filled Polymers
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Last Century - Mineral Fillers originally used in polymers solely to reduce production costs.
For 100 years use grew in tandem with polymer (mainly in rubber, PVC and thermosets)
Rapid growth during the 1970s for three reasons:
1. In 1973 the price of oil rose from US$5.43 to US$23.80/Kg
2. Commercialisation of PP and the development of PP composites
3. Environmental concerns about asbestos and other fibrous materials
This led to major research into replacement materials
Realisation that individual fillers imparted different properties (functional)
During the 1980s and 90s the use mineral fillers transformed from pure extension to
functional filling
Today Worldwide Filler Consumption into polymers approx 30,000,000 tonnes
What Advantages Can a Kaolin Filler Impart ?
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Increase in Weight (SG):
Useful for sound dampening and increasing mass of some products
Increase in Thermal Conductivity:
Leads to faster cooling and therefore cycle times
Improved Processability
Kaolin can reduces viscosity and improve flow
Reduction in Thermal Expansion:
Helps when plastics are used in engineering applications
(especially when in contact with metals)
Changes to Electrical Properties:
Calcined kaolin is a good insulator in polymers
Changes to Permeability:
Reduced by adding platey fillers such as kaolin
What Advantages Can a Kaolin Filler Impart ?
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g p
Reduced Flammability:
Kaolin can be used as a flame retardant
Changes to Ageing Behaviour:
Kaolin can help to stabilise relatively unstable polymers (e.g. PVC)
Improve Colour:
High brightness calcined kaolin can replace TiO2 and reduce expensive pigments
Changes to Impact Behaviour:
Silane treated calcined kaolins can improve impact resistance in polyamides
Increase Tensile Properties:
Very important for many types of rubber
Increase in Stiffness (Heat Distortion Temperature):
Major advantage of filled plastics
Use of Particulate Fillers in Polymers in Western
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Europe (000 tonnes)
Filler 1972 1982 1987 1998
ATH 3.5 24.0 35.0 160.0
Asbestos 60.5 12.0 6.0 Small
Ground Calcium Carbonate 244 783 854 1075Precipitated Calcium Carbonate 38 46 42 100
Calcined Kaolin 10.3 15.5 18.5 25.0
Hydrous Kaolin 15.2 29.5 35.9 96.0
Synthetic Silica 8.5 10.0 14.0 53.0
Crystalline Silica 6.5 4.5 6.0 3.0
Talc 9.5 15.0 17.0 19.0
Dominant Minerals in the Polymer Industry
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1. Kaolin (China Clay)
2. Ball Clay (Secondary kaolin)
2. Calcined Kaolin
3. Silane Treated Calcined Kaolin
4. Calcium Carbonates:
Chalk
Limestone
Marble
5. Stearate Treated Calcium Carbonate
Some Other Mineral Fillers Used
Precipitated calcium carbonate
Wollastonite
Quartz
Talc
The Use of Kaolins in Polymer Applications
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Particle Size
Particle Shape
Surface Chemistry
General Principles
The degree of effect from the filler is determined by
three main properties:
Particle Size
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Particle size directly effects reinforcement in polymers:
Fine particle size = bigger surface area = higher reinforcement When used at the optimum level
For example the finest kaolin from Australian China Clays is:
Microbrite CH40SR
This gives excellent reinforcement elastomers and canpartially replace expensive synthetic silica
The Effect of Filler Particle Size
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EPDM/60 phr Filler Loading
0
5
10
15
0 1 2 3 4
Mean Particle Size (um)
TensileStrength
(MPa)
Particle Size vs. Tensile Strength
Optimum Loading Concept
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0
10
20
3040
50
60
7080
Filler Volume Fraction
(%)
PhysicalP
ropertie
Reinforcing Filler
Semi-reinforcing
Filler
Non reinforcingFiller
Particle Shape and Chemistry
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Hydrous Kaolin
Characteristic plate-like shape gives unique properties in polymercompounds
High aspect ratio gives excellent impermeability to gas and liquid
Used in stoppers, hose, tube, chemical liners and membranes
Particles align themselves isotropically under stress improvingcompound flowability and extrusion performance, whilst reducing die-
swell and melt fracture
Particle Shape and Chemistry
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Calcined Kaolin
Interfacial fusion during calcination decreases the aspect ratio and givesthem an inert surface
Excellent electrical insulation performance and low dielectric loss due toamorphous structure
Widely used in the pharmaceutical, power cable insulation, extruded profileand film industries
Surface Modified Calcined Kaolins (Multibrite Range)Silane treatment is essential where:
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S a e t eat e t s esse t a e e
0
10
2030
40
50
60
7080
90
100
Tan Delta VR
Calcined Kaolin
Calcined Kaolin+silane
Calcined Kaolin
Pretreated
Calcined KaolinPretreated+silane
Maximum stress resistance is critical
Maximum moisture resistance is critical
Performance at elevated temperature is critical
Amino silane - Mainly used in polyamides (nylon) with some small use in rubber applicationsVinyl silane - Mainly used in the rubber EPR/EPDM cable industry
The Silane Reaction with Kaolin
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The silane reacts with the hydroxyl
groups on the kaolin surface
The functional group on the silane is
free to associate with the polymer
matrix
Gives a reinforced interface andimproved mechanical properties
In Amino Silane
Y = -NH2
In Vinyl SilaneY = -C2H5
Plastics Applications for Kaolin
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Flooring (EVA, pPVC)
EVA - hydrous kaolinPVC tiles - hydrous kaolin
Cables (pPVC)
High Voltage (metakaolin & fully calcined)
Engineering Thermoplastics (PA - Nylon)
Automotive (Surface treated calcined kaolins)
Film (PE, PP, PET)
Agricultural Thermal Barrier Film - calcined kaolin
Antiblock Film - calcined kaolin
Calcined Kaolin in Antiblock Film
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Used at low filler loadings (15003000ppm)
Competes with talc, silca, diatomaceous earth, carbonates
Calcined kaolin gives the best balance of film haze and antiblocking efficiency
Calcined kaolins can be used at higher concentrations than the competitive fillerswithout affecting the haze
Re-blocking testing shows calcined kaolin to be more efficient
High stability and unreactive surface results in minimal deactivation of expensivestabilisers and additives
Calcined Kaolin in Agricultural Film
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Used at filler loadings of up to 10 wt%
(restricted by greenhouse transparency requirements) Strong far infrared absorption for thermal barrier effect
High stability to resist ageing and degradation
Excellent processabilitylow moisture and good flow characteristics
Higher calcined kaolin loadings are claimed in
mulch and silage wrap applications
Calcined Kaolin in
PVC C bl A li ti
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pPVC Cable Applications
Calcined kaolins improve electrical properties of pPVC cable Works at low concentrations (up to 20phr) replacing CaCO3 Used where good electrical properties are required at high temperatures,
voltages and humidities
Improves the electrical performance of flame retardant and smoke suppressantpPVC compounds For example, replacing 14 phr of CaCO3 with calcined kaolin gives 10 x higher
volume resistivity
Calcined kaolin also improves all other dielectric properties of pPVC insulation
Calcined kaolin is also sometimes used in EVA cable compound
PVC and EVA Floor tiles
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Hydrous kaolin is used as a functional filler in pPVC and EVA floor tiles
The kaolin shape gives dimensional stability and melt-flow properties
A British Standard 3260 formulation for pPVC floor tiles is shown below
phr
PVC-PVA Copolymer 100
D.A.P. Plasticiser 33
Stabiliser/lubricants 10
Epoxidised Soya bean Oil 7
Coarse Limestone 150Kaolin 450
Mineral Fillers for the Rubber IndustryIntroduction
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Over 4 million tonnes of fillers is used in rubber every year:
Carbon Black
73%
Kaloin
15%
Calcium
Carbonate8%
Precipitated
Silica
4%
Definition of a FillerA filler is a particulate material added to rubber for one or more of the following reasons:
Modification of physical properties Modification of processing performance Reduction in cost
Filler Definitions
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1. Reinforcing Filler
Fine particle size carbon blacks and precipitated silica
2. Semi-reinforcing Filler
Coarse carbon blacks, fine particle size clays (Hard Clays) and precipitated calcium
carbonates
3. Non-reinforcing Filler
Mainly natural products - coarse clays (Soft Clays), calcium carbonate, talcs etc.
Classified into three broad groups according to the influence on a high quality natural
rubber gumstock
Classification of Fillers by Reinforcement
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Filler PrimaryParticle
Size (m)
Polymer-Filler
Adhesion
Particle Shape
Fumed Silicas 0.005 - 0.025 Very High StructuredPrecipitated Silicas 0.015 - 0.060 Very High Structured
Carbon Blacks 0.011 0.100 Very High Structured
Silane Treated Fine Kaolin 0.200 1.000 Very High Platey
Fine Kaolin 0.200 1.000 Low Platey
Silane Treated Calcined Kaolin 0.700 2.000 Very High Platey/Structured
Zinc Oxide0.090
0.150 Low SphericalPrecipitated Calcium Carbonate 0.050 0.100 Low Spherical
Micronised Talcs 1.000 2.000 Very Low Platey
Synthetic ATH 0.500 1.000 Low Particulate
Calcined Kaolin 0.700 2.500 Low Platey/Structured
Coarse Kaolin 1.000 5.000 Low Platey
Neuburger Chalk 1.000 5.000 Low Semi-Platey
Coarse Talcs 2.000 50.00 Very Low Platey
Ultrafine Chalks 0.700 1.200 Very Low Particulate
Natural ATH 5.000 - 1000 Very Low Particulate
Chalk/Limestone 2.000 - 1000 Very Low Particulate
Highly Reinforcing
Reinforcing
Semi-reinforcing
Non-reinforcing
Applications for Kaolin in Adhesives and Sealants
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Packaging adhesives
Woodworking adhesives
Glazing Sealants
Automotive Adhesives/Sealants
Construction Sealants
Kaolin Fillers for Adhesives and Sealants
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Packaging adhesives
PVA/PVOH
Fine kaolins
Medium fineness kaolins
Starch/Dextrin
Medium fineness kaolins
Woodworking adhesives
PVAMedium fineness kaolins
Kaolin Fillers for Adhesives and Sealants
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Glazing Sealants
Butyl Strip - Medium fineness kaolinsOil-based sealant/putties - Medium fineness kaolins
Automotive Adhesives/Sealants
PU assembly adhesives - Calcined kaolin
Construction Sealants
Polysulphide 1K - Calcined kaolins
Acrylic - Fine kaolins
Solvented Rubber - Fine kaolins
Benefits of Microbrite Calcined Kaolins in Sealants
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Very low irongood stability
Strong effect on sealant rheology
Low moisture content and pick-up
Low +10m content
Chemically inert
Temperature stable
Functionally variable
Benefits of Microbrite Calcined Kaolins in Sealants
Summary of Polymer Applications for ACC Kaolins
Mi b it F ll C l i d K li
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Microbrite Fully Calcined Kaolins
Pharmaceutical rubber
Profile extrusion
Thermoplastic vulcanisates (TPVs)
Rubber cable
High quality rubber flooringHose
Polyurethane sealants
Thermal barrier film
Antiblock film
Seals & Gaskets
Plasticised PVC cable
Summary of Polymer Applications for ACC Kaolins
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Metabrite Metakaolin
Plasticised PVC Cable
Low voltage rubber cable
Extrusion profile
Hose
Can be used as lower cost alternative to fully
calcined kaolin in less critical applications
Summary of Rubber Applications for ACC Kaolins
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Microbrite FH95
Non-black rubber compounds
Water based adhesives
pH sensitive rubber compounds
Summary of Rubber Applications for ACC Kaolins
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Microbrite CH98
Extension of coarse/medium carbon blackTechnical mouldings
Cable sheathing
Shoe soles
Rubber flooring
High strength adhesives
Summary of Rubber Applications for ACC Kaolins
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Microbrite CH40SR
Extension of carbon black
Replacement of precipitated silica
Tyres
Shoe soles
Flooring
Polymer Applications for Kaolin
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Rubber Applications for Kaolins
Belting Conveyer, toothed, v-belt
Hose Fuelling, brake, radiator, hydraulic, pneumatic, vacuum, ductingFootware Boots, sports, industrial, safety, soles, heels, sponge
Cables Sheathing, insulating, covering, plugs, sockets, connectors
Mountings Engine, machinery, instrument, shock absorbers, pads
Seals O-rings, shafts, grommets, window, diaphragms, valves, jar rings
Cellular Pillows, mattresses, upholstery, carpet underlay, packaging
Sports Bladders, grips, masks, balls
Pharmaceutical Lids, seals, stoppers, plungers
Extrusions Glazing, channeling, tubing, cord, profile
Rollers Printing, trailers, machines
Flooring Tiles, mats, sheeting - industrial, public buildings, sports tracks
Linings Tanks, pipes
Tyres Agricultural, bicycle, motorcycle, industrial, truck, application, passenger
Plastics Applications for Kaolins
Flooring Tiles, mats, sheeting
Film Antiblocking in LDPE & LLDPE
Cables Plasticised PVC general purpose cable
Metakaolin for Building Products
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Purpose-made, user friendlypozzolanic materials
Range of applications
High pozzolanic reactivity
Readily dispersed
Technical advantages Increased strength Reduced water absorption Reduced chloride penetration Increased sulphate resistance Increased acid resistance Elimination of ASR Efflorescence control
Range of Applications
1. Glass-reinforced composites2. Decorative concrete products
3. Flooring systems
4. Renders/mortars
5. Ready-mix concrete
6. Tile adhesives
7. Alkali-activated systems8. Lime-based systems
Summary of Miscellaneous Applications for ACC
Kaolins
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Kaolins
Waxes and polishcalcined kaolin Carrierscalcined kaolin Cosmeticshydrous kaolin Soaps/detergentshydrous kaolin
Animal feedhydrous kaolin Pigment/dyehydrous & calcined kaolin Pharmaceuticalshydrous kaolin
Product
Cross
Australian China Clays Imerys Engelhard Burgess Huber
Hydrous Kaolins
Microbrite HC1 Polwhite B, C NE NE NE
Microbrite FH95Polsperse 10/20
ASP 170/602 No 17/20Polyfil S
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Cross
Reference
Chart
Microbrite FH95p
SpeswhiteASP-170/602 No.17/20
y
Huber 80B
Microbrite FH100BP Light Kaolin BP
Calcined Kaolins
Microbrite C80/95 C1
Microbrite C80/92 C2(Depends on colour)
NeoGen EFP
NeoGen 2000NeoGen JDF
Ultrex 98
Satintone 5 NE NE
Microbrite C70/90 C2PoleStar 200R
Glomax LL
Whitetex
Satintone W
Iceberg
Icecap
Polyfil 70
Metabrite CMC
PoleStar 501
MetaStar 400
PoleStar 450
Satintone SP-33 No.30 Polyfil 40
Microbrite C75/95 C1
Microbrite C80/95 C1
(Depends on particle size)
Opacilite NEOptiwhite
OptimaxNE
Microbrite C80/95 C1
Microbrite C80/92 C2(Depends on colour)
PoleStar 400
Neogen 2000
Satintone 5
Ultrex 98
Icecap K Polyfil 90
Silane Treated Calcined Kaolin
Multibrite 1AS Polarite 102A Translink 445 Burgess 2211 Polyfil WC
Multibrite 2AS
Multibrite 3AS*Polarite 402A Translink 555 Burgess 2270 Polyfil WC426
Multibrite 1VS Polarite 103A Translink 37 Icecap KE NE
Multibrite 2VS Polarite 503S Translink 77 Burgess 5178 NE
Multibrite 3VS NE Translink 37S Burgess KE350 NE
(NE = No Equivalent) * = High purity/high stability version
N.B sometimes direct equivalents are not required and other kaolins can be substituted depending
on formulation and application specifications.
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Quality Control
Brightness
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Particle Size
Viscosity
Dispersion
Moisture To Name But A Few
Quality Control
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The two Chinese calcined kaolin factories have ISO9001 certification
Skardon River has Quality Control laboratories at the Wet Plant and at the Dry Plant
where hourly production samples are analysed
Skardon River Pilot Plant also has a laboratory for product development
Skardon River is working towards ISO9001 certification
Swan River Pilot Plant has a Quality Control laboratory
EnvironmentalAt Skardon River Kaolin we take the responsibility for our activities very seriously
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AUSTRALIANCHINACLAYSLIMITED
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Website: www.skardon.com.au
Thank You