acc europe training dec 06 v3

8/3/2019 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





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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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



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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


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.


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



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Microbrite CH98

Extension of coarse/medium carbon blackTechnical mouldings

Cable sheathing

Shoe soles

Rubber flooring

High strength adhesives



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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 C80/92 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



(Depends on particle size)

Opacilite NEOptiwhite

OptimaxNE


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

acc europe training dec 06 v3

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