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The evolution of the utilization of mineral fillers in the paper industry

Ewa Lewicka
Zeszyty Naukowe Instytutu Gospodarki Surowcami Mineralnymi Polskiej Akademii Nauk | 2018 | Nr 106 | 101-110 | DOI: 10.24425/124397
Keywords GCC PCC kaolin paper industry
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Abstract

Mineral fillers are mainly utilized in the production of printing and writing papers (P&W) to improve their optical features and their vulnerability to printing. With the high cost of pulp, the aim of their introduction has been to increase mineral loading in paper and reduce the overall cost of production. For many years the only method of paper formation was acid technology, while the only raw material of choice for filling and coating paper and cardboard was kaolin (in the beginning of the 1970s it was 80% of fillers and 94% of coating grades used in Western Europe, while in the USA – 92% and 96%, respectively). The onset on new methods of acid-free (alkaline) paper forming caused a drastic reduction in the kaolin demand for cost-competitive calcium carbonate: GCC – Ground Calcium Carbonate) and PCC – Precipitated Calcium Carbonate. This also resulted from the progressive self-destruction of machine-made acid papers. In 2013, the share of calcium carbonate in the total production of fillers was 83%, while kaolin accounted for 10%, and talc – 7%. The article presents the parameters of principal mineral fillers for the paper industry and the main reasons why they are suitable for particular kinds of paper. Kaolin, due to the platy nature of its main mineral constituent – kaolinite, is preferred in multiple coating papers. The choice of GCC is beneficial because of its low price and properties (especially whiteness). PCC , due to the possibility of shape and particle size modification serves as filler in uncoated woodfree papers, the key features of which are expected to be lightness and opacity. Size distribution is the main difference between PCC and GCC . The article also presents tendencies observed over the last several years in the paper market in Poland, i.e. in a significant growth in coated paper and board for packaging, as well as the decreasing demand for newspaper, which is a consequence of progressive digitalization.

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Authors and Affiliations

Ewa Lewicka

Influence of kaolinite crystallinity and calcination conditions on the pozzolanic activity of metakaolin

Yuanyuan Liu Qian Huang Liang Zhao Shaomin Lei
Gospodarka Surowcami Mineralnymi - Mineral Resources Management | 2021 | vol. 37 | No 1 | 39-56 | DOI: 10.24425/gsm.2021.136295
Keywords kaolin crystallinity calcination conditions pozzolanic activity
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Abstract

Two kaolin ores with the almost same fineness and purity of original kaolinite but possessing different kaolinite crystallinity (Hinckley Index) were selected to study the influence of crystallinity and calcination conditions on the pozzolanic activity of metakaolin after dehydroxylation. The different calcination conditions were conducted by altering the calcination temperature and holding time to obtain different metakaolin samples with different degrees of dehydroxylation. Then pozzolanic activities of metakaolin samples were tested by the modified Chapelle test, Frattini test and strength evaluations. Additionally, the apparent activation energies of two kaolin ores were calculated to study the thermal properties of kaolinite by isoconversional methods followed by iterative computations. The results showed that pozzolanic activities were dependent on the degree of dehydroxylation, except for the metakaolins calcined at 900℃ due to the fact that recrystallization and high pozzolanic activity was conducted by complete dehydroxylation (degree of dehydroxylation ≥ 90%). Moreover, the lower crystallinity of original kaolinite favored the removal of the structural hydroxyls, leading to a reduction of apparent activation energy and increase of pozzolanic activity, indicating that the higher calcination temperature or longer holding time was required during calcination to reach the same degree of dehydroxylation and finally highly ordered kaolinite converted into the less active metakaolinite, which was confirmed by the lower Ca(OH)2 consumption in the modified Chapelle test, higher [CaO] and [OH] in the Frattini test and weaker compressive strength.
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Authors and Affiliations

Yuanyuan Liu
1
ORCID: ORCID
Qian Huang
1
Liang Zhao
1
Shaomin Lei
2
  1. Yangtze Normal University, Chongqing Engineering Research Center for Structure Full-Life-Cycle Health Detection and Disaster Prevention, China
  2. Wuhan University of Technology, China

Effect of Composition on Melt Flow and Density of Polypropylene Copolymer/Kaolin Geo-Filler Composites

Zulaikha Zulkifli Yusrina Mat Daud Farah Farhana Zainal Mohammad Firdaus Abu Hashim Yurdakul Aygörmez
Archives of Metallurgy and Materials | 2023 | vol. 68 | No 1 | 369-373 | DOI: 10.24425/amm.2023.141513
Keywords Geo-filler kaolin composites polypropylene rheological
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Abstract

This study examined the effects rheological properties of different composition kaolin and kaolin geo-filler in polypropylene composites. Polypropylene composites with varying composition of kaolin geo-filler 0 wt%, 2 wt%, 4 wt%, 6 wt%, 8 wt%, and 10 wt% was prepared and compared with polypropylene composite with raw kaolin. Kaolin is an aluminosilicate based mineral filler was used to prepare geopolymer paste by combining with alkaline activator solution. The polypropylene composite was compounded using a twin-screw extruder and the melt flow index was determined by a constant weight pressure of 2.16 kg at 230°C in 10 min. Knowing the melt flow index is necessary to predict and control the process, the study has demonstrated that the composition of kaolin filler and kaolin geo-filler affects the melt flow, melt density and surface morphology at varies composition. Composites with kaolin geo-filler have demonstrated high melt flow index process and having better distribution and flow.
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Authors and Affiliations

Zulaikha Zulkifli
1
ORCID: ORCID
Yusrina Mat Daud
1 2
ORCID: ORCID
Farah Farhana Zainal
1 2
ORCID: ORCID
Mohammad Firdaus Abu Hashim
2 3
ORCID: ORCID
Yurdakul Aygörmez
4
ORCID: ORCID
  1. Universiti Malaysia Perlis, Faculty of Chemical Engineering Technology, 02600 Arau, Perlis, Malaysia
  2. University Malaysia Perlis (UniMAP), Green Technology (CEGeoGTech), 01000 Kangar, Perlis, Malaysia
  3. Universiti Malaysia Perlis, Faculty of Engineering Technology, Level 1, Block S2, UniCITI Alam Campus, Sungai Chuchuh, 02100 Padang Besar, Perlis, Malaysia
  4. Yildiz Technical University, Faculty of Civil Engineering, Civil Engineering Department, Davutpasa Campus, Istanbul, Turkey

Assessment of Geopolymer Concrete for Underwater Concreting Properties

Fakhryna Hannanee Ahmad Zaidi Romisuhani Ahmad Mohd Mustafa Al Bakri Abdullah Wan Mastura Wan Ibrahim Ikmal Hakem Aziz Subaer Junaidi Salmabanu Luhar
Archives of Metallurgy and Materials | 2022 | vol. 67 | No 2 | 677-684 | DOI: 10.24425/amm.2022.137805
Keywords Geopolymer Underwater concrete fly ash kaolin
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Abstract

For ages, concrete has been used to construct underwater structures. Concrete laying underwater is a very complex procedure important to the success or failure of underwater projects. This paper elucidates the influence of alkali activator ratios on geopolymers for underwater concreting; focusing on the geopolymer concrete synthesized from fly ash and kaolin activated using sodium hydroxide and sodium silicate solutions. The geopolymer mixtures were designed to incorporate multiple alkali activator ratios to evaluate their effects on the resulting geopolymers’ properties. The fresh concrete was molded into 50 mm cubes in seawater using the tremie method and tested for its engineering properties at 7 and 28 days (curing). The control geopolymer and underwater geopolymers’ mechanical properties, such as compressive strength, water absorption density, and setting time were also determined. The differences between the control geopolymer and underwater geopolymer were determined using phase analysis and functional group analysis. The results show that the geopolymer samples were optimally strengthened at a 2.5 alkali activator ratio, and the mechanical properties of the control geopolymer exceeded that of the underwater geopolymer. However, the underwater geopolymer was determined to be suitable for use as underwater concreting material as it retains 70% strength of the control geopolymer.
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Authors and Affiliations

Fakhryna Hannanee Ahmad Zaidi
1
ORCID: ORCID
Romisuhani Ahmad
1 2
ORCID: ORCID
Mohd Mustafa Al Bakri Abdullah
3 2
ORCID: ORCID
Wan Mastura Wan Ibrahim
1 2
ORCID: ORCID
Ikmal Hakem Aziz
3 2
ORCID: ORCID
Subaer Junaidi
4
ORCID: ORCID
Salmabanu Luhar
5 2
ORCID: ORCID
  1. Universiti Malaysia Perlis, Faculty of Engineering Technology, Sungai Chuchuh, 02100 Padang Besar, Perlis, Malaysia
  2. Universiti Malaysia Perlis (UniMAP), Geopolymer & Green Technology, Centre of Excellence (CEGeoGTech), Perlis, Malaysia
  3. Universiti Malaysia Perlis, Faculty of Chemical Engineering Technology, Taman Muhibbah, 02600 Jejawi, Arau, Perlis, Malaysia
  4. Universitas Negeri Makassar, Geopolymer & Green Material Group, Physics Department, FMIPA, Indonesia
  5. Frederick Research Center, P.O Box 24729, 1303 Nicosia, Cyprus

Enhancing photocatalytic performance of kaolin clay: an overview of treatment strategies and applications

Samor Boonphan Suriyong Prachakiew Khuruwan Klinbumrung Chananbhorn Thongrote Arrak Klinbumrung
Archives of Environmental Protection | 2024 | 50 | 3 | 54-64 | DOI: 10.24425/aep.2024.151686
Keywords Kaolin clay; Photocatalytic; Surface modification; Water treatment;
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Abstract

The objective of this study is to enhance the photocatalytic capabilities of kaolin clay to improve its efficiency in environmental remediation. Various techniques were employed to modify kaolin clay, including heat treatment, acid modification, and material integration. These methods aimed to reduce its bandgap and improve its selective adsorption properties, thereby enabling better visible light activation and pollutant removal. The study discovered that modified kaolin-derived nanomaterials exhibit remarkable potential in breaking down pollutants, disinfecting, capturing heavy metals, and eliminating airborne contaminants. These advanced materials have been successfully used in water filtration, air purification, and the development of self-cleaning surfaces.The modifications increased surface area, adsorption capacity, and overall catalytic performance. Unmodified kaolin, with its broad bandgap, has limitations that hinder its ability to be driven by visible light for photocatalytic purposes and to selectively absorb specific pollutants, including heavy metals. The novelty of this research lies in the systematic exploration and optimization of diverse modification strategies for kaolin clay, showcasing its versatility in photocatalytic applications. The tailored modifications of kaolin to address specific environmental needs have the potential to be a cost-effective and eco-friendly solution for sustainable environmental restoration.
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Authors and Affiliations

Samor Boonphan
1
Suriyong Prachakiew
1
Khuruwan Klinbumrung
2
Chananbhorn Thongrote
2
Arrak Klinbumrung
3 4
  1. Faculty of Science and Agricultural Technology, Rajamangala University of Technology Lanna, Chiang Rai, Thailand
  2. Scientific Instrument and Product Standard Quality Inspection Center, University of Phayao, Phayao, Thailand
  3. Unit of Excellence on Advanced Nanomaterials, University of Phayao, Phayao, Thailand
  4. School of Science, University of Phayao, Phayao, Thailand

Rational use of selected mining by-products in the ceramic industry in Poland

Ewa Lewicka
Gospodarka Surowcami Mineralnymi - Mineral Resources Management | 2020 | vol. 36 | No 1 | 59-76 | DOI: 10.24425/gsm.2020.132547
Keywords kaolin feldspathic raw materials by-products of the rock mining ceramic tiles sanitaryware
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Abstract

The paper discusses the issue of the utilization of selected raw materials obtained as by-products of rock mining and processing in the ceramic industry in Poland. The raw materials in question are: kaolinite-rich clayey substance remaining after quartz sand washing and alkalis-rich finest fractions generated in the course of the production of granite crushed aggregates. Despite usually high content of coloring oxides, they have been utilized for the production of ceramic goods, the high whiteness of which is not required after firing. High interest in these materials was connected with the implementation of the fast firing method as well as modernization and large scale expansion of the domestic ceramic industry, especially ceramic tiles and sanitaryware sectors. Between the mid-1990s and 2018, the annual consumption of kaolinite raw materials being by-products of quartz sand washing increased from ca. 20,000 to 100,000–120,000 Mg. At the same time the sales of secondary granite fractions utilized as a flux in the ceramic industry rose from 30,000 to 120,000 Mg per year in 2007–2008, and 50,000–70,000 Mg per year most recently. The development of the utilization of these raw materials has been an example of the rational and comprehensive management of all the minerals that occur in deposits in operation. This is particularly important in the context of the depletion of these raw materials reserves and the limited availability of their new deposits. Furthermore, this also makes a contribution towards reducing the scale of imports of raw materials for the ceramic tile industry, which is inevitable due to insufficient supplies from domestic sources.

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Authors and Affiliations

Ewa Lewicka

Susceptor-Assisted Rapid Microwave Sintering of Al-Kaolin Composite in a Single-Mode Cavity

V.S.S. Venkatesh Sunil Kumar Lokeswar Patnaik
Archives of Metallurgy and Materials | 2023 | vol. 68 | No 2 | 799-806 | DOI: 10.24425/amm.2023.142464
Keywords kaolin reinforcement microwave sintering mechanical properties powder metallurgy
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Abstract

The present research addresses the low-temperature sintering of 4% kaolin clay reinforced aluminium composite using susceptor-aided microwave sintering at 2.45 GHz frequency. Kaoline clay the naturally available mineral in the north-eastern regions of india. The study aims to convert this kaoline clay into the value added product with enhanced mechanical properties. The Al-x% Kaolin (x = 2, 4, 6, 8, 10) composite was fabricated through the powder metallurgy process by the application of 600 MPa compaction pressure. The composite corresponding to optimum ultimate tensile strength (U.T.S) was subjected to single-mode cavity microwave-assisted sintering by varying the sintering temperatures as 500°C, 550°C and 600°C. The effect of incorporating kaolin clay on the dielectric characteristics of composite powders, as well as the effect of sintering temperature on the microstructural changes and mechanical characteristics of Al-4%Kaolin composites were also examined. Results concluded that the addition of 4 wt% kaolin powder improves the dielectric characteristics of the composite powder. The maximum Hardness. Compression strength and U.T.S of 97 Hv, 202 MPa and 152 MPa respectively achieved for the Al-4% Kaolin composite sintered at 550°C. The higher fracture toughness of 9.56 Ma. m1/2 reveals the ductile fracture for the composite sintered at 550°C.
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Authors and Affiliations

V.S.S. Venkatesh
1
ORCID: ORCID
Sunil Kumar
2
ORCID: ORCID
Lokeswar Patnaik
3
ORCID: ORCID
  1. G.M.R Institute of Technology, Rajam, Andhra Pradesh, India
  2. Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Chennai, India
  3. School of Mechanical Engineering, Sathyabama Institute of Science and Technology (Deemed to Be University), Chennai, Tamil Nadu, 600 119, India

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