Process for the treatment of waste material suspensions

Abstract: There is disclosed a process comprising: (a) providing an aqueous suspension of particulate kaolin clay; (b) introducing into the aqueous suspension a reagent comprising a source of alkaline earth metal ions and a reagent comprising a source of carbonate ions to precipitate an alkaline earth metal carbonate in the said aqueous suspension of the said particulate kaolin clay whereby the said particulate kaolin clay present at the start of the process becomes entrained in the alkaline earth metal carbonate to form a mixed aggregated material.

Description: This invention relates generally to a process for the treatment of a suspension of particulate kaolin clay, such as by-products of wet-mineral refining processes and waste waters from paper mills, which have hitherto been found to be difficult to dewater when dispersed in aqueous suspension at low solids. Additionally, this invention relates to the aggregated product of such a process which have advantageous properties when used in paper making and paper coating, or when used as a filler or extender for paints, plastics compositions and the like. Many naturally occurring mineral materials are subjected to particle size separations in order to select those particles which have the most desirable distribution of sizes for a particular application. In many cases the natural mineral material contains a significant proportion of particles which are undesirably fine for the particular application for which the mineral material is being prepared, and it is necessary to remove these excessively fine particles. When the particle size separation is performed on a mineral material in suspension in a liquid, which would most commonly be water, and when the undesired fine particles have an equivalent spherical diameter of about 0.5µm or less, the suspension of the undesired fine particles is often recovered in the form of a dilute suspension which is extremely difficult to dewater by conventional methods. It is generally unacceptable, for environmental reasons, to allow such dilute suspensions of fine mineral particles to be discharged to rivers or lakes, and, as a result, such unwanted suspensions of very fine particles are often retained in lagoons, thus occupying large areas of land which could more profitably be used for other purposes. Organic wastes, for example the waste water from a paper mill in which the suspended solid material consists predominantly of cellulosic fibres usually in association with a smaller amount of an inorganic mineral filler, are also environmentally undesirable and difficult to dewater. It is well known that calcium carbonate of fine particle size can be chemically precipitated by contacting together a source of calcium ions and a source of carbonate ions. The source of carbonate ions may be, for example, carbon dioxide gas in the presence of water or an alkali metal carbonate such as soda ash. TAPPI Monograph Series No. 30, "Paper Coating Pigments", pages 34-35 describes three main commercial processes for preparing precipitated calcium carbonate which is especially suitable for use in the paper industry. In all three processes limestone is first calcined to produce quicklime, and the quicklime is then slaked in water to yield calcium hydroxide or milk of lime. In the first process the milk of lime is directly carbonated with carbon dioxide gas. This process has the advantage that no by-product is formed, and it is relatively easy to control the properties and purity of the calcium carbonate product. In the second process the milk of lime is contacted with soda ash to produce by double decomposition a precipitate of calcium carbonate and a solution of sodium hydroxide. The sodium hydroxide must be substantially completely separated from the calcium carbonate if this process is to be commercially attractive. In the third main commercial process the milk of lime is first contacted with ammonium chloride to give a calcium chloride solution and ammonia gas. The calcium chloride solution is then contacted with soda ash to produce by double decomposition precipitated calcium carbonate and a solution of sodium chloride. US-A-5082887 describes a process in which an aqueous suspension of fine mineral particles is treated with a high molecular weight carboxyl-containing polymer to flocculate the particles. An excess of calcium ion is then added to precipitate the calcium salt of the carboxyl-containing polymer in situ on the mineral flocs, thus forming aggregates of the mineral particles. Gaseous carbon dioxide is then added to the slurry to react with the remaining calcium ion in the slurry to precipitate calcium carbonate on to the polymeric carboxyl calcium salt. US-A-3152001 describes a process for the production of a filler in which a calcium carbonate is first precipitated from an aqueous solution and then the surface of the precipitated calcium carbonate is modified by SiO 2 . Thereafter, a finely divided silicate is precipitated onto the SiO 2 -modified calcium carbonate. The resultant filler is for use as a reinforcing filler for an elastomer. US-A-2470577 discloses a filler material prepared by precipitating calcium carbonate and calcium silicate simultaneously from a common reaction solution. According to a first aspect of the present invention there is provided a process for treating an aqueous suspension of particulate kaolin clay, which comprises the step of precipitating an alkaline earth metal carbonate in the said aqueous suspension of the particulate material whereby the said particulate material present at the start of the process becomes entrained in the alkaline earth metal carbonate precipitate. The particulate kaolin clay is preferably finely divided, by which we mean that it will generally have an average particle diameter smaller than 1µm, and usually smaller than about 0.5µm. The aqueous suspension is preferably dilute by which we mean that it contains no more than about 20% by weight of the dry particulate material on a dry weight basis, more preferably less than 10% by weight thereof. Where the waste suspension to be treated is a paper mill waste, the solids concentration thereof is likely to be considerably less than 10%, for example of the order of 1%. The present invention is directed to the aggregation of a particulate material which is an industrial by-product such as a finely divided kaolin clay. When the particulate material is an industrial by-product of this type which is finely divided, for example having an average particle diameter smaller than 1µm, and typically smaller than about 0.5µm, and which exists as an aqueous suspension containing not more than about 10% by weight of dry by-product, the present invention is particularly advantageous because suspensions of these materials are very difficult to dewater. An aqueous suspension of the aggregated product resulting from the process of the present invention is relatively easy to dewater. The alkaline earth metal carbonate is most preferably a calcium carbonate. In the process of the present invention, the alkaline earth metal carbonate precipitate may be formed by introducing into the suspension of the particulate mineral a source of alkaline earth metal ions and a source of carbonate ions. This will form the desired precipitate of alkaline earth metal carbonate in situ which will entrain the particulate mineral. The first reagent which is added should preferably be uniformly distributed throughout the aqueous suspension of the particulate material to avoid local concentration gradients. When the first reagent is sparingly soluble, as is the case with calcium hydroxide, thorough mixing is desirable. It is also desirable that the suspension should be agitated while the second reagent is added in order to ensure an even distribution of the precipitate. It is preferred to add the source of alkaline earth metal ions followed by the source of carbonate ions; when the alkaline earth metal is calcium, this ensures that the scalenohedral form of calcium carbonate is precipitated, which appears to give the best light scattering properties when the aggregated product is to be used in paper making or paper coating. The source of alkaline earth metal ions is conveniently the alkaline earth metal hydroxide (known as milk of lime when the alkaline earth metal is calcium), but it may alternatively be a water-soluble alkaline earth metal salt, for example the chloride or nitrate. The alkaline earth metal hydroxide may be added to the aqueous suspension already prepared, or may alternatively be prepared in situ, for example by slaking an alkaline earth metal oxide (e.g. quicklime, when an aqueous suspension of calcium hydroxide is desired) in the suspension. The source of carbonate ions is conveniently carbon dioxide gas which is introduced into the suspension containing the particulate material and the source of alkaline earth metal ions. The carbon dioxide gas may be substantially pure as supplied in gas cylinders or may be present in a mixture of gases such as flue gases. Alternatively, the source of carbonate ions may be an alkali metal or ammonium carbonate. Sodium carbonate is especially preferred on account of its relative cheapness and availability. When the process of the present invention is used for the treatment of a suspension of an organic waste, for example for the treatment of waste water from a paper mill, in which the suspended solid material consists predominantly of cellulosic fibres, the source of alkaline earth metal ions may be introduced into the suspension, either by slaking an alkaline earth metal oxide, for example calcium oxide or quicklime, in the suspension, or by adding to the suspension a separately prepared suspension of an alkaline earth metal hydroxide. Whether the alkaline earth metal oxide is slaked in waste water or in fresh water, the water may be at ambient temperature, but is preferably heated to a temperature in the range from 40°C to 50°C, and the suspension of the alkaline earth metal oxide in the water is preferably agitated vigorously for a time of up to 30 minutes to ensure that the slaking is complete. The quantity of the source of alkaline earth metal ions and the source of carbonate ions used is preferably such as to precipitate sufficient alkaline earth metal carbonate to increase the dry solids content of the aqueous suspension to within the range from 10% to 20% by weight. The weight ratio of fine mineral to alkaline earth metal carbonate (preferably calcium carbonate) will depend upon the nature of the fine mineral. For example bentonite may need at least 80% by weight of the mixture to be alkaline earth metal carbonate, while, in the case of fine kaolinite, only about 25% by weight of the mixture may need to be alkaline earth metal carbonate to give acceptable dewatering. The suspension containing the precipitate of alkaline earth metal carbonate (preferably calcium carbonate) and entrained particulate material (e.g. an industrial by-product) may be added directly in its relatively dilute form to a paper making composition to provide filler particles for the paper making fibres. Alternatively the suspension may be dewatered by any conventional method, for example by pressure filtration or in a centrifuge. If desired, a reducing bleaching agent may be added to the suspension containing the particulate material or by-product in order to improve its whiteness. The reducing bleaching agent may be, for example, a dithionite salt, such as sodium or zinc dithionite, or zinc dust and sulphur dioxide. The amount of the reducing bleaching agent used is preferably in the range from 1.5 to 7.5 grams of the reducing bleaching agent per kilogram of dry particulate material. The bleaching agent could be added after the addition of the first reagent, but before addition of the second reagent. The suspension of the precipitate of alkaline earth metal carbonate and entrained particulate material is found to be very much easier to dewater than the original suspension of the particulate material alone, because, when a cake of the mixed solid material is formed by filtration or by centrifuging, the packing of the particles is such that the cake is very much more permeable to water than is a cake of the particulate material by-product alone. Also the mixed solid material is found to give advantageous light scattering properties when used as a paper filler material or as a paper coating pigment. According to a second aspect of the present invention there is provided a composite mineral pigment/filler comprising aggregates consisting essentially of precipitated alkaline earth metal carbonate (preferably calcium carbonate) and a particulate material, the particles of which are entrained in the alkaline earth carbonate precipitate. Such aggregates can be used in the preparation of a paper-making composition or a paper-coating composition. A paper making composition will contain, in aqueous suspension, and in addition to the aggregated filler of the invention (and optionally other filler materials), cellulosic fibres and other conventional additives known in the art. A typical paper making composition would contain up to about 67% by weight of dry filler material, based on the dry weight of the paper making fibres, and may also contain a cationic or an anionic retention aid in an amount in the range from 0.1 to 2% by weight, based on the dry weight of the filler material. It may also contain a sizing agent which may be, for example, a long chain alkylketene dimer, a wax emulsion or a succinic acid derivative. The composition may also contain dye and/or an optical brightening agent. A paper coating composition will contain, in aqueous suspension, and in addition to the aggregated pigment of the invention (and optionally other filler materials), an adhesive. The formula of the paper coating composition will depend upon the purpose for which the coated paper is to be used, i.e. either for offset or gravure printing. Generally speaking, the amount of adhesive will be in the range from 3 to 35% by weight of adhesive solids, based on the dry weight of the coating pigment. There will also be present from 0.01 to 0.5% by weight, based on the dry weight of the coating pigment, of a dispersing agent. Sufficient alkali will generally be added to raise the pH to about 8-9. The adhesive solids may be a starch, a water dispersible synthetic resin or latex such as a styrene butadiene copolymer, a polyvinyl alcohol an acrylic polymer, polyvinyl acetate, a butadiene-acrylonitrile copolymer, a cellulose derivative such as methyl cellulose, sodium carboxymethyl cellulose or hydroxyethyl cellulose or a proteinaceous material such as casein, animal glue or a vegetable protein. The invention will now be illustrated by reference to the following Examples. EXAMPLE 1 Quicklime (252g) was added to 4,500cm 3 of an aqueous suspension at a temperature of 50°C containing 7.5% by weight of kaolin clay particles of average particle size 0.22µm. The suspension was stirred vigorously for 25 minutes to ensure adequate slaking of the quicklime. The pH of the suspension was then found to be 12.5. There was then introduced into the suspension of clay particles and calcium hydroxide a gas mixture containing 25% by volume of carbon dioxide at a rate of 5,242 cm 3 .min -1 , which corresponds to 0.013 moles of carbon dioxide per minute per mole of calcium hydroxide. The gas mixture was introduced into the suspension as a fine stream of bubbles and vigorous stirring was maintained throughout the introduction. The pH of the suspension was continuously monitored and the introduction of the gas mixture was continued until the pH of the suspension had fallen to below 8.0. The particulate component of the resultant suspension which contained 54% by weight of calcium carbonate was examined by means of an electron microscope and was found to comprise a co-aggregated mixed mineral (see the Figure in which the platy particles are the kaolinite and the white "fluffy" particles are the precipitated calcium carbonate). EXAMPLE 2 The experiment described in Example 1 was repeated several times there being added in each case to the suspension of kaolin clay particles a different amount of the quicklime such that the composition of the mixed mineral produced varied in the range from 35% to 73% by weight of calcium carbonate. As a control, a further suspension was prepared by slaking 252g of quicklime in 4,500cm 3 of water which was free of kaolin particles. In each case there was introduced into the suspension 0.013 moles of carbon dioxide per minute per mole of calcium hydroxide. The suspension of the mixed mineral produced in each case was filtered and the cake of mixed mineral was remixed with water to form a suspension containing 30% by weight of dry mixed mineral, which suspension was used to measure the Kubelka-Munk scattering coefficient, S, by the following method: A sheet of synthetic plastics paper material, sold by Arjo Wiggins Appleton plc under the Registered Trade Mark "SYNTEAPE", was cut into a number of pieces each of size 10cm x 6cm, and each piece was weighed and tested for percentage reflectance to light of wavelength 457nm when placed over a black background by means of an "ELREPHO" spectrophotometer to give the background reflectance R b . The preweighed pieces of plastics paper were then coated with different amounts of the suspension of mixed mineral to give coat weights in the range from 5 to 20g.m -2 . Each coating was allowed to dry in the air and the area of dry coating on each piece of plastics paper was standardised by placing a circular template over the coating and carefully removing surplus coating which lay outside the periphery of the template. Each piece of plastics paper bearing a coated area was then reweighed, and, from the difference in weight and the dimensions of the coated area, the coat weight X in kg.m -2 was calculated. Each coated area was then tested for reflectance to light of wavelength 457nm when the piece of plastics paper was placed (a) on a black background (R 0 ); and (b) on a pile of uncoated pieces of the plastics paper (R 1 ). Finally the reflectance to light of wavelength 457nm was measured for the pile of uncoated pieces alone (r). From these measurements the reflectance R c of the coating alone was calculated from the formula:- R c = R 1 . R b - R 0 . r ( R 1 - R 0 ) . rR b + Rb - r and the transmission T c of the coating from the formula:- T c 2 = ( R 0 - R c ) (1 - R c R b ) R b From these two quantities it is possible to calculate a theoretical value for the reflectance R oo , of a coating layer of infinite thickness of the same material from the formula: - 1 - T c 2 + R c 2 R c = 1 + R 00 2 R 00 The Kubelka-Munk scattering coefficient S in m 2 .kg -1 may now be calculated from the formula:- SX = 1 b coth -1 . 1 - aR c bR c where and The scattering coefficient S was plotted against the coat weight X and the value of S in each case for a coat weight of 8g.m -2 was found by interpolation. The results obtained are set forth in Table 1. weight % calcium carbonate scattering coefficient S 35 227 54 265 73 276 100 253 EXAMPLE 3 The experiment described in Example 1 was repeated except that there was added to the suspension of kaolin clay particles, before the quicklime, 1.69g of sodium dithionite as a reducing bleaching agent. The particulate component of the suspension on completion of the treatment with carbon dioxide gas was separated by filtration and dried in an oven for 16 hours at 80°C. The resultant dry cake was pulverised and the reflectances to light of wavelength 457nm and 570nm, respectively, were measured by means of an "ELREPHO" spectrophotometer. The experiment was repeated except that no sodium dithionite was added to the suspension of kaolin clay particles. The results obtained are set forth in Table 2 below: EXAMPLE 4 The experiment described in Example 1 was repeated several times there being added in each case to the suspension of kaolin clay particles a different amount of the quicklime such that the composition of the mixed mineral produced varied in the range from 0.5% to 99.5% by weight of calcium carbonate. In each case there was introduced into the suspension 0.013 moles of carbon dioxide per minute per mole of calcium hydroxide. A small sample of the suspension of the mixed mineral produced in each case was poured into a Buchner filter funnel provided with a piece of standard filter paper, the side arm of the filtrate flask being connected to the laboratory vacuum source. The filtrate was collected in a measuring cylinder inside the filtrate flask, and at intervals the volume of filtrate collected and the time which had elapsed since the start of filtration were recorded. The square of the volume collected was plotted graphically against the elapsed time, and a curve was obtained which had a large central straight line portion. The slope of this straight line portion was recorded in each case. The relationship between the square of the volume of filtrate collected and the elapsed time is given by the Carmen-Kozeny equation:- Q 2 T = 2 . A 2 . P . E 3 . ( y - 1) 5 . v . S 2 . (1 - E 2 ) . d 2 where: Q is the volume of filtrate collected; T is the elapsed filtration time; A is the area of the filter medium; P is the differential pressure across the filter medium; E is the fraction of voidage in the filter cake; v is the viscosity of the suspending medium; S is the specific surface area of the particulate phase; and d is the specific gravity of the particulate phase. The slope Q 2 /T of the straight line portion of the graph plotted for each suspension gave a measure of the filtration rate in each case and, since A, P, v, S and d can be assumed to be constant under the conditions of the experiment, a standardised filtration rate F can be found to be given by: F = Q 2 . R T where: R = 1 d + W c S c W s S s - W c S c where: W c is the weight fraction of water in the cake; S c is the weight fraction of solids in the cake; W s is the weight fraction of water in the suspension; and S s is the weight fraction of solids in the suspension. Suspensions were also prepared by mixing with 4,500cm 3 of the suspension of fine kaolin clay particles different quantities of precipitated calcium carbonate which had been prepared separately from the kaolin clay suspension by carbonating milk of lime. The filtration rate for each mixed suspension and the percentage by weight of dry material in the cake were measured as described above. The results obtained are set forth in Table 3 below: Precipitated in situ Separately mixed % by weight of precipitated calcium carbonate in mixture Filtration rate (F) % by wt. solids Filtration rate (F) % by wt. solids 0 0.001 73.8 0.001 73.8 35 0.380 42.7 50 0.167 55.9 54 1.090 38.1 100 7.880 35.4 7.880 35.4 These results show that, for a given percentage by weight of precipitated calcium carbonate in the mixture, a higher filtration rate is obtained if the calcium carbonate is precipitated in the presence of the fine kaolin than if it is precipitated separately and then added to the suspension of fine kaolin. EXAMPLE 6 11.25g of quicklime was added to 1000ml of an aqueous suspension containing 180g of a kaolin clay having a particle size distribution such that 80% by weight consisted of particles having an equivalent spherical diameter smaller than 2µm. The solids content of the kaolin clay suspension before the addition of the quicklime was 16.2% by weight. The suspension was maintained at a temperature of 50°C and vigorously stirred for 25 minutes to ensure adequate slaking of the quicklime. A gas mixture comprising 25% by volume of carbon dioxide was then introduced into the suspension as a fine stream of bubbles at a rate of 0.13 moles of carbon dioxide per minute per mole of calcium hydroxide. The temperature of the suspension was maintained at 45°C and the gas mixture was introduced with continuous agitation of the suspension until the pH of the suspension had fallen to below 8.0. The experiment described above was repeated three more times except that 11.25g of quicklime was added to 1000ml of an aqueous suspension containing, respectively, 60g, 20g and 6.7g of the kaolin clay. The solids content of the suspension of kaolin clay in each case before the addition of the quicklime was, respectively, 16.2%, 5.8%, 2.0% and 0.7% by weight. A suspension was also prepared containing 180g of the kaolin clay alone in 1000ml of the suspension. A further suspension was prepared by adding quicklime to 1000ml of water and carbonating the calcium hydroxide thus formed under the conditions described above. The filtration rate, F, and the percentage by weight of water retained in the filter cake were measured for each suspension as described in Example 4 above. The results obtained are set forth in Table 5 below: - % by wt. of precipitated calcium carbonate in mixture % by wt. of solids in kaolin suspension Filtration rate (F) % by wt. of solids in cake 0 16.2 0.06 66.9 10 16.2 0.21 58.1 25 5.8 0.61 50.1 50 20.0 0.93 49.4 75 0.7 1.38 44.7 100 0 2.54 40.1

Claims: A process comprising: (a) providing an aqueous suspension of particulate kaolin clay; (b) introducing into the aqueous suspension a reagent comprising a source of alkaline earth metal ions and a reagent comprising a source of carbonate ions to precipitate an alkaline earth metal carbonate in the said aqueous suspension of the said particulate kaolin clay whereby the said particulate kaolin clay present at the start of the process becomes entrained in the alkaline earth metal carbonate to form a mixed aggregated material. A process according to claim 1, wherein the mixed aggregated material is recovered and incorporated in a composition which is a paper making composition or a paper coating composition or a paint composition or a plastics composition. A process according to claim 1 or 2, wherein the kaolin clay has a particle size distribution such that at least 80% by weight consists of particles having an equivalent spherical diameter smaller than 2µm. A process according to claim 1, 2 or 3, wherein the solids content of the suspension of particulate kaolin clay is from 0.7 to 16.2% by weight. A process according to claim 1, 2, 3 or 4, wherein the suspension of particulate kaolin clay additionally comprises a reducing bleaching agent. A process according to claim 5, wherein the reducing bleaching agent is sodium dithionite. A process according to any preceding claim, wherein the first of the said reagents which is added is uniformly distributed throughout the aqueous suspension of the particulate material to avoid local concentration gradients. A process according to claim 7, wherein the aqueous suspension is agitated while the second of said reagents is added in order to distribute the precipitate evenly. A process according to any preceding claim, wherein the reagent comprising the source of alkaline earth metal ions is introduced into the aqueous suspension followed by the reagent comprising the source of carbonate ions. A process according to any preceding claim, wherein the source of alkaline earth metal ions comprises a source of calcium ions whereby a precipitate of calcium carbonate is formed in step (b). A process according to any preceding claim, wherein the source of alkaline earth metal ions is selected from the alkaline earth metal hydroxide and water-soluble alkaline earth metal salts. A process according to claim 11, wherein the source of alkaline earth metal ions is an alkaline earth metal salt selected from alkaline earth metal chlorides and alkaline earth metal nitrates. A process according to any preceding claim, wherein the source of alkaline earth metal ions introduced into the aqueous suspension is an alkaline earth metal oxide which converts to the corresponding alkaline earth metal hydroxide in the aqueous suspension. A process according to claim 13, when dependent on claim 10, wherein the source of alkaline earth metal ions is calcium oxide. A process according to any preceding claim, wherein the source of carbonate ions is carbon dioxide gas or an alkali metal carbonate or ammonium carbonate. A process according to any preceding claim, wherein the quantity of the source of alkaline earth metal ions and the source of carbonate ions used is such as to precipitate sufficient alkaline earth metal carbonate to increase the solids content of the aqueous suspension to within the range from 10% to 20% by dry weight. A process as claimed in claim 2 and wherein the mixed aggregated material is incorporated in a paper making or paper coating composition. A process according to claim 2, wherein the aqueous suspension containing the mixed aggregated material is dewatered. A process as claimed in claim 17 and wherein the mixed aggregated material is incorporated in the composition for paper making or paper coating in the form of an aqueous suspension. A process as claimed in claim 19 and wherein the aqueous suspension containing said mixed aggregated material is added directly in relatively dilute form to a paper making composition to provide filler particles for the composition. A mixed aggregated material for use as a particulate filler or pigment material in a filler or pigment containing composition, made by the process of any one of claims 1 to 16. A paper making composition comprising, in aqueous suspension, an aggregated material as claimed in claim 21 and cellulosic fibres and optionally other filler materials or additives. A paper coating composition comprising, in aqueous suspension, an aggregated material as claimed in claim 21 and an adhesive and optionally other filler materials.

Inventors: BLEAKLEY IAN STUART, BLEAKLEY, IAN STUART
Applicants: IMERYS MINERALS LTD, IMERYS MINERALS LIMITED
Application year: 1993
Main classification: C02F1
IPC codes: D21H17, C02F1, C09C1, D21H19, B01D21