Abstract:
A process for producing high grade metakaolin directly from kaolinzed sands ore body. In one embodiment, a source of kaolin ore is reduced in the size to a size distribution of between −2 inches and 10 mesh. The ore is then dried in a dryer at a temperature of not greater than 180° C. to a moisture content of not greater than 0.5% by weight to liberate kaolin and calcined at a temperature of not greater than 875° C. to produce metakaolin.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. Provisional Application No. 60/730,025, filed Oct. 26, 2005. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a method of producing metakaolin and more particularly, the invention relates to the formation of metakaolin using raw material directly from a kaolin ore body. 
     BACKGROUND OF THE INVENTION 
     Metakaolin is a very useful aluminosilicate material that has high value applications. For example, there is usage in various applications of the cement industry as found say with U.S. Pat. No. 6,230,804 and U.S. Pat. No. 5,158,613. With lower costs inherent in a new and simple metakaolin production process, the use of metakaolin could significantly increase, particularly in the cement industry, as high performance concretes formed with added metakaolin, are significantly stronger and more economically attractive. 
     The current method of producing metakaolin involves two distinct stages whereby high grade kaolin is first produced from kaolin ore in a multiple step procedure. The high grade kaolin is then heated in a high temperature furnace at about 500-900° C. to produce metakaolin. This is outlined in “Effect of Metakaolin on Durability of Concrete Structures and Bridges, V. H. Nejad, Univ. of Surrey, UK, 1995”. With calcinations of kaolin, care must be taken to complete the dehydroxylation of kaolin, but prevent heating beyond this point since this leads to the formulation of unreactive mullite, 3A12.2SiO2. 
     The production of high grade kaolin contains a number of steps and these lead to complex and expensive processes to obtain good quality kaolin necessary as a feedstock to produce metakaolin. The complexity is amply illustrated in the art taught in U.S. Pat. No. 6,186,335 (February, 2001) by Arrington-Webb et al. The inventors of this art have indicated that in excess of six steps could be required to produce good quality kaolin product from kaolin ore. The complexity of the overall process is a major factor in high capital and operating costs and high kaolin costs leading to expensive metakaolin. 
     There is also significant additional art on record to support the view that using high quality kaolin for metakaolin production is complex and costly. This is particularly true as the higher grade kaolin ore reserves have been depleted leaving primarily lower grade, high impurity, kaolin reserves left as kaolin feedstock. References related to this include as examples, U.S. Pat. Nos. 5,891,326; 5,545,599; 5,227,349; 5,047,375 and 4,492,628. 
     The result of the complex process for producing metakaolin is that the use of metakaolin is quite limited by the high costs associated with current methods of production. In addition, many highly beneficial potential uses of metakaolin, such as high strength and high performance concretes, are not pursued due to high costs of metakaolin. 
     What is needed is a new and low cost process route for the manufacture of metakaolin so that new and economical formulations of metakaolin, with alternate concrete formulations, can be manufactured and sold at much better pricing to significantly expand market use through superior materials performance. 
     SUMMARY OF THE INVENTION 
     To overcome the difficulties with complex and high cost production processes for metakaolin, this application presents a new process for the manufacture and production of metakaolin directly from kaolin ore. In the simplest embodiment of the process, raw kaolin ore is crushed and fed to a co-current dryer operating at about 150° C. with airflow from a calciner. The material is tumbled in the dryer liberating the kaolin. Kaolin of less than 10 microns is entrained by the airflow passing through the dryer to a cyclone and baghouse. This material is then transferred to a calciner operating at about 825° C. for production of metakaolin. This simple three stage operation produces high quality metakaolin. 
     This reserve has not been successfully developed despite a number of commercialization efforts. The ore body is known for low brightness of about 75 GE and a consequent low quality of produced kaolin. Advanced multiple step kaolin processing technology (U.S. Pat. No. 5,143,599; Canadian Patent No. 1,292,856) failed to yield a commercial operation. However, the White Mud reserve appears to have a significant population of kaolin particles consisting of stacks of kaolin platelets. 
     Without being bound by this explanation, the unanticipated successful delamination of these stacks is believed to be a factor in the success of the instant process along with a heat driven kaolin liberation unit operation. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Apparatus is not illustrated in view of the fact that all components are readily apparent to one skilled. 
     Raw kaolin ore, typically 7-10% moisture, is fed to a rock crusher and ground so that the output material has a −2 inch sizing. The bulk of the material is in the −10 mesh size range. The less than 2 inch output from the rock crusher is fed to a co-current rotary dryer operated at 110 to 175° C. with a waste heat process air stream from a downstream calciner. After tumbling in the dryer, the product is liberated, reduced in size to micron dimensions and carried through by the process air stream to a cyclone and baghouse. 
     Although not bound by this explanation, it is believed that the following contributed to the process for metakaolin production. The dryer has a series of flights in it designed to bring the coarser material close to the top of the circular arc of the dryer before falling down to the bottom of the dryer. 
     This vertical fall of lumps and particles as the dryer rotates generates an internal pulverization action. The tumbling of the dryer and the attrition action between particles breaks down the coarser kaolin ore lumps. This degradation is assisted by the liberation action of dehydration of the matrix at a temperature of about 150° C. 
     Once the ore reaches 0.5% and less moisture, there is significant liberation of the kaolin from the ore. The ore rapidly breaks down producing a −20 to −150 mesh working medium or matrix. The heat of the operation therefore assists in the liberation of the kaolin from the ore. It is also believed that the action of the ore matrix in the dryer de-laminates and liberates finer kaolin particles and stacks through a shearing process. 
     The matrix is primarily sand and therefore, with a similar density to the kaolin product, tends to shear the kaolin stacks rather than fracture them. The residence time is preferably in between 5 and 40 minutes, with 20 minutes being typical. Although not intended to be bound by this explanation, the platelet formation from stacks due to matrix pulverization and shearing action may well be assisted by steam pressure generated from an interplatelet molecular film of water during the high temperature pulverization process. 
     The tumbling action in the dryer may be said to be similar to that found with autogenous tumbling mills (Perry&#39;s Chemical Engineers Handbook, 6 th  Ed., p 8-34) but the operations relating to kaolin liberation, delamination and steam assisted shearing is not taught in the art nor is the preferred sizing, temperature, residence time, and nature of the shearing matrix. In addition, the dryer air flow process stream size classification wherein product is carried to a cyclone/baghouse is also absent the prior art. In summary, the features established supra are not taught in the art for the production of metakaolin. 
     Course material is drawn off the bottom of the co-current dryer and can be further processed if desired. The coarse material is passed through a scalping screen to remove the rocks. The undersize material is sent to a cage mill operating at about 1000 rpm where it undergoes attrition. The fine material goes to a cyclone where additional −20 micron kaolin is separated and fed to a calciner. 
     The −20 micron material is sent to a calciner held at 825° C. with a residence time of 0.5 hours for a rotary calciner. The product is then transferred to a cooler and then to product storage. Warm exhaust air from the calciner is sent to the rotary dryer to enhance the de-lamination process in the manner previously cited. 
     The overall manufacturing technique is a simple synchronous three step process in stark contrast to the prior art for producing metakaolin. Based upon prior unsuccessful attempts at the low quality kaolin ores, this process yielded the completely unexpected result of high quality metakaolin from a low grade kaolin ore body in a simple synchronous process. 
     Table 1 provides data evincing the high efficacy of the metakaolin produced by this process. With a regular 30 MPa concrete, the strength test gave results of 37.1 MPa after 28 days and 46.9 MPa after 91 days for a 15% cement replacement. With 20% metakaolin replacement of cement, the 28 day result was 39.8 MPa and the 91 day test was 46.7 MPa. The use of metakaolin, with its many beneficial properties including cost and favorable formulation characteristics and the outperformance of standard concrete mixes with 15 and 20% less cement. 
     Whitemud Metakaolin Evaluation 
     Cement Replacement 
     
       
         
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
                 TABLE 1 
               
             
             
               
                   
                   
               
               
                   
                 Mix Proportions 
                 Test Results 
               
             
          
           
               
                 Mix 
                   
                 Fly 
                   
                   
                   
                   
                   
                 Slump 
                 Conc. 
                   
                   
                 28 
                   
                 91 
                 Init set 
                 Final set 
               
               
                 No. 
                 Cem 
                 Ash 
                 Metakaolin 
                 Water 
                 Sand 
                 14 mm 
                 28 mm 
                 mm 
                 Temp 
                 3 day 
                 7 day 
                 day 
                 56 day 
                 day 
                 hrs. 
                 hrs. 
               
               
                   
               
             
          
           
               
                 Control 
                 240 
                 60 
                   
                 160 
                 844 
                 630 
                 430 
                 90 
                 16 
                 19.8 
                 28.0 
                 37.1 
                 44.5 
                 46.9 
                 6.8 
                 9.1 
               
               
                 2  
                 204 
                 60 
                 36 (15%) 
                 169 
                 779 
                 630 
                 430 
                 80 
                 17 
                 15.9 
                 30.2 
                 40.8 
                 45.3 
                 48.3 
                 6.0 
                 7.9 
               
               
                 3  
                 192 
                 60 
                 48 (20%) 
                 184 
                 788 
                 630 
                 430 
                 80 
                 17 
                 15.4 
                 30.2 
                 39.8 
                 42.3 
                 46.7 
                 5.7 
                 7.7 
               
               
                 4* 
                 163 
                 60 
                 29 (15%) 
                 177 
                 861 
                 630 
                 430 
                 80 
                 18 
                 10.4 
                 19.5 
                 29.0 
                 31.0 
                 34.0 
                 6.6 
                 8.9 
               
               
                 5* 
                 154 
                 60 
                 38 (20%) 
                 182 
                 845 
                 630 
                 430 
                 80 
                 17 
                 9.1 
                 18.9 
                 28.8 
                 31.8 
                 35.1 
                 6.6 
                 9.5 
               
               
                 8* 
                 163 
                 60 
                 29 (15%) 
                 183 
                 861 
                 630 
                 430 
                 80 
                 17 
                 10.7 
                 20.3 
                 30.5 
                 31.8 
                 38.2 
                 6.3 
                 8.8 
               
               
                 9* 
                 154 
                 60 
                 38 (20%) 
                 182 
                 845 
                 630 
                 430 
                 80 
                 17 
                 9.3 
                 20.0 
                 30.6 
                 32.4 
                 36.2 
                 6.3 
                 8.7 
               
               
                   
               
               
                 *20% less cement and Metakaolin 
               
               
                 All mixes contain water reducer @ 280 ml. per 100 kg. of cementitious. 
               
               
                 Percentage of Metakaolin is of cement only 
               
               
                 Mixes 8 and 9 - enhanced Metakaolin (experimental product) 
               
             
          
         
       
     
     In testwork in comparison with fumed silica, an expensive concrete setting agent, metakaolin produced by the process set forth here in proved very effective. Table 2 highlights the results in a sample of 15% fume silica, the 28 day strength was 41.3 MPa while the 91 day test had a strength of 45.3 MPa. With 15% metakaolin, the 28 day test was 40.8 MPa while it was 48.3 MPa at 91 days. 
     Whitemud Metakaolin Evaluation 
     Comparison of Metakaolin to Silica Fume 
     
       
         
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
                 TABLE 2 
               
             
             
               
                   
                   
               
               
                   
                 Mix Proportions 
                 Test Results 
               
             
          
           
               
                 Mix 
                   
                 Fly 
                 Silica 
                   
                   
                   
                 14 
                 28 
                 Slump 
                 Conc. 
                   
                   
                 28 
                 56 
                 91 
                 Init set 
                 Final 
               
               
                 No. 
                 Cem 
                 Ash 
                 Fume 
                 Metakaolin 
                 Water 
                 Sand 
                 mm 
                 mm 
                 mm 
                 Temp 
                 3 day 
                 7 day 
                 day 
                 day 
                 day 
                 hrs. 
                 set hrs. 
               
               
                   
               
             
          
           
               
                 2 
                 204 
                 60 
                   
                 36 (15%) 
                 169 
                 779 
                 630 
                 430 
                 80 
                 17 
                 15.9 
                 30.2 
                 40.8 
                 45.3 
                 48.3 
                 6.0 
                 7.9 
               
               
                 10 
                 204 
                 60 
                 36 (15%) 
                   
                 197 
                 783 
                 630 
                 430 
                 80 
                 17 
                 16.5 
                 25.3 
                 41.3 
                 45.0 
                 45.3 
                 6.6 
                 9.0 
               
               
                 11 
                 221 
                 60 
                   
                 19 (8%)  
                 184 
                 811 
                 630 
                 430 
                 70 
                 17 
                 18.4 
                 28.0 
                 39.6 
                 41.7 
                 46.7 
                 5.9 
                 7.9 
               
               
                 12 
                 221 
                 60 
                 19 (8%)  
                   
                 187 
                 785 
                 630 
                 430 
                 80 
                 17 
                 20.3 
                 29.4 
                 47.1 
                 49.4 
                 52.7 
                 6.4 
                 7.8 
               
               
                   
               
               
                 All mixed contain water reducer @ 280 ml. per 100 kg. of cementitious 
               
               
                 Percentage of Metakaolin is of cement only 
               
             
          
         
       
     
     These tests clearly indicate the high performance of the metakaolin produced by this process as a very economic concrete additive. 
     Although embodiments of the invention have been described above, it is not limited thereto and it will be apparent to those skilled in the art that numerous modifications form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention.