AUSTRALIAN CHINA CLAYS LIMITED

Btgenbach Belgium
December 2006 An Introduction To Australian China Clays

Company Profile

ACC- Company Structure

Minerals Corporation Limited
100%

Other Business Developments

96.6%

Australian China Clays Limited

100% 100% 100%

Skardon River Kaolin Limited

Swan River Kaolin Limited

ACC Europe

Kiss International Trading

AUSTRALIAN CHINA CLAYS LIMITED

ORGANISATION CHART Board of Directors Exec. Chairman: C.V. Alexander Chief Executive Officer C. V. Alexander

Non Exec. Directors: A. English G. Birch P. Lush Company Secretary: R. Lo

Managing Director Andrew Pleeth

Group Financial Controller Robert Lo

Kaolin Business Development James Marsh

Kaolin Operations Steve Downard Plant Superintendent

Swan River Kaolin Project Steve Downard

Paper Andrew Pleeth Polymers James Marsh Ceramics Neil Mifflin Paint Philip Sambells China William Wang Europe Alain Heck

Garry Donaldson Technical Manager Dr Sanjib Banerjee Cairns Office Financial Controller David Hockey Group Geology Exploration & Environment Sue Border (Consultant)

China Projects William Wang

Logistics Derek Bicknell

Australian China Clays Marketing Team

James Marsh Marketing Manager Polymers Andrew Pleeth Managing Director - Paper

Phil Sambells Business Manager Coatings

Alain Heck Business Manager - Europe

Neil Mifflin Business Manager Ceramics

William Wang Business Manager - China

Locations

Operations & Interests

Australian China Clays Limited (ACCs) operations, projects, exploration interest and business investments are based within Australia, as well as an Agency in PR China
Skardon River Kaolin Mine

Other Locations :

Key; Fully Operational Plant Pilot Plant Exploration Interests Business Investments

Calcined Kaolin Agency Agreement (China)

Swan River Kaolin Project

Skardon River
World class high-grade resource over 100 years mine life
fluvial deposit has the finest particle size of premium quality kaolin known worldwide overburden stripping ratio initially less than 3:1, compared to Georgia current ratios of over 9:1

Easy to mine ore body

Fully commissioned hi-tech stainless steel plant 175k tpa capacity Focus on global sale to paint, ceramics, rubber and paper industries

CHINA

KOREA

JAPAN

TAIWAN

THAILAND MALAYSIA

CANADA
West Coast

USA

INDONESIA
EUROPE AND MIDDLE EAST

AUSTRALIA

PROJECT

LOCATION
TASMANIA

NEW ZEALAND

Swan River Kaolin

Defined kaolin resource of 41m tonnes Pilot plant to supply paper mills in 2006 Full scale plant of 200,000 tonnes - completion 2007/8.

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

The Skardon River Production Process

Geology & Mining

Section Through the Deposit

K3

Fluvial

K3

Rolling Downs

Skardon River Kaolin-Kaolin Mining

Claystone Stockpile

The Production Process

The Wet Plant

Stage 1 Processing: Wet Plant

Kaolin Ore

Blunger
Degritting Centrifuge Sand Decanter Centrifuge Disc-nozzle Centrifuge Tailings Dam High Gradient Magnet Separator Membrane Filter Pipeline to Dry Plant

Windows Based Control System. This Automation Allows For An Efficient And Controlled Processing Environment

Loading up the front end of the wet plant with kaolin ore

Blunger

Screens

Degritting Centrifuges

Decanter Centrifuge

Disc Nozzle Centrifuge

Superconducting Magnet

Ultra Filtration System

The Production Process

The Dry Plant

Stage 2 Processing: Dry Plant

Pipeline from Wet Plant

Spray Dryer Pulveriser Calcining Kiln

Pulveriser

HYDROUS KAOLIN CALCINED KAOLIN

Access Road Connecting Wet & Dry Plant

Dry Plant At Skardon River Kaolin

Base Of Spray Drier

Rotary Kiln

Bagging & Warehouse Overlooking The Skardon River

3.4 The Pilot Plant at Skardon River Kaolin contains scaled down versions of all the unit processes

Mobile Tanks

Feed Hopper

Carpco Magnet

The Pilot Plant at Skardon River Kaolin contains scaled down versions of all the unit processes

Centrifuges & Spray Drier

Rotary Kiln

Shipping Skardon River Kaolin To The World

Break Bulk Shipments By Sea

Loose Bulk

Shipping By Road

Shipping By Container Load

The Swan River Pilot Plant

The Chinese Calcined Kaolin Production Process

Packaging
Hydrous Grades Bulk Shredded Typically for Ceramic applications Blends available Big Bags 500 1000Kg 25Kg paper bags Calcined Grades Big Bags 500Kg to 1000Kg 20Kg & 25kg paper bags Silane Treated Grades Big bags 500Kg to 1000Kg 25Kg paper bags Melt processable bags and special weights available

ACC Product Streams

Hydrous Kaolins Calcined Kaolins

Wide range of industrial applications Represents the bulk of world supply Targeting paint, polymers, ceramics, paper and ink markets.

Higher performance Better brightness, opacity Extends TiO2 Premium price Limited number of producers Targeting paint, polymers, paper, inks.

ACC Products and Nomenclature System

Microbrite Trade name for all non ceramic hydrous and calcined kaolins Kerabrite Trade name for all ceramic grade hydrous and calcined kaolins Metabrite Trade 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 Microbrite CH98 Microbrite FH95 Microbrite FH100 Microbrite FH100BP Microbrite CH40SR*

Kerabrite CH35 Kerabrite CH80 Kerabrite CH98 Kerabrite RH Kerabrite CR, FR, RR

*In this case the 40 = Surface Area/m2g, and SR = Synthetic Replacement

ACC Products and Nomenclature System

Chinese Calcined Grades Microbrite C75/95 C1 Microbrite C80/95 C1 Microbrite C70/90 C2 Microbrite C75/91 C2 Microbrite C80/92 C2 C = Calcined First two digits = % <2 Microns Second two digits = ISO Brightness C1 = China 1, C2 = China 2 Metabrite CMC (Calcined Metakaolin China) Swan River Hydrous Grade Microbrite HBF (High Brightness Filler) Chinese Hydrous Grade Microbrite HC1 (Hydrous Chinese 1)

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.

Kaolin - The Mineral

Kaolin
Naturally 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)

Al2O3 2SiO2 2H2O
Main Constituent: Kaolinite Minor: Mica, Quartz, Feldspar Aspect Ratio: Average: Specific Gravity: Refractive Index: MOH Hardness: 8/1 - 100/1 20/1 2.6 1.56 2.5

HO OH OH

OH

OH

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

Micrograph of Kaolin

Micrograph of Kaolin

Primary Kaolins & Secondary Kaolins

Primary kaolins Found where they were formed Usually large amounts of impurities (quartz (silica) & mica) Typically much Coarser than secondary kaolins Typically higher brightness than secondary kaolins

An example of primary kaolins is found in Cornwall, England. For every tonne of kaolin mined there are 8 9 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 saleable Very fine particle size Lower brightness

An example is the Skardon River deposit where purity is up to 93%

The continuous weathering washed the kaolin from the granite along with other minerals from the upland regions.

Reactivation of prehistoric fault lines led the ground to sink in places forming basins and shallow inland seas.

Streams from the uplands emptied into the basins 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 kaolin deposits. The fine clay particles remained in suspension in the water until a chemical reaction, making the water acidic causing the clay particles to clump together and form sedimentary layers.

Movement of the plates of the Earths crust cause the rock far below ground to melt. This molten rock bubles up and forms granite 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 upland areas were heavily forested by 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.

Australian China Clays Hydrous Grades for Europe

Higher value Australian grades: Microbrite FH95 Microbrite FH100 & FH100BP Microbrite CH40SR Advantages/Benefits Australian grades Extremely fine particle size Low yellowness Low crystalline silica Neutral pH
Chinese grades: Microbrite HC1 High brightness/ultrafine grade planned early 2007 Advantages/Benefits Chinese grade o Medium/coarse particle size o Good brightness o Cost effective

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

Micrograph of Calcined Kaolin

What is Calcined Kaolin?

Calcined kaolin is formed when kaolin is heated to above 980C It 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

What is Calcined Kaolin?

Differential Thermal Analysis For Kaolin Calcination

Exotherm

Loss of Crystallinity: 950 - 1050C

Fully Calcined (Amorphous)

Metakaolin Mullite Formation

Endotherm

Dehydroxylation: 450 - 750C

Australian China Clays Calcined Kaolin Grades for Europe

Chinese calcined kaolins: Metabrite CMC Microbrite C70/90 C2 Microbrite C75/91 C2 (Pharmaceutical rubber) Microbrite C80/92 C2 Microbrite C75/95 C1 Microbrite C80/95 C1 Advantages/Benefits Incredibly pure feed material Extremely consistent feed material Highly efficient calcination Highest brightness products commercially available Very low coarse particle content

Surface Modified Kaolins

Multibrite Range

Highest performance kaolin products

High price must be justified by significant performance improvements Essential where stress and moisture resistance at high temperatures is required
e.g. High voltage electric cables

Essential where physical performance at high temperature is required

e.g. Automotive engine components

Major Uses of Kaolin

Papermaking Pigment/Filler/Coating Pigment in paint/inks Polymers in Rubber/Plastics/Adhesives Pharmaceuticals/Cosmetics

Ceramics (Pottery)

Applications For Kaolin In Paints

Phil Sambells Business Development Manager Paints

What Is Paint ?
Traditionally the term paint described a pigmented liquid coating 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..

Desired functions imparted by a paint

Protection of a vulnerable substrate eg from air or water.

Decoration.

A purpose eg non refletive paint on military aircraft.

Information road marking, signs.

The Constituents Of Paint

Pigment.
Resin.

A volotile component or solvent.

(Additives).

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

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

Paint Types

Production
Decorative Paints (Architectural Coatings) 50%

Use of Extenders 85% 15%

Industrial Paints

50%

Decorative Paints
% of extender used

Water Based
Gloss. Semi Gloss. Matt (Flat) Interior. Matt (Flat) Exterior 05 5 15 15 50 5 15 05 5 15 5 15 15 50

Solvent Based
Gloss Semi Gloss Primers Undercoats

Industrial Paints Protective Coatings

Primers Undercoats Topcoats

Auto OEM
ED Primer Surfacer Colour Coat Clear Coat

Auto Refinish
Primer Colour Coat Clear Coat

General Industrial
Wood Metal

Coil Coatings
White Goods Cladding

Powder Coatings
Indicates potentials for SRK Materials

Common extenders used in Paints

Hydrous Kaolin.

Calcined Kaolin.
Calcium Carbonate.

Talc.
Mica.

Barium sulphate.
Silica

This presentation concentrates on the use of Kaolins & Calcined Kaolins as extenders in paints Specifically kaolins from Australian China Clays

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.

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.

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.

Pigments & Extenders Pigments

TiO2 Rutile White Refractive index of 2.7

Extenders
Hydrous & Calcined Kaolins Colour from Grey to White Refractive index 1.56

Expensive ~US$ 2.6 per Kg

Relatively cheap ~US$ 0.2 0.8

The refractive index of a substance equates to Laws of Physics

speed of light in a vacuum speed of light in a substance

The greater the difference in refractive index between two substances the greater the degree of refraction. eg. The different refractive indicies between air & water is illustrated when a straight object which is partly immersed in water and viewed at an angle appears to be bent.

Employing physics to create opacity

The greater the number of transitions between differing refractive 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 between the 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 the repeated difference in refractive index.

The effect on Opacity by TiO2 & Extender Particles below the Critical Pigment Volume Concentration (CPVC)

Light meter

Light meter

TiO2 Particles = 2.7

Resin / Latex = 1.5

Extender Particles = 1.56

substrate

Because the refractive index of the resin (1.5) and the extender (1.5 1.7) 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)

Defined as the percentage of pigment in a paint i.e. PVC = Pigment & Extender Volume Pigment, Extender + Binder Volume X 100

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)

Matt (Flat) Region Property Increases

CPVC Region Extender

TiO2

Dry Hiding

Gloss region

% PVC

100

The Effect of PVC on Scrub & Mud Cracking Resistance

Property Increases

Scrub Resistance

Mud Cracking Resistance

% PVC

CPVC Region

100

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 to partially 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 of expensive pigments & hence can reduce formulation costs by partial 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.

Light meter

Light meter

Latex / binder

Coarse extender

TiO2 Particles

Microbrite FH95 Particles

substrate

Hydrous Kaolin

Air Voids

Calcined Kaolin Hard & Irregular shape

Calcium Carbonate

Microbrite C70/90 C2
Is 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 C1
Is 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 opacity (hiding power) over coarse blocky extenders due to the trapped air increasing the changes in refractive indecies.

Light meter

Light meter

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).

substrate

Calcium Carbonate is easily dissolved in acid conditions making 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 high level of calcium carbonate has been used. Calcined kaolins are inert and unaffected by harsh chemicals.

substrate

Mudcracking is another factor which blocky extenders are prone 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

Coarse extender

TiO2 Particles

Microbrite FH95 Particles

substrate

At Skardon River Kaolin we have the ability to carry out a range of paint testing.

Microbrite FH95 - Printing Inks

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.

Applications For Kaolin In Polymers

History of Filled Polymers

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 ?

Increase in Weight (SG): Useful for sound dampening and increasing mass of some products Changes to Permeability: Reduced by adding platey fillers such as kaolin Changes to Electrical Properties: Calcined kaolin is a good insulator in polymers Reduction in Thermal Expansion: Helps when plastics are used in engineering applications (especially when in contact with metals) Increase in Thermal Conductivity: Leads to faster cooling and therefore cycle times Improved Processability Kaolin can reduces viscosity and improve flow

What Advantages Can a Kaolin Filler Impart ?

Reduced Flammability: Kaolin can be used as a flame retardant
Increase in Stiffness (Heat Distortion Temperature): Major advantage of filled plastics
Increase Tensile Properties: Very important for many types of rubber Changes to Impact Behaviour: Silane treated calcined kaolins can improve impact resistance in polyamides 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

Use of Particulate Fillers in Polymers in Western Europe (000 tonnes)

Filler ATH Asbestos Ground Calcium Carbonate Precipitated Calcium Carbonate Calcined Kaolin Hydrous Kaolin Synthetic Silica Crystalline Silica Talc

1972 3.5 60.5 244 38 10.3 15.2 8.5 6.5 9.5

1982 24.0 12.0 783 46 15.5 29.5 10.0 4.5 15.0

1987 35.0 6.0 854 42 18.5 35.9 14.0 6.0 17.0

1998 160.0 Small 1075 100 25.0 96.0 53.0 3.0 19.0

Dominant Minerals in the Polymer Industry

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

General Principles
The degree of effect from the filler is determined by three main properties:

Particle Size

Particle Shape
Surface Chemistry

Particle Size

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 can
partially replace expensive synthetic silica

The Effect of Filler Particle Size

Particle Size vs. Tensile Strength

EPDM/60 phr Filler Loading

15
Tensile Strength (MPa)

10 5 0 0 1 2 3 4 Mean Particle Size (um)

Optimum Loading Concept

80 70 60 50 40 30 20 10 0

Physical Properties

Reinforcing Filler Semi-reinforcing Filler Non reinforcing Filler

Filler Volume Fraction (%)

Particle Shape and Chemistry

Hydrous Kaolin

Characteristic plate-like shape gives unique properties in polymer compounds 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 improving compound flowability and extrusion performance, whilst reducing dieswell and melt fracture

Particle Shape and Chemistry

Calcined Kaolin

Interfacial fusion during calcination decreases the aspect ratio and gives them an inert surface Excellent electrical insulation performance and low dielectric loss due to amorphous structure Widely used in the pharmaceutical, power cable insulation, extruded profile and film industries

Surface Modified Calcined Kaolins (Multibrite Range)

Silane treatment is essential where:

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 applications Vinyl silane - Mainly used in the rubber EPR/EPDM cable industry

100 90 80 70 60 50 40 30 20 10 0 Tan Delta VR

Calcined Kaolin Calcined Kaolin+silane Calcined Kaolin Pretreated Calcined Kaolin Pretreated+silane

The Silane Reaction with Kaolin

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 In Amino Silane Y = -NH2 In Vinyl Silane Y = -C2H5

Gives a reinforced interface and improved mechanical properties

Plastics Applications for Kaolin

Flooring (EVA, pPVC) EVA - hydrous kaolin PVC 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

Used at low filler loadings (1500 3000ppm)

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 fillers without affecting the haze

Re-blocking testing shows calcined kaolin to be more efficient

High stability and unreactive surface results in minimal deactivation of expensive stabilisers and additives

Calcined Kaolin in Agricultural Film

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 processability low moisture and good flow characteristics

Higher calcined kaolin loadings are claimed in mulch and silage wrap applications

Calcined Kaolin in pPVC Cable Applications

Calcined kaolins improve electrical properties of pPVC cable Works at low concentrations (up to 20phr) replacing CaCO Used where good electrical properties are required at high temperatures,
3

Improves the electrical performance of flame retardant and smoke suppressant For example, replacing 14 phr of CaCO
volume resistivity

voltages and humidities

pPVC compounds

with calcined kaolin gives 10 x higher

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

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 D.A.P. Plasticiser Stabiliser/lubricants Epoxidised Soya bean Oil Coarse Limestone Kaolin 150 450 100 33 10 7

Mineral Fillers for the Rubber Industry

Introduction
Over 4 million tonnes of fillers is used in rubber every year:
Calcium Carbonate 8% Precipitated Silica 4%

Kaloin 15%

Carbon Black 73%

Definition of a Filler
A 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
Classified into three broad groups according to the influence on a high quality natural rubber gumstock
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.

Classification of Fillers by Reinforcement

Filler Primary Particle Size (m)
0.005 - 0.025 0.015 - 0.060 0.011 0.100 0.200 1.000 0.200 1.000 0.700 2.000 0.090 0.150 0.050 0.100 1.000 2.000 0.500 1.000 0.700 2.500 1.000 5.000 1.000 5.000 2.000 50.00 0.700 1.200 5.000 - 1000 2.000 - 1000

PolymerFiller Adhesion
Very High Very High Very High Very High Low Very High Low Low Very Low Low Low Low Low Very Low Very Low Very Low Very Low

Particle Shape

Highly Reinforcing

Fumed Silicas Precipitated Silicas Carbon Blacks Silane Treated Fine Kaolin Fine Kaolin

Structured Structured Structured Platey Platey Platey/Structured Spherical Spherical Platey Particulate Platey/Structured Platey Semi-Platey Platey Particulate Particulate Particulate

Reinforcing

Silane Treated Calcined Kaolin Zinc Oxide Precipitated Calcium Carbonate Micronised Talcs Synthetic ATH

Semi-reinforcing

Calcined Kaolin Coarse Kaolin Neuburger Chalk Coarse Talcs Ultrafine Chalks

Non-reinforcing

Natural ATH Chalk/Limestone

Applications for Kaolin in Adhesives and Sealants

Packaging adhesives
Woodworking adhesives Glazing Sealants

Automotive Adhesives/Sealants
Construction Sealants

Kaolin Fillers for Adhesives and Sealants

Packaging adhesives

PVA/PVOH
Fine kaolins Medium fineness kaolins Starch/Dextrin Medium fineness kaolins

Woodworking adhesives
PVA Medium fineness kaolins

Kaolin Fillers for Adhesives and Sealants

Glazing Sealants
Butyl Strip - Medium fineness kaolins Oil-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

Very low iron good stability

Strong effect on sealant rheology

Low moisture content and pick-up Low +10m content Chemically inert Temperature stable

Functionally variable

Summary of Polymer Applications for ACC Kaolins

Microbrite Fully Calcined Kaolins

Pharmaceutical rubber Profile extrusion Thermoplastic vulcanisates (TPVs) Rubber cable High quality rubber flooring Hose Polyurethane sealants Thermal barrier film Antiblock film Seals & Gaskets Plasticised PVC cable

Summary of Polymer Applications for ACC Kaolins

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

Microbrite FH95

Non-black rubber compounds Water based adhesives pH sensitive rubber compounds

Summary of Rubber Applications for ACC Kaolins

Microbrite CH98

Extension of coarse/medium carbon black Technical mouldings Cable sheathing Shoe soles Rubber flooring High strength adhesives

Summary of Rubber Applications for ACC Kaolins

Microbrite CH40SR

Extension of carbon black Replacement of precipitated silica Tyres Shoe soles Flooring

Polymer Applications for Kaolin

Rubber Applications for Kaolins
Belting Hose Footware Cables Mountings Seals Cellular Sports Pharmaceutical Extrusions Rollers Flooring Linings Tyres Conveyer, toothed, v-belt Fuelling, brake, radiator, hydraulic, pneumatic, vacuum, ducting Boots, sports, industrial, safety, soles, heels, sponge Sheathing, insulating, covering, plugs, sockets, connectors Engine, machinery, instrument, shock absorbers, pads O-rings, shafts, grommets, window, diaphragms, valves, jar rings Pillows, mattresses, upholstery, carpet underlay, packaging Bladders, grips, masks, balls Lids, seals, stoppers, plungers Glazing, channeling, tubing, cord, profile Printing, trailers, machines Tiles, mats, sheeting - industrial, public buildings, sports tracks Tanks, pipes Agricultural, bicycle, motorcycle, industrial, truck, application, passenger

Plastics Applications for Kaolins

Flooring Film Cables Tiles, mats, sheeting Antiblocking in LDPE & LLDPE Plasticised PVC general purpose cable

Metakaolin for Building Products

Purpose-made, user friendly pozzolanic materials Range of applications High pozzolanic reactivity Readily dispersed Range of Applications 1. Glass-reinforced composites 2. Decorative concrete products 3. Flooring systems 4. Renders/mortars 5. Ready-mix concrete 6. Tile adhesives 7. Alkali-activated systems 8. Lime-based systems

Technical advantages
Increased strength Reduced water absorption Reduced chloride penetration Increased sulphate resistance Increased acid resistance Elimination of ASR Efflorescence control

Summary of Miscellaneous Applications for ACC Kaolins

Waxes and polish calcined kaolin Carriers calcined kaolin Cosmetics hydrous kaolin Soaps/detergents hydrous kaolin Animal feed hydrous kaolin Pigment/dye hydrous & calcined kaolin Pharmaceuticals hydrous kaolin

Australian China Clays

Hydrous Kaolins Microbrite HC1 Microbrite FH95 Microbrite FH100BP Calcined Kaolins Microbrite C80/95 C1 Microbrite C80/92 C2 (Depends on colour) Microbrite C70/90 C2 Metabrite CMC

Imerys
Polwhite B, C Polsperse 10/20 Speswhite Light Kaolin BP NeoGen EFP NeoGen 2000 NeoGen JDF PoleStar 200R Glomax LL PoleStar 501 MetaStar 400 PoleStar 450

Engelhard
NE ASP-170/602

Burgess
NE No.17/20

Huber
NE Polyfil S Huber 80B

Ultrex 98 Satintone 5 Whitetex Satintone W Satintone SP-33

NE Iceberg Icecap No.30 Optiwhite Optimax Icecap K

NE Polyfil 70 Polyfil 40

Product Cross Reference Chart

Microbrite C75/95 C1 Opacilite Microbrite C80/95 C1 (Depends on particle size) Microbrite C80/95 C1 PoleStar 400 Microbrite C80/92 C2 Neogen 2000 (Depends on colour) Silane Treated Calcined Kaolin Multibrite 1AS Multibrite 2AS Multibrite 3AS* Multibrite 1VS Multibrite 2VS Multibrite 3VS (NE = No Equivalent) Polarite 102A Polarite 402A Polarite 103A Polarite 503S NE

NE Satintone 5 Ultrex 98

NE

Polyfil 90

Translink 445 Translink 555 Translink 37 Translink 77 Translink 37S

Burgess 2211 Burgess 2270 Icecap KE Burgess 5178

Burgess KE350

Polyfil WC Polyfil WC426 NE NE NE

* = 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.

Quality Control

Brightness
Particle Size

Viscosity

Dispersion

Moisture

To Name But A Few

Quality Control
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

Environmental
At Skardon River Kaolin we take the responsibility for our activities very seriously

AUSTRALIAN CHINA CLAYS LIMITED

Website: www.skardon.com.au

Thank You