Metal compound coated particulate mineral materials, methods of making them, and uses thereof

Abstract

Particulate mineral materials comprising at least one coating comprising at least one metal compound are disclosed. In one embodiment, the at least one metal compound is a metal silicate compound. In another embodiment, the at least one metal compound is a metal oxide compound. In one embodiment, the particulate mineral material is perlite. In another embodiment, the particulate mineral material is perlite microspheres. In a further embodiment, the particulate mineral material is diatomite. Methods of making particulate mineral materials coated with at least one metal compound are also disclosed. In one embodiment, the at least one metal compound may be injected into a perlite expander to form a metal compound coated perlite material. In another embodiment, the at least one metal compound may be applied through a low temperature coating process to the at least one particulate mineral material. Uses for metal compound coated particulate mineral materials are also disclosed.

1 - 70 . (canceled) 
     
     
         71 . A metal silicate coated particulate mineral material, comprising perlite and a coating comprising at least one metal silicate. 
     
     
         72 . The metal silicate coated particulate mineral material of  claim 71 , wherein the at least one metal silicate comprises an alumino silicate. 
     
     
         73 . The metal silicate coated particulate mineral material of  claim 71 , wherein the at least one metal silicate is chosen from at least one of a zirconium silicate, and a zinc silicate. 
     
     
         74 . The metal silicate coated particulate mineral material of  claim 71 , wherein the perlite material is non-expanded. 
     
     
         75 . The metal silicate coated particulate mineral material of  claim 71 , wherein the perlite is expanded. 
     
     
         76 . The metal silicate coated particulate mineral material of  claim 71 , wherein the perlite is in the form of microspheres. 
     
     
         77 . The metal silicate coated particulate mineral material of  claim 71 , wherein the at least one metal silicate comprises at least one metal component and at least one silicate component. 
     
     
         78 . The metal silicate coated particulate mineral material of  claim 77 , wherein the at least one silicate component is chosen from the group consisting of tetraethylorthosilicate, tetramethylorthosilicate, sodium silicate, alkali silicate, colloidal silica, solid silica, alkaline metal silicates, and sodium metasilicate. 
     
     
         79 . The metal silicate coated particulate mineral material of  claim 77 , wherein the at least one metal component is chosen from the group consisting of metal nitrates, metal sulfates, metal aluminates, sodium metals, metal chlorides, metal alkoxides, metal acetates, metal formates, bayerite, pseudoboehmite, gibbsite, colloidal metals, metal gels, metal sols, metal trichlorides, ammonium metal carbonates, metal hydrates, and metal chlorohydrates. 
     
     
         80 . The metal silicate coated particulate mineral material of  claim 77 , wherein the at least one metal component comprises at least one of aluminum, zirconium, boron, and zinc. 
     
     
         81 . The metal silicate coated particulate mineral material of  claim 77 , wherein the at least one metal component is chosen from aluminum nitrate, aluminum sulfate, sodium aluminate, and aluminum halides. 
     
     
         82 . The metal silicate coated particulate mineral material of  claim 77 , wherein the at least one metal component is chosen from zirconium sulfate, zirconium chloride, ammonium pentaborate octahydrate, and ammonium zirconium carbonate. 
     
     
         83 . The metal silicate coated particulate mineral material of  claim 77 , wherein the at least one metal component is chosen from zinc sulfate and zinc nitrate. 
     
     
         84 . A method of forming coated expanded perlite microspheres, comprising:
 introducing perlite microspheres into an expander heated to a temperature of from about 900° F. to about 1100° F.;   injecting into the expander at least one metal component and at least one silicate component; and,   allowing the perlite microspheres, the at least one metal component, and the at least one silicate component to reside in the expander for a time sufficient to coat the perlite microspheres with the at least one metal component and the at least one silicate component,   wherein the at least one metal component and the at least one silicate component form at least one metal silicate.   
     
     
         85 . The method of  claim 84 , wherein the at least one silicate component is chosen from the group consisting of tetraethylorthosilicate, tetramethylorthosilicate, sodium silicate, alkali silicate, colloidal silica, solid silica, alkaline metal silicates, and sodium metasilicate. 
     
     
         86 . The method of  claim 84 , wherein the at least one metal component is chosen from the group consisting of metal nitrates, metal sulfates, metal aluminates, sodium metals, metal chlorides, metal alkoxides, metal acetates, metal formates, bayerite, pseudoboehmite, gibbsite, colloidal metals, metal gels, metal sols, metal trichlorides, ammonium metal carbonates, metal hydrates, and metal chlorohydrates. 
     
     
         87 . The method of  claim 84 , wherein the at least one metal component comprises at least one of aluminum, zirconium, boron, and zinc. 
     
     
         88 . The method of  claim 84 , wherein the at least one metal component is chosen from aluminum nitrate, aluminum sulfate, sodium aluminate, and aluminum halides. 
     
     
         89 . The method of  claim 84 , wherein the at least one metal component is chosen from zirconium sulfate, zirconium chloride, ammonium pentaborate octahydrate, and ammonium zirconium carbonate. 
     
     
         90 . The method of  claim 84 , wherein the at least one metal component is chosen from zinc sulfate and zinc nitrate. 
     
     
         91 . A metal silicate coated particulate mineral material, comprising diatomite comprising a coating comprising at least one metal silicate selected from at least one of zirconium silicates and zinc silicates.