Paper coating pigments, their production and use

Abstract

There is disclosed a method for the preparation of a precipitated calcium carbonate (PCC) for use as a pigment in paper coating compositions, the method comprising the steps of (a) carbonating an aqueous lime-containing medium to produce an aqueous suspension of a PCC predominantly in a selected crystal form, (b) at least partially dewatering the PCC-containing suspension; and (c) subjecting the PCC-containing suspension to comminution by high shear attrition grinding with an attrition grinding medium. Steps (b) and (c) may be applied in either order, ie. (b) followed by (c) or alternatively (c) followed by (b). The dewatering step (b) is preferably carried out using a pressure filter device operating at a pressure of at least 5 MPa, preferably at least 10 MPa. A pH reduction step may be applied after steps (b) and (c). Also disclosed are pigments produced by the method and pigment and paper coating compositions including such pigments.

We claim:  
     
       1. A method for the preparation of a precipitated calcium carbonate (PCC) for use as a pigment in paper coating compositions, the method comprising the steps of (a) carbonating an aqueous lime-containing medium to produce an aqueous suspension containing a PCC in predominantly scalenohedral, rhombohedral, or aragonite crystal form, (b) at least partially dewatering the PCC-containing suspension; and (c) subjecting the PCC-containing suspension in wet form to comminution by high shear attrition grinding with an attrition grinding mediums  medium wherein the comminution step is carried out such as to dissipate in the aqueous suspension containing the PCC at least 100 kilowatt hours of energy per dry tonne of PCC and wherein the PCC product produced following steps (b) and (c) comprises particles having a particle size distribution such that at least 70% be  by weight of the particles have an equivalent spherical diameter as measured by sedimentation of less than 1 μm and at least 50% by weight of the particles have an equivalent spherical diameter of less than 0.5 μm. 
     
     
       2. A method as claimed in  claim 1  and wherein the dewatering step (b) is carried out using a pressure filter device operating at a pressure of at least 5 MPa. 
     
     
       3. A method as claimed in  claim 2  and wherein the pressure filter device comprises a tube press wherein material is pressure filtered between two co-axially disposed tubular bodies. 
     
     
       4. A method as claimed in  claim 1  wherein step (b) precedes step (c) and a dispersing agent for the PCC is added to the aqueous PCC-containing suspension prior to step (c). 
     
     
       5. A method as claimed in  claim 1  and wherein the grinding medium employed in step (c) comprises silica sand having a median particle diameter in the range 0.1 mm to 4 mm. 
     
     
       6. A method as claimed in  claim 1  and wherein an additional step (d) is applied after steps (b) and (c) to reduce the pH of the PCC-containing suspension. 
     
     
       7. A method as claimed in  claim 1  wherein step (c) precedes step (b) and wherein the aqueous suspension formed in step (a) and treated by comminution in step (c) has a solids concentration of from 10% to 25% by weight and wherein the aqueous suspension after application of step (b) has a solids concentration of at least 50% by weight. 
     
     
       8. A pigment for paper coating which comprises a PCC produced by the method claimed in  claim 1 , wherein the particle size distribution is such that the amount of particles having an equivalent spherical diameter of less than  0 . 25  μm ranges from  10 %  to  45   %  by weight.    
     
     
       9. A pigment as claimed in  claim 8 for paper coating which comprises a PCC produced by the method claimed in  claim 1 and wherein the predominate form of the PCC comprises at least 50% by weight aragonitic or scalenohedral crystals. 
     
     
       10. A dispersed aqueous suspension of the pigment claimed in claim  8   9 and which includes a dispersing agent for the PCC. 
     
     
       11. A pigment composition which comprises a pigment as claimed in claim  8   9 mixed together with one or more other pigments. 
     
     
       12. A composition as claimed in  claim 11  and wherein the PCC is mixed together with a platey kaolin clay. 
     
     
       13. A paper coating composition comprising an aqueous suspension comprising an adhesive and a suspension as claimed in  claim 10 . 
     
     
       14. A method as claimed in  claim 1  and wherein the PCC produced according to step ( a )  is in predominantly scalenohedral or aragonite crystal form.   
     
     
       15. A method as claimed in  claim 14  and wherein the PCC produced according to step ( a )  is in predominantly aragonite crystal form.   
     
     
       16. A method as claimed in  claim 14  or  15  and wherein the dewatering step ( b )  is carried out using a pressure filter device operating at a pressure of at least  5  MPa.   
     
     
       17. A method as claimed in  claim 16  and wherein the pressure filter device comprises a tube press wherein material is pressure filtered between two co- axially disposed tubular bodies.   
     
     
       18. A method as claimed in  claim 14  or  15  wherein step ( b )  precedes step  ( c )  and a dispersing agent for the PCC is added to the aqueous PCC - containing suspension prior to step  ( c ). 
     
     
       19. A method as claimed in  claim 14  or  15  and wherein the grinding medium employed in step ( c )  comprises silica sand having a median particle diameter in the range  0 . 1  mm to  4  mm.   
     
     
       20. A method as claimed in  claim 14  or  15  and wherein an additional step ( d )  is applied after steps  ( b )  and  ( c )  to reduce the pH of the PCC - containing suspension.   
     
     
       21. A method as claimed in  claim 14  or  15  wherein step ( c )  precedes step  ( b )  and wherein the aqueous suspension formed in step  ( a )  and treated by comminution in step  ( c )  has a solids concentration of at least  50   %  by weight.   
     
     
       22. A pigment for paper coating which comprises a PCC produced by the method claimed in  claim 14  or  15 . 
     
     
       23. A dispersed aqueous suspension of the pigment claimed in  claim 22  and which includes a dispersing agent for the PCC. 
     
     
       24. A pigment composition which comprises a pigment as claimed in  claim 22  mixed together with one or more other pigments. 
     
     
       25. A composition as claimed in  claim 24  and wherein the PCC is mixed together with a platey kaolin clay. 
     
     
       26. A paper coating composition comprising an aqueous suspension comprising an adhesive and a suspension as claimed in  claim 23 . 
     
     
       27. A method for the preparation of a precipitated calcium carbonate ( PCC )  for use as a pigment in paper coating compositions, the method comprising:    
         carbonating an aqueous lime - containing medium to produce an aqueous suspension containing a PCC in predominately scalenohedral or aragonite crystal form;    
         partially dewatering the PCC - containing suspension; and    
         subjecting the PCC - containing suspension in wet form to comminution by high shear attrition grinding with an attrition grinding medium wherein the comminution is carried out such as to dissipate in the aqueous suspension containing the PCC at least  100  kilowatt hours of energy per dry ton of PCC; and wherein the PCC product produced comprises particles having a particle size distribution such that at least  70   %  by weight of the particles have an equivalent spherical diameter as measured by sedimentation of less than  1  μm and at least  50   %  by weight of the particles have an equivalent spherical diameter of less than  0 . 5  μm.   
     
     
       28. A method for the preparation of a precipitated calcium carbonate ( PCC )  for use as a pigment in paper coating compositions, the method comprising:    
         carbonating an aqueous lime - containing medium to produce an aqueous suspension containing a PCC in predominantly aragonite crystal form;    
         partially dewatering the PCC - containing suspension; and    
         subjecting the PCC - containing suspension in wet form to comminution by high shear attrition grinding with an attrition grinding medium wherein the comminution is carried out such as to dissipate in the aqueous suspension containing the PCC at least  100  kilowatt hours of energy per dry ton of PCC; and wherein the PCC product produced comprises particles having a particle size distribution such that at least  70   %  by weight of the particles have an equivalent spherical diameter as measured by sedimentation of less than  1  μm and at least  50   %  by weight of the particles have an equivalent spherical diameter of less than  0 . 5  μm.   
     
     
       29. A method as claimed in  claim 27  or  28  and wherein the dewatering is carried out using a pressure filter device operating at a pressure of at least  5  MPa. 
     
     
       30. A method as claimed in  claim 29  and wherein the pressure filter device comprises a tube press wherein material is pressure filtered between two co- axially disposed tubular bodies.   
     
     
       31. A method as claimed in  claim 27  or  28  wherein the PCC- containing suspension is dewatered prior to comminution and a dispersing agent for the PCC is added to the aqueous PCC - containing suspension prior to comminution.   
     
     
       32. A method as claimed in  claim 27  or  28  and wherein the grinding medium employed during comminution comprises silica sand having a median particle diameter in the range  0 . 1  mm to  4  mm. 
     
     
       33. A method as claimed in  claim 27  or  28  and wherein the pH of the PCC- containing suspension is reduced after dewatering and comminution.   
     
     
       34. A method as claimed in  claim 27  or  28  wherein comminution precedes dewatering and wherein the aqueous suspension has a solids concentration of at least  50 %  by weight after comminution.   
     
     
       35. A pigment for paper coating which comprises a PCC produced by the method claimed in  claim 27  or  28 . 
     
     
       36. A dispersed aqueous suspension of the pigment claimed in  claim 35  and which includes a dispersing agent for the PCC. 
     
     
       37. A pigment composition which comprises a pigment as claimed in  claim 35  mixed together with one or more other pigments. 
     
     
       38. A composition as claimed in  claim 37  and wherein the PCC is mixed together with a platey kaolin clay. 
     
     
       39. A paper coating composition comprising an aqueous suspension comprising an adhesive and a suspension as claimed in  claim 36 .