Mineral fillers

Lecture 2: MINERAL FILLERS
Prof. Dr. H.Z. Harraz Presentation Nonmetallic Deposits
A short series of lectures prepared for the Third
Level of Special Geology, Tanta University
(GE3115)
2017- 2018
by
Hassan Z. Harraz
hharraz2006@yahoo.com

What and Why of Mineral Fillers
Mineral filler is ground up rock/mineral added to a
mix:
➢Therefore, mineral filler is an additive and modifier,
not the main product.
Fillers come in many types, shapes, and sizes.
Mineral fillers enhance and alter the product.
Mineral fillers help control product costs by
displacing more expensive ingredients and taking
up space in a product matrix.
A good understanding of the role of fillers can lead
to significant savings in material costs and expand
a compound’s performance envelope, allowing it
to compete in new areas and against other resins.
Prof. Dr. H.Z. Harraz Presentation Nonmetallic Deposits 2

Factors Typically Considered in Filler Minerals
Cost
Specific gravity (Density)
Hardness
Particle Size
Shape
Color
Refractive index properties
Chemical properties

The Role of Fillers
 Fillers are used for a wide variety of reasons:
➢ They can extend resin, increase stiffness and strength, improve
impact performance, and shorten cycle times.
➢ They prevent hang-up in dies and neutralize the products of
degradation.
➢ Fillers can also be used to add color, opacity, and conductivity to
a compound.
➢ Unique property combinations can be achieved through the use
of fillers.
➢ Traditionally a filler was a low cost material of relatively large
particle size that lowered a formulation’s cost simply because it
was less expensive than the other ingredients in the formulation.
❖ Today a “filler” can be a true performance additive. Advances in
compounding technology allow the use of much finer fillers that
could not be used in the past.
❖ Today’s filler products are tailored for specific applications and
designed to deliver value in new and interesting ways.
4

Mineral used as Filler
1) Calcium Carbonate: Calcium carbonate products are available
in a wide range of sizes. They are produced by grinding
limestone and by precipitation.
2) Clay: Calcined clay goes into wire and cable formulations
where it improves electrical properties. The remaining fillers find
their role in a variety of specialty applications
3) Talc
4) Pyrophyllite
5) Wollastonite
6) Gypsum
7) Perlite
8) Vermiculite
9) Barite
5

Used of Filler Minerals in:-
 Paper
 Paint and Ceramics
 Wallboard
 Plastics and Polymers
 Adhesives and Sealants
 Density Modifiers:
1)Lightweight Applications
2)Heavies Applications
Prof. Dr. H.Z. Harraz Presentation
Nonmetallic Deposits
6

Paper
 Paper uses fibers to provide strength, but the smoothness, and
reflective properties come from filler:
❖ Kaolin dominates and provides the brightness to the surface:
✓Need nice white grades of clay
✓Needs to thin down nice so you can get smooth thin coatings
(rheology)
❖ Calcium Carbonate is gaining ground:
✓Not making paper with acid chemistry as much so calcium
carbonate reactivity not a problem
✓Can get from natural grind or precipitation from solution
❖ Talc:
✓Helps prevent clumping of wood fibers
❖ Amorphous silicates:
✓Adsorb and prevent ink strike through

Paint and Ceramics
Many filler characteristics similar to paper
❖Pyrophyllite also used:
➢Pyrophyllite is an important ceramic filler;
✓Talc also used
✓Wollastonite plays similar roles
➢It provides permanent expansion on heating (great
if something else is shrinking)
❖Of course cheapies like calcium carbonate
and lesser talc are also valuable.

Wallboard
White filler powder packed in drywall is usually
gypsum
❖Can be mined but synthetic gypsum is also produced
by using limestone to scrub sulfur emissions out of
coal flue gas.
➢ Building whole new wallboard plants but that’s a lot of at risk
capital
❖The dark side of scrubber gypsum
▪ Small amounts of ash can give slight gray tone (acceptance)
▪ Need to control salt content or it will corrode drywall screws
Countries with a lot of Pyrophyllite fill wallboard
with Pyrophyllite

Plastics and Polymers
 Minerals used as fillers in plastic compounds have traditionally been used to reduce material costs
by replacing a portion of the polymer with a less expensive material.
 However, nowadays many functional fillers or mineral modifiers are required to modify processing
characteristics or finished part properties. Many are now also being used to reduce the level of
more expensive additives such as pigments, flame retardants and impact modifiers.
 Filler Types: Approximately 80% of all the filler used in PVC is calcium carbonate. Titanium dioxide
is second at around 12%, followed by calcined clay at about 5%. The remaining few percent is
taken up by other materials, including glass and talc
 Ground Powdered calcium carbonate the dominant material:
▪ Provides bright coloring
▪ Low absorbance of oil (an expensive glue in plastics)
▪ Provides high gloss
▪ Hardens against gouging and scaring
 Ground Talc:
▪ Soft but gives very smooth surfaces
▪ Makes easier to get out of molds – kind of lubricant like
 Calcined clay:
▪ Absorbs in plasticizers very well
 Small amounts of mica, silicates and even barites

Adhesives and Sealants
‫للتسرب‬ ‫المانعة‬ ‫والمواد‬ ‫الالصقة‬ ‫المواد‬
Calcium Carbonate and Kaolin:
➢They are cheap and fill a lot of space without
messing up flow characteristics.
Drilling mud uses barite for density control
Kaolin and diatomite prevent caking of
ANFO (or AN/FO, for ammonium nitrate/fuel oil) .
11

Density Modifiers
1) Lightweight Applications:
 Use rocks that start at normal density but have a tendency to
Pop or expand (a lot) when heated-Perlite:
▪ Good insulator with low thermal conductivity
▪ Sound adsorbing
▪ Relatively chemically inert
▪ Fire retardant
Perlite is used:
▪ In lightweight and lightweight precast concrete
▪ Acoustic ceiling tiles
▪ Loosefill insulation
▪ As a soil conditioner
▪ (from regulatory standpoint do need to check for silica
content)

More Lightweight Applications
Mica alters and stores lots of water
Rapid water expansion pops the mica like
worms
Vermiculite has more chemically active surfaces
than perlite:
▪ Is used as a carrier in insecticide sprays
▪ Soaking up and containing oil
▪ Used as a soil conditioner
▪ Also found in lightweight gypsum plasters
➢Fire resistant plaster boards
▪ Can be used as a loose insulator

2) Heavies Applications
Barite is used in drilling mud
▪ Its heavy, non-abrasive, and inert
It is used in heavy concretes
▪ Concretes needing to weight down pipes in marshy
areas
▪ Good neutron adsorber so barite based concrete can
reduce lead shielding at nuclear facilities
Ground form is a filler and extender
▪ Oil based paints because it does not adsorb oil
▪ Can be used as a tire filler to add weight
14

Relative Cost of Mineral Fillers
1
10
100
1000
10000
1900
1910
1920
1930
1940
1950
1960
1970
1980
1990
2000
$/ton
Wollast
Tit Diox
Mica
Talc/Pyr
Cal Carb
Kaolin
(Lime Price is used as a surrogate for Calcium Carbonate)
15

Wollastinite
CaSiO3
Hardness 4½ - 5
S.G. 2.86 - 3.09
Color White, gray-white, light green,
pinkish, brown, red, yellow 16Prof. Dr. H.Z. Harraz Presentation

Wollastinite Uses
17

Talc
Mg3Si4O10(OH)2
Hardness 1 (softest mineral)
S.G. 2.58 - 2.83
Color Colourless, white, pale green;
bright emrald-green to dark green,
brown, gray; Greasy feel
18

19

Pyrophyllite
Hardness 1 - 2
S.G. 2.65 - 2.9
Color: White, gray, pale blue, pale green,
pale yellow, brownish green
Pyrophyllite {Al2Si4O10(OH)2}; occurs in phyllite
and schistose rocks, often associated with kyanite,
of which it is an alteration product. It also occurs as
hydrothermal deposits. Typical associated minerals
include: kyanite, andalusite, topaz, mica and
quartz.
Pyrophyllite serves some of the same uses as
soapstone.
20
Al2Si4O10(OH)2
Same thing as
Talc with Al
instead of Mg

Introduction
Talc a product of metamorphism, is a hydrous magnesium silicate [Mg3Si4O10(OH)2], which when
finely ground, forms the familiar talcum powder. In loose form, it is the widely used substance known
as talcum powder.
▪ It occurs as foliated to fibrous masses, and in an exceptionally rare crystal form.
▪ Talc is not soluble in water, but it is slightly soluble in dilute mineral acids
▪ It has a perfect basal cleavage, and the folia are non-elastic, although slightly flexible.
▪ Talc is a tri-octahedral layered mineral; its structure is similar to that of pyrophyllite, but with
magnesium in the octahedral sites of the composite layers.
➢Talc is also name as:
i) Steatite: the massive compact cryptocrystalline variety of high-grade talc;
Used for making electronic tube insulators.
ii) French chalk : soft variety used for making cloth.
iii) Soapstone: massive gray to bluish or greenish talcose rock containing variable
talc (usually 50%), which is soft and soapy in nature.
➢There are three main varieties of talc minerals:
i) Talc steatite: Trade name used to describe pure, soft, massive, compact varieties of talc.
ii) Fibrous: flakes and fibres talc
iii) Agalite: A special name applied to fibrous talc from New York State.
Soapstone is a soft rock composed essentially of talc but also containing chlorite, serpentine,
magnesite, antigorite and enstatite and perhaps some quartz, magnetite or pyrite. It is a massive,
impure talcky metamorphic rock that can be quarried and sawed into large blocks.
Commercial talc may contain other minerals like quartz, calcite, dolomite, magnesite, serpentine,
chlorite, tremolite and anthophyllite as impurities.

22
Talc and Pyrite
Talc and Pyrite

23
Soapstone
Soapstone

24
Rod-Kharof Talc Mine, Aswan-Berenice

Talc Occurrence
Talc forms as a product of metamorphism on
hydrothermal alteration of Mg-rich rocks,
especially ultramafics, dolomites, basic
volcanics, and tuffs.
Commercial talc and soapstone deposits occur
in metamorphosed ultrabasic intrusives or
dolomitic limestones.
They are thus restricted to metamorphic area
and are largely confined to the Precambrian.
The important deposits of Ontario, New York,
North Carolina, Georgia, California, Bavaria and
Austria.

Deposits
1) The first type of talc deposits are made from Serpentines, which
provide 40% of the world's talc production. This type of Talc
forming the ore commonly known as "Soapstone“.
2) The second type of deposit is derived from Magnesium
Carbonates: Found in ancient metamorphosed carbonate
sequences. This talc deposit is usually the purest form of talc.
3) The third type of talc deposit is derived from Alumino-silicate rock.
Only about 10% of this type of talc deposit is mined to meet the
world's talc supplies.
26

Talc deposits are usually occuring in three
petrological assemblages:
1) Talc after mafic-ultramafic rocks:
2) Talc after Basic Volcanic rocks
❖ The most important occurrences are those
associated with the belt of island arcs hosting the
Zn-Cu-Pb volcanogenic massive sulfide deposits
3) Talc after Dolomite and Dolomitic Limestone rocks
27
Petrological Assemblages of Talc Deposits
BEST
QUALITY
TALC

 Talc is an alteration product of original or secondary mangnesian minerals of rocks.
 It is pseudomorphic after minerals such as termolite, actinolite, enstatite, diopside, olivine,
serpentine, chlorite, epidote and mica.
 It thus originates in:
i) regionally metamorphosed limestones,
ii) altered ultramafic igneous rocks and
iii) contact metamorphic zones adjacent to basic igneous rocks.
 Talc is a metamorphic mineral resulting from the metamorphism of magnesian minerals such as
serpentine, pyroxene, amphibole, olivine, in the presence of carbon dioxide and water.
 This is known as talc carbonation or steatization and produces a suite of rocks known as talc
carbonates.
 Talc is primarily formed via hydration and carbonation via the following reaction:
Serpentine [2Mg3Si2O5(OH)4 ]+ Carbon dioxide [3CO2] →
Talc [Mg3Si4O10(OH)2] + Magnesite [3MgCO3] + Water [3H2O]
 Talc can also be formed via a reaction between dolomite and silica, which is typical of skarnification
of dolomites via silica-flooding in contact metamorphic aureoles
Dolomite [3CaMg(CO3)2] + Silica [4SiO2] + Water [H2O] →
Talc [Mg3Si4O10(OH)2] + Calcite [3CaCO3] + Carbon dioxide [3CO2]
The BEST QUALITY TALC comes from metamorphosed dolomite
 Talc can also be formed from magnesian chlorite and quartz in blueschist and eclogite
metamorphism via the following metamorphic reaction:
Chlorite + Quartz → Kyanite + Talc + Water
28
Formation of Talc Deposits

29

Talc Grade
•It is generally graded as Grade 'A', Grade 'B', Grade 'C' and Grade ‘D’
30
Table : Gradewise Consuming Industries of Talc
Grade Grade
Whiteness
(%)
Colour Industry Asbestos
Content
Grade - A >90 to 95
Pure white to
Slightly green
i) Pharmaceutical
nil
ii) Cosmetic
Grade - B 85 to 90
Pale-greenish
to White
i) Superior grade paper
ii) Textile
iii) Ceramic
Grade - C 78 to 85
Light greenish-
grey
i) Paper (inferior grade)
ii) Paint
iii) Rubber
iv) Plastic
v) Detergent
Grade – D
(DDT grade)
78% or
below
Dark greenish-
grey to
Reddish-green
DDT (The DDT grade
material is considered to
be of a very poor quality).
variable

31Prof. Dr. H.Z. Harraz Presentation
Grade A Grade B Grade C
Chemical Analysis
SiO2 60 – 62 60 - 61 53 – 58
Al2O3 0. 3 – 0. 50 0. 5 - 1 1 – 2
Fe2O3 0.10 - 0.2 0. 4 - 0. 2 0. 7 - 0. 5
MnO 0. 01 0 . 01 0 . 01
MgO 31 - 32.5 30 – 31 28 – 30
L.O.I 4.5 -5.00 6. 5 – 5. 5 8 - 9
Mineralogical Analysis
Talc > 90.0 >80. 0
Chlorite >8.00 <12. 00
Carbonate < 2.00 < 4. 00
Asbestos Nil
Physical analysis
Whiteness – Z 90.00 (min) 86. 00(min) 83. 0 (min)
SP. gr 0.55 0. 55 0. 55
pH 7.00 7. 20 7. 20
Talc Grades

Talc and Pyrophyllite Uses
32
Uses of Talc and Pyrophylite
22
17
16
15
7
5
3
15 Plastics
Paint
Paper
Ceramics
Roofing
Cosmetics
Rubber
Other

Uses of Talc
 Talc is used in many industries such as paper making, plastic, paint and coatings, rubber,
food, electric cable, pharmaceuticals, cosmetics, ceramics, …etc.
 A coarse grayish-green high-talc rock is soapstone or steatite and has been used for
stoves, sinks, electrical switchboards, crayons, soap, etc. It is often used for surfaces of
lab counter tops and electrical switchboards because of its resistance to heat, electricity
and acids.
 Talc finds use as a cosmetic (talcum powder), as a lubricant, and as a filler in paper
manufacture.
 Talc is used in baby powder, an astringent powder used for preventing rashes on the area
covered by a diaper. It is also often used in basketball to keep a player's hands dry. Most
tailor's chalk, or French chalk, is talc, as is the chalk often used for welding or
metalworking.
 Talc is also used as food additive or in pharmaceutical products as a glidant. In medicine
talc is used as a pleurodesis agent to prevent recurrent pleural effusion or pneumothorax.
In the European Union the additive number is E553b.
 Talc is widely used in the ceramics industry in both bodies and glazes. In low-fire artware
bodies it imparts whiteness and increases thermal expansion to resist crazing. In
stonewares, small percentages of talc are used to flux the body and therefore improve
strength and vitrification. It is a source of MgO flux in high temperature glazes (to control
melting temperature). It is also employed as a matting agent in earthenware glazes and
can be used to produce magnesia mattes at high temperatures.

Perlite
Perlite is a water bearing natural glass
That contains Silica, Alumina, Iron, Titanium,
Calcium, Magnesium, Sodium and Potassium
Oxides
34

‫البيراليت‬
‫؟‬ ‫البيراليت‬ ‫ماهو‬
❖‫تجاري‬ ‫باسم‬ ‫ليس‬ ‫البيراليت‬
❖‫التك‬ ‫ذات‬ ‫الآلفا‬ ‫من‬ ‫المتكونة‬ ‫الشفافة‬ ‫البركانية‬ ‫الصخور‬ ‫من‬ ‫نوع‬ ‫ولكنه‬‫وين‬
‫المتبلر‬ ‫الماء‬ ‫على‬ ‫والحاوية‬ ‫المحدد‬ ‫الكيميائي‬.
❖‫من‬ ‫الحجم‬ ‫صغيرة‬ ‫بيضاء‬ ‫حبيبات‬ ‫عن‬ ‫عبارة‬ ‫البيراليت‬(1:5‫ملم‬)‫يتدرج‬ ،
‫األبيض‬ ‫إلى‬ ‫الرمادي‬ ‫من‬ ‫لونه‬
❖‫من‬ ‫تصل‬ ‫عالية‬ ‫حرارة‬ ‫درجات‬ ‫على‬ ‫وتسخينه‬ ‫الصخر‬ ‫طحن‬ ‫ويتم‬(900
‫الى‬1000‫مئوية‬ ‫درجة‬)‫مسبب‬ ‫بسرعة‬ ‫داخلها‬ ‫المتبلورة‬ ‫المياه‬ ‫فتتبخر‬ ،‫تمددها‬ ‫ة‬
‫من‬ ‫حجمها‬ ‫ليتضاعف‬4‫إلى‬20‫عليه‬ ‫وتتكون‬ ،‫األصلي‬ ‫حجمها‬ ‫قدر‬ ‫مرة‬
‫لل‬ ً‫ا‬‫واتساع‬ ً‫ا‬‫تمدد‬ ‫يحدث‬ ‫مما‬ ،‫الساخن‬ ‫الهواء‬ ‫خروج‬ ‫نتيجة‬ ‫هوائية‬ ‫فجوات‬‫حبيبات‬
‫كبيرة‬ ‫بصورة‬ ‫وانتفاخها‬
❖‫تمنح‬ ‫الحبيبات‬ ‫في‬ ‫التحصى‬ ‫هوائية‬ ‫فجوات‬ ‫هذه‬ ‫التمدد‬ ‫عملية‬ ‫عن‬ ‫ينتج‬‫البيراليت‬
‫الفر‬ ‫الخواص‬ ‫لهذه‬ ‫ونسبة‬ ، ‫ممتازة‬ ‫عزل‬ ‫خاصية‬ ‫له‬ ‫وتجعل‬ ‫الوزن‬ ‫في‬ ‫خفة‬‫يدة‬
‫العز‬ ، ‫االرضيات‬ ‫عزل‬ ، ‫الطوب‬ ‫جدران‬ ‫عزل‬ ‫في‬ ‫يستعمل‬ ‫البيراليت‬ ‫فإن‬‫في‬ ‫ل‬
‫ا‬ ‫في‬ ، ‫للياسة‬ ‫عازل‬ ‫مالط‬ ، ‫الوزن‬ ‫خفيفة‬ ‫البيراليت‬ ‫خرسانة‬ ، ‫التبريد‬‫البلوك‬ ‫نتاج‬
‫األسقف‬ ‫وعزل‬ ‫الوزن‬ ‫خفيف‬.
35

Perlite:
 Perlite is an amorphous volcanic
glass that has a relatively high water
content (i.e., typically formed of the
hydration of obsidian).
 It occurs naturally and has the
unusual property of greatly expanding
when heated sufficiently.
 It is an industrial mineral and a
commercial product useful for its light
weight after processing.
 Various grades resulting from
differences in the degree of hydration.
 Used primarily as an insulator with its
high heat resistance and high sound
absorption.
 Used in fertilizer
36

‫البيراليت‬(Perlite)
37
•‫البيراليت‬ ‫مواصفات‬ ‫أهم‬:
❖‫الناحية‬ ‫من‬ ‫ثابت‬ ‫تركيب‬ ‫ذو‬
‫ع‬ ‫القدرة‬ ‫لها‬ ‫ليس‬ ‫و‬ ،‫الفيزيائية‬‫لى‬
‫الكاتيوني‬ ‫التبادل‬.
❖‫الوزن‬ ‫خفيف‬.
❖‫بالم‬ ‫االحتفاظ‬ ‫على‬ ‫جيدة‬ ‫قدرة‬ ‫له‬‫اء‬.
❖‫للبيئة‬ ‫مرتفعة‬ ‫تهوية‬ ‫يتيح‬.
❖‫ي‬ ‫مما‬ ‫الشعرية‬ ‫بالخاصية‬ ‫يتميز‬‫سهل‬
‫الري‬ ‫طرق‬ ‫في‬ ‫كبيئة‬ ‫استخدامه‬
‫السطحي‬ ‫تحت‬.

Properties
➢ Perlite softens when it reaches
temperatures of 850–900 °C.
➢ Water trapped in the structure of the
material vaporizes and escapes, and
this causes the expansion of the
material to 7–16 times its original
volume.
➢ The expanded material is a brilliant
white, due to the reflectivity of the
trapped bubbles.
➢ Unexpanded ("raw") perlite has a bulk
density around 1100 kg/m3 (1.1 g/cm3),
while typical expanded perlite has a
bulk density of about 30–
150 kg/m3 (0.03-0.150 g/cm3).
38
SiO2 70 - 75
Al2O3 12 - 15
Na2O 3 - 4
K2O 3 - 5
Fe2O3 0.5 - 2
MgO 0.2 - 0.7
CaO 0.5 - 1.5
LOI 3 - 5

Production and Reserves of Perlite
39
Perlite output in 2015

‫البيراليت‬ ‫استخدامات‬
‫االنشائية‬ ‫االستخدامات‬:
❖‫اإلنشائي‬ ‫البيراليت‬ ‫يتمتع‬(‫أنسواليت‬)‫وعليه‬ ‫الوزن‬ ‫وخفة‬ ‫الحراري‬ ‫العزل‬ ‫بخاصية‬
‫الجدران‬ ‫عزل‬ ‫في‬ ‫واسع‬ ‫بشكل‬ ‫يستخدم‬ ‫فانه‬(‫الفراغات‬ ‫بمالء‬ ‫عزل‬)‫يم‬ ‫ولما‬‫تاز‬
‫به‬‫أنسواليت‬‫ع‬ ‫في‬ ً‫ا‬‫ايض‬ ‫يستعمل‬ ‫فهو‬ ‫للصوت‬ ‫وعزل‬ ‫للحريق‬ ‫مقاومة‬ ‫من‬‫زل‬
‫يخلط‬ ‫وعندما‬ ،‫الغاز‬ ‫خزانات‬‫أنسواليت‬‫خف‬ ‫خرسانة‬ ‫يكون‬ ‫والماء‬ ‫االسمنت‬ ‫مع‬‫يفة‬
‫للحرارة‬ ‫عازلة‬.‫االرض‬ ‫وعزل‬ ‫الجدران‬ ‫ولياسة‬ ‫االسقف‬ ‫لعزل‬ ً‫ا‬‫مثالي‬ ‫ويكون‬‫يات‬
‫االخرى‬ ‫االستخدامات‬ ‫من‬ ‫الكثير‬ ‫وهناك‬ ،‫المباني‬ ‫انواع‬ ‫مختلف‬ ‫في‬.
‫الزراعية‬ ‫االستخدامات‬:
❖‫الزراعي‬ ‫البيراليت‬ ‫فان‬ ‫الزراعة‬ ‫مجال‬ ‫في‬(‫اليت‬ ‫أقري‬)‫أنحاء‬ ‫جميع‬ ‫في‬ ‫يستخدم‬
‫واالحتف‬ ‫التهوية‬ ‫معدل‬ ‫لزيادة‬ ‫وذلك‬ ‫الزراعية‬ ‫التربة‬ ‫لخلطات‬ ‫كمكون‬ ‫العالم‬‫اظ‬
‫للنبات‬ ‫االفضل‬ ‫للنمو‬ ‫المناسبة‬ ‫بالرطوبة‬.‫فإن‬ ‫العقل‬ ‫إنبات‬ ‫في‬ ‫أما‬‫أقر‬‫ي‬
‫اليت‬‫وحده‬ ‫يستخدم‬100%‫استخدام‬ ‫عند‬ ‫واضحة‬ ‫نتائج‬ ‫الدراسات‬ ‫أعطت‬ ‫ولقد‬
‫المائية‬ ‫الزراعة‬ ‫بنظام‬ ‫البيراليت‬(‫الهيدروبونك‬).
❖pH‫وزنه‬ ‫خفة‬ ‫ذلك‬ ‫الى‬ ‫إضافة‬ ،‫الضارة‬ ‫االعشاب‬ ‫من‬ ‫وخالية‬ ‫معقمة‬ ‫مادة‬ ‫انه‬ ‫كما‬
‫الداخلية‬ ‫والنباتات‬ ‫المراكن‬ ‫في‬ ‫لالستخدام‬ ً‫ا‬‫مالئم‬ ‫يجعله‬ ‫مما‬.
❖‫الزراعي‬ ‫للبيراليت‬ ‫الزراعية‬ ‫االستخدامات‬ ‫ومن‬(‫اليت‬ ‫أقري‬)‫كمادة‬ ‫يعمل‬ ‫فهو‬
‫البذور‬ ‫وحماية‬ ‫وتبطين‬ ‫واآلفات‬ ‫الحشائش‬ ‫ومبيدات‬ ‫لالسمدة‬ ‫حاملة‬.‫ويعتب‬ً‫ا‬‫مناسب‬ ‫ر‬
‫في‬ ‫واسع‬ ‫نطاق‬ ‫على‬ ‫يطبق‬ ‫كما‬ ،‫الداخلية‬ ‫والنباتات‬ ‫المنزلية‬ ‫الحدائق‬ ‫في‬‫االنتاج‬
‫والمشات‬ ‫الحدائق‬ ‫وتنسيق‬ ‫المحمية‬ ‫البيوت‬ ‫في‬ ‫وبنجاح‬ ‫التجاري‬ ‫الزراعي‬‫ل‬.
‫الصناعية‬ ‫االستخدامات‬:
❖‫الصناعي‬ ‫البيراليت‬ ‫يستخدم‬(‫كريواليت‬)‫في‬ ‫عالية‬ ‫بكفاءة‬ ‫الصناعي‬ ‫المجال‬ ‫في‬
‫االس‬ ‫مع‬ ‫او‬ ‫البالستيك‬ ‫في‬ ‫مالئة‬ ‫كمادة‬ ‫استخدامه‬ ‫مثل‬ ‫االستخدامات‬ ‫من‬ ‫العديد‬‫منت‬
‫الكيماوي‬ ‫والمواد‬ ‫االطعمة‬ ‫او‬ ‫لالدوية‬ ‫منقية‬ ‫كمادة‬ ‫او‬ ،‫والماء‬ ‫البترول‬ ‫ابار‬ ‫في‬‫ة‬
‫المياه‬ ‫تنقية‬ ‫ومحطات‬ ‫والمسابح‬.‫والمنظ‬ ‫الصابون‬ ‫صناع‬ ‫في‬ ‫يستخدم‬ ‫كما‬‫فات‬
‫التلميع‬ ‫ومواد‬.‫الحد‬ ‫صناعة‬ ‫في‬ ‫االولوية‬ ‫له‬ ‫فان‬ ‫العزل‬ ‫بخاصية‬ ‫ولتمتعه‬‫والطوب‬ ‫يد‬
‫وخالفه‬ ‫االنابيب‬ ‫وعزل‬ ‫الطوب‬ ‫ومونة‬.
40

‫الفيرميكوليت‬
Vermiculite
43
(Mg,Fe,Al)3(Al,Si) 4O10(OH) 2·4H2O
• Hardness 1½ - 2
• S.G. 2.3 - 2.7
• Color Brown, bronze-yellow
‫الخام‬ ‫الفيرميكوليت‬
(Crude Vermiculite)

Vermiculite
42
VERMICULITE (also known as Micafil) is exfoliated Minerals

VERMICULITE
WHAT IS VERMICULITE?
➢Vermiculite is a hydrous phyllosilicate mineral
➢Vermiculite is the geological name given to a group of hydrated laminar minerals
which are aluminium-iron-magnesium silicates, resembling mica in appearance.
➢Rock and other impurities are removed from the crude ore which is then crushed
and sorted into sizes.
➢Vermiculite is a safe inert material and is light in colour.
Structure
➢Vermiculite is a 2:1 clay, meaning it has 2 tetrahedral sheets for every
one octahedral sheet.
➢It is a limited expansion clay with a medium shrink-swell capacity.
➢Vermiculite has a high cation exchange capacity (CEC) at 100-
150 meq/100 g.
➢Vermiculite clays are weathered micas in which the potassium ions
between the molecular sheets are replaced by magnesium and iron ions
Occurrence
➢It typically occurs as an alteration product at the contact between felsic and mafic or
ultramafic rocks such as pyroxenites and dunites.
➢It also occurs in carbonatites and metamorphosed magnesium rich limestone.
➢Associated mineral phases include: corundum, apatite, serpentine and talc.
➢It occurs interlayered with chlorite, biotite and phlogopite.
➢Vermiculite is formed by weathering or hydrothermal alteration of biotite or
phlogopite.
➢Large commercial vermiculite mines currently exist in USA, South Africa, China,
Russia, and Brazil.

‫الفيرميكوليت‬Vermiculite))
❖‫للحرارة‬ ‫تعرضه‬ ‫عند‬ ‫يتمدد‬ ،‫طبيعي‬ ‫معدن‬ ‫هو‬.
❖‫التجارية‬ ‫األفران‬ ‫في‬ ‫وتطبق‬ ‫التقشير‬ ‫تسمى‬ ‫التمدد‬ ‫عملية‬.
❖‫وعد‬ ‫المتحدة‬ ‫والواليات‬ ‫والبرازيل‬ ‫والصين‬ ‫أفريقيا‬ ‫جنوب‬ ‫في‬ ‫للفيرميكليت‬ ‫كبيرة‬ ‫تجارية‬ ‫مناجم‬ ‫توجد‬‫أخرى‬ ‫بلدان‬ ‫ة‬.
❖‫الكيميائي‬ ‫التركيب‬:(Mg,Fe,Al)3(Al,Si) 4O10(OH) 2·4H2O
‫الفيرميكوليت‬ ‫خصائص‬:
❖‫الفطريات‬ ‫نمو‬ ‫على‬ ‫يساعد‬ ‫فال‬ ‫ِه‬‫ت‬‫بطبيع‬ ‫معقم‬ ‫الفيرميكوليت‬.
❖‫الوزن‬ ‫خفيف‬.
❖‫عالية‬ ‫بدرجة‬ ‫بالماء‬ ‫يحتفظ‬.
❖‫عالية‬ ‫تبادلية‬ ‫سعة‬ ‫ذو‬.
❖‫واالستفاد‬ ‫امتصاصها‬ ‫يمكن‬ ‫للنباتات‬ ‫ميسرة‬ ‫صورة‬ ‫في‬ ‫والبوتاسيوم‬ ‫الماغنسيوم‬ ْ‫عنصري‬ ‫على‬ ‫يحتوى‬‫منها‬ ‫ة‬.
❖‫الوقت‬ ‫معظم‬ ‫بالماء‬ ً‫ا‬‫محتفظ‬ ‫يظل‬ ‫الماء‬ ‫امتصاص‬ ‫على‬ ‫العالية‬ ‫لقدرته‬ ‫ونظرا‬ ‫الفيرميكوليت‬ ‫أن‬ ‫إلى‬ ‫ونشير‬‫يفضل‬ ‫لذلك‬ ،
‫النباتات‬ ‫لنمو‬ ‫مناسبة‬ ‫البيئة‬ ‫رطوبة‬ ‫تظل‬ ‫وحتى‬ ،‫العالية‬ ‫الرطوبة‬ ‫من‬ ‫للتقليل‬ ‫أخرى‬ ‫بمواد‬ ‫خلطه‬.
‫االستخدامات‬:
❖‫العامل‬‫بوصفه‬‫المانع‬‫الحرارة‬
❖‫المياه‬‫غالية‬
❖‫صناعة‬‫ورق‬‫الجدران‬
❖‫التشحيم‬ ‫لزيوت‬ ‫ونتيجة‬
❖‫تمتلك‬‫التبادل‬‫الكاتيوني‬‫جيدة‬‫جدا‬

Production and Reserves of Vermiculite in 2014
Production and Reserves of
Vermiculite
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
Production Reserves/50
MetricTonnes
Other
Zimbabwe
South Africa
Russia
China
Brazil
Australia
United States
45

VERMICULITE EXPANSION
• When heated it expands (exfoliates) up to 30 times
its original volume.
• Exfoliation occurs when the mineral is heated
sufficiently, and the effect is routinely produced in
commercial furnaces.
• The exfoliation process converts the dense flakes of
ore into lightweight porous granules containing
innumerable minute air layers.
• Exfoliated (expanded) vermiculite is light and clean
to handle, has a high insulation value, acoustic-
insulating properties and will absorb and hold a
wide range of liquids.
• These granules are non-combustible, and are
insoluble in water and all organic solvents.
• Expanded vermiculite is easily poured, is light,
clean, highly absorbent and provides baffle against
impact shock when used for packaging.

Processing Vermiculite
Separating Vermiculite from gangue
Minerals is done by a variety of
methods
The interesting twist is
Launching down a wind
Tunnel
The largest plates settle
Out first.

Vermiculite Expansion
Drop the flakes right through gas burners (it does not burn) 1000 to 1500 F
Water in the weathered mica flashes to steam popping the flakes like pop-corn.
48

TYPICAL PROPERTIES
❖MORE AIR FILLED PORE SPARE (A.F.P.)
AFP provides a measure of the room available within a
compost for the essentials of growth - air, water, nutrients
and roots. Tests indicate that an AFP figure between 10-
15% is suitable for growing media.
❖MORE WATER CARRYING CAPACITY
It is essential that composts have the ability to hold water
ready for plant use. The unique properties of Vermiculite
ensure an excellent water holding ability.
❖MORE NUTRIENTS
There are several useful elements in Vermiculite potentially
available for plant growth. These involve replacing water in
the usual solubility tests with an extractant more closely
modelling conditions found in compost.

GRADES OF VERMICULITE
50
Nominal Particle
Size (mm)
Loose Bulk
Density (Kg/m3)
Applications
Large Grade
(Micafil)
3 – 15 70 Insulation, Concrete, Refractories,
Packaging, Extra winter drainage, bulb
culture and storage.
Medium Grade 2 – 8 85 Insulation, Horticulture, Refractories,
General purpose growing media.
Fine Grade 0.5 – 3 100 Horticulture, Friction, Seed growing and
moistening growing media
Superfine Grade 0.5 – 1.7 105 Friction, Animal Feed, Screeds
Micron Grade 0.1 – 1.0 120 Friction, Animal Feed
PREMIUM GRADES
pK Fine Grade pK Large Grade MEV Vermiculite
Dust-suppressed fine grade vermiculite
for insulating ceramic shells.
Dust-suppressed large grade
vermiculite for packaging.
Micronised vermiculite for specialist
applications. Average particle size ~20
microns.
STANDARD GRADES

Uses of Vermiculite
51
Vermiculite Uses
35
30
5
30
Lightweight
Construction
Horticulture Soils
Insulation
Other
❖ Vermiculite is supplied to the demanding
specifications required in today’s
marketplace. Numerous industries are
supplied with Vermiculite for a multitude of
different applications.
❖ Exfoliated vermiculite is used in the Friction
brake linings, high temperature insulation,
loft insulation, insulation material in
construction, insulation material in
lightweight aggregates, factory made
insulation, various construction products,
refractory mouldings and shapes, fire
resistant boards, animal feeds, horticulture,
growing media additive and soil improver.
❖ Vermiculite with its layered structure and
surface characteristics, is utilized in
products such as intumescent coatings and
gaskets, the treatment of toxic waste and
air-freight packaging of hazardous goods.

53
‫الحبيبات‬ ‫متوسط‬ ‫الزراعى‬ ‫الفيرميكوليت‬
Plant vermiculite growing medium

‫للموقد‬ ‫للمدفأة‬ ‫الحراري‬ ‫العزل‬ ‫الفيرميكوليت‬ ‫لوحات‬
Vermiculite Plates for Stove-Heat-Insulation
54

Expanded Crude Vermiculite Insulation
Indoor Garden Growing

USES
56
PACKAGING
Vermiculite is widely used as a packaging medium. Not only is it lightweight,
clean and easily poured around irregular shaped objects, it also acts as a
baffle against shocks caused by impact and improper handling. Being highly
absorbent, it safely retains leaks from packed materials such as hazardous
liquids. As an inorganic mineral, it does not present any fire hazard
INSULATION
Exfoliated Vermiculite is well established as an excellent thermal insulating
material capable of withstanding temperatures in excess of 1000°C. The free
flowing properties of loose-fill Vermiculite make installation very simple in
applications such as loft insulation. The insulating properties of Vermiculite
significantly reduce the loss of heat in cold weather and keep the interior
cool in hot weather. Vermiculite is clean to handle, nonabrasive, sound
absorbent, resistant to decay, odorless and non-irritant.
HORTICULTURE
Medium Grade Vermiculite will dramatically improve drainage when added to
heavy soils. Fine Grade combined with peat forms an excellent seed
growing compost. When Vermiculite is used with fertilizers, it makes them
more efficient, releasing more nutrients and therefore making them more
economical.
FRICTION

Barite
BaSO4
S.G. 4.5
Hardness 3 - 3½
Color Colourless, white, yellow, brown,
grey, blue, etc.; colourless in transmitted
light (also tinted yellow, brown, green,
blue, etc.)
57

Gypsum
CaSO4 · 2H 2O
S.G. 2.312 - 2.322
Hardness 2
Color Colorless to white,
often tinged other hues due to
impurities; colorless in transmitted light. 58

The solution, transportation, and deposition of calcium and magnesium
carbonate give rise to deposits of limestones, dolomite, and magnesite.
The calcium is derived from the weathering of rocks and is transported to the
sedimentary basins chiefly as the bicarbonate, in part as carbonate, and as
sulfate.
Calcium carbonate (CaCO3) is deposited :
✓at all Eh conditions but mostly at higher pH values.
✓by organic and mechanical means.
✓by the photosynthesis of plants.
Carbon dioxide plays a dominant role in inorganic processes because the
solution of the calcium carbonate in the sea is dependent upon it. If it escapes,
calcium carbonate is precipitated Organic deposition is brought about by Algae,
Bacteria, Morals, and Foraminifera.
➢ Entire limestone beds may consist of Foraminifera or Nummulite shells,
Coral, or larger fragmental shell formed mainly in shallow waters.
➢ The deposition has been brought about by chemical precipitation with
subsequent dehydration.
Ca2+ + CO3
2- CaCO3
5) Calcium Carbonate Deposits
59

Limestone
• Limestone is an extremely common rock formed as shell beds on a shallow sea floor. Purity
depends on the environment of deposition and the subsequent mineralogical and tectonic
history that may include metamorphism to marble.
• Limestone is exploited for uses ranging from construction aggregates and railroad ballast to
cement and lime manufacturing, and glassmaking to GCC used as functional fillers in paper,
plastics, and paint.
• The relatively modest price even for the high-calcium and high-brightness grades of GCC
(less than $200/t) means that consumption is generally close to the point of production (i.e.,
a local or regional market).
• In Western Europe, chalk is important in the United Kingdom, France, and Belgium, whereas
crushed marble is often used in Italy and Greece.
Dolomite
• Has many of the uses outlined for limestone, plus several others, including in refractories, in
seawater magnesia and magnesium metal production, and as a dimension stone. Although
less common than limestone, dolomite production, particularly for aggregates, is extremely
widespread.
• In the EGYPT, nonaggregate production is concentrated in Ain Al Suknai-Red Sea, Sinai,
and West Alexandria. Europe has an active dolomite industry where it is used extensively as
a raw material for refractories and seawater magnesia production.
• The main producers are Spain, the United Kingdom, Belgium, France, Germany, Norway,
Sweden, and Finland.
60

Limestones
Limestones
➢Limestones are non-clastic rock formed either chemically or due to
precipitation of calcite (CaCO3) from organisms usually (shell) {Limestones are
commonly containing abundant marine fossils}.
➢Limestones are the most common type of chemical sediment forming today by
evaporation and biogenic processing of seawater.
➢Limestones are of marine origin, and magnesium may in part replace the
calcium, giving dolomitic limestones even though dolomite is also of primary
origin. Impurities of silica, clay, or sand are commonly present, as well as minor
amounts of phosphate, iron, manganese, and carbonaceous material.
➢Limestones formed by chemical precipitation are usually fine grained, whereas,
in case of organic limestone the grain size vary depending upon the type of
organism responsible for the formation
✓Chalk: which is made up of Foraminifera is very fine grained
✓Fossiliferous Limestone: which medium to coarse grained, as it is
formed out of cementation of Shells.
✓Coquina: larger fragmental shell formed mainly in shallow waters
 Dolomite (or dolostone) is created by replacement of calcium by magnesium after
shallow burial of limestone. Dolomite usually forms in tropical shallow marine
environments.
61

Calcium Carbonate Deposits
Non-fossiliferous Limestone Fossiliferous Limestone
Fossiliferous
Limestone
Non-fossiliferous
Limestone
Oolitic Limestone
Oolitic LS Dunes,
Bahamas
Biogenic
Inorganic, ~clastic
62

Chemical and biochemical sedimentary Calcium Carbonate
Limestones – composed of calcite
Travertine Coquina
63

Limestones
Industrial Uses of Limestone Calcium Carbonate
 Limestone is widely used as a Construction, Building Construction Material –
)Concrete, blocks…etc).
 Limestone is used to strengthen and stabilize the sub-grade in road construction.
 Limestone is an alkali and is used extensively to neutralize acids – pH control.
 Limestone, the source material for all lime based value added products –
calcined.
➢ Calcined and Lime:
✓ Iron and steel the manufacture
✓ Water and effluent treatment.
✓ Chemical industry (e.g. Soda Ash), Gaseous effluent neutralization.
✓ Agriculture and food products.
✓ Manufacture - cement and glass
 Crushed: Glass making, Sugar refining, Flow gas desulphurization, Ceramics.
 Ground:
i) Fine to very fine fillers: Paper, Paint, Plastics, Adhesives, Sealants,
Pharmaceuticals, Food and Drinks
ii) Coarse to medium fillers: Agriculture, Carpet backing, Animal feeds,
Asphalt filler, Floor coverings and tiles.
 Paper, plastic, paint and rubber producers use calcium carbonate as a way to
improve quality and lower manufacturing costs.
64

Clay Grades are categorized into six groups:
1) Kaolin or China clay: white, claylike material composed mainly of
kaolinite industrial applications: paper coating and filling,
refractories, fiberglass and insulation, rubber, paint, ceramics,
and chemicals
2) Ball clay: kaolin with small amount of impurities industrial
application: dinnerware, floor tile, pottery, sanitary ware.
3) Fire clays: kaolin with substantial impurities (diaspore, flint)
industrial applications: refractories
4) Bentonite (smectite): clay composed of smectite minerals, usually
montmorillonite industrial applications: Oil well drilling fluids,
suspending agents; drilling muds, foundry sands
5) Fuller’s earth: nonplastic clay high in magnesia, a similar to
bentonite industrial applications: absorbents
6) Shale: laminated sedimentary rock consisting mainly of clay
minerals mud industrial application: raw material in cement and
brick manufacturing
Clay minerals:
65

Origin of Clay Minerals
 “The contact of rocks and water produces clays, either at or near the surface of the
earth” (from Velde, 1995).
Rock +Water  Clay
 For example,
➢ The CO2 gas can dissolve in water and form carbonic acid, which will become
hydrogen ions H+ and bicarbonate ions, and make water slightly acidic.
CO2 + H2O  H2CO3  H+ + HCO3
-
➢ The acidic water will react with the rock surfaces and tend to dissolve the K ion and
silica from the feldspar. Finally, the feldspar is transformed into kaolinite.
Feldspar + hydrogen ions + water  clay (kaolinite) + cations, dissolved + silica
2KAlSi3O8 + 2H+ + H2O  Al2Si2O5(OH)4 + 2K+ + 4SiO2
Note that:
✓ The hydrogen ion displaces the cations.
✓The alternation of feldspar into kaolinite is very common in the decomposed
granite.
✓The clay minerals are common in the filling materials of joints and faults (fault
gouge, seam) in the rock mass.
66

68
Generalized Chemical Weathering
 Temperate Climates
3KAlSi3O8 + 2H+ + 12H2O  KAlSi3O10(OH)2 + 6H4SiO4 + K+
(K-feldspar) (mica/illite) (silicic acid)
 Temperate Humid Climates:
2KAlSi3O8 + 2H+ + 3H2O  3Al2Si2O5(OH)4 + K+
(K-feldspar) (kaolinite)
 Humid Tropical Climate:
Al2Si2O5(OH)4 + 5H2O  2Al(OH)3 + 2K+ + 4H4SiO4
(kaolinite) (gibbsite)

References
• http://www.tdap.gov.pk/doc_reports/product_report_presentations.pdf
• http://www.nature.com/nature/journal/v207/n4994/abs/207283a0.html
• http://en.wikipedia.org/wiki/Talc
• http://www.mineralszone.com/minerals/talc.html
71

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