Synthetic carbide lime filler composition and method of making

Abstract

A method for making a white synthetic carbide lime filler composition of calcium hydroxide and calcium carbonate, wherein the calcium carbonate is in the form of surface carbonation on the calcium hydroxide. The method can include calcining calcium carbonate, hydrating the calcined material under controlled conditions which maintain a low moisture content and fracture the hydrated material into small particles of calcium hydroxide, carbonating the small calcium hydroxide particles to create the surface carbonation of calcium carbonate, and classifying the carbonated synthetic carbide lime particles to separate off oversized particles. The method can use a combined classifying and carbonating process, and a modified classifying vessel can be provided to carry out the combined process

1 - 94 . (canceled) 
     
     
         95 . A synthetic carbide lime composition comprising:
 a. 70-85% by weight calcium hydroxide;   b. 5-25% by weight calcium carbonate, said calcium carbonate being present in the form of surface carbonation on said calcium hydroxide; and   c. said composition being white in color.   
     
     
         96 . The composition of  claim 95  wherein said calcium carbonate comprises 10 percent by weight. 
     
     
         97 . The composition of  claim 95  comprising a moisture content of 0.1 percent or less by weight. 
     
     
         98 . The composition of  claim 95  comprising:
 a. an average particle size of 3 microns; and 
 b. a maximum particle size of 25 microns. 
 
     
     
         99 . The composition of  claim 95  comprising a specific gravity of 2.35 to 2.69 gm/cc. 
     
     
         100 . The composition of  claim 95  comprising an average particle size of about 1 micron. 
     
     
         101 . The composition of  claim 95  comprising a specific gravity of 2.25 to 2.35 gm/cc. 
     
     
         102 . A composition comprising a thermoplastic material and a synthetic carbide lime composition, wherein said synthetic carbide lime composition is a composition is a composition according to  claim 95 . 
     
     
         103 . The composition of  claim 102  comprising:
 a. 5 to 60 parts by weight of said synthetic carbide lime composition; 
 b. 20 to 95 parts by weight of said thermoplastic material; and 
 c. 0 to 60 parts by weight of at least one of lubricants, stabilizers, antioxidants, plasticizers, pigments and dyes; anti-blocking, anti-static, blowing and release agents; flame retardants; impact modifiers; coupling and wetting agents; processing aids and fibrous reinforcing agents. 
 
     
     
         104 . The composition of  claim 102  wherein the thermoplastic material further comprises at least one thermoplastic polymer, a thermoplastic elastomer and a thermoplastic rubber. 
     
     
         105 . The composition of  claim 102  wherein said synthetic carbide lime composition is inert with respect to said thermoplastic material. 
     
     
         106 . The composition of  claim 102  wherein said synthetic carbide lime composition ineracts with said thermoplastic material. 
     
     
         107 . The composition of  claim 102  in which the thermoplastic material is modified thermoplastic material. 
     
     
         108 . A synthetic carbide lime composition made by the process comprising:
 a. calcining calcium carbonate to produce calcium oxide;   b. hydrating said calcium oxide to produce calcium hydroxide and wherein said calcium hydroxide is fractured into particles;   c. simultaneously classifying and carbonating said calcium hydroxide particles by reacting said calcium hydroxide particles with carbon dioxide containing gas while said calcium hydroxide particles are suspended in air during said classification;   d. wherein said calcium hydroxide particles react with said carbon dioxide to create a synthetic carbide lime composition comprising calcium carbonate in the form of surface carbonation on said calcium hydroxide; and   e. wherein said synthetic carbide lime composition is white in color.   
     
     
         109 . A composition comprising a thermoplastic material and a synthetic carbide lime composition, wherein said synthetic carbide lime composition is a composition according to  claim 108 . 
     
     
         110 . The composition of  claim 109  comprising:
 a. 5 to 60 parts by weight of said synthetic carbide lime filler; 
 b. 20 to 95 parts by weight of said thermoplastic material; and 
 c. 0 to 60 parts by weight of at least one of lubricants, stabilizers, antioxidants, plasticizers, pigments and dyes; anti-blocking, anti-static, blowing and release agents; flame-retardants; impact modifiers; coupling and wetting agents; processing aids and fibrous reinforcing agents. 
 
     
     
         111 . A synthetic carbide lime composition made by the process comprising:
 a. calcining calcium carbonate to produce calcium oxide;   b. hydrating said calcium oxide to produce calcium hydroxide and wherein said calcium hydroxide is fractured into particles;   c. carbonating said calcium hydroxide particles by reacting said calcium hydroxide particles with carbon dioxide;   d. wherein said calcium hydroxide particles react with said carbon dioxide to create a synthetic carbide lime composition comprising calcium carbonate in the form of surface carbonation on said calcium hydroxide; and   e. wherein said synthetic carbide lime composition is white in color.   
     
     
         112 . A composition comprising a thermoplastic material and a synthetic carbide lime composition, wherein said synthetic carbide lime composition is a composition according to  claim 111 . 
     
     
         113 . The composition of  claim 112  comprising:
 a. 5 to 60 parts by weight of said synthetic carbide lime filler; 
 b. 20 to 95 parts by weight of said thermoplastic material; and 
 c. 0 to 60 parts by weight of at least one of lubricants, stabilizers, antioxidants, plasticizers, pigments and dyes; anti-blocking, anti-static, blowing and release agents; flame-retardants; impact modifiers; coupling and wetting agents; processing aids and fibrous reinforcing agents. 
 
     
     
         114 . An unstained, synthetic carbide lime composition comprising:
 a. 70-85% by weight calcium hydroxide;   b. 5-25% by weight calcium carbonate, said calcium carbonate being present in the form of surface carbonation on said calcium hydroxide; and   c. said composition being unstained.