To control a vast spectrum of applications and processes, an understanding of the morphologies of clay mineral assemblies dispersed in aqueous or non-aqueous media is important. As such, the objective of this study was to verify the relationship between dispersion medium type and the size and morphology of the clay aggregates that are formed, which can increase knowledge on the assembly formation process. Scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier-transform infrared (FTIR) spectroscopy were used in an attempt to describe kaolinite platelet organization in non-aqueous media and to compare it to the organization in aqueous media or in media with or without a selection of dissolved organic polymers. The SEM images indicated that the kaolinite platelet assembly process occurs during slow evaporation of the solvent. Because the experimental procedure was rigorously identical for all cases in this study, the SEM images compared how the effects of various media and environments on kaolinite platelet interactions can lead to different morphologies. Quite spectacular morphological differences were indeed observed between samples dispersed in aqueous and non-aqueous media, particularly when the kaolinite platelets were dispersed in an organic solvent with dissolved organic polymers. For kaolinite dispersed in water, only small aggregates were observed after slow evaporation. In contrast, large kaolinite booklets or vermiform aggregates were formed by slow solvent evaporation when kaolinite was first dispersed into some organic solvents. The aggregates were particularly large when an organic polymer was dissolved in the organic solvent. For example, kaolinite aggregates dispersed in a binary cyclohexane/toluene mixture with dissolved ethyl cellulose (EC) had top apparent surface areas (i.e. stacking length × width) of more than 3,000 µm2. Other dissolved polymers, such as polystyrene or the polysaccharide, guar gum, gave similar results. Kaolinite platelet aggregation resulted from face-to-face interactions as well as edge-to-face and edge-to-edge interactions. The XRD results showed that ethyl cellulose led to the formation of smaller kaolinite platelets with an increased tendency to form larger aggregates, which is due to the ability of EC to chemically interact with silanol and/or the aluminol groups of kaolinite.

This work examines possible new applications for common, clay-based formulations. We processed spray-dried grains of a common clay (ZA-4) and collected fines/rejects from the production of lightweight aggregates (LWA), which were used as filtration beds for removal of Pb2+ and Ni2+ from aqueous solutions. Experiments were performed at different contaminant concentrations and by testing several operational conditions. The removal performance of both tested materials is strongly dependent on the particle-size distribution of the batch, being better for beds made of smaller grain size, since packing density and specific contact area for removal are greater. In general, the efficiency for removal of Pb2+ was greater than for Ni2+. When compared with granular activated carbon, clay-based beds performed well. In particular, finer fractions of LWA show stable behaviour, without saturation after consecutive runs. Saturated beds can potentially be reused, in appropriate amounts, for production of new lightweight aggregates or common ceramic items (e.g. bricks), since retained contaminants will be fixed by firing in the clay matrix. Calcination of pressed pellets made of contaminated filter grains created consolidated ceramic components and sorbed metallic species became inert.