The intercalation degree of kaolinite by urea is 69% when aqueous mixing is used.
Bonds are formed between inner-surface hydroxyls of kaolinite and NH groups of urea.
Intercalation increases the densification rate and reduces the sintering temperature.
Intercalated kaolinite behaves similarly to intensively grounded kaolinite.
A high intercalation degree of kaolin can be attained in industrial processes.