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By H. E. Epstein, B. K. Parekh, W. M. Goldberger

Comminution is the single most expensive operation in mineral processing. It consumes about 50% of the energy required for mineral extraction (Agar, 1976). Current comminution technology is both energy-intensive and inefficient. A novel noncontact comminution process concept was developed in this study, whereby selective lib¬eration of minerals from an ore could be potentially achieved. The process involves application of electric and ultrasonic energy to liberate minerals from gangue particles. Introduction The mineral industry is a large user of energy in the US. Energy usage is increasing as the grade of ores processed decreases. It is es¬timated that comminution of ores uses about 32 000 kWh (115 trillion kJ), or 2% of the electric power produced in the US (NMAB-365, 1981). Among other minerals, ce¬ment, iron, and copper processing plants are the largest users of en¬ergy in comminution. Very little of this energy used in conventional grinding (about 1%) is used to gen¬erate new surface. The remainder is wasted (Table 1). Thus, there are substantial energy-saving and economic incentives to improve the efficiency of crushing and grinding techniques for mineral recovery. With an energy efficiency of only 1%, it would seem possible to devise methods to significantly improve comminution technology. This requires that breakage force be applied only where needed, not indiscriminately as in a conven¬tional ball mill (NMAB-365, 1981). Can apparatus and methods be de¬ veloped for large-scale commer¬cial use that allow energy to be fo¬cused at intergranular bounda¬ries? If this can be done, mono¬mineral grains would remain in¬tact and the grinding action would be selective and substantially more efficient. The novel comminution process concept described in this paper uses a combination of electric and ultrasonic energy. This energy breaks the ore and selectively lib¬erates minerals. The process has also been termed a two-stage or electroacoustical comminution process (Goldberger, Epstein, and Parekh, 1982). The mineral grain boundary is usually the weakest area in an ore. By applying electri¬cal energy to the ore, the rock frac¬tures mostly at grain boundaries. At the same time, the electric shock creates secondary hairline fractures in the ore. Additional application of ultrasonic energy to this ore provides further break¬age. The concept was proven on a molybdenum porphyry ore but needs additional study. Technical Background There have been substantial im¬provements in milling machinery and grinding operations, but rela¬tively few attempts have been made to develop alternatives to conventional impact milling. Sev¬eral methods, however, have been investigated that relate to this study. In the early 1970s there was considerable interest in a size re¬duction method known as the Snyder Process (Cavanaugh, 1972). It involved charging coarse ore into a pressure chamber, pressur¬izing with a gas, and activating a quick-opening (15 msec ) dis¬charge valve that connected the chamber to a discharge duct. This allowed solids to fluidize and ac¬celerate, subjecting the material to a variety of impulse phenomena that caused the desired size reduction. Other nonimpact means of achieving breakage and selective size reduction have been de¬scribed in technical and patent literature. Kanellopoulos and Ball (1975) considered using heat to induce thermal stress in quartz¬ite. This would cause cracking and, thus, increase grinding efficiency. The use of electrical energy to induce thermal stress was studied by the General Elec¬tric Co., in cooperation with the Montana School of Mines, under a research grant from the Anaconda

Jan 9, 1984

By G. L. Alston

The mine disaster last November in northern West Virginia has compelled the coal mining industry to take a closer look at the methods of transporting and applying rockdust. The USBM has indicated they would like to see a minimum of 80% incombustble in the back entries and want rockdust to be maintained to within 40 feet of the face at all times. With today's high rate of advance of mining machines it will be necessary to apply dust in the immediate returns continuously and the working places mutt have dust applied during the operating shift. The inspectors have become more demanding in requiring clean-up of coal and coal dust in the working place before rockdust is applied and are insisting on better clean-up and better rockdust applications along belt conveyors. Maintaining a constant application of rockdust in the back entries can be done with a Trickle-Duster. The machine is designed with hopper capacities of either 400 or 1,000 pounds of dust. The discharge rate of dust being fed through 1-1/2 inch diameter hose can be adjusted from 1/2 to 5 pounds per minute. The hose is extended into the return through the last open breakthrough and the return air carries the rockdust along w th the coal dust, depositing them uniformly on rib, roof and bottom.

Jan 1, 1969

By James K. Ballard

Leach dumps in Butte are relatively new in comparison with older established dumps in other areas throughout the West. With the exception of one 10 million ton dump, all dumps have been formed on a prepared base. This is necessary because the entire leach dump area overlies an alluvial fill which varies in depth from 100 to 400 feet and through which solution would be lost. Preparation of the leach pad consists of first removing all vegetative material and compacting the exposed surface with rollers. This surface is covered with a 4" layer of minus 1" crushed rock which in turn is roller compacted. A 3" compacted layer of asphalt hot mix is then applied to the crushed rock surface. Final sealing is effected by a 1/4'? coating of catalytically applied hot asphalt. Dump leaching was inaugurated in 1964. First solution applied was wholly made up of mine water pumped to surface through a central pump shaft. Sulfuric acid was added on surface at a surge pond to control pH of the leach solution. Acid addition is necessary not only to benefit the leach dumps, but to prevent the formation of ocher scale within the pipe line distribution system. Mine water pH is on the order of 2.8. The combination of ferrous and ferric iron as well as magnesium and aluminum salts is such that ocher forms at a pH of 2.38. It is therefore mandatory to control pH at 2.0. Dump effluent pH is held at 2.3 or less.

Jan 1, 1968

By Charles J. Hass

INTRODUCTION Deformation measurements are some of the simplest and most useful measurements that can be made by the mining/rock mechanics engineer in assessing the sta¬bility of openings in rock. A number of tools and tech¬niques are presently available. This chapter will de¬scribe the most common instruments, their application, and present the equations needed for data reduction. MECHANICAL STRAIN GAGE Description of Instrument A mechanical strain gage of the Whittemore type shown in Fig. I is a useful instrument for measuring deformations of pillars, sidewalls, and roofs of under¬ground mines. Measurement gage lengths typically range from 51 to 254 mm (2 to 10 in.), and the dial indicator reads to 0.0025 mm (0.0001 in.). The instru¬ment measures the deformation between precision gage points which are anchored in the rock. The anchor points are typically grouted in small holes drilled 12.5 mm (1/2 in.) or so deep into the rock. Strain a is calculated from the measured deformation AL with the equation [ ] where L is gage length. A necessary accessory for the instrument is a master bar normally made from invar steel having a low co¬efficient of thermal expansion. This bar allows one to check the instrument for changes in the mechanical zero point and to correct for temperature effects on the measuring instrument. The instrument is available from Soiltest, Inc. for a cost of approximately $340; the cost of the master bar is approximately $55; and nonreusable brass inserts which are anchored in the rock are nominally priced at $0.27 each. All prices are for 1978. Applications Two classes of applications may be considered, one where only one measurement direction is involved and the second where three measurement directions are em¬ployed. Applications where only one measurement di¬rection is necessary include: monitoring crack or frac¬ture separation or shear movement with anchor points on opposite sides of the discontinuity; measurement of vertical strain in a pillar or sidewall; and measurement of steel support deformations with anchors in the steel members. The more general application involves a strain ro¬sette consisting of three measurement directions which for convenience are oriented 1.04 rad (60°) apart to form an equilateral triangle as shown in Fig. 2. Strains in the three measurement directions [ ]

Jan 1, 1982

By G. R. O?Neil

The justification for a "ligand- selective' approach to fine mineral beneficiation via flocculation is established initially. Special emphasis is placed upon the need to identify non-selective, interfering and complicating adsorption effects. Specific strategies directed towards the design and synthesis of complementary selective flocculants are detailed using a number of different polymers and chelating agents as examples. In this regard, the affinity of polymer-bound ligands for metallic cations, ligand concentration, possible modes of attachment, the application of spaced-out ligands and other considerations in the preparation of selective flocculants are highlighted.

Jan 1, 1983

By W. Kemp Wait

Electronic ore sorting has been in use for over 15 years at many mining operations worldwide. Photometric ore sorting, which operates on the basis of measuring light reflectance levels of a rock surface, is in use at various locations on ores such as limestone, magnesite, gold, talc, spodumene, tungsten and coal. Radiometric sorters have been employed on uranium deposits in the western U.S.A. as well as at certain South African go1 d mines where preconcentrating gold is achieved using uranium association as a detector. A new ore sorter, employing two sensing parameters has been developed. Utilizing both photometric and conductivity sensing modes, this system has application to many gold ore types of North America. The first production machine has been installed at a gold mine near Beardmore, Ontario for the purpose of preconcentrating ore both from waste dumps from past production as well as within the ongoing mining operation.

Jan 1, 1987

By V. N. Sukhov

This set was developed to use the mathematical methods and computers in the data analysis and accumulation of the large amount of geological data to solve the typical geological problems at the deposit exploring stage as well as for planning and managing in the open cast deposit mining. That is to say, the set of tasks ensures the geological data base at the stage of the deposit exploring and also its further use and. updating at the exploration stage. The following main elements may be ear-marked in the complex: (1) geological data base (GDB), (2) the data input system, (3) GDB maintainance, (4) "Geologist" geological application package (GAP). Let us consider now each element purpose. 1) GDB logical structure is determined through five hierarchical substructures with a common root segment.

Jan 1, 1986

By Glenn Mallory, Margarete Kalin, Ben Romanin

A waste management area of a copper zinc mine which is expected to be generating acid exceeding 1000 years is used as a research facility to develop a passive treatment approach to decommissioning the site. One of the processes proposed to be implemented in a lake with a one million cubic metre volume is biological polishing. To determine the expected performance of the process, model is constructed from experimental data collected in the lake. The model results and the field data represent a weak fit, but the discrepancies are useful indicators of key factors affecting the process, such as iron cycling.

Jan 1, 1995

By Robert H. Scott

Developments during the past few years have brought coal-based composite fuels to commercial readiness. During the next few years, composite fuels will become available from a number of suppliers. Potential users must evaluate the combustion properties of these fuels to determine equipment and operating changes required for their use. Most work to date has been done with boiler applications. However, many potential non-boiler applications exist in the metals and minerals industry. These applications require specific evaluations appropriate for the processes involved.

Jan 1, 1982

By S. S. Klima, D. E. Pollock, J. A. Organiscak

"Airborne respirable coal dust capture by water sprays or wet scrubbers has been studied and developed over many decades as an engineering control to reduce dust exposure in coal mines and combat coal worker pneumoconiosis. Empirical relationships and deterministic models for particular dust capture experiments have previously been devised to show the key parameters involved in airborne coal dust capture. Many of the results from these models show that the significant parameters related to airborne dust capture are water spray pressure, water quantity, water droplet size, relative water droplet-to-dust particle velocity, and total operating air pressure of the scrubber. However, many airborne dust capture efficiency relationships and models developed for particular experiments cannot be readily applied to forecast the dust collection efficiency of different spray and scrubber design configurations, which rely on several key dimensional engineering measures. This study examines engineering measures from previous water spray and wet scrubber experiments conducted by the U.S. National Institute for Occupational Safety and Health (NIOSH) and the U.S. Bureau of Mines (USBM) to develop empirical models for wet collection of airborne dusts. A dimensionless empirical model developed for predicting airborne dust capture efficiency of water sprays and wet scrubbers is presented. IntroductionWater sprays have been one of the earliest mainstay engineering controls used to suppress respirable dust in underground coal mines. Some of the earliest reports of water spray usage on continuous mining machines indicated respirable coal mine dust reductions of 20 to 60 percent (Kobrick, 1970). Not long after the enactment of the 1969 Coal Mine Health and Safety Act, the U.S. Bureau of Mines (USBM) and others conducted extensive research into water spray and wet scrubber systems to control respirable dust in coal mines. The primary aspects of water spray dust control included prewetting for dust prevention, localized ventilation redirection and airborne dust capture, which are summarized in handbooks or best-practices guides (Kost, Yingling and Mondics, 1981; Kissell, 2003; Colinet et al., 2010). Initially, underground studies were conducted to identify the primary sources of dust during the mining processes and effective dust controls (Courtney, Jayaraman and Behum, 1978; Jankowski and Organiscak, 1983). Laboratory research systematically studied ventilation and airborne dust capture effects of water sprays and scrubbers to improve their application in underground coal mines (Tomb, Emmerling and Kellner, 1972; Divers and Janosik, 1978, 1980; Grigal et al., 1982; Ruggieri et al., 1983; Jayaraman, Jankowski and Kissell, 1985; Volkwein, Ruggieri et al., 1985; Jayaraman, Schroeder and Kissell, 1986; Divers, Jankowski and Kelly, 1987; Jones and James, 1987)."

Jan 10, 2018

By Robert A. Westman

The INRED process has been developed step by step by Boliden since 1972 at MEFOS, the Foundation for Metallurgical Research, at Lulea in Sweden. The demonstration - plant is number five in this series. The purpose of this plant, which has a nominal capacity of 60,000 tonnes per year of hot metal is to: 1) prove the process on a sufficiently large scale to provide the basis for construction of production plants, 2) test various kinds of raw materials on behalf of licensees, 3) train operators of the first production plant, 4) develop the process further for special applications.

Jan 1, 1983

By M. A. Berdine, C. N. Thompson, D. Brock

The raise bore method of shaft construction has been success-fully used in the mining and construction industries for over thirty years. In the mid 1990’s, Twentymile Coal Company (“TCC”), now affiliated with RAG American Coal Company, used this method for a moderately deep small diameter shaft and the raise bore and slash method for a shallow larger diameter shaft. In late 2001, TCC contracted to raise bore a 431-meter deep, 6.2-meter diameter shaft. During the raise bore and shaft lining processes, regional horizontal stress fields resulted in extensive elliptical caving beyond the original design diameter. This paper discusses the engineering approaches and procedures used to safely complete construction of the raise bore shaft.

Jan 1, 2004

By P-M. Dupond, S. Lowrie, C. Tauziéde, Z. Pokryszka, A. D. Jones

A physical model has been developed to simulate the flows and mixing of gases in the waste of a longwall retreat coalface. The model is used in conjunction with computational modelling, and the distributions of permeability and gas emission in the model waste follow those in computer simulations (Pokryszka et al 1996). The physical model represents at 1170th scale a 200 m long, 3 m high coalface with a waste extending up to 280 m to the face start line. The model is tilted to the same seam slopes as the real face, e.g. 22° ascensional ventilation along the face and 7" slope to the dip. The purpose is to investigate the flow of three components: ventilation seepage flow through the waste; methane; and nitrogen injected to quell spontaneous combustion. A heavier-than-air surrogate gas (SF,) is used in place of methane, and therefore the model is inverted so that gas layers form along the 'roof". The main forces driving the flows in the waste (pressure gradients due to ventilation and the density difference of gas layers) are kept in proportion by appropriate scaling of the permeability. Calibration and validation used data from a coalface at a mine in the Lorraine coalfield. The model is now in operational use.

Jan 1, 1997

By M. L. Harris, I. Zlochower, M. J. Sapko, I. E. Perera

Experiments conducted with limestone dusts and dolomitic marble dusts have indicated that when rock dust is wetted and subsequently dried, it becomes a solid, non-dispersible cake. However, in order to be effective, rock dust must be able to disperse as individual particles to inert. To counteract this, rock dust manufacturers created treated rock dusts that will resist caking after moisture exposure. National Institute for Occupational Safety and Health (NIOSH) researchers conducted a series of laboratory-scale experiments on four base rock dusts and their treated counterparts to assess the effectiveness of various anti-caking additives after being exposed to moisture and then dried. The dusts were exposed to moisture using humidity cabinets having a high relative humidity (99% RH) and by also exposing the rock dust bed to water through bottom wicking. The dusts were then evaluated for dispersibility after drying using the NIOSH-designed dust dispersion chamber. The anticaking additives were different concentrations of stearic acid, oleic acid, and xylene-based surfactants. All results were compared to a reference rock dust used to conduct large-scale experiments in the Lake Lynn Laboratory (LLL), Fairchance, PA. When the untreated dusts were dried after exposure to moisture for one day, no dispersion was measured. However, rock dusts treated with anti-caking agents were readily dispersible even after exposure to moisture for six months. This report details the analysis and characterization of anti-caking additives using the NIOSH-designed dispersion chamber and the 20-L explosion test chamber. INTRODUCTION In order for a coal dust explosion to propagate, five elements are required. In addition to the fire triangle in which three elements are necessary to sustain a fire—fuel (coal dust), heat (ignition source), and an oxidizer (oxygen in air)—a combustible dust explosion requires dispersion of a dust cloud (pressure wave) and confinement of a dust cloud (underground mine entry) (1). Coal dust explosions can originate anywhere in a mine. For example, when a small volume of a flammable methane and air mixture is ignited in a closed end, the high-temperature gases rapidly expand to create a pressure wave, sometimes referred to as a “pioneer wave,” that may steepen into a shock wave as it propagates away from the ignition source. The shock wave produces a wind that disperses the dust preferentially from any elevated and exposed surfaces (roof, ribs, belt structure, cribbing, etc.). Factors that are known to affect the intensity of an explosion are the dust particle size, the location of the dust within the entry, the dust dispersibility, and the volatility of the coal dust (1). Particles less than 75 μm (< 200 mesh) in size are most reactive (2). Dusts that are located on the roof, ribs, and elevated surfaces are more readily dispersed than dusts on the floor. Therefore, application of quality rock dust in sufficient quantities is essential to inert coal dust and to prevent continued flame propagation. 30 CFR 75.402 and 75.403 require 80% total incombustible content be maintained within 40 ft of the face, and 30 CFR 75.2 defines rock dust acceptable for use in underground coal mines. It also defined that “when rock dust is wetted and dried, will not form a cake”.

Jan 1, 2019

A Mark IV surface force apparatus (SFA) was used to conduct direct force measurements between mica surfaces in dodecylamine hydrogen chloride collector solutions at varying pH levels. It was found that long-range hydrophobic forces reach a maximum at pH 9.5, which also corresponds to the maxima attained by the contact angle and flotation recovery of quartz. The charge densities are comparable on both mica and quartz surfaces (0.40 to 0.48 nm2), making it possible to draw conclusions on the flotation of quartz from the direct force measurements conducted on mica. Therefore, it may be suggested that, in the pH range of 8.0 to 10.3, the maximum flotation recovery of quartz may be attributed to the appearance of a long-range hydrophobic force, which, in turn, can be related to the formation of a close-packed monolayer (or hemimicelle) in the presence of neutral amines formed as a result of hydrolysis.

Jan 1, 1998

By A. Iordanidis

Mining activities have recently been taken place in Vourinos mountain, northern Greece, exploiting the so-called ?olivinite?. A representative sample was collected from this mining area. Mineralogical analysis was conducted using X-Ray powder Diffraction (XRD). A thin section was prepared and analyzed under optical microscope. X-Ray Fluorescence (XRF) was employed for the chemical analyses of major, mi-nor and trace elements. Environmental Scanning Electron Microscopy coupled with energy dispersive x-ray analysis system (ESEM-EDX) was also applied for the characterization of the sample. Forsterite (Mg-rich olivine) and enstatite (Mg-rich orthopyroxene) were the main mineral phases determined by XRD, with a 56% and 44% content respectively. Trace amounts of chromite spinels were also determined. Based on this characterization, the industrial rock proved to be a hartzburgite (a type of peridotite in petrological terms). Optical microscopy and ESEM-EDX provided similar observations and confirmed the above-mentioned results. XRF revealed a composition of 43.31 MgO, 44.25 SiO2, 9.98 Fe2O3, 1.40 CaO, 0.67 Al2O3, 0.22 MnO, 0.01 TiO2 and negligible amount of LOI (<0.1%). Trace elements with high concentrations were Cr (2678 ppm) and Ni (2044 ppm). The comprehensive characterization of this mining product suggested the suitability for various uses, such as refractories, foundry and slag conditioner. Additional experiments are being carried out for environmental applications, e.g. wastewater treatment.

Jan 1, 2006

By Janusz S. Laskowski

Studies carried out over the last 10 years reveal that precipitating particles which may appear in alkaline solutions of long-chain amines and in acidic solutions of fatty acids exhibit clear isoelectric points around pH 10.6-1 1 for dodecylamine and around pH 2.5-3 for fatty acids. These colloidal species can accumulate at solid/liquid and liquid/gas interfaces and affect flotation. While the precipitate in solutions of fatty acids apparently can chemically interact with the mineral surfaces and is flotation-active if sufficiently long conditioning time is available, the cationic flotation of quartz in alkaline solutions is depressed by the colloidal precipitate. The experimental data available in literature on the adsorption, electrokinetic, contact angle and surface forces measurements in the solutions of the weak electrolyte collectors are analyzed and the role played by the precipitate is discussed. It is shown that these concepts allow for an explanation of the selective flotation of sylvite from halite with long-chain amines in potash ore flotation.

Jan 1, 1999

By Chris A. Minnucci

In 1978, the U.S. Department of Energy funded a 2-year study to identify and quantify causes of the post-1969 coal mine productivity decline. A large number of factors hypothesized to have affected productivity during this period were analyzed using regression techniques. The results were particularly interesting for two of the factors--mining method and shift scheduling. The study results indicate that the use of longwall mining has an insignificant impact on overall mine productivity, compared to other methods, and mines operating on a two-production shift per day schedule are more productive than mines employing other shift schedules.

Jan 1, 1984

By J. E. Moyle

Introduction In October 1983, Rio Algom Ltd. decided to develop the East Kemptville tin deposit. This decision was the result of intensive geological and metallurgical evaluation work, as well as careful studies of environmental and marketing aspects. The property is located about 54 km (34 miles) northeast of Yarmouth, Nova Scotia, near the village of East Kemptville. Geology The geological setting is a granitic intrusive at the contact with metasediment. The tin mineralization is in the form of cassiterite (SnO2), which is about 80% tin. Sulfides are associated with the deposit containing silver, copper, and zinc, which are recoverable as byproducts. The mineralization is associated with quartz veins and greisen alteration. In the center of the deposit, the zones are so close together they have the appearance of a massive or porphyry type deposit. Ore Reserves The mine plan is based on 56 Mt (62 million st) at 0.165% tin. Up to the ninth year, mill feed will average about 0.2% and lower grade material will be stockpiled. In later years, the average grade will be 0.16% tin. A 0.08% cutoff grade is planned for the entire 17 years of production. East Kemptville is a relatively low grade tin deposit, and only a combination of favorable circumstances has made it economic. • The ore body is situated at, or very close to the surface, permitting mining by open-pit methods at a very low stripping ratio. • The tin occurs in relatively large crystals that allow for good recovery by gravity techniques. • It is ideally located in a well-settled area, with all essential infrastructural requirements already in place. • The positive and cooperative response from various governmental agencies involved are encouraging. Mine Plan The mine plan incorporates an initial pit, followed by three expansions to the ultimate pit. Mining will be at 14 kt/d (15,000 stpd) and will include 9 kt (10,000 st) of ore plus 5 kt (5,500 st) of waste and low grade. After five years, the mining rate will increase to 21 kt/d (27,500 stpd). It is planned to drill vertical 165-mm (6.5-in.) blast holes on a 6-x 6-m (20- x 20-ft) pattern. Bulk slurry explosives will be used to break the rock. Loading will be with hydraulic shovels into 70 t (77 st) haulage trucks. The trucks will deliver the ore to a 13 x 20 m (42 x 65 ft) gyratory crusher, where it will be crushed to 150 mm (6 in.). Secondary and tertiary cone crushers will be used to further crush the ore to 13 mm (0.5 in.). Process Design Tin extraction technology is practically unknown in North America, but Rio Tinto Zinc, which has a 53% ownership in Rio Algom, is involved in tin production in the UK. Rio Algom has used this experience and expertise in metallurgical evaluation work and in tin-related aspects of plant design. Mineralogical and metallurgical test work have been performed, both on laboratory and pilot plant scales. Mineralogical work was done largely in the UK, the laboratory test program was carried out at the Lakefield research facility in Ontario, and pilot plant work was conducted in Australia. This program has resulted in significant improvements in recovery and concentrate grades, over best projections that could be made before this work was carried out. Concentrating Process The concentrator is being designed to process about 9 kt/d (10,000 stpd). The first step is to reduce the size of the ore to -700 µm (-24 mesh) in a rod mill/ball mill grinding circuit. The ball mill will operate in closed circuit with high capacity banana-type screens. The screened product will be deslimed to 30 µm (560 mesh) with cyclones, then passed over the pri-

Jan 4, 1984

By Joyce A. Ober

Minerals for electronic and optical uses divide easily into two sections: 1) quartz and 2) minerals other than quartz. QUARTZ The properties of quartz crystal that make it useful for radio communications were discovered in 1918. Since that time, an in¬dustry for the mining and processing of natural quartz crystal has grown, matured, and been almost entirely replaced by new tech¬nology. The new technology still involves quartz crystal, but ma¬terial that is grown rather than mined. An economic summary of the commercial growing of quartz crystals has a place in a handbook directed to the mineral engi¬neering industry because quartz crystals have long been an impor¬tant commercial mineral, and the raw material for cultured quartz - ¬that is to say, quartz crystals grown through the ingenuity of man - is still natural quartz. Nearly all the natural crystals that have been used for elec¬tronics and optics came from Brazil. The larger pieces which met rigorous standards of quality were used for electronic and, to a lesser extent, optical components. Smaller pieces and fragments were used for vitreous silica. The need for high quality material in quantity led to US government sponsored research and exploration programs in the 1940s. No deposits meeting the very rigid requirements for electronic-grade quartz were found, but other projects resulted in the development of a process for the factory growth of beautiful crystals of prescribed shape, size, and quality. Domestic deposits of appropriate quality were identified to use as raw materials for the quartz culturing process. The development of the cultured quartz crystal illustrates the success that technology can have in adapting a product of the mine to increasingly sophisticated uses. A remarkable achievement per¬haps, but foreshadowed by experiments by Giorgio Spezia (1908), an Italian geologist studying the relative effects of temperature and alkaline environment on the solubility of quartz. Modem radio equipment is most often controlled as to fre¬quency by the presence in the circuit of a separately added crystal¬ - the 1918 discovery responsible for the existence and growth of the quartz industry. The crystal is quartz, but this component is a carefully oriented and prepared slice from a crystal, but not a crystal as recognized by a rock hound or seen in a museum. How quartz operates to control frequencies is not a proper subject for a handbook on industrial minerals, and references should be consulted (Cady, 1964, Mason, 1964). Quartz belongs to a class of materials called dielectrics: those that do not conduct an electric current but permit electric fields to exist and act across them. Quartz shows the piezoelectric effect, which means that when a quartz plate is mechanically deformed against its natural stiffness, one of its surfaces becomes negatively charged, the other positively charged. When the plate is released quickly from the stress, the charges disappear as the plate regains its original shape, but because of mechanical momentum the plate deforms in the opposite direction (to a lesser amount) and the surfaces correspondingly become charged in the opposite direction. By thinly coating the two surfaces with metal and attaching flexible wires, these charges can be brought into an electronic circuit. If the surfaces are suddenly electrically charged by movement of current through the wires, the converse piezoelectric effect occurs and the plate deforms. Carry the thought further and it is realized that an alternating current flowing through the wires responds to the mechanical oscillation. By controlling the thickness of the plate, its mechanical vibration frequency can be varied through a wide range. One type of quartz plate, the AT-cut, has a precisely defined orientation with respect to the crystallographic axes of the crystal and vibrates on a microscopic scale much as a book would deform when placed flat on a table and the top cover moved parallel back and forth with the hand. At least 17 other orientations have been studied, some of which have preferred uses in various applications (Cady, 1964). The quartz crystal industry is composed of three main segments (excluding fused quartz and quartz used for optical purposes): 1. Natural electronic-grade quartz crystals. Mined quartz suitable for fabrication into piezoelectric units. Zlobik (1981a) esti¬mated the waste to ore ratio at 1:1000 to 1000 000, depending upon the deposit. 2. Lasca. Mined quartz usable as feedstock in the production of cultured quartz. Approximately 0.63 kg of lasca are required to produce 0.45 kg of cultured quartz. 3. Cultured quartz. Cultured quartz is produced from lasca feed¬stock in a process of crystal growth in an autoclave under conditions of heat, pressure, and time. It is estimated that 0.45 kg of cultured quartz is equivalent to 1.4 to 4.5 kg of natural quartz crystal in yield of commercial quartz suitable for slicing into piezoelectric units. The chronology of the development of the quartz crystal industry both natural and cultured follows: Date Comment 1918 Discovery of the piezoelectric effects of quartz crystal 1921 Application of the piezoelectric effects of quartz crystal in the circuitry of radios 1948 Establishment of a quartz crystal commodity stockpile by the US Government 1952 US consumption of natural quartz crystal at an all time high of 228 t 1958 First commercial production of cultured quartz crystal 1970 Cultured quartz crystal production exceeds imports of nat¬ural quartz crystal 1971 Cultured quartz crystal consumption surpasses natural quartz crystal consumption

Jan 1, 1994