EPA-600/2-77-023t
February 1977
Environmental Protection Technology Series
INDUSTRIAL PROCESS PROFILES FOR
ENVIRONMENTAL USE: Chapter 20.
The Mica Industry
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and application of
environmental technology. Elimfnation of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-77-023t
February 1977
INDUSTRIAL PROCESS PROFILES
FOR ENVIRONMENTAL USE
CHAPTER 20
THE MICA INDUSTRY
by
J.T. Reding, K. E. Bishop, P.E. Muehlberg
and B. P. Shepherd
Dow Chemical
Freeport, Texas 77541
Terry Parsons and Glynda E. Wilkins
Radian Corporation
Austin, Texas 78766
Contract No. 68-02-1319
Project Officer
Alfred B. Craig
Metals and Inorganic Chemicals Branch
Industrial Environmental Research Laboratory
Cincinnati, Ohio 45268
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
This report has been reviewed by the Industrial Environmental Research
Laboratory - Cincinnati, U.S. Environmental Protection Agency, and approved
for publication. Approval does not signify that the contents necessarily
reflect the views and policies of the U.S. Environmental Protection Agency,
nor does mention of trade names or commercial products constitute endorsement
or recommendation for use.
ii
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TABLE OF CONTENTS
CHAPTER 20
Page
INDUSTRY DESCRIPTION 1
Raw Materials . 2
Products 2
Companies 3
Environmental Impact 5
Bibliography 6
INDUSTRY ANALYSIS 7
Mica Production 9
Process No. 1. Wet Mining 11
Process No. 2. Dry Mining 13
Process No. 3. Crushing/Screening 15
Process No. 4. Humphreys Spiral 17
Process No. 5. Drying 19
Process No. 6. Dry Grinding 20
Process No. 7 Wet Grinding 21
Process No. 8 Drying Ground Mica 22
Mica Disc Production 23
Punching 25
Appendix A - Companies and Products 27
m
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LIST OF FIGURES
CHAPTER 20
Figure Page
1 Mica Industry Chemical Tree 8
2 Mica Production Flowsheet 10
3 Mica Disc Production Flowsheet 24
iv
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LIST OF TABLES
CHAPTER 20
Table Page
1 Mica Applications and Consumption During 1973 4
A-l Producers of Crude Flake Mica 28
A-2 Producers of Wet-and Dry-ground Mica 30
A-3 Producers of Mica Discs and Splittings 31
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ACKNOWLEDGEMENTS
This document was prepared for EPA by Dow Chemical, U.S.A., Texas Division,
Freeport, Texas under contract number 68-02-1329, Task 8. The authors
were J. T. Reding, K. E. Bishop, P. E. Muehlberg, and B. P. Shepherd.
Their contributions are gratefully acknowledged.
Helpful review comments from H. E. Hoon, H. Krockta and N. D. Phillips
were received and incorporated in this chapter.
vi
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MICA
INDUSTRY DESCRIPTION
Mica is a group name for a number of complex hydrous potassium-
aluminum silicate minerals having similar physical properties. Mica
minerals are characterized by excellent basal cleavage and by a high
degree of flexibility, elasticity, and toughness of extremely thin
cleavage flakes.
The mica industry has been divided into two segments for consider-
ation. The largest segment, Mica Production, consists of open-pit
mining of mica ore minerals, beneficiating of the mineral ore, and
grinding of the mica to desired sizes. Another segment is the Mica
Disc Production Segment which processes imported sheet mica.
Domestically mined mica ore yields "flake or scrap" mica while nearly
all "sheet" mica is imported. Sheet mica must be relatively flat, free ?
from most defects, and large enough to be cut into pieces at least 4.8 cm.
Industry processes are shown on Figures 2 and 3. Processing of
flake mica begins with wet or dry mining of mica ore. The ore is then
crushed and the mica is separated from gangue by screening or by passing
through a Humphreys spiral. The resulting flake mica is then dried. A
portion is marketed as flake mica, but the majority is either dry-ground
(~85 percent) or wet-ground (~15 percent). Wet-grinding produces a
finer, more valuable product than dry-grinding. Scrap mica from various
other sources is also ground with mined scrap mica. The wet-ground mica
is then dried before bagging. Processing of imported "sheet mica" pri-
marily involves punching of it to form mica discs.
In 1975, 27 companies mined mica ore at 34 locations. Twenty-three
companies operated a total of 28 plants which ground scrap and flake mica.
Sheet mica was processed by 12 companies. It is estimated that 450 people
were employed in the industry.
In 1973 the total domestic production of scrap and flake mica was
161,000 metric tons with a value of approximately $6,100,000. Production
of ground mica was 123,000 metric tons, and its value was $9,400,000.
Imports included 531 metric tons of uncut sheet mica valued at $1,270,000,
2,170 metric tons of manufactured mica valued at $4,325,000, and 2,300
metric tons of scrap valued at $116,000.
In 1973, North Carolina accounted for 60 percent of flake and scrap
mica production. The remaining output of scrap and flake mica comes
from Alabama, Arizona, Connecticut, Georgia, New Mexico, and South Caro-
lina. In 1975, mica was being mined in the additional states of Califor-
nia, Colorado, Massachusetts, South Dakota, and Texas.
Most mining operations for mica are located in low population density
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areas such as the western part of North Carolina. Grinding plants are
located near mines.
Scrap and flake mica production increased from 121,000 metric tons
in 1969 to 161,000 metric tons in 1973 and then decreased back to 121,000
metric tons in 1974. Despite the lower production in 1974 which was due
to low consumption by the building industries, the demand is expected to
grow at an annual rate of 3.7 ± 1 percent. At that rate demand will be
between 500,000 metric tons and 1,000,000 metric tons by the year 2000.
It is unlikely that future domestic production of sheet mica will be
significant. Sheet mica is imported primarily from India, Brazil, and
the Malagasy Republic where low manual labor costs make its production
economical.
No information is available concerning on-site power or steam gener-
ation in the mica industry.
Raw Materials
Mica is chiefly composed of hydrous potassium-aluminum silicate
compounds. Muscovite, "potassium mica", has the general formula K2Ali»
(Al2Si602o)(OHK. This is the variety of mica that is produced in the
United States. Another variety produced only outside the U.S. is "mag-
nesium mica", with the general formula K2(Mg Fe++)6AL2Sie02Fit(OH)it.
Flake or scrap mica is mined from pegmatites, granite, and mica-
rich metamorphic rocks. Scrap is also a by-product of mining sheet mica
(insignificant in the U.S.), trimming sheet mica, and fabricating sheet
mica. It can also be recovered from schists or from the beneficiation
of feldspar and kaolin.
The content of recoverable mica from presently mined deposits ranges
from 3 to 20 percent. Ore requirements for producing the 161,000 metric
tons of flake mica in 1973 are estimated to have been approximately
2,000,000 tons.
The disposal of solid wastes from open-pit mining and ore beneficia-
tion is a problem. Since recoverable mica content of mined ore varies
from 3 to 20 percent,9 the disposal of large quantities of gangue is
necessary. Craters left from open-pit mining are a second environmental
problem. Mica ores are non-toxic and do not create an environmental
hazard in themselves.
Products
Ground mica comprised approximately 80 percent of the scrap-and
flake-mica production in 1973. The other 20 percent was accounted for
by losses in grinding plus marketing of flake mica for use in reconsti-
tuted mica. Dry-ground mica accounted for 88 percent of total ground
aSchist ore contains up to 90 percent mica, but it is not certain that
these deposits are being mined.
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mica sales. It is used principally in joint cement, paint, rolled roofing,
and asphalt shingles. Wet-ground mica is used chiefly in wallpaper, rubber
goods, and paint. Final uses of ground mica in 1973 are listed in Table 1.
Sheet mica is used as a di-electric and insulating material in electronic
and electrical equipment, in shields for high-temperature steam-gage glasses,
and as regulator diaphragms. Replacements for sheet mica such as reconstituted
and glass-bonded mica, organic polymers, synthetic mica, alumina ceramics,
fused quartz, and talc are predicted to decrease and possibly eliminate the
need for it by the year 2000. In 1970, production of sheet mica did not occur
in the United States for the first time in over 100 years. Since then, very
small amounts of low quality sheet mica have been produced. Imports of all
forms of sheet mica in 1973 were 2,700 metric tons.
Companies
Companies operating in the mica industry are generally rather small
organizations whose primary business is processing of mica. Production is
spread among a large number of companies with no single firm dominating.
Twenty-seven companies operating 34 mines were producing crude flake
mica in 1975. These companies and the mine locations are listed in Appendix
A. The following companies account for approximately 80 percent of the
total production:
Buckeye Mica Company
Deneen Mica Company
The Feldspar Corporation
Franklin Mineral Products Company
Harris Mining Company
Jones Mining Company, Inc.
Kings Mountain Mica Company, Inc.
Mineral Industrial Commodities of America, Inc.
Mineral Mining Corporation
Thompson-Weinman and Company
Western Mica Company
Twenty-three companies operating 28 plants were grinding flake and scrap
mica in 1975. These companies and plant locations are listed in Appendix A.
The following companies account for approximately 75 percent of the total
wet-and dry-ground mica production:
Asheville Mica Company
Deneen Mica Company
Diamond Mica Company
Franklin Mineral Products Company
General Electric Company
Harris Mining Company
Kings Mountain Mica Company, Inc.
Micalith Mining Company, Inc.
U. S. Gypsum Company
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Table 1. MICA APPLICATION AND CONSUMPTION DURING 1973
Application
Quantity Consumed
103 Metric Tons
u
O«r
'
en -o
1 §
o o
Q S-
O)
(11
_c
co
(O
"O O
O) !-
s_
o
CL
i i
Joint Cement
Paint
Roofing
Rubber
Wallpaper
Plastics
Other
Total
Vacuum Tubes
Other
Film Mica
Built-up Mica
(from splittings)
46.5
34.0
19.6
5.2
0.4
0.4
16.4
T22TF
0.4
0.2
0.005
2.1
38
28
16
4
0.3
0.3
13
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Twelve companies operating 12 fabricating plants were punching sheet
mica splittings into discs in 1975. These companies along with plant
locations are listed in Appendix A. The following companies account for
approximately 90 percent of the total production:
American Mica Insulation Company
Asheville Mica Company
Cleveland Mica Company
Industrial Mica Company
Micacraft Products, Inc.
Mica Fabricating Company
New England Mica Company, Inc.
Spruce Pine Mica Company, Inc.
The Tar Heel Mica Company, Inc.
Victory Mica Manufacturing Company, Inc.
Environmental Impact
Dust from mining, grinding and screening is a source of emissions
No quantitative information is available. A more pressing problem is
disposal of gangue materials from ore oeneficiation and overourden from
mining. Another problem is craters formed by unused or abandoned open-
pit mines. Gangue materials and dust are non-toxic.
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BIBLIOGRAPHY
Lesure, F. 6. Mica. In: United States Mineral Resources Geological
Survey Professional Paper 820, U. S. Department of the Interior. Brobst,
D. A., and W. P. Pratt (ed.). Washington, D. C., U. S. Government Printing
Office, 1973. p. 415-422.
Montague, S. A. Mica. In: Industrial Minerals and Rocks, 3rd
Edition. Gillson, J. L. (ed.). New York, The American Institute of
Mining, Metallurgical, and Petroleum Engineers, 1960. p. 551-566.
Petkof, B. Mica. In: Mineral Facts and Problems, Bureau of Mines
Bulletin 650, U. S. Department of the Interior. Washington, D. C., U. S.
Government Printing Office, 1970. p. 1083-1098.
Petkof, B. Mica. Preprint from: Minerals Yearbook, Volume I,
Bureau of Mines, U. S. Department of the Interior. Washington, D. C.,
U. S. Government Printing Office, 1973. p. 1-9.
Shell, H. R. Mica. In: Kirk-Othmer Encyclopedia of Chemical
Technology. Standen, A. (ed.). New York, John Wiley and Sons, Inc.,
1967. p. 412-415.
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INDUSTRY ANALYSIS
The mica industry is relatively small by most standards. Data from
the literature are often incomplete and scanty. For example, very little
information on dust emissions is available. Data given on waste streams
are estimates.
Often an estimated range of inputs, utilities, or waste streams is
given rather than a single value. This was done because the values de-
pend upon the concentration of mica in the ore; the size of mining,
beneficiating, and grinding equipment, and other factors. Data were taken
from sources which are considered to be reliable, up-to-date, and accurate.
The chemical tree of Figure 1 gives a qualitative overview of the
mica industry from a raw material-product-use standpoint. The four major
domestic products are dry-ground mica, wet-ground mica, flake mica, and
mica discs.
Flowsheets for both segments of the mica industry are included.
Figure 2 represents the Mica Production Segment, and Figure 3 represents
the Mica Disc Production Segment. The interior of each of the rectangular
"process blocks" appearing on the flowsheet represents at least one of the
sequential, real processes of the mica industry. A number and title have
been placed within each of the process blocks. These identifying symbols
are used in the process descriptions later in this report.
The flowsheet of Figure 2 shows the processes used in the mica indus-
try. The interior of each of the rectangular "process blocks" appearing
on the flowsheet represents at least one of the sequential, real processes
of the mica industry. A number and title have been placed within each of
the process blocks. These identifying symbols are used in the process
descriptions later in this report.
Flag symbols at the upper right-hand corner of the process block
indicate the nature of the waste streams, if any, discharged from the
process. A circle is used for atmospheric emissions, a triangle for
liquid wastes, and a rhombus for solid waste. The flags do not differen-
tiate between inadvertent (fugitive) and designed wastes.
A verbal process description has been written to characterize each
process further; to relate it to other processes and quantify its operating
parameters.
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Raw Materials
End Products
Uses
Mica-bearing
pegmatite,
kaolin or schist
Dry-ground mica-
Wet- ground mica-
Flake mica
Oil well drilling mud
Welding rods
Asphalt shingles
Joint cement
Rolled roofing
Rubber goods
Plastics
Paint
Wallpaper
Paint
Rubber goods
-» Reconstituted mica
(paper)
Sheet mica
(imported)
-* Mica discs
Insulation
Vacuum tubes
Capacitors
Heaters
Figure 1. MICA INDUSTRY CHEMICAL TREE
8
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MICA PRODUCTION
The operations of the Mica Production Segment are defined by eight process
descriptions: Wet Mining, Dry Mining, Crushing/Screening, Humphreys Spiral,
Drying, Dry Grinding, Wet Grinding, Drying Ground Mica. In these operation
steps flake mica is produced from ore deposits of mica.
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HtO
Wet mining
Dry mining
Fig. 3
Crushing/
screening 3
H20
Humphrey's
spiral
Dry grinding
Figure 2. MICA PRODUCTION FLOWSHEET
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MICA PRODUCTION PROCESS NO. 1
WET MINING
1. Function
This process (see Figure 2) removes the mica ore from open-pit mines.
Water from high-pressure hydraulic nozzles breaks up the ore which
then flows in suspension to a collection sump. The slurry is trans-
ported or pumped to the beneficiation plant, Process 3 or 4.
2. Input Materials
2 to 30 metric tons ore per metric ton ground mica product
3. Operating Parameters
. Ore veins - 1 to 40 meters in thickness
. Recoverable mica content - 3 to 90 percent
. Water pressure ^7 kg per cm2 -
. Typical water flow rate - 3 to 15m per minute
Equipment for overburden removal is assumed to be similar
to that used in road building and earth moving.
4. Utilities
. Electrical energy - 12 to 18 kWh per metric ton ground mica
product
. Water usage - 7 to 12 metric tons per metric ton ground mica
product
5. Waste Streams
. 7 to 12 metric tons runoff water per metric ton ground mica
product
6. EPA Source Classification Code
None
7. References
Lesure, F. G. Mica. In: U. S. Mineral Resources Geological Survey
Professional Paper 820, U. S. Dept. of the Interior. Brobst, D. A.,
and W. P. Pratt (eds.). "Washington, D. C., U. S. Government Printing
Office, 1973. p. 415-422.
Petkof, B. Mica. In: Mineral Facts and Problems, Bureau of Mines
11
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Bulletin 650, U. S. Department of the Interior. Washington, D. C.,
U. S. Government Printing Office, 1970. p. 1083 - 1098.
12
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MICA PRODUCTION PROCESS NO. 2
DRY MINING
1. Function
This process (see Figure 2) removes mica ore from open-pit mines to
the beneficiation plant, Process 3 or 4.
Heavy equipment (bulldozers and dredglines) is used to remove over-
burden. Power shovels, trucks, and bulldozers remove and transport
the ore to beneficiating, Process 3 or 4.
2- Input Materials
. 2 to 30 metric tons mica ore per metric ton ground mica product
3. Operating Parameters
. Ore veins 1 to 40 meters in thickness.
. Recoverable mica content 3 to 90 percent.
. Equipment is similar to that used for roadbuilding and earthmoving.
4. Utilities
. Fuel for vehicles - approximately 6000 kcal per metric ton ground
mica product.
5. Waste Streams
. Dust emissions of unknown amount are released to the air.
. Overburden quantity varies over a wide range.
6. EPA Source Classification Code
None
7. References
Lesure, F. 6. Mica. In: United States Mineral Resources Geological
Survey Professional Paper 820, U. S. Department of the Interior.
Brobst, D, A. and W. P. Pratt (eds.). Washington, D. C., U. S. Gov-
ernment Printing Office, 1973. p. 415-422.
Petkof, B. Mica. Preprint from: Minerals Yearbook, Volume II,
13
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Bureau of Mines, U. S. Department of the Interior. Washington, D. C.
U. S. Government Printing Office, 1973. 9 p.
Shell, H. R. Mica. In: Kirk-Othmer Encyclopedia of Chemical Tech-
nology. Standen, A. (ed.). New York, Oohn Wiley and Sons, Inc.,
1967. p. 412-415.
14
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MICA PRODUCTION PROCESS NO. 3
CRUSHING/SCREENING
1. Function
This process (see Figure 2) receives mined ore from Process 1 or 2,
crushes the ore, and separates gangue from mica flakes.
The ore is roll-crushed and transported as a slurry to a series of
screens. Gangue materials pass through the screens. Flat mica flakes
are caught on the screens. They are then washed from the screens to
a draining bin before drying, Process 5.
2. Input Materials
. 2 to 30 metric tons of ore per metric ton ground mica product.
3. Operating Parameters
. Typical crusher size -1x2 meter opening. 2
. Ore compressive strength - 420 to 850 kg per cm .
4. Utilities
. Electrical energy - 15 kWh per metric ton ground mica product.
. Wash water - 5 cubic meters per metric ton ground mica product.
5. Waste Streams
. Solid wastes - 1 to 29 metric tons per metric ton ground mica
product
. Liquid wastes - water amounting to 5 cubic meters per metric ton
mica product and containing participates in an amount up to 0.1
metric ton per metric ton ground mica product.
. Dust is emitted to the air from the crushing of the ore. No
quantitative information is available.
6. EPA Source Classification Code
None
7. References
Handbook of Mineral Dressing. Taggart, A. F. (ed.). New York, John
Wiley and Sons, Inc., 1945. p. 4-55 to 4-77.
Petkof, B. Mica. In: Mineral Facts and Problems, Bureau of Mines
15
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Bulletin 650, U. S. Department of the Interior. Washington, D. C.,
U. S. Government Printing Office, 1970. p. 1083 - 1098.
16
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MICA PRODUCTION PROCESS NO 4
HUMPHREYS SPIRAL
1. Function
This process (see Figure 2) crushes, washes, and separates mica from
gangue. It then forwards the mica to drying, Process 5.
Primarily schist ore is crushed, usually in a jaw crusher, before it is
wet-ground in a rod mill. The slurry is then fed to a Humphreys
spiral which separates gangue minerals from the more easily suspended
mica flake. The exiting mica concentrate is screened to eliminate
water plus some remaining fine sand or clay slimes. The purified wet
mica then goes to drying, Process 5.
2. Input Materials
. 2 to 30 metric tons ore per metric ton ground mica product.
3. Operating Parameters
. Typical spiral size - 0.6 meter x 0.6 meter floor space x 2 meters
tall.
. Spiral capacity - 1-1/2 metric tons feed per hour containing 20 to
50 percent solids.
. Mica recovery - 75 percent.
4. Utilities
. Water - 5 to 100 cubic meters per metric ton ground mica product.
. Electrical energy - 15 kWh per metric ton ground mica product.
5. Waste Streams
. Dust is released to the air in the crushing process. No quantita-
tive data are available.
. Wet tailings from the Humphreys spiral and water plus fines from
the final screening are combined. This stream may vary from 5 to
100 cubic meters per metric ton ground mica product and may contain
up to 30 percent solids. It is released to area streams.
6. EPA Source Classification Code
None
17
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References
Adair, R., W. T. McDaniel, and W. R. Hudspeth. Mining Eng. 3;
252-254, March 1951.
Goldberter, W. M. Liquid-Liquid and Solid-Solid System. In: Chemical
Engineers Handbook, 5th Edition. Perry, R. H., and C. H. Chilton
(eds.). New York, McGraw-Hill Book Company, 1973. p. 21-53, 21-54.
Thompson, J. V. The Humphreys Spiral Concentrator. Mining Eng. 10,
p. 84-87, January 1958.
18
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MICA PRODUCTION PROCESS NO. 5
DRYING
1. Function
This process (see Figure 2) drys beneficiated mica from Processes 3
or 4 and forwards dry flake to Process 6 or 7. A screw feeder trans-
ports beneficiated mica to a rotary dryer. The dryer is a long
cylinder mounted at a slight incline. It slowly revolves while the
mica flake and combustion gases pass through. Lifters inside the
dryer help expose the mica to the hot gases. A small portion of the
dry flake is used in the manufacture of reconstituted mica and is not
ground. The remainder is forwarded to grinding.
2. Input Materials
. 1.2 metric ton beneficiated mica flake per metric ton ground mica
product.
3. Operating Parameters
. Dryer cylinder - 1 to 2 meters diameter x 3 to 10 meters long.
. 5 to 12 metric tons wet mica feed per hour
4. Utilities
. Electrical energy - 2 kWh per metric ton ground mica product
. Fuel - 100,000 kcal per metric ton ground mica product.
5. Waste Streams
. Combustion product gases from oil or coal fired dryers are
released to the air. These gases may contain pollutants.
6. EPA Source Classification Code
None
7. References
Handbook of Mineral Dressing. Taggart, A. F. (ed.). New York,
John Wiley and Sons, Inc., 1945. p. 17-08 to 17-12.
19
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MICA PRODUCTION PROCESS NO. 6
DRY GRINDING
1. Function
"-' ' '". "J, ' r.'\ ' ''. . : \ : '
-...- t
This process (see Figure 2) grinds 85 percent of the dry mica flake
from Process 5, screens the ground product, and packages the product.
Buhr Mills, rod mills, high-speed hammer mills, or micronizers grind
dry flake mica. Air separators recycle oversize mica for additional
grinding and discharge fine material to screens. Various fractions
are bagged for marketing.
At present, high-speed hammer mills are most frequently used in dry-
grinding.
2. Input Materials
1.1 metric tons dry flake mica per metric ton ground mica product.
3. Operating Parameters
. 1 to 3 metric tons product per hour with a 50 cm diameter hammer.
4. Utilities
. Electrical energy - 1 to 3 kWh per metric ton ground mica product.
5. Waste Streams
. 0.05 metric ton gangue per metric ton ground mica product.
. An unknown quantity of dust emissions to the air
6. EPA Source Classification Code
None
7. References
'.'>;.:' ? :'' '
Petkof, B. Mica. In: Mineral Facts and Problems, Bureau of Mines
Bulleton 650, U. S. Department of the Interior. Washington, D. C.,
U. S. Government Printing Office, 1970- p. 1083 - 1098.
Shell, H. R. Mica. In: Kirk-Othmer Encyclopedia of Chemical
Technology. Stahden, A. (ed.). New York, John Wiley and Sons, Inc.,
1967. p. 412-415.
20
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MICA PRODUCTION PROCESS NO. 7
VIET GRINDING
1. Functi on
This process (see Figure 2) grinds 15 percent of the dry mica flake
from Process 5 and forwards the ground mica to Process 8.
Dry mica flake is fed into chaser mills which employ wood for grind-
ing surfaces. The mill usually consists of a steel tank, lined with
wooden blocks. Wooden rollers revolve at 15 to 30 rpm. Water and
mica are fed into the mill to form a thick paste. When the mica is
ground to the desired size, the tank contents are drained into settling
bins. Heavy impurities sink. The mica slurry overflows to a settling
tank.
2. Input Materials
. 1.1 metric tons flake mica per metric ton ground mica product.
3- Operating Parameters
. Chaser mills are usually 1 m deep x 3 m diameter with wheels about
75 cm in diameter.
. 5 to 8 hours grinding per batch.
4. Utilities
. Electrical energy - 2 kWh per metric ton ground mica product
. Water - 2 cubic meters per metric ton ground mica product.
5. Waste Streams
. 0.05 metric ton solids per metric ton ground mica product
. 1 metric ton water per metric ton ground mica product is released.
This water may contain up to 2 percent solids.
6. EPA Source Classification Code
None
7. References
Taggart, A. F. (ed.). Handbook of Mineral Dressing. New York, John
Wiley and Sons, Inc., 1945. p. 3-64 to 3-66.
Shell, H. R. Mica. In: Kirk-Othmer Encyclopedia of Chemical Tech-
nology. Standen, A. (ed.). New York, John Wiley and Sons, Inc.,
1967. p. 412-415.
21
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MICA PRODUCTION PROCESS NO. 8
DRYING GROUND MICA
1. Function
This process (see Figure 2) dries wet-ground mica from Process 7,
screens it, and bags it for shipment.
Steam-heated kettles or rotary dryers are used to drive water
from the mica.
2. Input Materials
. 2 metric tons wet-ground mica per metric ton ground mica product.
3. Operating Parameters
. 1 kg water evaporated per 1.5 kg steam used.
. 0.7 kg per cm^ steam pressure.
4. Utilities
. Fuel - 500,000 kcal per metric ton ground mica product.
5. Haste Streams
None
6. EPA Source Classification Code
None
7. References
Handbook of Mineral Dressing. Taggart, A. F. (ed.). New York, John
Wiley and Sons, Inc., 1945. p. 17-10 to 17-12.
Petkof, B. Mica. In: Mineral Facts and Problems, Bureau of Mines
Bulletin 650, U. S. Department of the Interior. Washington, D. C.,
U. S. Government Printing Office, 1970. p. 1083 - 1098.
22
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Mica Disc Production
The Mica Disc Production Segment of the Mica Industry processes a very small
volume of material. Data on processing parameters are meager.
The flowsheet of Figure 3 shows the single punching process of the Mica
Disc Segment. The symbols used in the process block are described in the
Industry Analysis section of this report.
Scrap mica from this process is recycled to the Mica Production Segment
as shown on the flowsheets, Figure 2 and Figure 3.
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Figure 3. MICA DISC SEGMENT FLOWSHEET
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MICA DISC PRODUCTION PROCESS NO.9
PUNCHING
1. Function
This process (see Figure 3) receives primarily imported sheet mica
and punches it into discs of specified shapes and sizes.
Power presses are used to punch discs from imported hand "cobbed"
and "rafted" sheet mica.
2. Input Materials
. 1.2 metric ton sheet mica per metric ton punched discs.
3. Operating Parameters
4. Utilities
. Electrical energy - 50 kWh per metric ton punched discs.
5. Waste Streams
. 0.2 metric tons scrap per metric ton punched discs is used as
feed in the grinding process. (Figure 2, Process 6 or 7).
6. EPA Source Classification Code
None
7. References
Montague, S. A. Mica. In: Industrial Minerals and Rocks. Gillson,
0. L. (ed.). New York, American Institute of Mining, Metallurgical,
and Petroleum Engineers, 1960. p. 551-566.
25
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APPENDIX A
COMPANIES AND PRODUCTS
27
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Table A-l. PRODUCERS OF CRUDE FLAKE MICA
Company
George Bland
Buckeye Mica Co.
Deneen Mica Co.
Deneen Mica Co., Inc.
Drifted Snow 1 and 2
The Feldspar Corp.
The Feldspar Corp.
Sullins Mine
Monticello Mine
Wiseman Mine
Foote Mineral Co.
Franklin Mineral
Products Co.
Gulf Resources
Lithium Corp.of Am.
Harris Mining Co.
Brushy Creek Mine
Gusher Knob Mine
Jarita Mining and
Investment Co.
Russell A. Johnson
Jones Mining Co., Inc.
L. W. Judson
Kings Mtn. Mica Co.
Moss Mine
Patterson Mine
Lawson United Feldspar
Mining Co.
Mineral Industrial
Commodities of
America, Inc.
The Mineral Mining
Corp.
Company Location
Custer, South Dakota
Buckeye, Arizona
Newdale, N. Carolina
Burnsvilie, N. Carolina
Canoga Park, California
Spruce Pine, N. C.
Spruce Pine, N. C.
Spruce Pine, N. C.
Spruce Pine, N. C.
Kings Mountain, N. C.
Wilmington, Maine
Location of Operation
Custer Co., South Dakota
Buckeye Co., Arizona
Yancy Co., N. Carolina
Yancy Co., N. Carolina
Imperial Co., California
Mitchell Co., N. Carolina
Mitchell Co., N. Carolina
Jasper Co., N. Carolina
Mitchell Co., N. Carolina
Cleveland Co., N. C.
Hart Co., Maine
Gastonia, N. Carolina Cleveland Co., N. C.
Spruce Pine, N. C.
Spruce Pine, N. C.
Espanola, New Mexico
Ft. Collins, Colorado
Waleska, Georgia
Hermosa, S. Dakota
Kings Mountain, N. C.
Kings Mountain, N. C.
Spruce Pine, N. C.
Santa Fe, New Mexico
Kershaw, S. Carolina
Avery Co., N. Carolina
Avery Co., N. Carolina
Rio Arriba Co., N. M.
Larimer Co., Colorado
Cherokee Co., Georgia
Pennington Co., S. D.
Cleveland Co., N. C.
Cleveland Co., N. C.
Mitchell Co., N. C.
Taos Co., New Mexico
Lancaster Co., S. C.
(Continued)
28
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Table A-1. (continued). PRODUCERS OF CRUDE FLAKE MICA
Company
Richard O1Laugh!in
Pacer Corporation
Pendleton Mining Co.
San Antonio Mine Co.
Thompson-Weinman & Co.
U.S. Beryllium Corp.
V. B. West
Western Energy Corp.
Rio Arriba Minerals
Western Mica Co.
Div'n of U.S. Gypsum
Kings Mountain Mine
Company Location
Location of Operation
Custer, South Dakota
Custer, South Dakota
Keystone, N. Dakota
Ajo, Arizona
Cartersville, Georgia
Pueblo, Colorado
Amarillo, Texas
Santa Fe, New Mexico
Chicago, Illinois
Chicago, Illinois
Custer Co., South Dakota
Custer Co., South Dakota
Undefined Co., S. Dakota
Pima Company, Arizona
Cherokee Co., Georgia
Chaffee Co., Colorado
Maricopa Co., Arizona
Rio Arriba Co., N. M.
Randolph Co., Alabama
Cleveland Co., N. C.
29
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Table A-2. PRODUCERS OF WET-AND DRY-GROUND MICA
Company
Arrow Mining
Asheville Mica Co.
George Bland
Buckeye Mica Co.
Concord Mica Corp.
Deneen Mica Co.
Diamond Mica Co.
Diamond Mica Co.
Diamond Mica Co.
The English Mica Co.
Franklin Mineral
Products Co.
Franklin Mineral
Products Co.
General Electric Corp.
General Electric Corp.
Harris Mining Co.
Kings Mountain
Mica Co., Inc.
Lawson United Feldspar
and Mineral Co.
Micalith Mining Co.
Mineral Industries
Commodities of
America, Inc.
Mineral Mining Corp.
Pacer Corp.
Thompson-Weinman & Co
U.S. Gypsum Co.
U.S. Gypsum Co.
U.S. Mica Co., Inc.
Western Energy Corp.
Rio Arriba Minerals
J. H. Wood, Jr.
Company Location
Hot Springs, S. Dakota
Newport News, Virginia
Custer, South Dakota
Buckeye, Arizona
Wayland, Maine
Newdale, N. Carolina
Middleton, Cn.
Spruce Pine, N. C.
Spruce Pine, N. C.
Stamford, Cn.
Wilmington, Maine
Wilmington, Maine
Schnectady, New York
Schnectady, New York
Spruce Pine, N. C.
Location of Operation
Fall River Co., S. Dakota
Buncombe Co., N. Carolina
Custer Co., South Dakota
Maricopa Co., Arizona
Merrimack Co., N. Hampshire
Yancy Co., N. Carolina
Middlesex Co., Cn.
Yancy Co., N. Carolina
Mitchell Co., N. C.
Cleveland Co., N. C.
Hart Co., Georgia
Macon Co., Georgia
County - Undefined
Coshocton Co., Ohio
Mitchell Co., N. C.
Kings Mountain, N. C. Cleveland Co., N. C.
Minpro, North Carolina
Phoenix, Arizona
Santa Fe, New Mexico
Kershaw, S. C.
Custer, S. D.
Cartersvilie, Georgia
Chicago, Illinois
Chicago, Illinois
Stamford Conn.
Santa Fe, New Mexico
Huntsville, Alabama
Mitchell Co., N. Carolina
York Co., Pennsylvania
Santa Fe Co., New Mexico
Lancaster Co., S. C.
Brule Co., S. Dakota
Bartow Co, Georgia
Cleburne Co., Alabama
Tarrant Co., Texas
Cook Co., Illinois
Rio Arriba Co., N. M.
Marion Co., Alabama
30
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Table A-3. PRODUCERS OF MICA DISCS AND SPLITTINGS
Company
American Mica Insula-
tion Co.
Asheville Mica Co.
Carpenter & Phillips
Mica Co.
Cleveland Mica Co.
Industrial Mica
Div. of Columbia
Technical Corp.
Micacraft Products,
Inc.
Mica Fabricating Co.
New England Mica Co.,
Inc.
Reliance Mica Co., Inc.
Spruce Pine Mica Co.,
Inc.
The Tar Heel Mica Co.,
Inc.
Victory Mica Mfg. Co.,
Inc.
Company Location
Manasquan, New Jersey
Newport News, Virginia
Spruce Pine, N. C.
Lakewood, Ohio
Location of Operation
Monmouth Co., New Jersey
Newport News Co., Va.
Mitchell Co., N. Carolina
Franklin Co., Ohio
Englewood, New Jersey Bergen Co., New Jersey
Newark, New Jersey
Rochelle Park, N. J.
Needham Heights, Maine
Brooklyn, New York
Spruce Pine, N. C.
Essex Co., New Jersey
Bergen Co., New Jersey
Norfolk Co., Maine
Kings Co., New York
Mitchell Co., N. C.
Plumtree, N. Carolina Avery Co., N. Carolina
Brooklyn, New York
Kings Co., New York
31
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-6oO/2-77-023t
3. RECIPIENT'S ACCESSION>NO.
4. TITLE AND SUBTITLE
Industrial Process Profiles for Environmental Use:
Chapter 20. The Mica Industry
5. REPORT DATE
February 1977
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
J.T.Reding, K.E.Bishop, P.E.Muehlberg & B.P.Shepherd
(Dov Chem.); Terry Parsons & G.E.Wilkins, Editors
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Radian Corporation
8500 Shoal Creek Blvd., P.O. Box 99^8
Austin, Texas 78766
10. PROGRAM ELEMENT NO.
1AB015
11. CONTRACT/GRANT NO.
68-02-1319/Task 3k
12. SPONSORING AGENCY NAME AND ADDRESS
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. ENVIRONMENTAL PROTECTION AGENCY
Cincinnati, Ohio
13. TYP.E OF REPORT AND PERIOD COVERED
Initial: 8/75-11/76
14. SPONSORING AGENCY CODE
EPA/600/12
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The catalog of Industrial Process Profiles for Environmental Use was developed as
an aid in defining the environmental impacts of industrial activity in the United
States. Entries for each industry are in consistent format and form separate
chapters of the study. Mica is a group name for a number of complex hydrous
potassium-aluminum silicate minerals characterized by excellent cleavage and by
a high degree of flexibility, elasticity, and toughness of extremely thin cleavage
flakes. The Mica industry has been divided into two segments for consideration:
(l) Mica Production and (2) Mica Disc Production. One chemical tree, two process
flow sheets and nine process descriptions have been prepared to characterize the
industry. Within each process description available data have been presented on
input materials, operating parameters, utility requirements and waste streams. Data
related to the subject matter, including company, product and raw material data, are
included as appendices.
)7. KEY WORDS AND DOCUMENT ANALYSIS
a. DESCRIPTORS
Pollution
Industrial Processes
Chemical Engineering
Mica
13. DISTRIBUTION STATEMENT
Release to Public
b. IDENTIFIERS/OPEN ENDED TERMS
Process Assessment
Environmental Impact
19. SECURITY CLASS (This Report)
Unclassified
20. SECURITY CLASS IFhispaxe)
Unclassified
c. COSATl Field/Croup
13B
13H
07A
08G
2V NO. OF PACKS
"}R
iJ\J
22. PRICE
EPA Form 2220-1 (9-73)
32
*USGPO: 1978 757-086/0807
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