"^0^ -'U.r^ MQf •' ^^ ^•^°- 'bv" .^*^°- • ^^"^ "- •••• »<" %■'■" / ... V'"''"*^' . % ■•■'■• *=• 0" .0 ^ .■^ • ^'?- '^^ <^ *1 ^^•^.^ '« -n^o^ . "•, ^^0^ \>^^ -^ "^ ■t^° "^. '-»To' ,-e,'«- "o. '*rri*' -^o•' <*:^ '*::'^o* ^'?- >^" - . . . '"^^^ ' " " " ' -N* . . „ ^-^^ — .f cv. * " "- /.*i-;^'-V ./..i^>>o ..**\c:^,\ /•"-•••-■ '^^ bv .'j^ii^::^'-. -^^o^ o'^^^ia'- '>-ov*' y^M^>^\ ^f^rS 'bv v-o^ ♦^•v. t* '>V, '^..*" •• ^^-"'^ v-^' 'bV" .•i°«. . . o ' ^^^ ^^^^^^ -^^^'^ ^^^-^^"^ -*SK: ""^^^^^ 4 •n.0^ .To' ^V 4 o ', o o^\l IC ^^^ Bureau of Mines Information Circular/1981 Alumina Availability— Domestic A Minerals Availability System Appraisal By Gary R. Peterson, Robert L. Davidoff, Donald I, Bleiwas, and Richard J. Fantel UNITED STATES DEPARTMENT OF THE INTERIOR Information Circular 8861 Alumina Availability— Domestic A Minerals Availability System Appraisal By Gary R. Peterson, Robert L. Davidoff, Donald I. Bleiwas, and Richard J. Fantel UNITED STATES DEPARTMENT OF THE INTERIOR James G. Watt, Secretary BUREAU OF MINES (f As the Nation's principal conservation agency, the Department of the Interior has responsibility for most of our nationally owned public lands and natural resources. This includes fostering the wisest use of our land and water re- sources, protecting our fish and wildlife, preserving the environmental and cultural values of our national parks and historical places, and providing for the enjoyment of life through outdoor recreation. The Department assesses our energy and mineral resources and works to assure that their development is in the best interests of all our people. The Department also has a major re- sponsibility for American Indian reservation communities and for people who live in Island Territories under U.S. administration. This publication has been cataloged as follows: Alumina availibility— domestic. (Information circular / Bureau of Mines ; Includes bibliographical references. Supt. of Docs, no.: 1 28.27:8861 8861) 1. Aluminum oxide. 2. Aluminum industry and trade. 1. Gary R. , 1948* . II. Title. III. Series: Information circu States. Bureau of Minee) ; 8861. Peterson, ar (United TN295.U4 [TN490.A5] 553.4'926 81-607823 AACR2 I or sale by the Superintendent of Documents, U.S. Ciovernnicnt Printinj; Office Washinston, D.C. 20402 PREFACE The Bureau of Mines Minerals Availability Program is assessing the world- wide availability of nonfuel minerals. The program identifies, collects, compiles, and evaluates information on active, developed, and explored mines and deposits and on mineral processing plants worldwide. Objectives are to classify domestic and foreign resources, to identify by cost evaluation resources that are reserves, and to prepare analyses of mineral availabilities. This report is part of a continuing series of MAS reports to analyze the avail- ability of minerals from domestic and foreign sources. Analysis of supply from other minerals is currently in progress. Questions about the MAS program should be addressed to Director, Division of Minerals Availability, Bureau of Mines, 2401 E Street, N.W., Washington, D.C. 20241. CONTENTS Page Page Preface iii Types of deposits — Continued Abstract 1 Alunites 12 Introduction 2 Anortliosites 12 Acl c 1,2, 3 .\ '<^ Hawaii c> Figure 4. — Location of domestic alumina properties. Table 5. — Property type, status, and resource data for anorthosite deposits^ Demonstrated, million tons Map Grade, Index Current percent Mineralized Contained Property name State numbers^ status^ AI2O3 material AI2O3 San Gabriel California 22 Exp 27.00 16,200 30,000 Boehls Idaho 17 Exp 29.00 1,000 290 Cedar Creek Idaho 16 Exp 29.00 1,600 464 Goat Mountain Idaho 15 Exp 29.00 2,000 580 Stillwater anorthosite Montana 19 Exp 30.00 4,000 1,200 13th Lake anorthosite New York 49 Dev 25.50 10,200 2,601 Adirondack Park New York 48 Exp 25.50 350,000 89,250 Carthage anorthosite New York 46 Exp 25.50 500 128 Rand Hill anorthosite New York 47 Exp 24.50 2,660 652 Raggedy Mountain Gabbroic Oklahoma 33 Exp 28.00 1,380 386 Corry Peat Products Pensylvania 45 Exp 25.50 1,000 255 Laramie Range Wyoming 20 Exp 27.00 65,000 17,550 Total NAp N Ap NAp NAp 469,340 121 ,456 NA Not applicable. ' Anorthosites are not included in the reserve base but have potential for future production. ^ Map index number refers to map on figure 4. ' Exp— Explored prospect; Dev— Developing prospect; all deposits are proposed to be mined by open pit methods. Identified, million tons Mineralized material Contained AhOa 8,100 2,000 3,200 4,000 8,000 10,200 350,000 500 2,660 5,000 2,000 130,000 577,560 60,000 580 928 1,160 2,400 2,601 89,250 128 652 1,400 510 35,100 150,909 12 TYPES OF DEPOSITS GENERAL Aluminum, the third most abundant element in the Earth's crust, occurs in combined form in virtually every geologic setting. In this study, a deposit is con- sidered as a potential source of alumina if it contains aluminum significantly greater than the average crustal abundance, may be amenable to chemical separation on a commercial scale, and has future economic potential. Currently, only bauxite ore is mined and refined to alumina and smelted to metallic aluminum. One of this study's criteria for a potential alumina source is that smelting grade alumina can be produced. General types of deposits analyzed in this study are described in the following paragraphs. BAUXITES Bauxite, the principal ore of aluminum, is composed of aluminum hydroxide minerals w/ith impurities of free silica, clay, silt, and iron hydroxides (24). Bauxite is formed as a residual soil in humid, tropical, or sub- tropical regions where good drainage is present. Under the extreme weathering conditions common to tropical climates, the iron and aluminum silicates are decom- posed and'Silica, with many other elements, is removed by leaching through downward percolation of water. Bauxite deposits typically assay 28 to 55 pet AI2O3. Domestic metallurgical-grade bauxite deposits ana- lyzed include the ALCOA, Quapaw, and Reynolds deposits of Arkansas and the ferruginous bauxite de- posits located in Oregon, Washington, and Hawaii. CLAYS Clays are fine-grained, earthy materials composed mainly of hydrous aluminum silicates (24). They may be predominantly one clay mineral or mixtures of clay minerals and nonclay materials. Clay minerals include kaolin, montmorillonite, illite, and halloysite. Domesti- cally, the best clays are high-alumina kaolinites formed by chemical weathering of crystalline rocks. Kaolin clays are the only clays considered in this study as a potential raw material for aluminum based upon known processing technology. A typical representation of kaolinite deposits in this study are those located in Georgia, which average 28.3 pet AI2O3. Twenty clay deposits were analyzed in this study, including those found in Arizona, California, Georgia, Idaho, Illinois, Mississippi, Missouri, Montana, Okla- homa, Oregon, Tennessee, Texas, Vermont, and Washington. ALUNITES The mineral alunite is a sulfate of potassium and aluminum formed by sulfateric action of hot acid waters upon feldspathic rocks. Alunite deposits can occur as fine-grained and massive rock but can also be altered under similar conditions to alunite with clays and, in some cases, to mostly kaolinitic clays. Alunite contains an average of 37 pet AI2O3, but the eight deposits analyzed in this study are diluted with country rock to as little as 11 pet AI2O3. These de- posits are located in Arizona, Colorado, and Utah. ANORTHOSITES Anorthosite is a plutonic igneous rock composed almost entirely of plagioclase feldspar, which is usually labradorite. Labradorite is a lime-soda aluminosilicate, a plagioclase feldspar intermediate between anorthite and albite. Anorthosites are usually large rock bodies exposed in the cores of older mountain ranges. As a group they constitute possibly the largest potential resource of aluminum, with grades averaging about 27 pet AI2O3; unfortunately, current state-of-the-art technology does not provide a feasible process for alumina recovery from anorthosites. Therefore, anor- thosite deposits are not included in this study's analysis of availability from domestic resources. A list of anor- thosite deposits is given in table 5. (See figure 4.) DAWSONITE A potentially economic occurrence of the mineral dawsonite is located in the so-called oil shales of the Piceance Creek Basin in Colorado. Oil shale aver- ages some 12 pet dawsonite, which in its pure form Na3AI(C03)3.2AI(OH)3 contains 35.4 pet AI2O3 and is considered 65 to 75 pet recoverable (7). However, as a percentage of whole rock, recoverable alumina from dawsonite amounts to only 2 to 3 pet. While oil shale resources may amount to billions of tons, demonstrated reserves of dawsonite have not yet been delineated, and any economic recovery of alumina is entirely de- pendent upon the mining of oil shale; therefore, daw- sonite can only be considered as a potential aluminum resource prior to development of an oil shale industry. 13 REFINERY TECHNOLOGY The physical nature and chemical composition of potential ore dictate the type of extraction technology. All the refining techniques considered in this report require chemical leaching of ore followed by the pre- cipitation of an alumina-bearing intermediate product. Usually, the intermediate product, hydroxide or chloride (depending on the extraction process), is then calcined to aluminum oxide (alumina). The following processes have been selected for treatment of the various aluminum-bearing resources included in this study. BAYER PROCESS FOR BAUXITES High-silica bauxites presently mined in Arkansas are amenable to the combination Bayer process, whereas the ferruginous bauxite of Hawaii and the Pacific North- west could possibly use a modified classic Bayer process. Approximately 2 pet of mineralized material at the demonstrated level may be processed using this technology. In the classic Bayer process, aluminum and other soluble elements in bauxite are dissolved at elevated temperatures and pressures in a hot, strong alkali solution, generally NaOH, to form sodium aluminate. After separation of the "red mud" tails, the sodium aluminate solution is cooled and seeded, and aluminum trihydrate is precipitated in a controlled form. The trihydrate is dewatered and calcined to the anhydrous crystalline form, alumina. This is the most suitable form for later use in the electrolytic reduction to aluminum metal using the Hall-Heroult process. This form is traded commercially and can be used in feedstock, abrasives, or chemical alums. High-silica bauxites such as those from Arkansas require additional processing for optimum separation of alumina. The Combination Process is applied to the red mud residue from the standard Bayer processing to extract additional amounts of alumina and to recover sodium values [26). The additional extraction step consists of mixing the red mud with limestone and sodium carbonate, and then sintering the mixture. The silica is converted to calcium silicate and the residual alumina to sodium aluminate. The sintered products are water leached to produce sodium aluminate solution, which is filtered to remove undigested solids and rejoined with the main- stream from Bayer processing for precipitation or separately precipitated. The residual solids (brown mud) are slurried to a waste lake. The purification standards required for producing refined alumina from the raw ore are very strict. Under present technology, substitutes for bauxite must yield aluminum at least equal in quality to that obtained from bauxite. Any increase in impurities will decrease the recovery efficiency of the electrolytic cells (used in reducing alumina to aluminum), and impurities may be carried through to the metal. HCI LEACH OF CLAYS High-alumina kaolinitic clays may be a preferred raw material for alumina production in place of bauxites. They are abundant, have a comparatively high alumina grade, have a high ratio of acid-soluble alumina to impurities, and do not consume large amounts of reagents during processing (2, p. 219). Based on Bureau of Mines test-scale processing of clays, optimum results are obtained by hydrochloric acid extraction with HCI gas-induced crystallization (16). Approximately 97 pet of the mineralized material studied at the demonstrated resource level may be amenable to such technology. In this process, the prepared clay ore is calcined to change the alumina into an acid-soluble form. Calcina- tion also removes free and combined water and destroys any organic matter in the clay as mined. The calcined clay is then digested with hot hydrochloric acid at atmospheric pressure to produce aluminum chloride-rich liquor. The liquor is settled and filtered, and the washed mud residue is sent to waste ponds. Dissolved iron is removed by solvent extraction and thermal conversion and then reacted with calcined clay to form aluminum chloride and iron oxide, which is sent to the waste pond. The iron-free liquor is con- centrated by evaporation and then the alumina crystal- lized as aluminum chloride hexahydrate by HCI gas. The crystals are separated mechanically from the mother liquor and then decomposed thermally to the product alumina. Reagents are recycled and waste heat recovered under the most efficient operating conditions. Although the potential recovery of alumina from kaolin c'ays was investigated in this study based on hydrochloric acid extraction using HCI gas induced crystallization technology tested at the "miniplant" level, there are other existing experimental tech- nologies for the extraction of alumina from kaolin clays. A hydrochloric acid process has been studied in detail by Anaconda, which operated a successful pilot plant during the 1960's capable of extracting 6.4 tons per day of alumina from kaolin {13, p. 81). The Bureau of Mines investigated a nitric acid extraction process during miniplant testing in 1975 (2, p. 247); Arthur D. Little, Inc., also investigated a nitric acid process. ALUNITE PROCESSING Before chemical processing, the raw alunite ore is crushed, ground, and sized, the prepared ore is first fed to a roaster where free and combined water are volatilized. The hot calcine is then fed to a reducing roast where most of the sulfur is removed. The removed sulfur passes to a sulfuric acid plant in the proposed commercial-scale operation. Some of the sulfur re- mains bound with potassium. The reduced calcine is again roasted to oxidize iron and other sulfides so that they do not interfere with the modified Bayer process recovery of alumina. The temperatures and residence time for the different roasts must be carefully con- trolled in order to remove water and most of the sulfur, and to avoid converting alumina to a caustic insoluble form. Potassium sulfate is leached from the reoxidized calcine by dissolution in hot, dilute recycled potassium sulfate solution and potassium hydroxide. The potas- sium sulfate product may be processed in a separate circuit to manufacture fertilizer. The solids left after leaching sulfate and potassium are about 20 pet AbOi, and the balance is mainly silica with small amounts of iron and titanium oxides. This slurry is washed and then treated in a modified Bayer process to recover alumina. Leaching in lime and soda solution to separate alumina as the trihydrate and then decomposition of the trihydrate to the product alumina follow the conventional Bayer process. Waste heat and reagents are recycled for operating efficiency with the additional recovery of sulfate and potassium in a commercial-scale operation. A commercial-scale plant for the extraction of alunite has been operated in the Soviet Union, and small pilot 14 plants have been operated in Mexico and in Golden, Colo. The Alumet Consortium partnership, comprised of Earth Sciences Inc., National Steel Corp., and South- wire Corp., reported favorable results from tests at their pilot plant in Golden, which was shut down in 1978. LIME SINTER OF ANORTHOSITE The largest domestic potential resources of alumina are contained in anorthosite rock bodies {4, p. 2). Anorthosite is an almost monominerallic igneous rock of plagioclase feldspars. The feldspars are near the calcium-rich end of the soda-lime isomorphous series. These deposits are a potential source of virtually un- limited amounts of alumina, if the alumina can be extracted on a competitive basis. The alumina is in a very strong chemical combination with silica, calcium, sodium, and potassium. Major amounts of limestone and fuel, such as coal, are required for the processing of anorthosite. A large amount of solid material similar to cement clinker is the main byproduct of commercial- scale processing of anorthosite. The separation of alumina from anorthosite by sinter- ing with lime and soda was tested by the Bureau of Mines at a pilot-plant scale {19). For the processing considered- here, the mined, crushed, and classified anorthosite ore is mixed with water and lime, then is dried, pelletized, and sintered. The sintering step ties the alumina with the alkalis, combines silica into dicalcium silicate, and produces large amounts of CO2 flue gas. The sinter product is soaked in a rotary calciner to produce self-disintegrating crystal. Leach- ing is by a concentrated sodium carbonate solution with approximately 75 pet of the contained alumina extracted. Gelation in the leaching step is a technical problem that has delayed development of alumina extraction from anorthosite. Almost two-thirds of the feed weight is removed as solid waste after leaching. The disposal of such large amounts of solid waste may present significant problems. Under proper market con- ditions, however, this solid waste could possibly be processed to portland cement. The silica is next removed from the pregnant liquor by seeding. The desilicated solution is seeded and carbonated with washed flue gas to precipitate alumi- num trihydrate. Coarse aluminum trihydrate crystals are separated, washed, and dewatered. Calcining de- composes the crystals to the alumina product. Waste heat and reagents are recovered and washed flue gas used in the process. Although the problem of gelation during separation of alumina from anorthosite appears to have been solved on a laboratory scale, larger scale work has not confirmed the laboratory studies, necessitating further Bureau of Mines research in this area. For this reason, plus the extremely high energy requirement of the lime-soda sinter technique, this process is not con- sidered feasible on a commercial scale. Because of their, enormous potential, anorthosite deposits are listed on table 5, but they were not included in this analysis to determine the domestic potential avail- ability of alumina. 15 AVAILABILITY OF ALUMINA FROM DOMESTIC DEPOSITS GENERAL Alumina availability in this study was determined at the demonstrated and identified resource levels. Ton- nages potentially available at these levels from each deposit are shown in table 4. The bauxite reserve base, established to estimate aluminum reserves and resources, is that portion of demonstrated resources that has a probability of eco- nomic availability (27). The subeconomic resources of aluminum-bearing materials analyzed in this study may have a probability of economic availability in the future depending upon the economics of the industry and technological improvements but, as yet, are not con- sidered part of the reserve base for aluminum. For 1980, the domestic bauxite reserve base was estimated to be 38 million tons of ore containing 18 million tons of alumina, of which approximately 15.6 million tons is estimated to be recoverable. Total resources at the demonstrated resource level (Arkansas bauxite plus subeconomic alternate sources) were esti- mated to be about 4,500 million tons of contained alumina with slightly over 4,000 million tons estimated to be recoverable. Total resources at the identified resource level are approximately 6,000 million tons of contained alumina, with a little more than 5,500 million tons considered to be recoverable. Resource availability curves have been developed to illustrate potential total and annual domestic alumina production based upon each deposit's "incentive price" for alumina. The computed incentive price equals an individual mine's average total cost of production over its entire life including a 15-pct rate of return on investment. These curves show the quantity of alumina that is recoverable after all mining and processing losses. Approximately 93 pet of domestic alumina re- sources are estimated to be recoverable using state- of-the-art technology. This study is a static analysis based on the current bauxite reserve base and identified resource estimates and on proven and experimental technology. However, as exploration and development yield additional knowl- edge of grades and tonnages, and as experimental processing technologies become feasible on a com- mercial scale, portions of this material may be reclassi- fied. Historically, domestic mineral resources that can be produced economically have increased because of exploration and technologic improvements that enable the mining of lower grade materials or the processing of materials previously considered as waste. Also, as prices for alumina produced from bauxite increase, nonbauxitic sources of alumina will likely become more competitive in the future. The analyses of nonbauxitic sources of alumina in this study are based on nascent technologies, which will likely be proven at a com- mercial scale in the future, thereby improving the competitive position of these sources. In order to determine the quantity of alumina that could potentially be produced on an annual and cumulative basis over the life of each deposit and the cost of this production, the following assumptions have been made: 1. Development of each deposit began in 1980. 2. Each operation can produce at full operating ca- pacity throughout the life of the mining operation. 3. Each operation will be able to sell all of its output at the alumina price required to receive at least the desired 15-pct rate of return. The assumptions used for this study were based upon the desire to determine potential availability of domestic alumina under an emergency situation. As a result, time lags involved in filing environmental impact statements and receiving necessary permits, financing, etc., are not included in this study. Under existing laws and regulations, production from some deposits in- cluded in this study would likely be limited by environ- mental, political, legal, or other constraints. For ex- ample, it is highly unlikely that the State of Hawaii would allow the mining of bauxite on the picturesque islands of Maui and Kauai, for obvious reasons. TOTAL RECOVERABLE ALUMINA For this study, the portion of the resource availability curves representing potential alumina production from resources other than Arkansas bauxite mines have been shaded in order to emphasize the technological uncertainties inherent in estimating the cost of pro- ducing alumina from nonbauxitic sources based on miniplant test date. The shaded areas is not intended to represent a confidence interval. The portion of the curves accounted for by the Arkansas bauxite proper- ties is not shaded since the Bayer process technology is well established. Figure 5 shows total recoverable alumina at various alumina prices including at least a 15-pct rate of return. Analyses indicate that, at the demonstrated resource level, a total of 15.6 million tons is recoverable from Arkansas bauxite properties that are currently producing, and 4,114 million tons from nonbauxitic and ferruginous bauxite deposits that have been explored. At a 1980 price of $0.12 per pound ($264 per ton), all 15.6 million tons of alumina from Arkansas bauxite deposits are recoverable. At an alumina price of $0.26 per pound ($573 per ton), 4,130 million tons of alumina is potentially recoverable. At these prices, all properties could produce alumina and earn at least a 15-pct return on investment. Potential total production of alumina at the identified resource level is shown in figure 6. Analyses indicate that a total of 15.6 million tons of alumina is recover- able from Arkansas bauxite properties that are currently producing, and 5,649 million tons is recoverable from explored nonbauxitic and ferruginous bauxite deposits. In general, the lower cost deposits on both the curves are bauxitic, followed by a mix of ferruginous bauxite, clays, and alunite deposits. The clay deposits form the majority of the resource tonnage on both curves. (See table 4.) POTENTIAL ANNUAL ALUMINA PRODUCTION Annual production curves for alumina at various price levels, including at least a 15-pct rate of return, are illustrated in figure 7 at the demonstrated resource level. The curves are based on current and expected production capacities at producing mines and non- producing deposits. The curves were generated in order to reflect the fact that an increase in production cannot be obtained immediately. The time required to initiate production depends on factors such as the relative location of the deposit and the necessity for 16 0.30 o "o •o O 00 *-. -20 CO 3 o> 3 I- < 3 o Q. a: UJ Q. UJ o a: 0. 3 -J < T 1 \ — r T I I I r T — I r Total alumina recoverable from domestic alumina sources; demonstrated resource level; 15-percent rate of return 1^1^ Shaded areas highlight the technological uncertainties of '■■'■''■'■■■ producing alumina from nonproducing deposits I W*W»»»WWIIII M IIPII M Ii m i |" ii " '''lll* " l " ***»W****W*WWW'*******' "M II M t MMM I M III|i W ii HW iMtW M I MM II M Hili" " "***! J Q ' J. lb Z 3 9 •" .16 - o 1 cc — i*""^ 111 o •rfl Q. -o 14 _J iiSSsSSiS* liJ O i^ I O *^ r^ mf — a> p: cc — Q. ^ .12 Iw V) :-:•: < = :•:•• z y' ?< .10 — O -I < nn 1 1 1 1 I I I L 10 20 30 40 50 RECOVERABLE ALUMINA, million tons I I I I I I I I 1,000 2,000 3,000 4,000 TOTAL RECOVERABLE ALUMINA, million tons Figure 5. — Total domestic aluminum resources potentially available at various alumina prices — demonstrated resource level. 5,000 exploration, development, and plant construction. Thus, an examination of the curves indicates that if all non- producers had begun preproduction development in 1980, very little increase in production would be noted immediately. Substantial increases could occur by 1983, when production could be as much as 8.2 million tons of alumina per year. Full production could be realized by 1986, when 10.5 million tons of alumina could be produced. After 1986, production of alumina from all sources would appear to slowly decline until 2005, which is also when the exhaustion of known low-priced bauxite deposits would occur. This is re- flected in an upward shift of the curve from the $0.08 per pound ($176 per ton) range in 1980 to the $0.15 per pound ($331 per ton) range in 2005. Alumina production from domestic bauxites could be approximately 1.15 million tons in 1986. Domestic demand for alumina in that year is expected to be almost 20 million tons (20, derived from aluminum de- mand forecast in its table 11). Thus the share of alumina production from domestic bauxite will continue to drop from the current 10 pet to 5.8 pet by 1986. Annual production curves at the identified resource level are illustrated in figure 8. 17 1 — r T — I — r 1 — r 0.30 Total alumina recoverable from domestic alumina resources; Identified resource level; 15-percent rate of return Shaded areas highlight the technological uncertainties of producing alumina from nonproducing deposits 0.25 < o .10 - 10 20 30 40 50 RECOVERABLE ALUMINA, million tons J L J I I I L 1,000 2,000 3,000 4,000 TOTAL RECOVERABLE ALUMINA, million tons 5,000 6,000 Figure 6. — Total domestic aluminum resources potentially available at various alumina prices — identified resource level. 18 30 1 1 1 1 1 1 1 1 1 1 1980 Costs include 15-percent rate of return on 20 - invested capital - 10 n II Ill 30 - 20 - 10 T r I I I r 1983 I \ ^ L. UJ cc 0- < 3 < 30 - 20 10 1986 r". I \ L. J I I I L ■ 2 345 6 7 89 10 II ANNUAL RECOVERABLE ALUMINA, oiillion tons Figure 7. — Potential domestic annual alumina produc- tion in selected years at various alumina prices — demonstrated resource level. The shaded areas highlight the technological uncertainties of producing alumina from nonproducing deposits. 60 1 1 — 1 \ — 1 r- 1980 — 1 1 — -1 1 1 ' — 1 — 1 — 1 — r - Costs include i5-percent rate of return on invested capital 40 - - 20 n . 1 1 1 1 1 1 1 1 1 1 1 1 1 - 60 - 40 - o- 20 £ T 1 1 1 1 1 1 1 1 1 1 1 1 1 — r 1983 'J I I J \ I I I Lu 60 - 40 - 20 - T 1 — r — r — r 1986 1 — I — I r 1 1 — I r J I I L J I L J I I II I 60 - 40 - 20 I T 1 1 1 1 1 \ 1 1 r 2005 J I I I I I I I I I I I I I I I 2 3 4 5 6 7 8 9 10 II 12 13 14 15 16 ANNUAL RECOVERABLE ALUMINA, million tons Figure 8. — Potential domestic annual alumina produc- tion in selected years at various alumina prices — identified resource level. The shaded areas highlight the technological uncertainties of producing alumina from nonproducing deposits. 19 CONCLUSIONS The demonstrated and identified resource levels for domestic alumina are comprised of 31 and 39 proper- ties, respectively. These properties are inclusive of three different types of deposits; bauxites (primarily ferruginous bauxites), clays, and alunites. All of these properties were analyzed to determine the quantity of alumina available from each deposit and the alumina price required to provide each operation with a 15-pct rate of return. The 1980 domestic bauxite reserve base (demonstrated resource level) is 18 million tons of alumina, of which approximately 15.6 million tons are recoverable. Subeconomic aluminum resources at the demonstrated level amount to 4,440 million tons of alumina, of which 4,114 million tons of alumina is con- sidered recoverable. Total contained alumina at the identified resource level is 6,117 million tons, with 5,665 million tons of alumina considered to be recoverable. For those properties classified as subeconomic re- sources, an alumina price of $0.26 per pound ($573 per ton) would be required if all properties, producing and nonproducing, were to produce alumina and re- ceive at least a 15-pct rate of return. Including those properties at the identified resource level, the needed alumina price would be $0.50 per pound ($1,102 per ton), which is almost 5 times the current price. There are only three Arkansas bauxite deposits currently comprising the U.S. bauxite reserve base, and the amount of alumina contained in these deposits is small. In fact, the alumina contained in these three deposits comprises less than 1 pet of total domestic alumina resources. Although the Bureau of Mines, in conjunction with the private sector, is continually re- searching alternative methods of processing alumina from other known aluminum-bearing deposits (that is, alunite, clays, anorthosites), this study indicates that these deposits as yet cannot economically compete with the rest of the world's huge economic bauxite reserves. As a result, the United States will likely con- tinue to import the majority of the bauxite and alumina necessary to meet current and projected aluminum consumption at least through the year 2000. Domestic nonbauxitic resources represent a large potential source of alumina. Continuing efforts by the Bureau of Mines and cooperating companies to im- prove technologies for recovering alumina from these sources will be necessary to provide stable supplies of alumina in the next century. Supplies of alumina from nonbauxitic sources would be required much sooner if the Nation were to face an embargo or cutoff of bauxite and alumina supplies from foreign sources. Furthermore, the existence of the ongoing U.S. program to develop new technologies to recover alumina from nonbauxitic sources could restrain foreign bauxite producers from raising prices above the point that would make domestic sources of alumina competitive with them. 20 REFERENCES 1. Arthur D. Little, Inc. Economic Impact of Environmental Regulations on the United States Copper Industry. Rept. to the U.S. Environmental Protection Agency, January 1978, con- tract 68-01-2842; reproduced and distributed by the American Mining Congress, Washington, D.C. 2. Bengtson, K. B. A Technological Comparison of Six Processes for the Production of Reduction-Grade Alumina From Non-Bauxite Raw Materials. Met. Soc. AIME, Paper LM-79-14, 1979, pp. 217-281. 3. Davldoff, R. L. Supply Analysis Model (SAM): A Minerals Availability System Methodology. BuMines IC 8820, 1980, 45 pp. 4. Fitzpatrick, K. T. The Economics of Alumina Production From the Laramie Range Anorthoslte, Albany County, Wyo- ming. M.S. Thesis, Colorado School of Mines, Golden, Colo., 1979, 95 pp. 5. Herbert, I. C, and J. F. Castle, Extractive Metallurgy, Mining Annual Revlevi^ 1980, Mining Journal Ltd., London, June 1980, p. 305. 6. Hoppe, R. Point Comfort, Refining Bauxite to Alumina — the Midpoint Between Mine and Metal. Eng. and Min. J., July 1979, pp. 114-119. 7. Husted, J. E. Potential Reserves of Domestic Non- Bauxltlc Sources of Aluminum. Met. Soc. AIME, Paper A74- 65, 1974, 20 pp. 8. International Bauxite Association. Quarterly Review. V. 5, Nos. 2 and 3, December 1979-March 1980, 52 pp. 9. . Quarterly Review. V. 5, No. 4, June 1980, 39 pp. 10. Kellogg, H, H. Sizing Up the Energy Requirements for Producing Primary Materials. Eng. and Min. J., April 1977, pp. 61-65. 11. Kurtz, H. F. 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BuMlnes Bull. 577, 1959, 129 pp. 20. Stamper, J. W., and H. F. Kurtz. Aluminum. BuMlnes Miner. Commodity Profiles, May 1978, 29 pp. 21. Stermole, F, J. Economic Evaluation and Investment Decision Methods. Golden, Colo., 1974, 443 pp. 22. STRAAM Engineers Inc. Capital and Operating Cost Estimating System Manual for Mining and Beneficiatlon of Metallic and Nonmetallic Minerals Except Fossil Fuels In the United States and Canada. Submitted to the BuMines under contract J0255026, December 1977, 374 pp. Available from the BuMlnes, Minerals Availability Field Office, Denver, Colo. Also available as: Clement, G. K., Jr., R. L. Miller, P. A. Seibert, L. Avery, and H. Bennett. Capital and Operating Cost Estimating System Manual for Mining and Beneficiatlon of Metallic and Non- metallic Minerals Except Fossil Fuels in the United States and Canada. BuMlnes Special Pub., 1980, 149 pp. 23. U.S. Bureau of Mines. The Bureau of Mines Minerals Availability System and Resource Classification Manual. IC 8654, 1974, 199 pp. 24. . A Dictionary of Mining, Mineral, and Related Terms. Washington, D.C, 1968, 1,269 pp. 25. . Minerals and Materials/A Monthly Survey. Wash- ington, D.C. 26. U.S. Environmental Protection Agency. Development Document for Effluent Limitations Guidelines and New Source Performance Standards for the Bauxite Refining Subcategory of the Aluminum Segment of the Nonferrous Metals Manu- facturing Point Source Category. Washington, D.C, March 1974, 98 pp. 27. U.S. Geological Survey. Principles of a Resource/ Reserve Classification for Minerals. Circ, 831, 1980, 5 pp. 28. Wilson, L. L. Aluminum — Bright Spot In the Economy. Min. Cong. J., December 1979, pp. 33-36. 21 >< O Z UJ Q. 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