(IJ^M^ IM 111 MINERAL INDUSTRY ILLINOIS IN 1991 and Review of Preliminary Mineral Production Data for 1992 Samson Irma E. UBRARY SURVM ILLINOIS MINERALS 111 1994 FE§, <3S>1995 Department of Energy and Natural Resources ILLINOIS STATE GEOLOGICAL SURVEY MINERAL INDUSTRY ILLINOIS IN 1991 and Review of Preliminary Mineral Production Data for 1992 Irma E. Samson *<y of & <c ILLINOIS MINERALS 111 1994 ILLINOIS STATE GEOLOGICAL SURVEY Morris W. Leighton, Chief Natural Resources Building 615 East Peabody Drive Champaign, Illinois 61820-6964 Printedby authority ofthe State ofIllinois/1994/450 printedonrecycledpaperusingsoybeanink 9911 CONTENTS EXECUTIVE SUMMARY 1 MINERALS EXTRACTED 3 Fuels 3 Coal 3 Crude Oil 7 Natural Gas 10 Industrial and Construction Materials 10 Primary Barite 10 Clays 1 Fluorspar 1 Sand and Gravel 12 Industrial Sand 13 Stone 14 Tripoli 14 Metals 15 Zinc, Lead, Silver, and Copper 15 Other Minerals 16 Peat 16 Gemstones 16 MINERALS PROCESSED 16 Ground Barite 16 , Columbium and Tantalum 16 Calcined Gypsum 16 Crude Iodine 17 Iron Oxide Pigments 17 Natural Gas Liquids 17 Expanded Perlite 17 Pig Iron and Raw Steel 17 Slag (Iron and Steel) 17 Recovered Elemental Sulfur 17 Exfoliated Vermiculite 18 Primary and Secondary Slab Zinc 18 PRODUCTS MANUFACTURED FROM MINERALS 18 Cement 18 Clay Products 1 Coke 1 Glass 19 Lime 19 PRELIMINARY PRODUCTION DATA: 1992 20 Minerals Extracted 20 Fuels 20 Industrial and Construction Materials 21 Metals and Other Minerals 21 Minerals Processed 21 Products Manufactured from Minerals 21 11 1 FIGURES 1 Mineral production and mineral-processing plants in Illinois 1 2 Energy used in Illinois, 1960-1991 3 3 Illinois coal production in 1991 4 4 Trends in Illinois coal production, 1955-1991 5 5 Trends in the numberof Illinois coal mines, 1955-1991 5 6 Trends in the productivity of Illinois coal mining, 1955-1991 7 7 Coal consumption in Illinois, 1968-1991 8 8 Annual crude oil production in Illinois, 1935-1991 8 9 Illinois crude oil production, 1991 9 10 Consumption of natural gas in Illinois, 1955-1991 10 1 Trends in clay production in Illinois, 1955-1991 1 12 Illinois districts and counties producing sand and gravel in 1990 13 13 Illinois districts and counties producing stone in 1991 15 14 Illinois production and consumption offinished portland cement, 1955-1991 19 15 Trends in consumption of quicklime and hydrated lime in Illinois, 1955-1991 20 TABLES 1 Illinois minerals extracted, processed, and manufactured into products, 1989-1991: production and value 22 2 Illinois mineral production compared with U.S. mineral production, 1990-1991 24 3 Minerals extracted, processed, and manufactured bycounty in Illinois, in 1991 25 4 Employment and wages in the Illinois mineral industry, 1990-1991 27 5 Minerals consumed in Illinois, 1990-1991 27 6 Fuels and energyconsumed in Illinois, 1990-1991 28 7 Coal production in Illinois counties, 1990-1991 29 8 Coal production in Illinois counties, 1833-1991 30 9 Employment and production by method of coal mining in Illinois, 1980-1991 31 10 Coal production of Illinois companies, 1990-1991 32 1 Coal shipped from Illinois to otherstates, 1987-1991 33 12 Sources of coal consumed in Illinois, 1987-1991 34 13 Crude oil production in Illinois counties between 1888 and 1991; value for 1990 andl991 35 14 Crude oil production from majorfields in Illinois, 1990-1991 36 15 Petroleum products consumed in Illinois, 1987-1991 37 16 Natural gas production in Illinois, 1984-1991 37 17 Natural gas production from large fields in Illinois counties, 1989-1991 38 18 Natural gas consumed in Illinois, 1990-1991 38 19 Production and value of Illinois stone by district, 1991 39 20 Illinois stone production by size of operation, 1989 and 1991 39 21 Use of crushed and broken stone produced in Illinois, 1989 and 1991 40 22 Portland cement manufactured in Illinois, 1990-1991 41 23 Illinois mineral production datafor 1991 compared with preliminary data for 1992 41 24 Illinois coal shipped to consumers in the United States, 1990-1992 42 25 Coal shipments from Illinois to otherstates, 1990-1992 42 EXECUTIVE SUMMARY This report covers three types of mineral industry operations in Illinois (fig. 1): • extracting minerals from the ground • processing crude minerals (mined primarily out of state) into raw industrial materials • manufacturing mineral products such as coke, lime, and cement from minerals extracted and processed primarily, but not exclusively, in Illinois. 1991 Reported Value The total reported value of minerals extracted, processed, and manufactured in Illinois during 1991 was $2,907.4 million, 0.3% lowerthan the 1990 total. The total value reported to the U.S. Bureau of Mines (USBM) is not necessarily the actual value because many producers do not re- port their production figures. Minerals extracted accounted for 90% of the reported value; crude minerals processed and manufactured minerals accounted forthe remaining 10%. Coal contin- ued to lead in value, followed bycommodities from the industrial and construction materials cate- gory and oil (table 1; tables begin on page 22). COMMODITIES • coal oilandgas A limestone/dolomite (D sandandgravel fluorspar,metals,barite A A\ clay Dm * peat # tripoli PLANTS C cement P petroleumrefinery S iron/steel M miscellaneous mineralprocessingplants Figure 1 Mineral production and mineral-processing plants in Illinois. . Illinois produced 6% of the tonnage and about 8% of the value of the coal produced nationally. The state continued to lead the nation in the production offluorspar, industrial sand, and tripoli. Production of stone and sand and gravel were 6.2% and 3.8% of the national total, respectively (table 2). Extracted Minerals In 1991 the value of commodities mined in Illinois was $2,617.2 million, a 0.3% decrease from 1990. Mineral fuels (coal, crude oil, and natural gas) accounted for79.8% of the total. Industrial and construction materials such as clay, fluorspar, sand and gravel, stone, and tripoli accounted for 19.9%. The remaining 0.3% came from metals, such as lead, zinc, and silver, and from other minerals, such as peat and gemstones. Mineral extraction in 1991 was reported from 97 ofthe 102 counties in Illinois (table 3, fig. 1). Only Cass, Knox, Mercer, Pope, and Stark Counties had no reported mineral extraction. Perry, Saline, and Franklin Counties, majorproducers of coal and crude oil, accounted for 11%, 8.7%, and 7.2% of the state's total value of minerals produced, respectively. Processed Minerals Figures fortotal reported value of processed minerals in 1991 are incomplete. The total includes onlythe figures forground barite, expanded perlite, sulfur, calcined gypsum, exfoliated vermicu- lite, iron oxide pigments, and slag. Minerals not included on this list, but processed in the state, are natural gas liquids, bismuth, columbium, tantalum, and primary and secondary slab zinc. Manufactured Mineral Products Mineral products manufactured in Illinois, primarilyfrom minerals mined within the state, include cement (portland and masonry), coke, clay products, lime, and glass. The average unit value of sales of portland cement decreased about 1%; no figures were given for masonry cement in 1991 Lime production was down 9.1% and its unitvalue was down 8%. Clay products decreased 28.5% in value. Figures are no longeravailable forcoke or glass. Employment The Illinois Department of Labor reported thatjobs in mining, quarrying, and oil and gas extrac- tion continued a downward trend, decreasing 2%, from 19,600 in 1990 to 19,200 in 1991. The total nonagricultural employment went down 1.3%, from 5,288,300 in 1990 to 5,220,100 persons in 1991. Employment in the goods producing sectordecreased 4.7%, from 1,222,200 to 1,165,100 employees in 1991, and in the service producing sectorfrom 4,066,100 to 4,055,100 (table 4). According to the "Annual Coal, Oil and Gas Report, 1991," published bythe Illinois Department of Mines and Minerals, employment in the Illinois coal industry decreased 4.6%, from 10,129 in 1990 to 9,667 in 1991 (table 9). Mineral Shipments Mineral shipments are a large part of the Illinois transportation industry. Stone and sand and gravel are usually shipped bytruck, since these products are used primarily neartheir sources. Coal is primarily shipped by rail, barge, orcombination of both; only about 4% of the coal was moved to mine-mouth electricity-generating plants by conveyor belt. Crude oil and natural gas are mainlytransported by pipeline. Other materials, such as fluorsparand clay products, are shipped by rail, truck, and barge. Pig iron and coke are generally used on site by integrated mills. Consumption In 1991, the value of the state's consumption of mineral commodities was about 4.5% to 5% of the nation's total, orabout the same proportion as Illinois' share of the total U.S. population. In physical units, Illinois' mineral consumption varied from less than 1% of the U.S. total (for residual fuel oil) to almost 16% (forzinc) (table 5). The high zinc consumption reflects Illinois' status as a major manufacturing state. The state's energy consumption was estimated at 3.4 quadrillion Btu in 1991 (4.2% of the U.S. total), about the same as in 1990 (table 6). Fossil fuels provided about 77% of the state's energy needs: 25.8% was provided by oil and oil products, 29.8% by natural gas, and 21.6% by coal (fig. 2). Illinois' consumption of nuclear power in 1991 increased from 768 trillion in 1990 to 772 trillion , total consumption oil products coal 1960 1965 1970 1975 1980 1985 1990 Figure2 Energy used in Illinois, 1960-1991. Btu in 1991. Forthe third year, consumption of nuclear-generated electricity exceeded the amount produced by coal in Illinois. MINERALS EXTRACTED Fuels Coal Production In 1991, Illinois continued to rankfifth in coal production, behind Wyoming, West Vir- ginia, Kentucky, and Pennsylvania. Coal production in Illinois declined from 61.7 million tons in 1990 to 60 million tons in 1991 (table 7), a 2.6% decrease. Total value was $1,701 million; unit value was $28.35 perton, a 2.2% increase in value perton from 1990 (table 1). Eighteen counties produced coal in 1991 (fig. 3), compared with 19 in 1990. Edgar County's only coal mine, Peabody Coal Company's Universal Mine, closed in December 1990. Perry, Saline, Randolph, and Franklin Counties togetheraccounted for 50.9% ofthe state's total production. Perry County was the state's top producer, contributing 16.8% of all coal produced in the state. Approximately 87% of Perry County's output was from surface-mined coal. The county produced more than 55% of the state's total output of surface-mined coal. In Saline County, more than 85% of the coal was produced from underground mines, contributing more than 15% to the state's total underground production. More than 77% of Randolph County's coal came from underground mines, accounting for 11% of the state's total underground mined production. Franklin County, with all of its tonnage from underground mines, contributed more than 14%. Othercounties that contributed substantially to underground coal mine production were Jefferson (9.7%), Wabash (8.4%), and Macoupin (7.9%). Approximately 73.5% ofthe state's total production came from underground and about 26.5% was from surface mines (fig. 4). The number of coal mines operating in Illinois has steadily declined since the early 1900s. There were 920 mines in 1900. By the 1950s, approximately 200 mines were in operation. A further rapid decline to about 60 mines had occurred by 1970. In the latter half of the 1970s, the number of mines increased to about 70 as new mines opened afterthe first oil price shock of 1974. Demand forcoal did not increase, however, and the number of mines again dropped. By 1991 only 44 mines remained in operation: 29 underground and 15 surface mines (fig. 5). Since 1833, Illinois mines have produced more than 5.5 billion tons of coal (table 8). Surface mines operating since 1911 have accounted for 1.31 billion tons or23.8% of the total. The aver- age output per underground mine reached a new peak of 1.65 million tons in 1990, but dropped 8% to 1.52 million tons in 1991. The average surface-mine output, which has increased each Hi 6,000,000 or more 4,000,000 - 5,999,999 3,000,000 - 3,999,999 \ 2,000,000 - 2,999,999 1,000,000 - 1,999,999 < 1,000,000 no production reported Figure3 Illinois coal production in 1991. yearsince 1977 except for a 10% decline in 1985, reached a high of 1.31 million tons in 1989. In 1991, output decreased forthe second yearto 1.1 million tons (table 9). The trend in Illinois is toward fewer but la—rgercoal companies. Ofthe 23 coal mining companies in Illin—ois in 1991, the top five companies Zeigler, Peabody, Consolidation, AMAX, and Arch of Illinois contributed 61.25% of the state's total output (table 10). The share ofthe top five companies changed slightly in 1990 as Zeigler purchased all the Old Ben Coal mines, making Zeiglerthe largest coal com- pany in Illinois. Zeigler, with seven underground mines, remained the top company in 1991. By comparison, the top five U.S. companies produced 25.7% of the national total in 1991 Peabody, Consolidation, and AMAX are also among the top five companies in the United States.. Employment and wages In 1991 employment in Illinois coal mines again declined (4.6%) to 9,667 from 10,129 in 1990 (table 9). Employment in the mines has declined 47.7% from the 1979 high of 18,499. Employment in underground mines increased 1.3% and decreased 23.7% in sur- face mines.