Part 3

The hills of extreme southern Illinois contain several mineral materials that are entirely or largely restricted, in important quantities, to that part of the state. Some of them, such as silica and novaculite, come directly from bedrock deposits of great age; others, such as some of the sands and gravels, are of more recent origin.

Silica (Tripoli)

A mineral material unique in Illinois is the amorphous silica, or tripoli, mined in the hills of southern Illinois about 20 miles north of Cairo.

Most of the silica mines are found at the heads of valleys or in tree-covered hill slopes along the less traveled roads. An arched opening (fig. 20) with a road leading into it may be all that is visible of the mine from the outside. Inside are many rooms, some 30 feet high, separated by rounded pillars about 20 feet thick that have been left to support the arched mine roof.

Most of the silica in the mines is white, and this is the part that is mined. A silica deposit is made up of layers—some of white, powdery rock material, others that look chalky but are firm or hard.

In the mines the silica is blasted loose from the natural deposit and loaded into trucks that take it to the processing mills at Elco and Tamms, where it is crushed and then transferred to huge grinding mills that pulverize it to a very fine powder. Air currents of different velocities separate the powder into various grades of fineness, and the finished silica goes into large paper bags for shipment.

_Origin of Silica._—Some of the history of the formation of silica deposits is not fully known, but it seems probable that their original character was quite different from what it is today. Investigations by Survey geologists suggest that the parent rock formation was limestone and chert. The limestone was composed of the mineral calcite, but scattered through it were myriads of small particles of quartz. Interlayered with it were bands and beds of chert that contained varying amounts of calcite.

As the rocks above them were worn away by the ceaseless erosion of streams and rivers, these original deposits were uncovered. Rain and snow-water then worked down into the limestone and chert deposits through cracks and crevices and dissolved the calcite in the rock. The quartz remained because it is much less soluble than the calcite. After many thousands of years all the calcite had been removed, leaving behind a “skeleton” of quartz—the silica deposits of today.

_Uses of Silica._-The silica mined and milled in southern Illinois has many uses. A superfine grade, known as white rouge, is used to polish optical lenses. Other grades are used in scouring compounds, metal polishes, paints, electrical resistors, high-temperature pipe coverings, fiberglass manufacture, plastics, silicone rubber, wood filler, caulking compounds, ceramic products, floor tile, billiard cue chalk, as foundry parting or facing, concrete admixture, in the manufacture of buffing compounds that are used to polish metal objects, and for other purposes. Industry uses many thousands of tons of silica each year.

Chert and Chert Gravel

Deposits of chert, chert gravel, and ganister also are among the variety of mineral materials found in extreme southern Illinois. Chert consists principally of minutely crystalline particles of quartz. Some chert is popularly called flint. In southern Illinois chert occurs in two principal kinds of deposits, those composed of solid ledges and those consisting of gravel. The term novaculite is used in southern Illinois for those solid deposits that are white, comparatively thick, and free of other interlayered materials. No novaculite is mined at present, but it is said to have been sold in past years for making sodium silicate and silica brick.

The chert gravels of southern Illinois are of three kinds—novaculite gravel, Elco gravel, and “Lafayette” Gravel. The novaculite and Elco gravels consist of fragments of chert plus lesser amounts of fine silica particles and clay. The chert fragments of the novaculite gravel are angular, but the Elco gravel includes both angular and rounded fragments. These gravels are white, yellow, brown, or reddish brown, the novaculite gravel usually being the more highly colored. Deposits in Union and Alexander Counties have been used for road surfacing and other purposes. Deposits of chert gravel also occur in Hardin and Saline Counties, and some stream valleys in southern and western Illinois also contain such gravel.

“Lafayette” Gravel consists principally of brown chert pebbles. Most of the pebbles are rounded and have a smooth, semi-polished surface. The sand and clay occurring with the gravel are brown or dark red. In some places there are deposits of coarse, red quartz sand. The gravel is most abundant in the four southernmost counties of the state, and deposits may be as much as 65 feet thick. It is used principally as a road-surfacing material.

Ganister

Ganister occurs in the hills of Alexander and Union Counties and is a loosely consolidated, granular material consisting of irregular particles up to about an inch in diameter or of masses of material readily disintegrated into such particles. The particles are composed mainly of fine crystalline quartz. Ganister is white, cream, light yellow, or red and occurs in deposits up to 25 feet or more thick. Relatively small tonnages of the light colored ganister are now used, principally in making refractories, but ganister is said to have been more widely used in that field in the past. It is produced from underground mines. Some red ganister, or ganister like material, mined from open pits has been used for road surfacing.

Studies of Southern Illinois Materials

Survey geologists have mapped the chert- and silica-bearing formations of Alexander and Union Counties and also many of the various kinds of gravel deposits. Samples have been tested to determine their chemical composition and the size of the particles composing them. Laboratory studies by ceramists indicate that novaculite and novaculite gravel, when suitably processed, can be used for making silica brick, which withstands great heat. Canister and the gravels of southern Illinois offer a variety of raw materials awaiting increased industrial use.

Sands of Extreme Southern Illinois

In southern Illinois deposits of sand laid down in an arm of the ocean that once extended northward into Illinois from the Gulf of Mexico are found in Alexander, Union, Pulaski, Pope, and Massac Counties. The deposits are commonly a light color—white, cream, yellow, or gray.

The grains of the sand are almost all quartz and generally are angular. Some of the sands are of almost powder-like fineness, others are fine or medium grained. Many of the sands contain flakes of white mica, a glistening, silvery-looking mineral often mistaken for silver or platinum. Unlike these metals, however, mica is comparatively light in weight and is not metallic. Also present in some sands are small flakes of the mineral graphite.

The southern Illinois sands have not been widely used, but some of them have been employed in making concrete. They also may have possibilities for molding and core sand.

As a result of work by Survey geologists, the location and properties of many of the southern Illinois sand deposits are known.

CLAY AND SHALE

Man has used clay in various ways for many hundreds of years. From it he made, and still makes, bricks to build his dwellings, pottery utensils of many kinds, and other useful products.

Everyone knows what clay is, yet it is a substance difficult to define. All clays are earth materials, most of them plastic or sticky when wet but firm when dry. If heated sufficiently (fired) they become hard.

Clays are composed of various minerals. Of these, the so-called clay minerals—complex substances composed mostly of alumina, silica, and water—generally are the most important. They impart the property of plasticity and also cause clays to become hard when fired.

Most clays are what geologists call unindurated (unhardened) rocks. Clay that has been indurated and occurs in layered deposits is commonly called shale. The layers may be from a fraction of an inch to several inches thick. Most Illinois shales are not plastic when dug from freshly exposed deposits, but they become plastic when crushed and kneaded with water. The clays and shales of Illinois are the basis of a huge and important industry.

Early Uses in Illinois

Clays and shales are useful because they can be made plastic by adding water, formed into desired shapes, and fired to a rock like hardness. As a result, various kinds of bricks, drain tile, pottery, and other useful products are made from them. In its early years, Illinois had many widely distributed potteries that used clay from nearby deposits to make a variety of jugs, crocks, and bowls that served in place of many present-day glass or metal articles.

Drain tile has been of major importance in the development of the state. Early settlers found many low lying, swampy areas and tracts of land that drained poorly after heavy rains. Ditches were dug to carry away the water from some areas, but others were drained by means of drain tile—pieces of fired clay pipe several inches in diameter and about a foot long that were laid end to end in trenches below plough depth and then covered with earth. Water seeped into the tile, which discharged it into ditches. Tile factories, built throughout Illinois near clay or shale deposits, did an active business. Gradually, however, as more and more farm land was drained the demand slackened and many tile factories went out of business. Although there are fewer factories, much drain tile is still manufactured in Illinois.

Many of the early tile plants also made bricks to be used for making foundations, buildings, sidewalks, and other structures. The bricks were made by hand-operated equipment. Some of the old hand-molded bricks may still be seen in older buildings. Now the brick-making process is highly mechanized and even though there are fewer plants they produce more bricks.

Clay and Shale Deposits

Illinois shales are a part of the bedrock—that is, they are associated with indurated rocks such as sandstone and limestone. Most clays are surficial rocks occurring in deposits near the surface, where they lie above the bedrock. Exceptions are certain clays found in extreme southern Illinois and the underclays, also called fireclays, that occur beneath coal seams and are part of the bedrock.

The surficial clays are of two principal kinds—till and loess. Till is a deposit left by glaciers. It is a gray, blue-gray, or brown clay containing varying amounts of sand, pebbles, cobbles, and even boulders. Till is found at many places in the state and is used for brick making, especially in the Chicago area.

Loess is a wind-deposited silty clay or clayey silt and is found in many parts of Illinois. It is thickest on or near the bluffs of the Mississippi, Illinois, and Ohio Rivers. It generally is brown and stands in steep faces in roadcuts and other excavations. It once was widely used for making brick and tile.

Of major importance in making clay products in Illinois are the bedrock shales and the clays associated with the coal-bearing rocks that underlie much of the state. The shales, and the clays to a lesser extent, are dug at many places for making structural clay products such as bricks, structural tile, and drain tile. They also are used to make lightweight aggregate for concrete. The underclays of some of the older coal seams are used to make buff-colored brick, stoneware, and a highly heat-resistant brick (firebrick) that is used in industrial furnaces or in other operations involving high temperatures. Some fireclay, ground as fine as flour, is added to molding sand to make it coherent enough to form into molds for metal casting. Sewer pipe and flue lining also are made from underclays.

Clays unlike those found elsewhere in the state occur in extreme southern Illinois. One of these has the property of removing color from oils and was so used at one time by petroleum refineries. Another, kaolin, was extensively used during World War I for making crucibles.

Clay Minerals

The uses of clay and shale are determined to a large degree by the properties of their clay minerals and to a lesser degree by the impurities present. A clay or shale containing the clay mineral illite, and other similar but less important clay minerals, commonly becomes red when fired and gets hard at a relatively low temperature. It therefore is used to make red bricks, drain tile, building tile, and other structural clay products.

Another clay mineral, kaolinite, generally burns to a light color and is difficult to fuse. Therefore, clays composed wholly or mainly of kaolinite can be used for making buff or light-colored bricks and for the manufacture of highly heat-resistant (refractory) bricks.

The clay mineral in the southern Illinois clay that was used to decolorize oil is montmorillonite. This clay is now used in sweeping compounds, as an oil absorbent, as animal litter, and for other purposes.

Studies of Clay and Shale

In view of the significant relationship between the clay minerals and the utilization of the clays and shales in which they occur, the Illinois Geological Survey has investigated extensively the clay minerals in the clay and shale deposits of Illinois. Many samples were studied by means of powerful microscopes, X-ray, and chemical analysis. Most of the surface clays and shales proved to be composed principally of illite or related minerals. The kaolin clay of extreme southern Illinois contains the mineral kaolinite. The older underclays also contain kaolinite, but many of them also contain smaller amounts of illite.

The Survey also has tested many clays to determine their burning properties and color when fired, and hence their potential uses. The bonding capabilities of other clays have been measured to find out whether they can be used as a bonding material for molding sand. The bloating properties of Illinois clays and shales from many deposits have been studied to determine which are suitable for making lightweight aggregate for the manufacture of concrete.

The object of these studies has been to discover the location, character, and possible uses of the state’s clay and shale resources. Special studies are continuing in several parts of the state. Illinois is well endowed with clays and shales that can be used for a variety of purposes and has resources to fill future as well as present needs.

How Bricks Are Made

Conversion of Illinois clays and shales into useful products is an interesting process and is exemplified by the making of building bricks. Mechanical shovels dig the clay or shale and load it into trucks or small railroad cars that take it to the brick plant. There, machines grind the raw material and mix water with it until it has the consistency of stiff mud.

Next, a machine, which operates somewhat like a meat grinder, extrudes a brick-sized column of clay. As the column moves forward, it is automatically cut into bricks by wires. The bricks are then dried in large heated rooms.

From the driers, the bricks go to huge ovens (kilns) and are heated until they are hard and have attained the desired color. This is known as firing or burning the bricks. Temperatures employed are rarely lower than 1800° F.

Three kinds of kilns are used in Illinois for burning bricks—beehive, tunnel, and scove. A beehive kiln (fig. 21) has a round base and a dome-shaped top and somewhat resembles an oversized beehive. Unfired bricks are stacked in the kiln and the doors are sealed with burned bricks and clay. Fires are started in hearths or fire boxes in the wall of the kiln and the heat is circulated into and through the kiln. It usually takes several days to fire the bricks adequately and let the kiln cool so that the bricks can be removed.

Tunnel kilns, made from heat-resistant bricks, are actually tunnels big enough for a man to stand in. The unburned bricks are loaded on flat steel cars on top of a layer of refractory blocks that protect the steel from the heat. The cars enter the kiln and heating begins. As they move through the kiln, they carry the bricks through a firing area, then through a cooling zone, and finally out into the air.

In some brickyards in the Chicago area, dried unburned bricks are carefully stacked by machines into piles about 17 feet high, 35 feet wide, and 115 feet long, which are known as scoves or scove kilns. A layer of burned bricks that is plastered with clay covers the sides of the scove. A jet of flame is directed through small tunnels at the base of the scove, and the heat fires the bricks.

During 1963, more than 325,000,000 bricks were produced by Illinois brick plants. In the same year, the value of all the clay and clay products produced in Illinois was nearly $54,000,000. Besides brick and drain tile, the products of the clay and shale industry of Illinois include refractory brick, building block and tile, fire-proofing, sewer pipe, flue liners, stoneware, lightweight bloated burned clay aggregate for concrete, and a variety of unburned clays for special purposes, including bonding clay, refractory fireclays, absorbent for use on garage floors, and litter for animal cages.

PEAT

After the retreat of the last of the great ice sheets from Illinois, numerous ponds and lakes were left in northern Illinois, especially in the eastern section. Some of them were soon drained by natural processes, but others remained. In the shallow water along their shores grew various plants, chiefly reeds and sedges and, locally, a variety of moss. As the plants died, their partially decomposed remains were preserved beneath the water. Ultimately, the ponds and lakes were overgrown and more or less completely filled by the plants and their remains, giving rise to peat (fig. 22) bogs.

Some peat bogs have been drained and are now used as farm land. Others remain and a few of them are the source of peat or humus for horticultural purposes. Producing operations are located in northeastern Illinois and in Whiteside County in northwestern Illinois.

OTHER MINERAL RESOURCES

In the future, new uses will be made of the Illinois industrial minerals already discussed. In addition, other mineral resources of the state that are not now being used may be the bases of new mineral industries. Some of these minerals are at present too costly to mine because the deposits are deeply buried or are not sufficiently rich to be worked at a profit. Others are not convenient to markets, and still others have no present commercial use. In years to come, however, changes may occur that will make it practical to mine, process, and use some of these resources. Furthermore, some other mineral deposits that are now being utilized in a limited way may have greater future use. The Illinois Geological Survey continues to study the location, character, and composition of many such mineral materials and is alert for the development of new uses. Some of the materials are discussed briefly below.

Gypsum and Anhydrite

Gypsum is a mineral that consists of calcium sulfate plus two molecules of water (CaSO₄·2H₂O). By suitably heating it, the amount of water can be reduced, and a product called calcined gypsum (plaster of paris) results. This material changes back to gypsum if mixed with an appropriate quantity of water. The ability of calcined gypsum to “set” when water is added makes it important in the manufacture of a variety of plasters and related products, especially building materials. Gypsum also is used in cement making and in agriculture.

Anhydrite (CaSO₄) is like gypsum except that it contains no water and hence cannot be made into plaster of paris. Its uses are limited in the United States.

Wells that were drilled for oil, water, or coal have encountered gypsum and/or anhydrite in some parts of south-central Illinois, but the gypsum and anhydrite are not known to crop out at the surface. A study of diamond drill cores and well cuttings on file at the Survey showed that the shallowest gypsum and anhydrite reported occurred at a depth of 470 feet in Madison County. The greatest continuous thickness of gypsum found was 2 feet; but in one well, over 6 feet of strata was penetrated that averaged almost 75 percent gypsum. It is possible that thicker deposits of gypsum might be found if drilling were done especially in search of it.

Feldspar-Bearing Sands

Feldspar is the name applied to a group of minerals that are mainly silicates of potassium, sodium, and calcium. Various kinds of feldspar are used industrially in making glass, enamels, pottery, and other products. All the feldspar now used in Illinois is shipped into the state. The discovery by the Illinois Survey that some Illinois sands contain considerable feldspar led Survey geologists and chemists to find where deposits highest in feldspar occur, what kinds of feldspar they contain, and whether it could be separated from the sand in which it occurs. Beach sands, river sands, dune sands, and sands from other kinds of deposits were studied.

It was found that many sands contain more than 15 percent feldspar and some as much as 25 percent. Means of separating the feldspar from the sand are believed to exist, but problems relating to the purity of the separated spar remain to be solved.

Brines

No salt is now produced in Illinois, but at one time the state was a major salt producer. Salt works were in operation near Equality, Central City, Murphysboro, St. John, Danville, and possibly other places. The salt was obtained by evaporating salt water (brine) that came from natural springs or from wells. The Equality area was a particularly important producer of salt in the 1800’s. Discovery elsewhere in the Middle West of deposits of rock salt and brines that contained more salt than those of Illinois is said to have been responsible for the discontinuance of salt making in the state.

No salt beds crop out in Illinois, nor are any known to have been encountered in the many wells that have been drilled for coal, oil, or water. However, most oil well drilling encounters brines containing various amounts and kinds of salts, including the common table salt, sodium chloride.

For reasons relating to the production of oil, Survey geologists and chemists have collected and analyzed many samples of Illinois oil field brines, and data are therefore available on their salt content. No commercial use is being made of the brines as sources of salt.

Oil Shale

Illinois has a large oil-producing industry that obtains oil from wells. The state also contains beds of shale that yield oil when the shale is heated.

In order to estimate the present and future importance of the oil shale resources, the Survey collected and tested more than 100 shale samples from 41 Illinois counties. A few samples contained more than 25 gallons of oil per ton of shale, but most contained less than 15 gallons per ton. A study of the crude oil distilled from selected shale samples showed it to be somewhat different from the oil that comes from wells. It could, nevertheless, be made to yield gasoline, fuel oil, and other products if suitably processed.

The shale strata generally the richest in oil are found above coal seams, are black, and are sometimes called slate by coal miners. They are rarely more than 3 feet thick, but they extend over large areas.

Sandstone