INDUSTRIAL MINERALS IN ARIZONA’S
PAINT INDUSTRY
Open File Report 89-1
May 1989
by Ken A. Phillips
Chief Engineer
Arizona Department of Mines & Mineral Resources
1502 West Washington
Phoenix, Arizona 85007
This is a preliminary report,
subject to technical and
editorial revision.
Arizona Department of Mines and Mineral Resources
Open-file Report 89-1
May, 1989
INDUSTRIAL MINERALS IN ARIZONA’S
PAINT INDUSTRY
by Ken A. Phillips, Chief Engineer
ABSTRACT
This report briefly describes Arizona’s paint manufacturing industry, and in more detail, the specifi-cations
and quantities of industrial minerals consumed.
The Arizona paint industry uses a larger variety of industrial minerals as extender pigments and
functional fillers than any other Arizona industry. Minerals used include limestone, kaolin, silica, dia-tomaceous
earth, feldspar, bentonite clay, talc, attapulgite clay, mica, pyrophyllite, barite, perlite,
nepheline syenite, and pumice. More than 10 million pounds of minerals, with a value in excess of two
million dollars, are imported by Arizona annually for use in manufacturing paint. Deposits of most of
the minerals discussed in this report are known to exist in Arizona. Since a number of these minerals are
not currently produced here, a market for local material exists.
The development of mines and the production of these minerals in Arizona would aid the state’s
economy. Additionally, these minerals could be available to manufacturers in Arizona, California, and
other southwestern states at lower prices due to savings in transportation costs.
Acknowledgements
I would like to take this opportunity to ex-press
my appreciation to all of the Arizona
paint manufacturers who provided assistance
and information. Without their cooperation
the data to assemble this report would not
have been available.
Dick Wade, Cardinal Industrial Finishes,
Phoenix
Bill Heiber, Universal Paint Corporation,
Tempe
Jim Ladehoff, Ladehoff Paint and Manu-facturing,
Mesa
Virginia Coker and Harry McHenry,
Pioneer Paint & Varnish Co., Tucson
Harris Langejans, Southwestern Paint &
Varnish Co., Tucson
Lyle E. Beierlein, Sunland Coatings
Manufacturing, Tempe
Dale Krog, Sunlife Premium Paint,
Phoenix
Joe Hook, Bert’s Paint aka Sunburst
Coatings, Phoenix
Bill Dow, Dunn-Edwards, Tempe
Wendy Bailey, Soberg Industries, Phoe-nix
Michael Sylvester, Spectrum Paint Co.,
Flagstaff
Michael Ketchner, Classic Paint, Pres-cott
Dom Commisso, Grigg’s Paint of Dom-com
Distributors, Phoenix
A special thank you is extended to Jerry
Moore of Ribelin Sales, Tempe, along with
Dick Wade and Bill Heiber, listed above, for
taking the time to provide an education on paint
manufacturing and raw materials and for their
review of this chapter.
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Development Potential in Arizona
An opportunity for development of Arizona
mineral deposits exists because few of these
minerals are currently mined in Arizona; despite
the likelihood that significant deposits occur
within the state. Further, there are additional
markets in the Southwest and potential export
markets.
Paint in General
The paint industry, more properly referred to
as the coatings manufacturing industry, is an
important consumer of ground industrial miner-als
in Arizona. Paint is generally divided into
industrial coatings and architectural coatings
(also known as “trade sales”) coatings. Indus-trial
coatings include such paints as automotive,
highway striping, and appliance paints, while
architectural coatings include interior and exte-rior
house paint, whether used for homes, office
complexes, or factories.
For the purpose of explanation, the composi-tion
of paint can be divided into a solid portion
and a liquid portion. The solids are referred to as
the pigment and the liquid portion is referred to
as the vehicle. The pigment portion includes
both hiding and extender pigments as well as
any mineral matter used for flatting or other
purposes. It is the pigment portion of the paint
formulation and, more importantly, the extender
pigments that are of interest to the potential de-velopment
of mineral resources in Arizona.
The vehicle is the complete liquid portion of
the paint. Normally it consists partly of non-volatile
matter and partly of volatile matter. The
non-volatile portion of the vehicle is the vehicle
solids which is the binder or film former. The
volatile portion is the solvent or diluent. The
vehicle is nearly always a combination of manu-factured
organic chemicals with or without
added water. Generally these chemicals do not
contain industrial minerals.
Paints may also be classified as alkyd resin
“oil” base or water emulsion resin “water” base
(also called latex paint). Oil base paints use one
or more hydrocarbon solvents, while water base
paints use water as the solvent. Most paint is
now formulated in dispersers (high speed mix-ers),
while a small amount, especially some in-dustrial
paints, are still ground in pebble mills or
sand mills. Dispersers do not cause any particle
size reduction to the paint ingredients; therefore
industrial minerals to be used in most paints
must be supplied to the paint manufacturer to
meet very rigid fine particle size requirements.
Pigments
Pigments are divided into hiding pigments
and extender pigments. Hiding pigments are
those that provide hiding ability and color. Ex-tender
pigments extend the hiding ability of the
hiding pigments, add bulk to the paint formula-tion,
and impart a number of other characteris-tics
to both the liquid formulation and the final
coating film.
Hiding pigments include both natural min-eral
pigments and manufactured organic and
inorganic chemical compounds. They are further
divided into color pigments and white pigments.
The red, yellow, brown, orange and black iron
oxides (minerals; hematite, limonite and mag-netite)
are the predominant natural mineral pig-ments
used in paint. They may also be produced
synthetically. Ultramarine blue was at one time
ground lapis lazuli, but has long been made syn-thetically.
Other inorganic color pigments are
manufactured iron, zinc, chromium, cadmium,
lead, or molybdenum compounds. Additionally,
there are a large number of manufactured or-ganic
color pigments. The strongest white pig-ment
is titanium dioxide an inorganic chemical
manufactured from the titanium minerals rutile
and ilmenite. Titanium dioxide is the most
highly used hiding pigment in the paint industry.
Other, less frequently used white pigments, are
manufactured inorganic compounds of lead,
zinc, or antimony.
The red iron oxide, hematite, a natural min-eral
color pigment, has been mined in Arizona
for use in paint. Efforts in Arizona to produce
red mineral pigment from hematite have not yet
been fully successful. The intensity of market-ing
required, and the need to produce a product
that meets industry approval cannot be over em-phasized.
Mean particle size, particle size distri-bution,
purity, color strength, resistance to fad-
3
ing, and consistency from one production batch
to another are very important.
Deposits of minerals that can be mined as
hiding pigments exist in the state. Mica and py-rite
have previously been mined for this pur-pose.
Additionally, numerous deposits of “mi-caceous”
hematite (specularite) and magnetite
occur in Arizona.
An often-repeated comment by the paint
manufacturers interviewed relates to the current
shortage and high prices of titanium dioxide.
Many asked about Arizona’s potential to pro-duce
the product. Arizona does have occur-rences
of the titanium minerals ilmenite and
rutile. Known placer concentrations of ilmenite
and titaniferous magnetite have been described.
Further, low, but possibly economically recov-erable
concentrations of rutile occur as a by-product
in the state porphyry copper ores. Re-search
may be justified to evaluate Arizona’s
titanium resources relating to their availability
and acceptability to feed a titanium dioxide
plant. Such a plant is a major industrial devel-opment
and a decision to install such a plant is
only slightly related to local availability of raw
materials.
Arizona’s Paint Industry
Arizona’s paint manufacturing industry con-sists
of 13 to 16 plants producing over 4 million
gallons of coatings a year. These plants manu-facture
about 30 percent of the paint consumed
in the state. Eight plants produce architectural
water emulsion resin latex paints; 1 produces
industrial coatings, and 4 produce some combi-nation
of coatings products. Specialty coatings
such as swimming pool paint, highway striping
paint, and antiskid floor paints are included. At
least four of the plants are Arizona operations of
larger national or southwestern-based paint
companies.
Quantity Prices paid by consumers
Minimum Maximum
Commodity
Pounds Tons
cents/lb $/ton cents/lb $/ton
LIMESTONE 4,800,000 2,400 2.4 48 12 240
KAOLIN 2,000,000 1,000 6.7 134 48 960
SILICA 1,600,000 800 16.4 328 21.3 426
DIATOMACEOUS
EARTH
810,000 405 27.6 552 29.6 592
FELDSPAR 490,000 245 16.6 332
BENTONITE CLAY 420,000 210
TALC 400,000 200 5.08 102 18.8 376
ATTAPUGITE CLAY 140,000 70 10.4 208
MICA 130,000 65 11.9 238 71 1420
PYROPHYLLITE <100,000 <50
BARITE <50,000 <25 24.1 482
PERLITE na
NEPHELINE SYENITE 18.2 364
PUMICE
Combined total of
26,000 lb to avoid dis-closing
individual
company data.
na
Table 1. Industrial minerals used by Arizona’s paint manufacturers – typical annual consumption.
Industrial Minerals in Paint
Arizona paint manufacturers consume at
least 14 different industrial minerals as extender
pigments or functional fillers. Table No.1 above
lists all 14 by descending order of use.
Typical price ranges are given to help esti-mate
the size of the market. Lowest prices are
often those paid by warehouses and the largest
bulk users while the highest prices are often in
quantities of single pallet loads or single bags.
2
Most material is supplied in 50-pound bags and
most prices are for bagged material.
A majority of the industrial minerals used in
paint manufactured in the state are described in
the remainder of this chapter. All are very finely
ground and must conform to detailed specifica-tions.
Some are interchangeable in certain uses.
Those interested in developing new sources
of these minerals should be fully aware of the
idiosyncrasies of the industrial minerals indus-try.
Suppliers of minerals to the paint industry
are expected to provide sufficient technical data
and support to consumers to tell them how to
use their product.
Calcium Carbonate
The most used extender pigment in paint is
calcium carbonate, primarily as fine ground
white limestone or marble. All grades are finer
than 325 mesh. Calcium carbonate supplies vol-ume
solids at a low cost; at about $1.35 per gal-lon,
it is the cheapest ingredient in paint. It is
used extensively in interior and exterior latex
paints, particularly in pastel colors.
Dark color exterior paints can use only lim-ited
amounts because of calcium carbonate’s
tendency to “frost” or “chalk” when repeatedly
wetted by rain or sprinklers. Such chalking
gives the appearance of color fading, though in
fact it is the calcium carbonate particles break-ing
down at the exposed surface and diluting the
color pigment. In dark colored exterior latex
paints ground silica or ground feldspars are used
in place of a portion of the calcium carbonate.
Nearly all of the ground limestone used by
Arizona paint manufacturers is imported from
Lucerne Valley in southern California. The cost
of shipping ground limestone from Lucerne Val-ley
to Phoenix area manufacturers is approxi-mately
$25.00 per ton in bulk trucks.
Calcium carbonate for paint use is typically available
in 5 or 6 average particle sizes:
0.75 microns
4 microns
5 microns
8 microns
10 microns
15 microns
(U.S. sieve mesh 325 is approximately 44 microns)
The Hegman grind gage is typically used to
denote the largest size particle size in a particu-lar
grind. Hegman grinds of 3 and 4 are used in
flat paints, 7 grind is used in full and semigloss
paints. Whiteness is preferred to be 95 or better
on the G.E. scale, but much material in the low
90’s is used. If cheap enough, material with a
brightness as low as the mid 70’s can be used in
some paints.
Calcium carbonate has essentially no hiding
power, that function being accomplished
primarily by titanium dioxide. Precipitated
calcium carbonate is a manufactured product
that is becoming more popular in place of
ground natural calcium carbonate. It is
extremely pure, has tightly controlled particle
size and shape, and some hiding power.
A typical specification for fine ground cal-cium
carbonate is shown below:
Typical Chemical Analysis
CaCO3 minimum 97-98 %
MgCO3 1%
Acid insoluble 2%
Typical Particle Size Distribution
Retention on 325 mesh screen Nil
Mean particle size 6 Microns
Percentage by weight finer than:
Microns %
30 99.8
20 97
10 75
6 50
Typical Physical Characteristics
Brightness 93
Gallons per pound 0.0445
Pounds per gallon 22.5
Specific gravity 2.71
Moisture less than 0.20%
ph Factor 9.5
Oil absorption 11
Hegman grind 5-6
Kaolin
Kaolin, also known kaolin clay or kaolinite,
and sometimes referred to as china clay or alu-minum
silicate, is an extender pigment that has
some hiding power, more if calcined. It is sec-ond
to calcium carbonate as an extender pig-ment
in paint. Its hiding power is a result of the
3
delaminated clay particles piling up and over-lapping.
As an extender in paints it is chemi-cally
inert, has a high covering power, gives de-sirable
flow properties, is low in cost, is white,
and reduces the amount of expensive white and
color pigments required. In addition, it has ex-cellent
suspension properties and is available in
a wide range of particle sizes that can be used in
many types of paints. For example, coarse-particle
kaolins are used in paints where a dull
or flat finish is required, and fine-particle kao-lins
are used in high-gloss paints.
Large quantities of calcined kaolin and hy-drous
kaolin are used in interior flat wall paints
and in metal primers. Water-beneficiated grades
of kaolin disperse easily in water and are, there-fore,
particularly suited to latex paints manufac-tured
in high speed dispersers. Some kaolin is
chemically treated to make it organophilic or
hydrophobic and thereby suitable for use in ex-terior
oil-base paints. Paint manufacturers are
using calcined kaolin, because of its resistance
to abrasion and dry covering properties, in in-creasingly
large quantities. Calcined kaolin is an
excellent extender for titanium dioxide, the
leading paint pigment, particularly in latex
types. Its use reduces costs and simplifies the
formulation of the paint.
Nearly all of the kaolin clay used by Arizona
paint manufacturers is imported from the Geor-gia/
Florida area of the southeastern United
States. The cost of shipping kaolin clay from the
southeast U.S. to Phoenix area manufacturers is
approximately $90.00 per ton in truckload quan-tities.
A typical specification for fine ground kao-lin
is shown below:
Typical Chemical Analysis
Al203 38.8 %
Si02 45.2%
Na2O 0.05-0.3 %
Ti02 0.6-1.7%
CaO 0.02%
Fe2O3 0.3-0.9%
MgO 0.03 %
K2O 0.05-0.2%
Loss on ignition 13.6-14.2%
Typical Particle Size Distribution
Retention on 325 mesh screen 0.15%
Mean particle size 4.8 Microns
(Equivalent Spherical Diameter)
Percentage by weight finer than:
Microns
20 99+
10 85
5 50
2 21
Typical Physical Characteristics
Physical form Highly Pulverized Powder
Brightness 79-82
Gallons per pound 0.047
Pounds per gallon 21.5
Specific gravity 2.58
Moisture less than 1.0%
ph Factor 3.5-5.0
Oil absorption 30-35
Hegman grind 4+
Refractive index 1.56
Bulk density (Loose) 24 lbs/cu ft
” ” (Tamped) 45 lbs/cu ft
Silica
Fine ground quartz, or ground microcrystal-line
silica, is used as an extender pigment, par-ticularly
in exterior latex paints. Its high purity
and neutral ph make it virtually non-reactive
with other chemical compounds. In paints it
provides flatting with uniformity of gloss and
sheen over surfaces of varying porosity and tex-ture,
while providing uniform suspension and
complete pigment dispersion. Ground silica is
non-chalking and unaffected by exposure to ul-traviolet
light and therefore improves the
weatherability of exterior paints when used in
place of some of the calcium carbonate.
Nearly all the ground silica used by Arizona
paint manufacturers is imported from Illinois.
The cost of shipping ground silica from Illinois
to Phoenix area manufacturers is in the range of
$50 to $70 per ton in truckload quantities.
A typical specification for fine ground silica
or quartz is shown below:
Typical Chemical Analysis
Si02 98.6 %
Al203 0.70 %
Na2O 0.03 %
TiO2 0 .05 %
CaO 0.04 %
Fe2O3 0.05 %
4
MgO 0.04 %
K2O 0.05 %
Loss on Ignition 0.44 %
Typical Particle Size Distribution
Retention on 200 mesh screen 0.06%
Mean particle size 4.8 Microns
(Equivalent Spherical Diameter)
Retention on 325 mesh screen 1.20 %
Retention on 400 mesh screen 2.30%
Retention on 500 mesh screen 4.70 %
Typical Physical Characteristics (Silica)
Brightness 85
Gallons per pound 0.045
Pounds per gallon 22.1
Specific gravity 2.65
Moisture 0.25 %
ph Factor 6-7
Oil absorption 27-31
Hegman grind 4+
Refractive index 1.54-1.55
Bulk density (Loose) 27-29 lbs/cu ft
Hardness (MOHS) 7.0
Specific surface area 5.2 m2/gm
Diatomaceous Earth
Diatomaceous earth is an extender pigment
primarily used as a flatting agent. Because of
the physical structure of the individual particles
making up diatomaceous earth, they lay in a
random, three-dimensional pattern that stiffens,
reinforces and improves the durability of the
filled paint system. The variety of shapes also
provides low density and high absorption. The
effective density of diatomaceous earth fillers is
among the lowest of any mineral fillers at 1.98
to 2.33 grams per cubic centimeter. Diatoma-ceous
earth occupies up to 30 % more volume
per pound than most other filler minerals. This
advantage is critical in those applications requir-ing
light weighting.
A typical specification for fine ground dia-tomaceous
earth or diatomite is shown below:
Typical Particle Size Distribution
Retention on 325 mesh screen 3.0%
Mean particle size 5.2 Microns
(Equivalent Spherical Diameter)
Typical Physical Characteristics
Color Cream
Brightness 72
Specific gravity (Effective) 2.2
Moisture 6.0%
ph Factor 6.5-8.5
Water absorption (weight %) 250
Oil absorption (weight %) 180
Hegman grind 4
Specific surface area 4.5 m2lgm
Bentonite Clay
Bentonitic clays are used as thixotropic
agents due to their gelling ability. Bentonite is
typically classified as an additive instead of an
extender pigment. Its use inhibits running or sag
in the application of the coating.
Attapulgite Clay
Attapulgite clay is used as a thickener and/or
thixotropic agent that aids in spreadability of the
final product and the holding of ingredients in
suspension.
Nearly all of the attapulgite clay used by
Arizona paint manufacturers is imported from
the Georgia - Florida area. The cost of shipping
attapulgite clay from the southeast U.S. to
Phoenix area manufacturers is approximately
$90.00 per ton in truckload quantities.
Feldspar and Nepheline Syenite
Both feldspar and nepheline syenite are used
by some paint manufacturers as a substitute for
ground silica in those paints requiring an eco-nomical
replacement of calcium carbonate in
exterior applications.
Fine ground feldspar and nepheline syenite
are used as an extender pigment, particularly in
exterior latex paints. As with ground silica, it
provides flatting with uniformity of gloss and
sheen over surfaces of varying porosity and tex-ture,
while providing uniform suspension and
complete pigment dispersion. Ground feldspar is
non-chalking, unaffected by exposure to ultra-violet
light, and contains very little free silica.
Ground nepheline syenite contains no free sil-ica.
Both improve the weatherability of exterior
paints when used in place of some of the cal-cium
carbonate.
All of the ground feldspar and nepheline
syenite used by Arizona paint manufacturers is
imported from the east coast of the U.S. or east-ern
Canada. The cost of shipping ground feld-spar
and nepheline syenite to Phoenix area
5
manufacturers is in the range of $80 to $110 per
ton in truckload quantities.
Typical specifications for fine ground
nepheline syenite and feldspar are shown below:
Typical Physical Characteristics
Nepheline
Syentite
Feldspar
Brightness (green filter) 94 95
Oil absorption (rub-out)
ASTM D-281-31
22-23 18-19
Hegman grind 3-4 3-4
PH 9.9 9.3
Coarseness (microns) 44 44
Mean particle size
(microns)
7.5 8
% finer than
74 microns (200 mesh)
100 100
% finer than
44 microns (325 mesh)
99.98 99.95
% finer than 30 microns 98 94
% finer than 20 microns 92 88
% finer than 10 microns 65 60
% finer than 5 microns 37 30
Surface area (m2/g) 0.9-1.0 1.0-1.3
Specific gravity 2.61 2.60
Weight per solid gallon
(lb/U.S. gal)
21.7 21.6
Bulking value (U.S. gal/Ib) 0.0459 0.0463
Apparent built density
(lb/cu ft), loose
58 40
Apparent bulk density
(lb/en ft), packed
70 60
Moisture content (%) 0.1 0.1
Refractive index, average 1.53 1.53
Hardness (MOHS) 5-6 6-6
Particle shape Nodular Nodular
Talc
Talc is a common extender pigment. Its
platy grain structure improves the covering abil-ity
of the paint.
Most of the ground talc used by Arizona
joint cement manufacturers is imported from
Montana. The cost of shipping ground talc to
Phoenix area manufacturers is approximately
$55 per ton in truckload quantities.
A typical specification for fine ground talc is
shown below:
Typical Chemical Analysis
SiO2 61.2%
MgO 31.7%
Al203 0.7 %
GaO 0.19%
Fe2O3 1.1%
Acid solubles 1.9 %
Loss on ignition 5.0%
Typical Particle Size Distribution
Retention on 325 mesh screen nil
Mean particle size 2 microns
(Equiv. Spherical Diameter)
Typical Physical Characteristics
Dry Brightness (G.E.) 90.5
Gallons per pound 0.0445
Specific gravity 2.70
ph Factor 8.8
Oil absorption 50
Hegman grind 6+
Bulk density (Loose) 6.7 lbs/cu ft
Wollastonite is not currently (1989) used in
Arizona’s paint manufacturing industry al-though
some are considering its use. Wollaston-ite
is primarily an asbestos replacement. It will
provide paint film reinforcement, sag resistance,
resistance to cracking, and corrosion resistance.
Mica
Most Mica (wet ground -325, -160, and -100
mesh) is used in paint systems that can take ad-vantage
of the ground mineral’s platy structure
and high aspect ratio (area: thickness). Its parti-cle
shape acts to form a barrier in paints and
coatings. The smooth surfaces aid in lubrication
and luster effects.
Most of the ground muscovite mica used by
Arizona joint cement manufacturers is imported
from North Carolina or the New England States.
The cost of shipping ground muscovite mica
from these locations to Phoenix area manufac-turers
is at least $100 per ton in truckload quan-tities.
A typical specification for fine water ground
muscovite mica is shown below:
6
Typical Chemical Analysis
Theoretical chemical formula H2KAlS(SiO4)3
Typical Physical Characteristics
Color White and lustrous
Particle Shape very thin and platy
Nominal particle size -325, -160, -100 mesh respec-tively
Chemical activity Essentially inert except to H2
Loss on ignition 4-5 %
Pounds per gallon 23.57
Gallons per pound 0.0424
Specific gravity 2.8-3.0
Moisture 0.25 %
Oil absorption 54
Refractive index 1.58
Bulk density (Apparent Loose) 10 lbs/cu ft
Hardness (MOHS) 2.5
Pyrophyllite
Pyrophyllite is used in paints in the same
manner as mica.
Perlite
Perlite is used in an expanded, then a ground
form, as a lightweight filler. Perlite used in
paints must be very white when expanded and
expand into competent “popped” particles.
Barite
Barite (called bayrtes in the paint industry)
is referred to as a “very hard” extender pigment
of very low oil absorption. It is most often used
in epoxy-based paints. It also provides excellent
water resistance and is used in outdoor paints to
protect metal.
All of the ground barite used by Arizona
paint manufacturers is imported from Alberta,
Canada or the east coast of the U.S. The cost of
shipping ground barite to Phoenix area manu-facturers
is in the range of $65 to $110 per ton
in truckload quantities.
A typical specification for fine ground barite
is shown below:
Typical Chemical Analysis
Barium Sulfateminimum 97%
Free Silica 0.03 %
Iron Oxide 0.50%
Typical Particle Size Distribution
Retention on 325 mesh screen trace
Mean particle size 3 Microns
Percentage by volume finer than:
Microns %
16 100
11 100
8 95
6 87
4 71
3 51
2 29
Typical Physical Characteristics
Brightness 93
Specific gravity 4.35+
Oil absorption 10 - 10.5
Hegman grind 6.5-7
Color white
Conclusions
Arizona’s paint industry uses a large variety
of industrial minerals, all of which are imported
into Arizona. The consumption of a few of these
minerals with special properties might be suffi-cient
to justify a small, specialized producer. In
general the Arizona paint industry alone does
not use a sufficient quantity of industrial miner-als
to justify development of a producer. South-ern
California is however, a large market for
industrial minerals in paint. Further, very favor-able
freight rates are available from Arizona to
southern California. It is hoped that the investi-gation
of the paint industry in southern Califor-nia
and other Arizona industries will yield con-sumption
data that will produce totals of suffi-cient
quantities to justify development of new
mines in Arizona. Detailed information on de-posits
of industrial minerals in Arizona may be
obtained from the Department of Mines and
Mineral Resources.