CFAD V. Anacor, |PR2015—01776, CFAD EXHIBIT 1058 - Page 1 of 107
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`

`
`Borates _
`
`....—.o\..-m—o..:»-«:4-u-o-¢vnv:\.—.:'*a4uv~Aa*:;y..-A/4&4»:>.N.«x;»L».\L*::'.\::J:.mean»uh‘>«'n::.aJo;»£a~:...»u,a—w.-§w7‘.:1p\~{?<:E4.;
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`CFAD V. Anacor, |PR2015-01776, CFAD EXHIBIT 1058 - Page 2 of 107
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`

`
`Borates
`
`Handbook of Deposits,
`Processing, Properties, and Use
`
`Donald E. Garrett
`SALINE PROCESSORS. INC.
`OJA1. CALIFORNIA
`
`ACADEMIC PRESS
`San Diego London Boston New York Sydney Tokyo Toronto
`
`
`
`CFAD V. Anacor, IPR2015-01776, CFAD EXHIBIT 1058 - Page 3 of 107
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`

`
`
`
`Academic Press
`a division of Harcottrl Brace & Company
`525 B Street. Suite 1900, San Diego, California 92101-4495. USA
`http://\vw\v.t\pnot.com
`Academic Press Limited
`24~28 Oval Road. London NW! 7DX, UK
`itttp://www.hbuk.co.uk/upl
`
`Library of Congress Catalog Card Number: 98-86055
`
`internutionni Standard Book Number: 042-2760606
`
`PRINTED IN THE UNITED STATES OF AMERICA
`9899i‘)00l
`02 03138987654321
`
`CFAD v. Anacor, iPR2015-01776, CFAD EXHIBIT 1053 - Page 4 of 107
`
`From cover plmzograph: The 20-mule team used to haul borax
`from Death Valley. to Mojave. 1883-1890.
`(For more details,
`see Chapter 4. Figure 7.)
`
`This book is printed on acid-free paper.
`
`Copyright «:3 [998 by ACADEMIC mass
`
`All Rights Reserved.
`No part of this publication may be reproduced or transmitted in any form or by any
`means, electronic or mechanical. including photocopy. recording. or any information
`storage and retrieval system, without permission in writing from the publisher.
`
`

`
`Contents
`
`Preface
`/lcknowlezlgmenrs
`
`.
`
`Chapter 1 Boratc Minerals and the Origin of Borate Deposits
`
`“SW 10 haul bowl
`(For more details,
`
`‘
`
`ransmittcd in any form or by any
`‘copy. recording‘ or any mmmauon
`in writing from the publisher.
`
`-
`
`2
`E
`
`;2m1,4495’ USA
`
`’055
`6o_3
`
`1.1 Bomte Crystal Structure
`
`1.2 Boron Phase Chemistry
`
`1.3 Specific Origin Theories
`1.3.1 Sodium Bomtes
`1.3.2 Colcmanito, Ulcxitc, and Proberlitc Deposits
`1.3.3 Marine Deposits
`1.3.4 Location of Bomle Deposits
`
`References
`
`-
`-
`.
`Chapter 2 Boxax and Sassohte Deposits
`Z1 Borax
`2.1.1 Argentina
`2.1.2 China and Tibet
`2.1.3 India
`2.1.4 Nepal
`2.1.5 Turkey
`2.1.6 United States
`2.1.7 Minor Occurrences
`
`2.2 Sassolite
`
`2.2.1 Italy and Larderelio (also spelled Lardarello)
`2.2.2 Venezuela
`2.2.3 Minor Occurrencci;
`
`5
`
`.4
`
`3
`
`2
`
`[
`
`References
`
`'
`
`xi
`xv
`
`23
`
`29
`31
`32
`41
`44
`46
`
`49
`
`51
`51
`58
`64
`66
`67
`72
`100
`
`101
`
`101
`106
`107
`
`108
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`CFAD V. Anacor, IPR2015-01776, CFAD EXHIBIT 1058 - Page 5 of 107
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`

`
`Vi
`
`Conlcms
`
`Chapter 3 Calcium, Magnesium, or Silicate Buried Deposits
`3.1 Argentina
`3.1.1 Sijas (Pastas Grands)
`
`3.2 China
`3.2.1 Linoning
`
`3.3 Mexico
`
`3.3.] Magdalena Area
`
`3.4 Russia
`
`3.5 Turkey
`3.5.1 Bigadic
`3.5.2 Bmcl
`3.5.3 Kestclck
`3.5.4 Sullancnyiri
`
`3.6 United States
`3.6.] Calico District, California
`3.6.2 Chctco Priceite Deposit, Oregon
`3.6.3 Coastal Range, California (Los Angelcs Area)
`3.6.4 Death Valley, California
`3.6.5 Muddy Mountains, Nevada
`
`3.7 Yugoslavia
`3.7.1 Jnrzmdol Basin, Serbia
`3.7.2 Other Areas, Raska
`
`3.8 Minor Occurrences
`3.8.1 Albania, Greece, and Samoa Island
`3.8.2 Iran and Italy
`3.8.3 North Koren, Romania, Russia, and South Africa
`3.8.4 United States
`
`3.9 Special Borates or Fomiations
`3.9.1 Skams
`3.9.2 Metal Deposits
`3.9.3 Tourmaline
`3.9.4 Boron-Bearing Potassium Feldspar
`3.9.5 Boron-Bearing Albite (Recdmergneriic)
`3.9.6 High-Boron Clays
`References
`
`113
`113
`
`116
`116
`
`119
`119
`
`121
`
`122
`122
`128
`131
`133
`
`134
`134
`139
`140
`145 _
`159
`
`162
`"162
`163
`
`164
`164
`164
`165
`165
`
`167
`167
`168
`169
`170
`170
`171
`
`172
`
`CFAD V. Anacor, lPR20‘l5—O1776, CFAD EXHIBIT 1058 - Page 6 of 107
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`

`
`or Silicate Buried Deposits
`
`_
`9"“"“ ““°")
`
`lsoum Africa
`
`bnlc)
`
`9?
`
`g.»
`
`Chapter 4 Calcium or Magnesium Surface
`(Playa or Mantle) Deposits
`4.1 Argentina
`4.1.] General
`4.1.2 Salnrs
`4.1.3 Geysers, Springs, and Their Mantles
`
`‘
`4.2 Bolivia
`4.2.1 Salllrs do Uyuni and Coipasa
`4.3 Chile
`4.3.1 Chilean Nitrate Deposits
`4.3.2 Slllars
`
`'
`
`‘
`
`4.4 bchina
`4.4.1 Tibet
`
`4.5 Peru
`
`4.5.1 Lagunn Salinas
`4.6 United States
`4.6.1 Alvord Valley, Oregon
`4.5.2 Columbus Marsh, Nevada
`4.6.3 Death Valley and Amargosn Valley, California
`4.6.4 Rhodes Mzlrsll, Ncvnda
`4.6.5 Minor Playas
`4.7 Miscellaneous Sources
`References
`
`‘.
`
`- ..
`-.
`.
`Chapter 5 Lake 01 Brine Deposits
`5.1 Argentina
`5.1.1 Salzlr dc I-Iombrc Mus:-to
`5.2 Chile
`
`5.2.1 Salat dc Atacama
`-
`.
`5.3 China
`5.3.1 Xiao Qzlidzlm Lake
`5.3.2 Da Qaidam
`5.3.3 Nei Mongol Plateau
`
`113
`113
`116
`116-
`
`119
`1] 9
`
`121
`122
`
`122
`128
`131
`
`133
`
`1,34
`134 V
`139
`140
`145.
`159
`3
`](2
`162
`163
`
`164
`164
`164
`165
`155
`167
`167
`
`{[68
`169
`170
`170
`171
`
`172
`
`Contents
`
`vii
`
`183
`183
`184
`194
`
`197
`197
`199
`199
`199
`
`204
`2204
`
`204
`
`204
`206
`206
`209
`212
`218
`222
`223
`224
`
`227
`227
`231
`
`231
`
`235
`235
`237
`237
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`
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`CFAD V. Anacor, lPR2015-01776, CFAD EXHIBIT 1058 - Page 7 of 107
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`

`
`viii
`
`Contents
`
`5.4 Russia
`5.4.1 Indcr Luke and Other Sources
`
`5.5 United States
`
`5.5.1 Plachinhama (Little Borax) Lake, California
`5.5.2 Owens Lake, California
`5.5.3 Senrlcs Lake, California
`55.4 Soda Lakes, Nevada
`
`5.6 Miscellaneous Brine Sources
`
`5.7 Geothermal Brines
`5.7.1 Salton Sea Geothermal Brine and Cerro Prieto, Mexico
`5.7.2 Miscellaneous Hot Springs
`References
`
`Chapter 6 Marine Borate Occurrences: Isotropic Distribution
`6.1 Marine Borate Occurrences
`6.1.1 General
`6.1.2 Asia Minor. Bosnia, and Hercegovina
`6.1.3 Canada
`6.1.4 England
`6.1.5 Germany
`6.1.6 Russia
`6.1.7 Thailand
`6.1.8 '1‘urkey
`6.1.9 United States
`
`6.2 Isotope Ratio, “B/1°13; r5‘”B
`6.2.1 General
`6.2.2 Isotope Distribution
`6.2.3 Factors Determining 6"B
`References
`
`Chapter 7 Mining
`
`7.1 Open Pit Mining
`7.1.1 Argemiria
`7.1.2 Turkey
`7.1.3 United States
`
`7.2 Underground Mining
`7.2.1 Turkey
`7.2.2 United States
`
`CFAD V. Anacor, IPR2015-01776, CFAD EXHIBIT 1058 - Page 8 of 107
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`

`
`Conlcnts
`
`~
`
`-
`
`ix
`327
`327
`
`328
`330
`
`333
`333
`334
`334
`ass
`346
`347
`347
`347
`347
`355
`356
`360
`360
`361
`362
`363
`363
`364
`364
`355
`365
`366
`366
`376
`3'76
`
`385
`385
`389
`390
`
`401
`
`406
`
`7.3 Playas
`7.3.1 Argentina
`
`7.4 Solution Mining
`References
`
`_
`Chapter 8 Processing
`
`8.1 Borax and Kemite
`8.1.1 Argentina
`8.1.2 Tibet
`g_1_3 Turkey
`8.1.4 United States
`8.1.5 Bcneficlation
`8.2 Colemanite
`8.2.1 Argentina
`3.2.2 Turkey
`8.2.3 United States
`8.2.4 Processing
`8.2.5 Bencficiation
`8.3 Ulexite, Probertite, and Othc1'Borates
`8.3.1 Argentina
`8.3.2 Bolivia
`8.3.3 Chile
`8.3.4 China
`8.3.5 Peru
`8.3.6 Russia
`8.3.7 United States
`8.3.8 Processing
`8.3.9 Beneficiation
`,.
`8.4 Bime
`8.4.1 Searles Lake
`8.4.2 Owens Lake
`8.4.3 Miscellaneous Processes
`
`.
`
`8.5 Health and Safety
`8.5.1 Worker Studies: Toxicology
`8.5.2 Environment
`References
`
`A
`Chapter 9 Uses of Boratcs
`9.1 Glass
`
`9.2 Abrasives and Refractories
`
` H
`
`.
`.
`
`_
`
`_
`
`1
`
`‘
`
`240
`340
`
`241
`
`7/43
`244
`
`245
`
`245
`245
`250
`251
`
`I
`
`255
`255
`
`266
`267
`268
`272
`273
`273
`I
`276
`276
`277
`292
`298
`
`305
`305
`307
`309
`
`313
`313
`315
`
`Cnmorma
`
`Cerro Prieto, Mexico
`
`rences: Isotropic Distribution
`
`/ma
`
`
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`CFAD V. Anacor, lPR2015-01776, CFAD EXHIBIT 1058 — Page 9 of 107
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`

`
`
`
`9.3 Agriculture
`9.3.1 Function of Boron in Plants
`9.3.2 Boron's Quantitative Effects on Growth
`9.3.3 Boron Deficiency Symptoms and Fertilization Rxucs
`9.4 Cleaning Compounds and Blcaches
`9.5 Fibers and Composites of Boron and Borides
`9.6 Flame Retardants
`9.7 Fuels
`9.8 Glazes, Frits, and Enamels
`99 Medicine
`9.10 Metallurgy
`9.11 Nuclear Applications
`9.12 Miscellaneous
`References
`
`407.
`407
`
`413
`415
`418
`419
`420
`421
`422,
`423
`424
`425
`425
`428
`
`431
`431
`431
`431
`439
`441
`441
`441
`446
`447
`447
`452‘
`
`453
`453
`467
`469
`
`X
`
`Contents
`
`Chapter 10 Boratc Industry Statistics
`10.1 World Borate Production
`10.1.1 Argentina. Bolivia, Chile, and Peru
`10.1.2 Turkey
`10.1.3 United States
`10.1.4 Other Countries
`10.2 Borate Reserves
`10.3 Boratc Plant Capacity
`104 United States Consumption of Borates
`10.5 United States Borate Prices
`10.6 United States Exports and Imports
`10.7 Product Specifications
`References
`
`Chapter 11 Phase Data. and Physical Properties of Boratcs
`11.1 Solubility Data
`11.1.1 Sodium Boratcs
`References
`
`Index
`
`CFAD V. Anacor, IPR2015-01776, CFAD EXHIBIT 1058 - Page 10 of 107
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`

`
`
`
`Chapter 8
`
`Processing
`
`The processing of each of the commercial borate minerals is a comparatively
`simple procedure, but the desire for good purity, low costs, high recovery
`and efficiency has led to many interesting and sometimes complex variations
`on the operations. This technology is discussed in the following section, in
`addition to the brief reviews given for some of the deposits in the geology
`chapters.
`
`8.1 BORAX AND KERNITE
`
`8.1.1 Argentina
`
`8.1.1.1‘ Loma Blanca
`
`S.R. Minerals (Barbados) mines borax, ulexite, and inyoite from different
`beds in the Loma Blanca deposit, and delivers the ore to drying pads near
`the mine. After drying 3-5 days, each borate is separately run through a
`magnetic separator to remove some of the clay, producing ores with. at least
`26% B203. These are then trucked 180 km southeast to a 4~hectare processing
`plant at Palpada (near Juju). There the ore is further‘ crushed, kiln dried, and
`again sent through magnetic separators, taking the B203 content to 38%. The
`products can also be calcined to 54-55% B203, and sized from 2 mm to 325
`mesh. Shipments are made in 45- to 50—kg sacks or 900- to 1000-kg bulk bags
`(Solis, 1996).
`
`8.1.1.2 Tincalayu
`
`The borate processing capacity of Boroquimica SAMICAF in 1990 was
`rated at 37,700 metric tons/year at its Campo Quijano (Quyano) plant near
`Salta, 227 km (250 mi) northeast of the Tincalayu mine (Norman, 1990). The
`16-18% B203 ore was first ‘given a “cold washing” treatment to remove the
`soluble salts and some slirnes, thus raising its purity (on a dry basis) to 28%
`B203. Next the ore was dissolved in hot mother liquor and water. the brine
`settled, and the clarified hot liquor sent to tanks to cool and crystallize. When
`completed, the brine was decanted and the crystals removed, centrifuged,
`washed, and dried to produce 99.9% borax or pentahydrate. Some anhydrous
`product was also claimed (Dublanc, Malca, and Leale, 1993).
`
`
`
`333
`
`
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`)
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`
`
`334
`Chapters Processing
`
`
`8.1.2 Tibet
` Before the 19003, the processing of borax from Tibet was a closely guarded
`
`
`secret and difficult because the sheep caravan drivers who delivered the borax
`“ore” coated the crystals with any available fat, oil, or grease to reduce
`
`
`the watcr—dissolving loss during transport. The Indian merchants acting as
`
`
`wholesalers also often adultcrated the borax, making each. shipment quite
`
`
`variable. Dissolving and recrystallization was always the first -processing step,
`
`
`but these crystals also had to be redissolved and their brine purified. The
`
`
`initial solution may have required treatment by activated carbon, clay, or
`
`
`equivalent adsorbant to remove the organics, as well as a precipitant for some A
`
`
`impurities, and then a bleed stream removed. For the second crystallization, .
`
`
`7
`perhaps only adsorbents and filtration were required. There was also a need)
`
`
`.
`to produce large crystals as a sign of high quality. Poor refining yielded “small 9
`
`
`crystals with a yellow color imparted by the grease with which the tincal was
`
`
`9
`V
`A
`covered.” Because of its complexity, processing became somewhat of an art,
`
`
`with the Dutch operation in 1773 having its “secret step,” such as clarifying L
`
`
`the initial leach solution with “the aid of the white of an egg or its equivalent a
`
`
`slaked lime and slate.” A picture of borax processing in 1556 is shown in Fig.
`
`8.1 (Travis and Cocks, 1984).
`9
`
` 8.1.3 Turkey
`8.1.3.1 Kirka
`
`
`Borax shipments from the open pit mine at Kirka began in 1972. Mined
` figure 8.1 Borax refining in the sixteentl
`t
`ore, ~40 cm in size, was first distributed onto ‘a 3000-metric-ton stockpile,
`lizer, (D) copper rods, and (E) grinding. (I<\-<
`'. Borax Inc.)
`and starting in 1974 it was was then sent to a 200-metric-ton silo to feed a -
`V
`i
`400,000-metric-ton/year washing plant (Fig. 8.2; later expanded to 600,000 A
`
`metric tons/year; Anac, 1988). In it the ore was first conveyed to a series of
` s 65-mesh filter cake could be sent tr
`crushcrs working in closed circuit with screens, where it was initially reduced
`overflow from the hydroclassifer w:
`to --10 cm, then to ~25 cm with hammer mills, and finally to e-6 mm with’.
`'
`slimes) discarded, and the overflow’
`roll mills. The -2.5-cm ore had been sent to 10,000-metric-ton surge bins to .
`was more than a 10% product loss
`be metered into the roll mills, and the mills’ discharge was screened at a 1-
`0
`1985 the concentrator plant operate
`mm (6-mesh) size. The two fractions (+6 and ~6 mesh) were repulped and ,
`the Sunday shifts used for mainten
`sent to separate scrubbers (vigorously agitated tanks). Then the 1 to 6-mm‘
`maximum output was 2400 metric tr
`fraction was pumped to spiral classifiers (Fig. 8.3), and its coarse fraction ‘
`various potential borax ore benefici
`centrifuged and sent to product bins. The original —1—mm particles were '
`The derivatives (or purified prod:
`9
`repulped in the spiral classilier’s undersize slurry. Then the mixture was cyrc '
`
`metric tons/year of pentahydrate, 17
`V
`cloned and the overflow sent to a hydroclassifcr. Both the cyclone and hydro-
`classifier’s underflow streams (+65 mesh) were filtered. The filter cake was
`. metric tons/year of anhydrous bora
`added to the coarser fraction if the concentrate was to be sold directly, the
`by conveyor belt at 50 metric tons/h
`mixture containing about 32% B203 and 6—8% water. It was then dried and
`lion. It was first dissolved in steam-he
`stored in silos for shipment to the port at Bandirma. Alternateiy, the 6- T0
`0 Solution (saturated at 89°C). The re
`
`
`
`‘
`
`
`
`CFAD V. Anacor, |PR2015-01776, CFAD EXHIBIT 1058 — Page 12 of 107
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`

`
`
`
`
`
`Borax and Kernitc
`
`vnmmmu um«mwmm«wmmm%nm&w
`
`rm Tibet was a closely guarded
`drivers who delivered the borax
`e fat, oil, or grease to reduce
`‘he Indian merchants acting as
`c, making each shipment quite
`always the first processing step,
`I and their brine purified. The
`t by activated carbon, clay, or
`as well as a precipitant for some
`. For the second crystallization,
`equired. There was also a need
`ity. Poor refining yielded “small
`rease with which the tincal was a
`rig became somewhat of an art,
`‘secret step," such as clarifying‘.
`vhite of an egg or its equivalent
`messing in 1556 is shown in Fig.
`
`
`
`at Kirka began in 1972. Mined
`to a 3000-metric-ton stockpile,
`a 200—metric—ton silo to feed a
`
`8.2; later expanded to 600,000
`'as first conveyed to a series of
`s, where it was initially reduced
`ills, and finally to --6 mm with r
`10,000-metric~ton surge bins to ‘
`discharge was screened at a 1-
`1 -6.mesh) were repulped and
`:d tanks). Then the 1 to 6—mm
`g. 8.3), and its coarse fraction, ,
`iriginal —-1-mm particles were j
`Jrry. Then the mixture was cy—
`:1‘. Both the cyclone and hydro;
`re filtered. The filter cake was
`
`ate was to be sold directly, the
`%2 water. It was then dried and
`andirma. Alternately, the 6- to
`
`Figure 8.1 Borax refining in the sixteenth century. (A) Dissolvcr, (B) evaporator, (C) crystal~
`lizcr, (D) copper rods, and (E) grinding. (From Travis and Cocks, 1984; picture courtesy of U.S.
`Borax Inc.)
`
`65-mesh filter cake could be sent to the refinery for further processing. The
`overflow from the hydroclassifer was sent to a thickener, its underflow (the
`slimes) discarded, and the overflow brine was returned to the repulper. There
`was more than a 10% product loss in the washing operation (Table 8.1). In
`1985 the concentrator plant operated three shifts, 7 days/week, with one of
`the Sunday shifts used for maintenance. There were 95 employees, and the
`maximum output was 2400 metric tons/day. Demircioghi (1978) reviewed the
`various potential borax ore beneficiation methods
`The derivatives (or purified product) plant in 1988 had a capacity of 160,000
`metric tons/year of pentahydrate, 17,000 metric tons/year of borax, and 60,000
`metric tons/year of anhydrous borax (Anac, 1988). The washed ore entered
`by conveyor belt at 50 metric tons/hr from either a stockpile or direct produc-
`tion. It was first dissolved in steam-heated tanks at 98°C to form a 26% Na2B4O7
`solution (saturated at 89°C). The resultant slurry was sent to countercurrent
`
`CFAD v. Anacor, |PR2015-01776, CFAD EXHIBIT 1058 - Page 13 of 107
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`

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`
`
`Chapter 8 Processing
`336
`
`
`
`
`
`Figure 8.2 The Klrka borax processing plant. (From Btibank. 1994; pictures courtesy of
`Etibanlo)
`
`Figure 8.3 Spiral classifiers at the Kit
`courtesy of 1'3tibank.)
`
`
`
`.
`and Balutcu (1994) noted th '
`drolyzed polyacrylamlde (PAM) coagulant, 10% anionic, produced a clear ‘
`
`brine with hot, saturated high-montmorillonite slimes (with a “blue color’’)_, '
`but did little for high-calcite or dolomite sllmes. Nonionic polyethylenoxlcle
`(PEO) gave a clear overflow with dolomite slimes at 1200 ppm, and had a_'
`slightly poorer performance at 400 ppm. Cebi, Yerscl, Poslu, Behar, Nesner . A
`and Langenbrick (1994) found that 55- to 61-wt% slurries could be obtained
`from centrifuged (solid bowl) slimes with the aid of a coagulant, but the
`centrate still contained 0.4-2.6% solids.
`The clear brine from the hot thickeners was next filtered in eight pressure
`filters and sent to a 1000-metric-ton surge tank. It then went to either of this "
`vacuum—cooled, growth-type crystallizer circuits. In the pentahydrate unttlt,
`was cooled to 66°C at a 0.23-atm vacuum. Excess fines were removed In
`cyclones and redissolved to allow the production of a coarse product that
`could be centrifuged to a 4—5% moisture content. Borax was produced 111 the
`same manner, but the exit temperature was 46°C. The centrifuged products
`were dried in oil-fired rotary dryers (except one for horax, which was a steamfl
`
`tube unit), The dried products Wt
`bagged shipment.
`part of the bomx was dehydmt
`1anhydmu3- borax‘ The resultant
`and sc1.eened_ Oversized matefia.
`mdersjzed material was rammed
`' megawatt power plant, both baa
`better thermal efficiency with its
`trucked either to the port at B3
`Degmnenozu with its truck dum.
`1meh.ic_ton Storage buildings. Am.
`‘could deliver product to an of th
`mokthe Products to 50_tQn bins 0.
`jsimujtancousty’ using hopper cm-5
`the concenu-ates, The products w.
`ziud the dust from belts and bins
`
`.1
`
`
`
`CFAD V. Anacor, IPR2015-01776, CFAD EXHIBIT 1058 - Page 14 of 107
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`

`
`Borax and Kernitc
`
`337
`
`Figure 8.3 Spiral classifiers at the Kirka borax washing plant. (From Etibank, 1994; pictures
`courtesy of Elihnnlc.)
`
`tube unit). The dried products were screened and sent to storage for bulk or
`bagged shipment.
`Part of the borax was dehydrated in a special furnace at 1100°C to produce
`anhydrous borax. The resultant melt was then cooled, solidified, crushed,
`and screened. Oversized material was recmshcd and screened, whereas the
`undersized material was remeltecl. The processing plant also had its own 3.2-
`megawatt power plant, both, because of its remote location and to achieve
`better thermal cfficiency with its steam-power balance. The products were
`trucked either to the port at Bandirrna, or 18 km to a rail connection at
`Deglrmenozu with its truck dumps into 12 small silos, and its eight 10,000-
`metric-ton storage buildings. Automated vibrating feeders on conveyor belts
`could deliver product to all of the storage buildings, and reclaim conveyors
`took the products to 50-ton bins over the rail lines. Three cars could be loaded
`simultaneously, using hopper cars for the purified products and gondolas for
`the concentrates. The products were weighed and analyzed before shipment,
`and the dust from belts and bins was returned to the plant (Dickson, 1985).
`
`
`
`. (From Etibank, 1994; pictures courtesy of
`
`washed and discarded. Gur, Turkay,
`:1 (of the dry slimes present) of hy-7
`ant, 10% anionic, produced a clea __
`llonite slimes (with a “blue color
`3 slimes. Nonionic polyethylenoicclc
`nite slimes at 1200 ppm, and had ‘
`Cebi, Yersel, Poslu, Behar, Nesner —
`o 61-wt% slurries could be obtained 0
`ith the aid of a coagulant, but the“
`
`0
`
`
`
`rs was next filtered in eight pressure.
`ge tank. It then went to either of Lthe
`circuits. In the pentahydrate unitirt
`tum. Excess fines were removed :in, ~-
`iroduction of a coarse product that’
`. content. Borax was produced in th
`was 46°C. The centrifuged prod A
`:pt one for borax, which was a steam
`
`
`
`‘
`
`
`
`CFAD V. Anacor, lPR2015-01776, CFAD EXHIBIT 1058 - Page 15 of 107
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`

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`
`
`338
`
`Chapter 8 Processing
`
`3
`,
`1,1‘ i
`
`Table 8.1
`Examples of the Kirka Borax Ore and Concentrator Strcams"
`__.._________._________..__.__...._.._..._.__..._.._..____
`A. Chemical analyses (wt%)
`Elements
`Ore
`
`Concentrate
`
`Slimes”
`
`‘
`
`1518
`13.08
`11.84
`13.58
`0.80
`45.52
`
`41.44
`23.09
`27.16
`7.91
`0.40
`100.00
`
`34.56
`2.36
`1.65
`1.54
`0.12
`59.77
`
`88.43
`4.35
`2.60
`1.63
`2.99
`100.00
`
`26.40
`B303
`7.42
`MgO
`5.83
`CnO
`5.60
`S101
`0.12
`R;O3
`54.63
`I-I10, etc.
`Minerals. dry basis (wt%)
`Borax
`69.11
`Dolomite
`13.76
`Clay
`11.14
`Calcite
`3.80
`Ulcxitc
`2.19
`Total
`100.00
`B. Concentrate screen analyses (wt%)
`Wt% on screen
`Mesh size. Tyler no.
`Size (mm)
`3.5
`+3.5
`+6
`17.5
`5
`4-6
`50.5
`16
`102-4
`28.0
`65
`0.2-1.02
`
`--0.2-65 0.5
`
`" Albayrnk and Protopnpas, 1985.
`" In some samples a high percentage of montmotillonitc clay was ’
`present (Gur, Turkay, and Bulntcu. 1994).
`
`The initial plant to refine Turkish borate ore was located at the shipping
`port ofBandirma (Fig. 8.4), and starting in 1975 produced about 55,000 metric iv
`tons/year of borax and 35,000 metric tons/year of boric acid (made from
`colcmanite; Anac, 1988). In 1984, 20,000 metric tons/year of sodium pcrborate,
`and in 1986 an additional 100,000 metric tons/year of boric acid capacity were.
`added. The handling capacity of the port for refined products and concentrates
`was 1.5 million metric tons/year in 1995 (Norman, 1995). All of the borate
`operations were owned and operated by Etibank, a state-owned company.
`
`
`A.
`
`1
`
`8.1.4 United States
`
`>
`
`'
`
`—
`
`I
`
`Figure 8.4 Views ofthe Bnndirma boratc
`1995; pictures courtesy of Etibnnk.)
`
`8. 1.4.1 Boron
`A new processing plant was built in 1956 at the Kramer (boron) deposit
`(at the same time that it converted to open pit mining) to handle the anticipated
`
`CFAD v. Anacor, |PR2015-01776, CFAD EXHIBIT 1058 - Page 16 of 107
`
`

`
`Borax fllld Kcrnilc
`
`
`339
`
`
`
`3$.
`
`5
`
`E
`g
`—
`I
`§
`
`S
`
`‘
`
`3§
`g
`‘
`
`I
`,
`
`V
`
`1 a
`
`nd Concentrator Streams"
`.___..__.....____.._____.
`
`
`
`Conccntraie
`34.55
`2.35
`1.65
`1.54
`0.12
`59.77
`
`Slimcs°
`15.13
`13.08
`11.84
`13.53
`0.80
`45.52
`
`41.44
`
`88.43
`
`4.35
`2.60
`1.63
`2.99
`10000
`
`23.09
`27.16
`7.91
`0.40
`100.00
`‘
`5)
`.__._.__._...._......_..__..
`ymm)
`Wt% on screen
`3.5
`17.5
`6
`50.5
`4
`28.0
`1.02
`0.5
`.___._..__.._..._._.._._._.
`
`‘age of montmoriflonitc clay was
`1994).
`
`I
`
`rate on: was located at the shipping
`in 1975 produced about 55,000 metric
`:ons/year of boric acid (made from
`rnetric touslyear of. sodium perborate,
`tons/year of boric acid capacity were
`for refined products and concentrates
`3 (Norman, 1995). All of the borate 0
`.1 Etibanlc, a stat.e~owned company.
`
`M_
`
`Figure 8.4 Views of the Bzmdirma home processing and shipping facility. (From Etibnnk.
`1995; pictures courtesy of Elibzmk.)
`
`..
`|
`
`.
`
`1956 at the Kramer (boron) deposit‘ -‘
`npitmuixing) to handlethe anticipated, 5
`
`1
`
`r
`
`V C
`
`FAD v. Anacor, |PR2015-01776, CFAD EXHIBIT 1058 — Page 17 of 107
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`

`
`
`
`340
`
`Chapter 8 Processing
`
`lower-grade ores (from 28 to 23% 13203). More handling and washing capacity
`of insolubles was also needed, and an allowance was made for future expan~
`sion, causing the site to be enlarged to 32 hectares (0.32 km: or 80 acres).
`The high~intensity magnetic separators and some of the crude borax partial A
`dehydration equipment (to produce pentahydrate by heating the ore to 110-
`121°C; Corkill, 1937) was then shut down, but the facilities to produce crude,
`anhydrous borax (called “Rasorite”) were maintained.
`In the new plant in 1958 the process started with the blending of different
`grades of ore, keeping the B203 content within a range of several percentage
`points. The ~10-cm (—-4-in.; also quoted as --8-in.) ore from the mine went
`to an automatically programmed stacker belt that discharged it in horizontal
`layers onto a,54,000~metric-ton, 223 X 34 X 13.7-m (730 X 112 X 45-ft) storage
`pile. A reclaiming tunnel 3 m (10 ft) in diameter, 244 in (800 ft) long, and
`0.3 m (1 ft) deep was located under the pile, with 16 withdrawal chutes feeding
`a '76~cm (30-in.) conveyor belt (Dayton, 1957). However, it soon developed
`that outside (machine) reclaiming was necessary for all of the ore, and two
`overhead 1100-metric-ton/hr bucket~wheel reclaimers for each plant (borax
`and boric acid) were later installed (Anon., 1996b). After passing by a tramp
`iron magnet, the ore went to an impactor working in closed circuit with two
`screens to reduce its size to -1.9 cm (—-3/4 in.). It was then sampled and
`conveyed to four 910~metric-ton (1000-ton) ore silos (Fig. 8.5). A fifth silo
`contained crude troua from Owens Lake to convert metaborate in the leach
`solution back to borax, to minimize calcite scaling, and to slightly react with
`the colemanite and ulexite in the ore.
`4
`The 20-25% B203 ore and a small amount of trona were removed from g
`the silos (with some additional blending) and repulped with heated recycle ‘
`brine. The slurry went in series flow through three (a fourth was maintained
`as a spare) 7570-liter (2000-gal) steam-jacketed, agitated dissolving tanks with
`internal steam coils, and having a residence time of 3-4 min. It then was
`passed over 1.9-cm (40-mesh; another reference said 60-mesh) 'I‘yrock vibrat-
`ing screens to remove the coarser undissolved ore, which was washed and
`discarded. The slurry next went to four countercurrent hot thickeners, where
`the slimes settled (originally aided by Separan coagulant), and were washed
`with the limited amount of water allowed bythe plant's water balance. They
`were then discarded, still containing 3-4% B203. Later this mud was centri- .
`fuged (solid bowl), repulped in water (causing some difficulties because it
`tended to peptize to a colloidal state), combined with the screened large solids.
`and pumped to a tailings pond. Heat exchangers reheated the slurry as it was .
`transferred between the 70-m- (230~ft-) diameter, covered, insulated, 2.4-m-
`(8-ft—) high (holding 13.2 million liters, or 3.5 million gal of slurry) tl1ickenerS-
`The clarified hot leach solution overfiowed from the first (later also the second)
`of the thickeners, and was polish-filtered in six Sweetland 46.5-tn’ (500-ftz)
`pressure leaf filters, except for that portion formerly made into _a slightly
`
`.
`
`V
`
`,
`
`_
`
`‘
`
`_
`'
`
`CFAD V. Anacor, IPRZO15-01776, CFAD EXHIBIT 1058 - Page 18 of 107
`
`

`
`
`
`
`
`
`
`
`
`Figure8.5U.S.Borax’:publishedflowsheetofitsboronplant.(FromAnon,1996b;drawingcourtesyofUS.BoraxInc.)"I
`
`
`
`
`
`
`
`
`
`
`
`
`
`. More handling and washing capacity
`llowance was made for future expan-
`) 32 hectares (0.32 km’ or 80 acres),
`and some of the crude borax partim
`itahydrate by heating the ore to 110..
`In, but the facilities to produce crude’,
`ere maintained.
`started with the blending of different
`t within a range of several percentage
`:d as -8-in.) ore from the mine went
`:1‘ belt that discharged it in horizontal
`1 X 13.7-m (730 X 112 X 45—ft) storage
`n diameter, 244 m (800 ft) long, and
`lile, with 16 withdrawal chutes feeding"
`1, 1957). However, it soon developed
`necessary for all of the ore, and two
`heel reclaimers for each plant (borax
`.on., 1996b). After passing by a tramp
`:or working in closed circuit with two
`(-3/4 in.). It was then sampled and
`-ton) ore silos (Fig. 85). A fifth silo
`ce to convert metaborate in the leach“
`cite scaling, and to slightly react with
`
`amount of trona were removed from
`mg) and repulped with heated recycle‘
`rough three (a fourth was maintained
`acketed, agitated dissolving tanks with
`iclence time of 34 min. It then was
`eference said 60-mesh) Tyrock vibrat- 1
`lissolvecl ore, which was washed and
`countercurrent hot thiekeners, where
`Separan coagulant), and were washed’ _
`ed by the plant’s water balance. They
`-4% B203. Later this mud was centri-
`(causing some difficulties because it
`)I‘I1bil’16d with the screened large solids,
`:changers reheated the slurry as it was
`) diameter, covered, insulated, 2.4-m-
`or 3.5 million gal of slurry) thickencrs.
`‘ed from the first (later also the second)
`‘ed in six Sweetland 46.5-m2 (500-ft’) 1
`-ortion formerly made into a slightly
`
`
`
`fine ore bins
`
`
`
`Economizer
`
`ii‘?
`
`.-_.=_v._,35
` .Centn'tuge
`
`
`
`
`’:Thickeners2A&23..
`»;-Thid<ener3f€3§§l-
`
` +'4_Frirnarythtckener§1i, t
`
`L—n:gn'
`
`
`
`Sumpwaters
`
`'Silos
`
`il
`
`iToshipping Silos
`
`1
`
`.,
`gfi '1
`M U
`
`‘
`
`.3
`§°§
`9 9. «“'
`
`V
`
`Hat soft water
`
`
`
`5Mo!liquor
`
`h-B31815Gangue
`“Thickeners1A8:18'-
`
`
`
`CFAD v. Anacor, |PR2015-01776, CFAD EXHIBIT 1058 - Page 19 of 107
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`

`
`
`
`342
`
`Chapter 8 Processing
`
`'
`
`was monitored from a central control 1
`
`maintenance, warehouse, laboratory, bv
`from a fossil aquifer went to a 38~mill
`and then to a 36.6-m- (120-ft-) high, 3,80
`Boiler water was treated by the lime-
`1959). Later, boric acid fusion furnaces
`drous B203 (Anon., 1965b).
`Jensen and Schmitt (1985) noted thz
`modified in numerous ways to increase
`new twin—boom automatic ore stacker
`
`drop height and thus dust) was installe-
`borax and kernite. Six clay—lined solar
`recover part of the horax that was in th
`The largest was 0.49 km” (120 acres) at
`yield of 6% was claimed, bringing the
`have been less than 70%, ‘including the
`borate losses.) In 1985 the borax plant‘
`the boric acid plant as needed to meet
`A 46-megawatt gas turbine cogenera
`(400,000 lbs) of steam per hour at 173
`to replace live of the original six oil/gas—t
`a 3500-hp air blower, and evaporative a
`50% excess capacity over the plant need:
`a 5-year pay—out period. Some plant <
`pcntahydrate, and a 363-metric-tons/hr
`automatically fill and weigh rail cars anc‘
`and shipping costs were reduced, and d1
`mentation and automation, as well as c
`nance, purchasing, and sales were also
`In 1985 the Rasorite line of products
`pean import duties on refined products
`twin air-supported product storage struc
`lopes held to the ground by corrosion
`small internal pressure). There were airlc
`nel entry. The structures were 91 m (30(
`metric tons of product (Anon., 1976). I
`(hemispheric storage structures) were 2
`U.S. Borax’s 91,000-metric-ton/year
`Los Angeles harbor (Wilmington), 2401
`and mud disposal costs became prohibi‘
`ton/year, $80-million boric acid plant v
`at Boron. It had 12 44.5-in (146-ft; also
`and featured “a continuous rotary dn
`
`impure product (classified as an ore, “Rasorite,” to reduce European im-
`port duties).
`The hot 99°C (210°F) brine next passed into one of three (a fourth was a
`spare) Struthers Wells, Oslo-type vacuum crystallizers, which made different
`products on a campaign basis. The brine was cooled to 37.8°C (100°F) when
`borax was being made, and 65.6°C (1S0°F) for pentahydrate (and formerly
`Rasorite). Several patents were issued (Taylor and Council, 1953, 1956, 1957)
`on additives to reduce the borate supersaturation, to minimize equipment
`scaling, and to provide more controlled crystallization. The pentahydrate crys-
`tallizers had a 3123-l/min (825-gal/min) feed rate and 95,000-l/min (25,000-
`gal/min.) internal circulation flow. Washouts were required on a cycle of about
`4 weeks, and an organic phosphate ester dcfoamant was used. The product
`(50% +50-mesh borax; 10% +30-mesh pentahydrate) was centrifuged origi-
`nally in 16 Sharples automatic basket centrifuges for the refined products,
`and three solid bowl centrifuges (operating at 800 rpm) for the crude pcntahy-
`drate. The later units were replaced in 1996 with vacuum belt filters, which
`provided much better product washing (three stages) and reduced crystal
`breakage and dust (from 12 to 5%). The impurities: S04, CO3, Cl, and As
`were also reduced, as was product loading times. The moisture content did 1
`increase, however, along with caking problems, until the dryers were modified
`(Anon., 1996c). A dilute boric acid wash was used to reduce the product's
`caking tendency.
`The borax was next dried in one fluid-bed, three oil-fired rotary, and seven
`steam-heated Wyssmont Turbo dryers. The Turbo dryers had multiple rotating
`trays, with rakes turning the product and advancing it from tray to tray. This 9,
`provided very gentle heating to prevent dehydration of the products (except
`for the pentahydrate, which was purposely sold with 4.75 moles of water).
`Some of the borax was next partly dehydrated in four rotary kilns and then
`melted in four rectangular, side-fed, V-shaped-bottom, gas~fired reverbratory
`furnaces. The molten borax was solidified on 1.2-m- (4-ft-) diameter chilled
`rolls, further cooled on 0.91 X 18.3-in (3 X 60-0’) Carrier vibrating conveyors.
`broken with r