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Environmental and Climate Technologies
doi: 10.2478/rtuect-2013-0006

_________________________________________________________________________________________________2013 / 11

Technologies for Decreasing Mining Losses
Ingo Valgma1, Vivika Väizene1, Margit Kolats1, Martin Saarnak1, 1Tallinn University of Technology
Abstract - In case of stratified deposits like oil shale deposit in
Estonia, mining losses depend on mining technologies. Current
research focuses on extraction and separation possibilities of
mineral resources. Selective mining, selective crushing and
separation tests have been performed, showing possibilities of
decreasing mining losses. Rock crushing and screening process
simulations were used for optimizing rock fractions. In addition
mine backfilling, fine separation, and optimized drilling and
blasting have been analyzed. All tested methods show potential
and depend on mineral usage. Usage in addition depends on the
utilization technology. The questions like stability of the material
flow and influences of the quality fluctuations to the final yield
are raised.
Keywords – oil shale, losses, mining, extraction.

I. INTRODUCTION
In case of stratified deposits like oil shale deposit in
Estonia, mining losses depend on mining technologies.
Stratified deposits are being developed from lower bedding
depth to deeper and more complicated conditions [23].
Continuously the environmental or social restrictions require
increasing coefficients that increase mineral losses [20]. This
could be limited with the help of technological development
[34,13, 36]. During the period starting from 1916 many
technologies have been used and tested [31]. Currently the
market economy is the main driving force for choosing
technologies. This causes short term choices and works
against sustainability.
Current research focuses on extraction and separation
possibilities of oil shale. Selective mining, selective crushing
and separation tests have been performed, showing
possibilities of decreasing mining losses. Rock crushing and
screening process simulations were used for optimizing
fractions. In addition mine backfilling, fine separation of oil
shale, and optimized drilling and blasting have been analyzed.
All tested methods show potential and depend on mineral
usage [37]. Usage also depends on the utilization technology.
Questions like stability of the material flow and influences of
the quality fluctuations to the final yield are raised. Tonnage,
calorific value and size distribution of the product form the
quality indicators [43]. Avoiding losses in any of these
processes decreases mining losses and has a positive effect on
resource usage and sustainability. In addition, decreasing
losses increases the amount of resource and sustainability of
energy supply for the country [30, 32]. If optimized
technology allows maintaining required productivity, it could
be applied, even if fitting into the existing technological
structure is taking longer than technically available [33, 35, 8].

The aim of the current study is to clarify what technical
solutions could be applied for decreasing oil shale mining
related losses.
II. ANALYSES AND TESTS
A. Selective mining
Selective extraction of oil shale seam was analyzed to
understand following methods:
1. Cutting with bulldozer and excavator rippers
2. Cutting with surface miners
3. Cutting with longwall miners
4. Cutting with shortwall miners.
a) Cutting with rippers
Selective extraction of the oil shale seam can be done by a
bulldozer ripper or hydraulic excavator ripper. Ripping is a
low-selective technology [42]. In deeper surface mining areas,
100 tonnes class bulldozers were used and in more weathered
areas or partial ripping zones, the 60 tonne class was used.
One disadvantage of bulldozer ripping is excessive crushing of
oil shale by heavy bulldozers with crawlers [18].
b) Cutting with surface miners
Tests with surface miners Vermeer T1255 and Wirtgen
2500 SM were carried out. The tests were followed after
longer period tests with smaller class surface miners during
the last 25 years. Tests have been performed with different oil
shale and limestone layers. Surface miners are considered as
BAT (Best Available Technology) for surface oil shale mining
extraction [12, 42, 18, 15, 5].
c) Cutting with longwall miners
The planning and testing has been done for longwall mining
possibilities. Shearers were used and tested for 30 years in five
oil shale mines in Estonia [1]. Longwall technology has also
been chosen as one of the alternatives for phosphate rock
mining [41]. Technologically, this technological solution has
improved compared with initial possibilities. Since the
hydraulic support system was limiting the height of the
longwall face (1,5 m) and the power of the shearers was
relatively low (210 kW) the losses have been 50% in longwall
section. Today’s sharers utilize power in the range of 2200
kW, which is 10 times higher than in the tested units. Since
the productivity (equal to income) could be increased,
longwall technology is one of the possibilities for lowering
losses. In case of removing protective side pillars between
longwall section, rough estimation shows, that losses could be
lowered down to 5% taking into account the geological
dislocations and disfollowing the exact horizontal plane of the
oil shale seam. The main obstacle of longwall shearing

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technology is solving environmental and social questions,
regarding subsiding the ground and accepting certain areas
where such subsiding could be allowed. In comparison to the
surface mining stripping in the open cast mining areas,
longwall mining could be considered as a technology which
causes less impact to the landscape. The ground would be
lowered by up to 70% of the created space. That makes 2
meters. In open casts, even the fluctuations in the leveled
overburden spoil could be 5 meters. In trench or ditches areas,
the level fluctuations are up to 40 meters. This makes longwall
mining the most sustainable mining method for oil shale.
d) Cutting with shortwall miners
Evaluations of breakability have been made with
roadheaders F2 and 4PP-3. As a recommendation, a doubledrum road header was proposed. Currently the power of the
machines has increased and pick properties allow cutting
harder rock. It is proposed, that both longitudinal or transverse
head continuous miners (roadheaders) could be used for
cutting oil shale [12]. The selectivity option is directly related
to the waste material handling and should be tested in the mine
[11].
Shortwall miner utilization could be the solution for making
development entrances, drifts and rooms for mining. In case of
satisfactory cutting performance, it could be used for
extracting oil shale in production sections as well. The tests
have shown, that shortwall mining is a promising technology
and requires, as with longwall mining, surface miner mining
and axle bucket crushing changes in some operations and
processes in mining technology. Shortwall mining requires
fast roof supporting technology. The supporting could be in
addition in some extent easer because of lower possible
fragmentation of rock caused by absence of blasting in the
mine.
B. Selective crushing
For selective crushing, the following methods were tested:
1. crushing in a drum (Bradford drum) with help of rock
falling impact and hammer crusher inside the drum;
2. impact crusher in underground sections as first stage
crusher or impact crusher for aggregate production
from oil shale waste rock;
3. axle crusher buckets with cutting and skimming
process.
An impact crusher has been used in underground sections as
a first stage crusher and for aggregate production from oil
shale waste rock that is limestone [27].
The purpose of underground crushing is to reduce ROM
(run of mine) size to the required size of up to 300 mm for
transporting it on belt conveyors to the surface.
C. Separation
Separation tests have been performed by jigging and
cycloning. The purpose was to find out the percentage of the
fine material that could be separated. Jigging tests have shown
relatively good results allowing separating initially mixed
material into five different fractions. The calorific value of
best fraction is highest and the limestone fraction in opposition

should be considered as the ready selected material for
limestone aggregate. Up to now the main focus has been
mechanical experimenting with jig. The main obstacle of the
technology could be achieving required productivity. It is
similar to the filter press technology where the productivity of
the single unit could be low. On the other hand, if the
production line could be completed with different stages, the
required productivity could also be to some extent lower. To
decrease required machine productivity for the same output,
drum crushing or axle crushing could be used prior to the
jigging.
Cycloning has shown that the calorific value of cycloned
and non- cycloned fine material has no remarkable difference.
Since cycloning could be done on many variations, the initial
test could be considered as failed because of short time and no
variations. These tests should be continued, preferably with
apilot unit or laboratory units at first.
D. Rock crushing
For crushing, the following options have been analysed:
1. Crushing with sizers
2. Crushing with impact crushers
3. Crushing with double drum crushers
4. Crushing with drum crusher
5. Crushing with jaw crusher.
Crushing process simulations were used to evaluate the
distribution curves of the final product. The necessary data for
this purpose is bulk density of material and the maximum size
of the particles going for crushing. In order to get optimal
results on certain cases, crushing units, crushers and mobile
crushers can be added to the scheme. This gives extra value in
lowering engineering costs, on experimenting with different
devices and on further changes [19, 45].
As an example, material data for thesimulation program has
been:

Input material < 1000 mm

Solid density 1,84 t/m3

Crushability 85% - which is the maximum

Productivity 1000 t/h

Gravel 31% - does not influence the results (Fig. 1.).
The value of abrasiveness has been between 0,1…1500 g/t,
calculations show that this does not affect the simulation
results. Neither does moisture. The crusher output cavity is set
on 180mm which means that the maximum size of the
outcoming particle is 200mm.
The workload of the impactor crusher is 97% of the
maximum capacity. After crushing, the feed moves to the
roller screen, where the feed flows into three classes:

0…25 mm 22,8%

12…107 mm 55,2% - which include 11% 12…25
mm (Fig.2.)

107…200 mm 22% .
It can be detected that the fines part is 28,9%.

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programme. Sizers are even more complex, because they have
been used only a few years and therefore are relatively new
products among crushers. In Estonia there are a lot of
questions concerning the fines in the crushing process.

Fig. 1. Experiments resulted in fines generation of 2,2% [10]

E. screening
Two basic screening solutions have been analysed in
addition to the traditional vibration screening:
1. Screening in drum screen
2. Screening on rotary screen
3. Screening on roller screen.

Fig. 1. Material data insertion window

F. Mine backfilling
The tests contained testing of mixes properties of the
backfill material, testing of backfilling technology and
analyzing backfilling material flows. The main hypotheses are
that backfilling reduces mining losses and the amount of waste
on the ground surface [27]. In addition it increases land
stability [12]. Stability issues have been developed in sense of
information availability. Mapping, special information
systems and seismological methods allow one to detect any
collapses which have occured [21, 25].
G. Fine separation
Fine separation tests were carried out with CDE equipment
and with jigging equipment. The aim of the fine separation test
is to separate fines from pulp before they reach sedimentation
pond and to take it into use as a product.

Fig. 2. Flow data

Fines are added on the secondary crushing/particle size is
107...200 mm. Calculations have shown that in this way 5% of
fines are added. At the present moment the best crushing
option in making the minimum fines is crushing with the sizer.
Experiments show that the minimum in generating fines is
achieved when the rotating speed of sizer was 175 rpm. In
slow rotation the generation was 11,8% and fast rotation gave
6,5% of fines (Fig.3).
As experiments show, it is possible to decrease the fines
generation which mostly is considered to be waste.
Each simulation manufacturer focuses on separation
methods or some part in the separation process. When it
comes to crushers, then simulations are also manufacturer
based and reflect types and models, what the company offers
[7, 4]. Newer products are introduced in the simulation
programmes later. In case of the roll crusher for example, the
characteristics and behaviours are still added to the

III. RESULTS AND DISCUSSION
A. Selective mining
a) Cutting with rippers
In Ubja oil shale open cast, the productivity of oil shale
hydraulic ripping was nearly 600 m3/h. At the Ubja open cast,
overall oil shale losses are 0% based on the Environmental
Register. Bulldozer ripping is considered as semi-selective
ripping where seam losses make 12% in comparison to 5%
with surface miners [42]. The first problem of ripping
technology has been power of ripping machines. Before 100
tonnes class bulldozers were applied, the low ripping power
was one of the main concerns. Excavator ripping is in similar
stage like bulldozer ripping has been in its beginning stage.
The power of the excavator ripper is not satisfactory to reach
required productivity. Excavator ripping does not solve the
losses question because of the principle of vertical movement.

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Excavator ripping could be considered in low bedding areas,
where drilling and blasting is prohibited, the oil shale seam is
weathered meaning weaker bonds between layers. A bulldozer
ripper, therefore could be used as low selective miner, but it is
limited by availability of keeping losses down. The main
problem is limestone and oil shale pieces and lumps that
contain both material and could not be separated by the ripper.
If needed, one of the solutions could be skimming with axle
crushers.
b) Cutting with surface miners
It was found that extracting with a high selective surface
miner is the main possibility of decreasing losses in case of
surface mining. The main obstacle for using such technology
is the partly unsolved overburden stripping technology. In the
future, combined methods should be considered like high
selective cutting plus selective axle crushing for aggregate
separation.
Mining with surface miner Wirtgen 2500 SM helps to
reduce losses and improve calorific value of oil shale. It is
possible to mine limestone and oil shale seams separately with
higher accuracy than rippers (2-7 cm) with deviations about
one centimetre [42]. Losses can be decreased from 12 percent
to 5 percent compared to ripping [18]. Based on practical data,
the surface miner enables to increase the output of oil shale up
to 1 tonne per square meter. The oil yield increases 30%,
reaching up to 1 barrel per tonne of oil shale during the oil
shale retorting, because of better quality, meaning higher
calorific value of the material that is sent to the retorts [42].
c) Cutting with longwall miners
It was found that distribution of required large particles of
oil shale is possible with longwall shearers.
The practice with longwall shearers shows that the subject
for cutting is oil shale and the larger size is distributed to the
limestone fraction [1]. This is due to the hardness difference of
the rocks. Longwall mining could decrease horizontal losses
by 20 to 40%.
d) Cutting with shortwall miners
One of the main advantages that a shortwall miner could
present are the possibility of avoiding weakening pillars in the
mine by blasting [20].
This in addition could give the possibility to decrease pillar
size and to decrease losses left to the pillars. Pillar losses that
are caused by pillars with cross section area of 16 to 49 square
meters could be decreased therefore by 16 to 28% with
avoidance of the 0,3 zone by sides of the pillars.
The pillas strength and stability of the ground are directly
related but have the opposite influence on sustainability. In
case of backfilling this dilemma could be solved [22]. In some
areas also smooth and directed subsidence could be solution.
B. Selective crushing
The underground crushing process where ROM (run of
mine) size is reduced to the required size up to 300 mm has no
direct influence on the percentage of losses. Nevertheless,

ROM size distribution is influenced by impact crushing and
fines are produced. In case of oil production with vertical
generators, fines and small classes of oil shale are considered
as waste, if no other uses are found, like cement, electricity or
oil production with SHC technology.
Selective crushing is important both for cleaning and sizing
oil shale and cleaning and sizing limestone. Therefore
selective crushing or selective mining methods are
recommended [27].
C. Rock crushing
a) Crushing with sizers
One of the options could be using slow rotating or
optimized rotating sizer for oil shale ROM crushing.
According to the recommendations of crusher producers, all
crusher types are suitable for crushing oil shale [25]. In
relation to the moisture content, jaw crusher and gyratory
crushers are unsuitable, requiring relatively dry material
(<5%) . A roll sizer should be able to crush up to 175 MPa
material and up to 15% moisturised material. In comparison to
the other types of crushers, a sizer should give the smallest
percentage of fines [24, 17, 10, 2, 9, 6]. The productivity of
the sizer could reach 10000 tonnes per hour (Table 1)
TABLE I
SIZER PRODUCERS
Producer
Sandvik [24]
MMD [17]
FLSmidth [6]
Williams Patent
Crusher
and
Pulverizer
Company [44]
Thyssenkrupp
[25]
McLanahan [16]
Joy [10]
Caterpillar [3]

Sizer or feeder
breaker
Sizer
Sizer
Sizer

Model
CR610
MMD 1500
ABON

Producti
vity, t/h
8000
10000
10000

Feeder breaker

Williams
Feeder
Breakers

5000

Sizer

Thyssenkrupp
1500

10000

Sizer/Feeder
breaker
Sizer/Feeder
breaker
Feeder breaker

1800

Fines share could be reduced down to 2,2 % from 6 to 12%
with low and fast rotation in addition with Matched Velocity
Technology (MTV) [9].
D. Fine seperation
The possibility of using fine oil shale that is flushed away
by the HMS (Heavy Media Separation) process could increase
energy of used oil shale and avoid the need for settling ponds
or filter presses [38]. The main idea could be the separation of
fine oil shale from fine clay and limestone particles.
Fine separation tests were carried out with cyclones and
fine screens and with jigging. The amount of fines thatwere
separated from the separation pulp was in the range of 0,2-5,1
%. The average amount of fine that was separated was 2,7 %
of inflow (TABLE II). 2,7 % of fine was divided into two
classes with size 0-8mm and 0-5mm. The calorific value of
inflow was in the range of 10,3-10,8 MJ/kg with an average of

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10,5 MJ/kg and outflow was in the range 1,2-2,4 MJ/kg with
an average 1,8 MJ/kg.
TABLE II
TEST RESULTS OF FINE SEPERATION
Sediment %

Water %

Average concentrate Inflow

21

79

Average concentrate Outflow

18

82

Average concentrate

2,7

E. Optimised drilling and blasting
Drilling and blasting as the main method for extracting oil
shale has been used and in some extent optimized.
CONCLUSIONS

Losses vary from mine to mine considerably depending on
different factors. The main factor is geological bedding, the
second is legal framework and the third -- mining technology.
Mining technology is the main factor that could be changed
realistically by miners. Currently surface mines leave less
losses and advanced technologies create less losses. Up to now
the technical ultimate yield has not been reached. In the future,

the percentage of losses will increase because mining is
moving in deeper zones (Fig. 2, Fig. 3, Fig. 4). The largest
mine “Estonia” alone accounts for most of the losses if it takes
into account only tonnes. In practice, logistics quality and
availability are also factors that have to be considered. On the
other hand, requirements for the continuous flow of good
quality oil shale will be required and environmental costs will
increase. A tTechnological solution should be analyzed and
tested for implementing. Currently the oil shale mining
industry is missing broad and objective analyze for
technological development.
In addition in case of surface mining, stripping technologies
should be evaluated. In many cases fragmented overburden
placement and usage of overburden bridges could also give
positive results for decreasing mining losses [39, 12]. In case
of smooth stripping technology, influence to the landscape
could also be decreased [29, 28].
Using continuous technologies for decreasing mining losses
could give positive effects on the even distribution of fuel oil
shale [14]. In the future, rapid development, computerized
directing, and virtual analyzing could be applied [40, 37].

40
4400
30

3900

Losses, kt/y 2006
Losses, kt/y 2007

3400
20

Losses, kt/y 2008
Losses, kt/y 2009

2900

Losses, kt/y 2010
Losses, kt/y 2011

2400

10

Losses, kt/y 2012
Average losses, kt/y 2006‐2012

1900

Losses, %, 2006
0

1400

Losses, %, 2007
Losses, %, 2008
Losses, %, 2009
Losses, %, 2010

900
‐10

Losses, %, 2011
Losses, %, 2012

400

Average losses, %, 2006‐2012
‐100

‐20

Fig. 2 Tonnage and percentage of oil shale mining losses in Estonian mines from 2006 to 2012 
9000

8000

7000

Oil shale, kt/y

6000

5000

Production, kt/y 2012
Losses, kt/y 2012

4000

3000

2000

1000

0

Estonia 
mine

Sirgala open  Viru mine
cast

Narva open  Aidu open 
cast
cast

Ojamaa 
mine

Põhja‐Kiviõli  Sompa mine Vanaküla 
open cast
open cast

Ubja open 
cast

Fig. 3. Tonnage of oil shale mining production and losses in Estonian mines in 2012

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19500

Oil shale, kt/y

14500

9500

4500

‐500

Ubja open cast
Viru mine

Prod Used 
Prod Used 
Prod Used 
Prod Used 
Prod Used 
Prod Used 
Prod Used 
Losse
Losse
Losse
Losse
Losse
Losse
Losse
uctio resou
uctio resou
uctio resou
uctio resou
uctio resou
uctio resou
uctio resou
s, 
s, 
s, 
s, 
s, 
s, 
s, 
n, 
rce, 
n, 
n, 
rce, 
rce, 
n, 
n, 
rce, 
rce, 
n, 
rce, 
n, 
rce, 
kt/y 
kt/y 
kt/y 
kt/y 
kt/y 
kt/y 
kt/y 
kt/y  kt/y 
kt/y  kt/y 
kt/y  kt/y 
kt/y  kt/y 
kt/y  kt/y 
kt/y  kt/y 
kt/y  kt/y 
2006
2011
2007
2012
2008
2009
2010
2006 2006
2011 2011
2007 2007
2012 2012
2008 2008
2009 2009
2010 2010
101 101
109 109
162 162
58
58
59
59
146 146
107 107
627

1706 2333

Sompa mine

0

Sirgala open cast

275

Põhja‐Kiviõli  open  cast 101

2345 2620
818

660
18
331

1761 2421
33

708

51

2779 3110

1699 2407
1

334

1

12

2587 2921

31

42

2261 2589

624
17
398

1836 2460
77

94

2813 3211

638
58
368

1730 2368
315

373

2677 3045

554
83
286

1828 2383
299

381

2696 2982

919

53

896

950

57

908

965

51

868

919

70

885

955

40

637

676

37

615

652

12

26

38

43

96

139

6

12

18

79

204

283

36

288

324

240

799

1039

244

1542 1786

Narva open cast

119

727

846

195

1375 1571

136

1090 1226

Vanaküla open cast

‐88

516

428

‐83

832

‐55

761

Aidu open cast

328

1740 2446

0

Ojamaa mine

Estonia mine

706

749

706

224
7

1147 1371
410

417

340
6

1493 1832
481

487

324
10

1539 1863
575

586

15

299

314

2158 4478 6636 2147 4499 6646 2356 4738 7094 2359 4500 6859 3004 5537 8541 3126 6188 9313 2555 5699 8254
53

1286 1339

69

1682 1750

75

1664 1739

100

1582 1682

147

1724 1871

156

1770 1926

29

1060 1088

Fig. 4. Production tonnage and tonnage and percentage of oil shale mining losses in Estonian mines from 2006 to 2012 

IV. ACKNOWLEDGEMENTS
The research is supported by study: Sustainable and
environmentally acceptable Oil shale mining No. 3.2.0501.110025 and Doctoral School of Energy and Geotechnology II
DAR8130/1.2.0401.09-0082.
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17. MMD sizers. Available: http://www.mmdsizers.com/ [Accessed:
04.2013]
18. Nikitin, O.; Väli, E.; Pastarus, J.; Sabanov, S. The Surface Miner
Sustainable Oil-shale Mining Technology Testing Results in Estonia.
Proceedings of the Sixteenth International Symposium on Mine
Planning and Equipment Selection and the Tenth International
Symposium on Environmental Issues and Waste Management in Energy
and Mineral Production: Mine Planning and Equipment Selection and
Environmental Issues and Waste Management in Energy and Mineral
Production. Bangkok, Thailand, December 11-13, 2007. p.678.
19. Nikolov, S. A performance model for impact crushers. Minerals
Engineering, 2002.vol.15(10), p.715.-721.
of Tallinn University of Technology, Tallinn, pp 113
20. Orru, M.; Väizene, V.; Pastarus, J.-R.; Sõstra, Y.; Valgma, I.
Possibilities of oil shale mining under the Selisoo mire of the Estonia oil
shale deposit. Environmental Earth Sciences, 2013, p.1-11.
DOI 10.1007/s12665-013-2396-x
21. Otsmaa, M.; Soosalu, H.; Valgma, I. Detection of Mine Collapses with
Seismic Methods in the Estonian Oil Shale Mining Area. 12th
International Symposium "Topical Problems in the Field of Electrical
and Power Engineering", Kuressaare, Estonia, 2012, p.171 – 172.
22. Reinsalu, E.; Valgma, I Geotechnical processes in closed oil shale
mines. Oil Shale, 2013., vol. 20(3), p.398 - 403.
23. Reinsalu, E.; Valgma, I. Oil Shale Resources for Oil Production. Oil
Shale,2003, vol. 24, p.9 - 14.
24. Sandvik Sizers. Available: http://mining.sandvik.com/ [Accessed:
04.2013]
25. Soosalu, H.; Valgma, I. Detection of mine collapses with seismic
methods- a case study from Estonia. Resource Reproducing, Lowwasted and Environmentally Protecting Technologies of Development of
the Earth Interior, p.1.
26. Thyssenkrupp.
Available:
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27. Tohver, T. Utilization of waste rock from oil shale mining. Oil Shale,
2010., vol. 27(4), p. 321 - 330.
28. Valgma, I. An evaluation of technological overburden thickness limit of
oil shale open casts by using draglines. Oil Shale,1998., vol. 15(2), p.
134 - 146.

46
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Environmental and Climate Technologies

_________________________________________________________________________________________________2013 / 11
29. Valgma, I. Post-stripping processes and the landscape of mined areas in
Estonian oil shale open casts. Oil Shale 2000, vol. 17(2), p. 201 - 212.
30. Valgma, I. Estonian oil shale resources calculated by GIS method. Oil
Shale 2003, vol. 20(3), p. 404 - 411.
31. Valgma, I. Oil shale mining in Estonia and Russia. Encyclopedia of life
support systems. EOLSS Publishers, 2000
32. Valgma, I. Geographical Information System for Oil Shale Mining MGIS. Tallinn: 2002 Tallinn Technical University Press
33. Valgma, I. Dependence of the mining advance rate on the mining
technologies and their usage criteria. Valgma, I. (Toim.). Resource
Reproducing,
Low-wasted
and
Environmentally
Protecting
Technologies of Development of the Earth Interior (2 pp.), 2009.
Tallinn: Department of Mining TUT; Russian University of People
Friendship
34. Valgma, I. Oil Shale mining-related research in Estonia. Oil Shale,
2009, vol. 26(4), p.445 - 150.
35. Valgma, I.; Karu, V.; Viil, A.; Lohk, M. Oil shale mining
developments in Estonia as the bases for sustainable power industry. In:
4th International Symposium "Topical Problems in the Field of
Electrical and Power Engineering" : Doctoral School of Energy and
Geotechnology: 4th International Symposium "Topical Problems in the
Field of Electrical and Power Engineering", Kuressaare, Estonia, 15..20.01.2007. (Toim.) Lahtmets, R.. Tallinn: Tallinn University of
Technology, Faculty of Power Engineering, 2007, p.96 - 103.
36. Valgma, I.; Kattel, T. Low depth mining in Estonian oil shale depositAbbau von Ölschiefer in Estland. In: Kolloquium Schacht, Strecke und
Tunnel 2005 : 14. und 15. April 2005, Freiberg/Sachsen: Kolloquium
Schacht, Strecke und Tunnel 2005 : 14. und 15. April 2005,
Freiberg/Sachsen. Freiberg: TU Bergakademie, 2005, p.213 - 223.
37. Valgma, I.; Leiaru, M.; Karu, V.; Iskül, R.. Sustainable mining
conditions in Estonia. 11th International Symposium "Topical Problems
in the Field of Electrical and Power Engineering", Doctoral Scholl of
Energy and Geotechnology, Pärnu, Estonia, 16-21.01.2012 p.229 – 238).
38. Valgma, I.; Reinsalu, E.; Sabanov, S.; Karu, V. . Quality control of
Oil Shale production in Estonian mines. Oil Shale,2010, vol. 27(3), p.
239 - 249.
39. Valgma, I.; Torn, H.; Erg, K. The impact of infiltration dam on the
groundwater regime in the Kurtna landscape reserve area. Oil Shale,
2006, vol. 23(1), p. 3 - 14.
40. Valgma, I.; Västrik, A.; Kõpp, V. Sustainable mining technologies for
Estonian minerals industry. Lahtmets, R (Toim.). 9th International
Symposium Pärnu 2010 “Topical Problems in the Field of Electrical and
Power Engineering” and “Doctoral School of Energy and
Geotechnology II”, Pärnu, Estonia, June 14 - 19, 2010, p.69 – 73.
41. Valgma, I.. Sustainable phosphate rock mining. Proceedings of the
Estonian Academy of Sciences. Engineering,2010, vol. 3(1), p.13 - 22.
42. Väli, E. Best Available Technology for the Environmentally Friendly
Mining with Surface Miner. PhD thesis, 2010.
43. Väli, E.; Valgma, I.; Reinsalu, E. Usage of Estonian oil shale. Oil
Shale, 2008, vol. 25, p. 101 - 114.
44. William
sizer.
Available:
http://www.williamscrusher.com/feeder_breaker/default.asp [Accessed:
04.2013]
45. Zhao, L.M.; Chen, L.J.; Zhang, D.B.; Li, Y. Modelling and
Simulation of Particle Breakage in Jaw Crushers. Editor(s): Zhao, H.
Mechanical And Electronics Engineering Iii, PTS 1-5. Applied
Mechanics and Materials. Vol.130-134, 2012 p.1148-1151.

Ingo Valgma has owned his Dr. Eng
degree from Tallinn Technical University
in 2002. His fields of studies are mining
technology, geographical information
systems and environmental aspects of
mineral industry.
He is PROFESSOR at Chair of Mining
Engineering in Tallinn University of
Technology and the head of the
Department of Mining.
He is member of the board of Estonian
Association of Engineers, member of the
Professional board of Estonian Explosives
Engineers and Workers, member of the board of Oil Shale Competence
Center, member of Editorial Board of Oil Shale journal, member of the
Professional board of Estonian Engineers, member of IOC of World
Mining Congress and member of the Society of Mining Professors.
Address: Ehitajate tee 5, 19086, Tallinn, Estonia
E-mail: ingo.valgma@ttu.ee
Vivika Väizene is specialist in Department
of Mining at Tallinn University of
Technology. She obtained her Master
degree
(MSc)
in
Geotechnology
specialization in mining in 2010. She has
been working in Department of Mining
since 2007. Her research interests are
mining technologies, evaluations of oil
shale resources, estimations of oil shale,
computer modeling, environmental impacts
and protection. She is member of
Competence committee for valuating shift
foremen and Estonian Mining Society.
Address: Ehitajate tee 5, 19086, Tallinn, Estonia
E-mail: vivika.vaizene@ttu.ee
Margit Kolats has owned her bachelor
degree in Geotechnology in 2008 and
studies currently in Master degree in
Tallinn University of Technology. She has
been working in Department of Mining at
Tallinn University of Technology since
2007 as a specialist. Her research interests
are mining technologies, field works and
laboratory tests.
Address: Ehitajate tee 5, 19086, Tallinn,
Estonia
E-mail: margit.kolats@ttu.ee 

Martin Saarnak studies currently in
bachelor degree of Geotechnology in
Tallinn University of Technology. He is
laboratory assistent in Department of
Mining at Tallinn University of
Technology since 2012. His research
interests
are
mineral
processing
simulations modeling.
Address: Ehitajate tee 5, 19086, Tallinn,
Estonia
E-mail: martin.saarnak@ttu.ee
 

47
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Valgma losses

  • 1. Environmental and Climate Technologies doi: 10.2478/rtuect-2013-0006 _________________________________________________________________________________________________2013 / 11 Technologies for Decreasing Mining Losses Ingo Valgma1, Vivika Väizene1, Margit Kolats1, Martin Saarnak1, 1Tallinn University of Technology Abstract - In case of stratified deposits like oil shale deposit in Estonia, mining losses depend on mining technologies. Current research focuses on extraction and separation possibilities of mineral resources. Selective mining, selective crushing and separation tests have been performed, showing possibilities of decreasing mining losses. Rock crushing and screening process simulations were used for optimizing rock fractions. In addition mine backfilling, fine separation, and optimized drilling and blasting have been analyzed. All tested methods show potential and depend on mineral usage. Usage in addition depends on the utilization technology. The questions like stability of the material flow and influences of the quality fluctuations to the final yield are raised. Keywords – oil shale, losses, mining, extraction. I. INTRODUCTION In case of stratified deposits like oil shale deposit in Estonia, mining losses depend on mining technologies. Stratified deposits are being developed from lower bedding depth to deeper and more complicated conditions [23]. Continuously the environmental or social restrictions require increasing coefficients that increase mineral losses [20]. This could be limited with the help of technological development [34,13, 36]. During the period starting from 1916 many technologies have been used and tested [31]. Currently the market economy is the main driving force for choosing technologies. This causes short term choices and works against sustainability. Current research focuses on extraction and separation possibilities of oil shale. Selective mining, selective crushing and separation tests have been performed, showing possibilities of decreasing mining losses. Rock crushing and screening process simulations were used for optimizing fractions. In addition mine backfilling, fine separation of oil shale, and optimized drilling and blasting have been analyzed. All tested methods show potential and depend on mineral usage [37]. Usage also depends on the utilization technology. Questions like stability of the material flow and influences of the quality fluctuations to the final yield are raised. Tonnage, calorific value and size distribution of the product form the quality indicators [43]. Avoiding losses in any of these processes decreases mining losses and has a positive effect on resource usage and sustainability. In addition, decreasing losses increases the amount of resource and sustainability of energy supply for the country [30, 32]. If optimized technology allows maintaining required productivity, it could be applied, even if fitting into the existing technological structure is taking longer than technically available [33, 35, 8]. The aim of the current study is to clarify what technical solutions could be applied for decreasing oil shale mining related losses. II. ANALYSES AND TESTS A. Selective mining Selective extraction of oil shale seam was analyzed to understand following methods: 1. Cutting with bulldozer and excavator rippers 2. Cutting with surface miners 3. Cutting with longwall miners 4. Cutting with shortwall miners. a) Cutting with rippers Selective extraction of the oil shale seam can be done by a bulldozer ripper or hydraulic excavator ripper. Ripping is a low-selective technology [42]. In deeper surface mining areas, 100 tonnes class bulldozers were used and in more weathered areas or partial ripping zones, the 60 tonne class was used. One disadvantage of bulldozer ripping is excessive crushing of oil shale by heavy bulldozers with crawlers [18]. b) Cutting with surface miners Tests with surface miners Vermeer T1255 and Wirtgen 2500 SM were carried out. The tests were followed after longer period tests with smaller class surface miners during the last 25 years. Tests have been performed with different oil shale and limestone layers. Surface miners are considered as BAT (Best Available Technology) for surface oil shale mining extraction [12, 42, 18, 15, 5]. c) Cutting with longwall miners The planning and testing has been done for longwall mining possibilities. Shearers were used and tested for 30 years in five oil shale mines in Estonia [1]. Longwall technology has also been chosen as one of the alternatives for phosphate rock mining [41]. Technologically, this technological solution has improved compared with initial possibilities. Since the hydraulic support system was limiting the height of the longwall face (1,5 m) and the power of the shearers was relatively low (210 kW) the losses have been 50% in longwall section. Today’s sharers utilize power in the range of 2200 kW, which is 10 times higher than in the tested units. Since the productivity (equal to income) could be increased, longwall technology is one of the possibilities for lowering losses. In case of removing protective side pillars between longwall section, rough estimation shows, that losses could be lowered down to 5% taking into account the geological dislocations and disfollowing the exact horizontal plane of the oil shale seam. The main obstacle of longwall shearing 41 Brought to you by | Tallinn Technical Authenticated | 193.40.249.178 Download Date | 10/17/13 10:07 AM
  • 2. Environmental and Climate Technologies 2013 / 11_________________________________________________________________________________________________ technology is solving environmental and social questions, regarding subsiding the ground and accepting certain areas where such subsiding could be allowed. In comparison to the surface mining stripping in the open cast mining areas, longwall mining could be considered as a technology which causes less impact to the landscape. The ground would be lowered by up to 70% of the created space. That makes 2 meters. In open casts, even the fluctuations in the leveled overburden spoil could be 5 meters. In trench or ditches areas, the level fluctuations are up to 40 meters. This makes longwall mining the most sustainable mining method for oil shale. d) Cutting with shortwall miners Evaluations of breakability have been made with roadheaders F2 and 4PP-3. As a recommendation, a doubledrum road header was proposed. Currently the power of the machines has increased and pick properties allow cutting harder rock. It is proposed, that both longitudinal or transverse head continuous miners (roadheaders) could be used for cutting oil shale [12]. The selectivity option is directly related to the waste material handling and should be tested in the mine [11]. Shortwall miner utilization could be the solution for making development entrances, drifts and rooms for mining. In case of satisfactory cutting performance, it could be used for extracting oil shale in production sections as well. The tests have shown, that shortwall mining is a promising technology and requires, as with longwall mining, surface miner mining and axle bucket crushing changes in some operations and processes in mining technology. Shortwall mining requires fast roof supporting technology. The supporting could be in addition in some extent easer because of lower possible fragmentation of rock caused by absence of blasting in the mine. B. Selective crushing For selective crushing, the following methods were tested: 1. crushing in a drum (Bradford drum) with help of rock falling impact and hammer crusher inside the drum; 2. impact crusher in underground sections as first stage crusher or impact crusher for aggregate production from oil shale waste rock; 3. axle crusher buckets with cutting and skimming process. An impact crusher has been used in underground sections as a first stage crusher and for aggregate production from oil shale waste rock that is limestone [27]. The purpose of underground crushing is to reduce ROM (run of mine) size to the required size of up to 300 mm for transporting it on belt conveyors to the surface. C. Separation Separation tests have been performed by jigging and cycloning. The purpose was to find out the percentage of the fine material that could be separated. Jigging tests have shown relatively good results allowing separating initially mixed material into five different fractions. The calorific value of best fraction is highest and the limestone fraction in opposition should be considered as the ready selected material for limestone aggregate. Up to now the main focus has been mechanical experimenting with jig. The main obstacle of the technology could be achieving required productivity. It is similar to the filter press technology where the productivity of the single unit could be low. On the other hand, if the production line could be completed with different stages, the required productivity could also be to some extent lower. To decrease required machine productivity for the same output, drum crushing or axle crushing could be used prior to the jigging. Cycloning has shown that the calorific value of cycloned and non- cycloned fine material has no remarkable difference. Since cycloning could be done on many variations, the initial test could be considered as failed because of short time and no variations. These tests should be continued, preferably with apilot unit or laboratory units at first. D. Rock crushing For crushing, the following options have been analysed: 1. Crushing with sizers 2. Crushing with impact crushers 3. Crushing with double drum crushers 4. Crushing with drum crusher 5. Crushing with jaw crusher. Crushing process simulations were used to evaluate the distribution curves of the final product. The necessary data for this purpose is bulk density of material and the maximum size of the particles going for crushing. In order to get optimal results on certain cases, crushing units, crushers and mobile crushers can be added to the scheme. This gives extra value in lowering engineering costs, on experimenting with different devices and on further changes [19, 45]. As an example, material data for thesimulation program has been:  Input material < 1000 mm  Solid density 1,84 t/m3  Crushability 85% - which is the maximum  Productivity 1000 t/h  Gravel 31% - does not influence the results (Fig. 1.). The value of abrasiveness has been between 0,1…1500 g/t, calculations show that this does not affect the simulation results. Neither does moisture. The crusher output cavity is set on 180mm which means that the maximum size of the outcoming particle is 200mm. The workload of the impactor crusher is 97% of the maximum capacity. After crushing, the feed moves to the roller screen, where the feed flows into three classes:  0…25 mm 22,8%  12…107 mm 55,2% - which include 11% 12…25 mm (Fig.2.)  107…200 mm 22% . It can be detected that the fines part is 28,9%. 42 Brought to you by | Tallinn Technical Authenticated | 193.40.249.178 Download Date | 10/17/13 10:07 AM
  • 3. Environmental and Climate Technologies _________________________________________________________________________________________________2013 / 11 programme. Sizers are even more complex, because they have been used only a few years and therefore are relatively new products among crushers. In Estonia there are a lot of questions concerning the fines in the crushing process. Fig. 1. Experiments resulted in fines generation of 2,2% [10] E. screening Two basic screening solutions have been analysed in addition to the traditional vibration screening: 1. Screening in drum screen 2. Screening on rotary screen 3. Screening on roller screen. Fig. 1. Material data insertion window F. Mine backfilling The tests contained testing of mixes properties of the backfill material, testing of backfilling technology and analyzing backfilling material flows. The main hypotheses are that backfilling reduces mining losses and the amount of waste on the ground surface [27]. In addition it increases land stability [12]. Stability issues have been developed in sense of information availability. Mapping, special information systems and seismological methods allow one to detect any collapses which have occured [21, 25]. G. Fine separation Fine separation tests were carried out with CDE equipment and with jigging equipment. The aim of the fine separation test is to separate fines from pulp before they reach sedimentation pond and to take it into use as a product. Fig. 2. Flow data Fines are added on the secondary crushing/particle size is 107...200 mm. Calculations have shown that in this way 5% of fines are added. At the present moment the best crushing option in making the minimum fines is crushing with the sizer. Experiments show that the minimum in generating fines is achieved when the rotating speed of sizer was 175 rpm. In slow rotation the generation was 11,8% and fast rotation gave 6,5% of fines (Fig.3). As experiments show, it is possible to decrease the fines generation which mostly is considered to be waste. Each simulation manufacturer focuses on separation methods or some part in the separation process. When it comes to crushers, then simulations are also manufacturer based and reflect types and models, what the company offers [7, 4]. Newer products are introduced in the simulation programmes later. In case of the roll crusher for example, the characteristics and behaviours are still added to the III. RESULTS AND DISCUSSION A. Selective mining a) Cutting with rippers In Ubja oil shale open cast, the productivity of oil shale hydraulic ripping was nearly 600 m3/h. At the Ubja open cast, overall oil shale losses are 0% based on the Environmental Register. Bulldozer ripping is considered as semi-selective ripping where seam losses make 12% in comparison to 5% with surface miners [42]. The first problem of ripping technology has been power of ripping machines. Before 100 tonnes class bulldozers were applied, the low ripping power was one of the main concerns. Excavator ripping is in similar stage like bulldozer ripping has been in its beginning stage. The power of the excavator ripper is not satisfactory to reach required productivity. Excavator ripping does not solve the losses question because of the principle of vertical movement. 43 Brought to you by | Tallinn Technical Authenticated | 193.40.249.178 Download Date | 10/17/13 10:07 AM
  • 4. Environmental and Climate Technologies 2013 / 11_________________________________________________________________________________________________ Excavator ripping could be considered in low bedding areas, where drilling and blasting is prohibited, the oil shale seam is weathered meaning weaker bonds between layers. A bulldozer ripper, therefore could be used as low selective miner, but it is limited by availability of keeping losses down. The main problem is limestone and oil shale pieces and lumps that contain both material and could not be separated by the ripper. If needed, one of the solutions could be skimming with axle crushers. b) Cutting with surface miners It was found that extracting with a high selective surface miner is the main possibility of decreasing losses in case of surface mining. The main obstacle for using such technology is the partly unsolved overburden stripping technology. In the future, combined methods should be considered like high selective cutting plus selective axle crushing for aggregate separation. Mining with surface miner Wirtgen 2500 SM helps to reduce losses and improve calorific value of oil shale. It is possible to mine limestone and oil shale seams separately with higher accuracy than rippers (2-7 cm) with deviations about one centimetre [42]. Losses can be decreased from 12 percent to 5 percent compared to ripping [18]. Based on practical data, the surface miner enables to increase the output of oil shale up to 1 tonne per square meter. The oil yield increases 30%, reaching up to 1 barrel per tonne of oil shale during the oil shale retorting, because of better quality, meaning higher calorific value of the material that is sent to the retorts [42]. c) Cutting with longwall miners It was found that distribution of required large particles of oil shale is possible with longwall shearers. The practice with longwall shearers shows that the subject for cutting is oil shale and the larger size is distributed to the limestone fraction [1]. This is due to the hardness difference of the rocks. Longwall mining could decrease horizontal losses by 20 to 40%. d) Cutting with shortwall miners One of the main advantages that a shortwall miner could present are the possibility of avoiding weakening pillars in the mine by blasting [20]. This in addition could give the possibility to decrease pillar size and to decrease losses left to the pillars. Pillar losses that are caused by pillars with cross section area of 16 to 49 square meters could be decreased therefore by 16 to 28% with avoidance of the 0,3 zone by sides of the pillars. The pillas strength and stability of the ground are directly related but have the opposite influence on sustainability. In case of backfilling this dilemma could be solved [22]. In some areas also smooth and directed subsidence could be solution. B. Selective crushing The underground crushing process where ROM (run of mine) size is reduced to the required size up to 300 mm has no direct influence on the percentage of losses. Nevertheless, ROM size distribution is influenced by impact crushing and fines are produced. In case of oil production with vertical generators, fines and small classes of oil shale are considered as waste, if no other uses are found, like cement, electricity or oil production with SHC technology. Selective crushing is important both for cleaning and sizing oil shale and cleaning and sizing limestone. Therefore selective crushing or selective mining methods are recommended [27]. C. Rock crushing a) Crushing with sizers One of the options could be using slow rotating or optimized rotating sizer for oil shale ROM crushing. According to the recommendations of crusher producers, all crusher types are suitable for crushing oil shale [25]. In relation to the moisture content, jaw crusher and gyratory crushers are unsuitable, requiring relatively dry material (<5%) . A roll sizer should be able to crush up to 175 MPa material and up to 15% moisturised material. In comparison to the other types of crushers, a sizer should give the smallest percentage of fines [24, 17, 10, 2, 9, 6]. The productivity of the sizer could reach 10000 tonnes per hour (Table 1) TABLE I SIZER PRODUCERS Producer Sandvik [24] MMD [17] FLSmidth [6] Williams Patent Crusher and Pulverizer Company [44] Thyssenkrupp [25] McLanahan [16] Joy [10] Caterpillar [3] Sizer or feeder breaker Sizer Sizer Sizer Model CR610 MMD 1500 ABON Producti vity, t/h 8000 10000 10000 Feeder breaker Williams Feeder Breakers 5000 Sizer Thyssenkrupp 1500 10000 Sizer/Feeder breaker Sizer/Feeder breaker Feeder breaker 1800 Fines share could be reduced down to 2,2 % from 6 to 12% with low and fast rotation in addition with Matched Velocity Technology (MTV) [9]. D. Fine seperation The possibility of using fine oil shale that is flushed away by the HMS (Heavy Media Separation) process could increase energy of used oil shale and avoid the need for settling ponds or filter presses [38]. The main idea could be the separation of fine oil shale from fine clay and limestone particles. Fine separation tests were carried out with cyclones and fine screens and with jigging. The amount of fines thatwere separated from the separation pulp was in the range of 0,2-5,1 %. The average amount of fine that was separated was 2,7 % of inflow (TABLE II). 2,7 % of fine was divided into two classes with size 0-8mm and 0-5mm. The calorific value of inflow was in the range of 10,3-10,8 MJ/kg with an average of 44 Brought to you by | Tallinn Technical Authenticated | 193.40.249.178 Download Date | 10/17/13 10:07 AM
  • 5. Environmental and Climate Technologies _________________________________________________________________________________________________2013 / 11 10,5 MJ/kg and outflow was in the range 1,2-2,4 MJ/kg with an average 1,8 MJ/kg. TABLE II TEST RESULTS OF FINE SEPERATION Sediment % Water % Average concentrate Inflow 21 79 Average concentrate Outflow 18 82 Average concentrate 2,7 E. Optimised drilling and blasting Drilling and blasting as the main method for extracting oil shale has been used and in some extent optimized. CONCLUSIONS Losses vary from mine to mine considerably depending on different factors. The main factor is geological bedding, the second is legal framework and the third -- mining technology. Mining technology is the main factor that could be changed realistically by miners. Currently surface mines leave less losses and advanced technologies create less losses. Up to now the technical ultimate yield has not been reached. In the future, the percentage of losses will increase because mining is moving in deeper zones (Fig. 2, Fig. 3, Fig. 4). The largest mine “Estonia” alone accounts for most of the losses if it takes into account only tonnes. In practice, logistics quality and availability are also factors that have to be considered. On the other hand, requirements for the continuous flow of good quality oil shale will be required and environmental costs will increase. A tTechnological solution should be analyzed and tested for implementing. Currently the oil shale mining industry is missing broad and objective analyze for technological development. In addition in case of surface mining, stripping technologies should be evaluated. In many cases fragmented overburden placement and usage of overburden bridges could also give positive results for decreasing mining losses [39, 12]. In case of smooth stripping technology, influence to the landscape could also be decreased [29, 28]. Using continuous technologies for decreasing mining losses could give positive effects on the even distribution of fuel oil shale [14]. In the future, rapid development, computerized directing, and virtual analyzing could be applied [40, 37]. 40 4400 30 3900 Losses, kt/y 2006 Losses, kt/y 2007 3400 20 Losses, kt/y 2008 Losses, kt/y 2009 2900 Losses, kt/y 2010 Losses, kt/y 2011 2400 10 Losses, kt/y 2012 Average losses, kt/y 2006‐2012 1900 Losses, %, 2006 0 1400 Losses, %, 2007 Losses, %, 2008 Losses, %, 2009 Losses, %, 2010 900 ‐10 Losses, %, 2011 Losses, %, 2012 400 Average losses, %, 2006‐2012 ‐100 ‐20 Fig. 2 Tonnage and percentage of oil shale mining losses in Estonian mines from 2006 to 2012  9000 8000 7000 Oil shale, kt/y 6000 5000 Production, kt/y 2012 Losses, kt/y 2012 4000 3000 2000 1000 0 Estonia  mine Sirgala open  Viru mine cast Narva open  Aidu open  cast cast Ojamaa  mine Põhja‐Kiviõli  Sompa mine Vanaküla  open cast open cast Ubja open  cast Fig. 3. Tonnage of oil shale mining production and losses in Estonian mines in 2012 45 Brought to you by | Tallinn Technical Authenticated | 193.40.249.178 Download Date | 10/17/13 10:07 AM
  • 6. Environmental and Climate Technologies 2013 / 11_________________________________________________________________________________________________ 19500 Oil shale, kt/y 14500 9500 4500 ‐500 Ubja open cast Viru mine Prod Used  Prod Used  Prod Used  Prod Used  Prod Used  Prod Used  Prod Used  Losse Losse Losse Losse Losse Losse Losse uctio resou uctio resou uctio resou uctio resou uctio resou uctio resou uctio resou s,  s,  s,  s,  s,  s,  s,  n,  rce,  n,  n,  rce,  rce,  n,  n,  rce,  rce,  n,  rce,  n,  rce,  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  kt/y  2006 2011 2007 2012 2008 2009 2010 2006 2006 2011 2011 2007 2007 2012 2012 2008 2008 2009 2009 2010 2010 101 101 109 109 162 162 58 58 59 59 146 146 107 107 627 1706 2333 Sompa mine 0 Sirgala open cast 275 Põhja‐Kiviõli  open  cast 101 2345 2620 818 660 18 331 1761 2421 33 708 51 2779 3110 1699 2407 1 334 1 12 2587 2921 31 42 2261 2589 624 17 398 1836 2460 77 94 2813 3211 638 58 368 1730 2368 315 373 2677 3045 554 83 286 1828 2383 299 381 2696 2982 919 53 896 950 57 908 965 51 868 919 70 885 955 40 637 676 37 615 652 12 26 38 43 96 139 6 12 18 79 204 283 36 288 324 240 799 1039 244 1542 1786 Narva open cast 119 727 846 195 1375 1571 136 1090 1226 Vanaküla open cast ‐88 516 428 ‐83 832 ‐55 761 Aidu open cast 328 1740 2446 0 Ojamaa mine Estonia mine 706 749 706 224 7 1147 1371 410 417 340 6 1493 1832 481 487 324 10 1539 1863 575 586 15 299 314 2158 4478 6636 2147 4499 6646 2356 4738 7094 2359 4500 6859 3004 5537 8541 3126 6188 9313 2555 5699 8254 53 1286 1339 69 1682 1750 75 1664 1739 100 1582 1682 147 1724 1871 156 1770 1926 29 1060 1088 Fig. 4. Production tonnage and tonnage and percentage of oil shale mining losses in Estonian mines from 2006 to 2012  IV. ACKNOWLEDGEMENTS The research is supported by study: Sustainable and environmentally acceptable Oil shale mining No. 3.2.0501.110025 and Doctoral School of Energy and Geotechnology II DAR8130/1.2.0401.09-0082. REFERENCES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Adamson. A. Breakage of oil shale by mining // Oil Shale. 1998. Vol. 15 , p. 186–205. CAT feeder breaker. Available: https://mining.cat.com/cda/files/2884840/7/ [Accessed: 04.2013] Caterpillar feeder breakers. Available: https://mining.cat.com/products/underground-mining/room-andpillar/feeder-breakers [Accessed: 04.2013] Deniz, V. A new size distribution model by t-family curves for comminution of limestones in an impact crusher. Advanced Powder Technology. 2012. ,vol.22, p. 761-765 Dey, K.; Ghose A.K. Review of Cuttability Indices and A New Rockmass Classification Approach for Selection of Surface Miners. Rock Mechanics And Rock Engineering. 2011. vol.44 (5), p. 601-611. FLSmidth ABON sizers. Available: http://www.flsmidth.com/search.aspx?k=sizer [Accessed 04.2013] Gierga, C . Intelligent impact crusher technology in primary crushing operations. Zkg International., 2002Vol.55 (12), p. 40. Hood, M.; Gurgenci, H.; Hatherly, P. Underground mines of tomorrow. Seventh Ausimm Underground Operators' Conference. Australasian Institute Of Mining And Metallurgy Publication Series, 1998, vol. 98 (3), p 187.-191. JOY MTV technology. Available: http://www.phmining.com [Accessed: 04.2013] JOY.Available: http://www.joy.com [Accessed: 04.2013] Karu, V.; Valgma, I.; Rahe, T. Mining Waste Reduction Methods. 13th International Symposium "Topical Problems in the Field of Electrical and Power Engineering", Doctoral Scholl of Energy and Geotechnology II, Pärnu, Estonia, 14-19.01.2013 (278 - 280). Tallinn: Elektrijam Karu, V.; Västrik, A.; Anepaio, A.; Väizene, V.; Adamson, A.; Valgma, I. Future of oil shale mining technology in Estonia. Oil Shale, (2008), vol. 25(2S),p.125. - 134. Karu, V.; Västrik, A.; Valgma, I. Application of modelling tools in Estonian oil shale mining area . Oil Shale, 2008, vol. 25(2S), p.134 144. 14. Koitmets, K.; Reinsalu, E.; Valgma, I Precision of oil shale energy rating and oil shale resources. Oil Shale, 2003., vol. 20(1), p.15 - 24. 15. Lohk, M.; Väli, E.; Tohver, T.; Pastarus, J.-R. Surface miner technology impact on the environment. In: 5th International Symposium "Topical problems in the field of electrical and power engineering". Tallinna Tehnikaülikool, 2008,p. 44 - 47. 16. McLanahan sizers and feeder breakers. Available: http://www.mclanahan.com [Accessed: 04.2013] 17. MMD sizers. Available: http://www.mmdsizers.com/ [Accessed: 04.2013] 18. Nikitin, O.; Väli, E.; Pastarus, J.; Sabanov, S. The Surface Miner Sustainable Oil-shale Mining Technology Testing Results in Estonia. Proceedings of the Sixteenth International Symposium on Mine Planning and Equipment Selection and the Tenth International Symposium on Environmental Issues and Waste Management in Energy and Mineral Production: Mine Planning and Equipment Selection and Environmental Issues and Waste Management in Energy and Mineral Production. Bangkok, Thailand, December 11-13, 2007. p.678. 19. Nikolov, S. A performance model for impact crushers. Minerals Engineering, 2002.vol.15(10), p.715.-721. of Tallinn University of Technology, Tallinn, pp 113 20. Orru, M.; Väizene, V.; Pastarus, J.-R.; Sõstra, Y.; Valgma, I. Possibilities of oil shale mining under the Selisoo mire of the Estonia oil shale deposit. Environmental Earth Sciences, 2013, p.1-11. DOI 10.1007/s12665-013-2396-x 21. Otsmaa, M.; Soosalu, H.; Valgma, I. Detection of Mine Collapses with Seismic Methods in the Estonian Oil Shale Mining Area. 12th International Symposium "Topical Problems in the Field of Electrical and Power Engineering", Kuressaare, Estonia, 2012, p.171 – 172. 22. Reinsalu, E.; Valgma, I Geotechnical processes in closed oil shale mines. Oil Shale, 2013., vol. 20(3), p.398 - 403. 23. Reinsalu, E.; Valgma, I. Oil Shale Resources for Oil Production. Oil Shale,2003, vol. 24, p.9 - 14. 24. Sandvik Sizers. Available: http://mining.sandvik.com/ [Accessed: 04.2013] 25. Soosalu, H.; Valgma, I. Detection of mine collapses with seismic methods- a case study from Estonia. Resource Reproducing, Lowwasted and Environmentally Protecting Technologies of Development of the Earth Interior, p.1. 26. Thyssenkrupp. Available: http://www.thyssenkrupp-resourcetechnologies.com [Accessed: 04.2013] 27. Tohver, T. Utilization of waste rock from oil shale mining. Oil Shale, 2010., vol. 27(4), p. 321 - 330. 28. Valgma, I. 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Oil Shale mining-related research in Estonia. Oil Shale, 2009, vol. 26(4), p.445 - 150. 35. Valgma, I.; Karu, V.; Viil, A.; Lohk, M. Oil shale mining developments in Estonia as the bases for sustainable power industry. In: 4th International Symposium "Topical Problems in the Field of Electrical and Power Engineering" : Doctoral School of Energy and Geotechnology: 4th International Symposium "Topical Problems in the Field of Electrical and Power Engineering", Kuressaare, Estonia, 15..20.01.2007. (Toim.) Lahtmets, R.. Tallinn: Tallinn University of Technology, Faculty of Power Engineering, 2007, p.96 - 103. 36. Valgma, I.; Kattel, T. Low depth mining in Estonian oil shale depositAbbau von Ölschiefer in Estland. In: Kolloquium Schacht, Strecke und Tunnel 2005 : 14. und 15. April 2005, Freiberg/Sachsen: Kolloquium Schacht, Strecke und Tunnel 2005 : 14. und 15. April 2005, Freiberg/Sachsen. Freiberg: TU Bergakademie, 2005, p.213 - 223. 37. Valgma, I.; Leiaru, M.; Karu, V.; Iskül, R.. Sustainable mining conditions in Estonia. 11th International Symposium "Topical Problems in the Field of Electrical and Power Engineering", Doctoral Scholl of Energy and Geotechnology, Pärnu, Estonia, 16-21.01.2012 p.229 – 238). 38. Valgma, I.; Reinsalu, E.; Sabanov, S.; Karu, V. . Quality control of Oil Shale production in Estonian mines. Oil Shale,2010, vol. 27(3), p. 239 - 249. 39. Valgma, I.; Torn, H.; Erg, K. The impact of infiltration dam on the groundwater regime in the Kurtna landscape reserve area. Oil Shale, 2006, vol. 23(1), p. 3 - 14. 40. Valgma, I.; Västrik, A.; Kõpp, V. Sustainable mining technologies for Estonian minerals industry. Lahtmets, R (Toim.). 9th International Symposium Pärnu 2010 “Topical Problems in the Field of Electrical and Power Engineering” and “Doctoral School of Energy and Geotechnology II”, Pärnu, Estonia, June 14 - 19, 2010, p.69 – 73. 41. Valgma, I.. Sustainable phosphate rock mining. Proceedings of the Estonian Academy of Sciences. Engineering,2010, vol. 3(1), p.13 - 22. 42. Väli, E. Best Available Technology for the Environmentally Friendly Mining with Surface Miner. PhD thesis, 2010. 43. Väli, E.; Valgma, I.; Reinsalu, E. Usage of Estonian oil shale. Oil Shale, 2008, vol. 25, p. 101 - 114. 44. William sizer. Available: http://www.williamscrusher.com/feeder_breaker/default.asp [Accessed: 04.2013] 45. Zhao, L.M.; Chen, L.J.; Zhang, D.B.; Li, Y. Modelling and Simulation of Particle Breakage in Jaw Crushers. Editor(s): Zhao, H. Mechanical And Electronics Engineering Iii, PTS 1-5. Applied Mechanics and Materials. Vol.130-134, 2012 p.1148-1151. Ingo Valgma has owned his Dr. Eng degree from Tallinn Technical University in 2002. His fields of studies are mining technology, geographical information systems and environmental aspects of mineral industry. He is PROFESSOR at Chair of Mining Engineering in Tallinn University of Technology and the head of the Department of Mining. He is member of the board of Estonian Association of Engineers, member of the Professional board of Estonian Explosives Engineers and Workers, member of the board of Oil Shale Competence Center, member of Editorial Board of Oil Shale journal, member of the Professional board of Estonian Engineers, member of IOC of World Mining Congress and member of the Society of Mining Professors. Address: Ehitajate tee 5, 19086, Tallinn, Estonia E-mail: ingo.valgma@ttu.ee Vivika Väizene is specialist in Department of Mining at Tallinn University of Technology. She obtained her Master degree (MSc) in Geotechnology specialization in mining in 2010. She has been working in Department of Mining since 2007. Her research interests are mining technologies, evaluations of oil shale resources, estimations of oil shale, computer modeling, environmental impacts and protection. She is member of Competence committee for valuating shift foremen and Estonian Mining Society. Address: Ehitajate tee 5, 19086, Tallinn, Estonia E-mail: vivika.vaizene@ttu.ee Margit Kolats has owned her bachelor degree in Geotechnology in 2008 and studies currently in Master degree in Tallinn University of Technology. She has been working in Department of Mining at Tallinn University of Technology since 2007 as a specialist. Her research interests are mining technologies, field works and laboratory tests. Address: Ehitajate tee 5, 19086, Tallinn, Estonia E-mail: margit.kolats@ttu.ee  Martin Saarnak studies currently in bachelor degree of Geotechnology in Tallinn University of Technology. He is laboratory assistent in Department of Mining at Tallinn University of Technology since 2012. His research interests are mineral processing simulations modeling. Address: Ehitajate tee 5, 19086, Tallinn, Estonia E-mail: martin.saarnak@ttu.ee   47 Brought to you by | Tallinn Technical Authenticated | 193.40.249.178 Download Date | 10/17/13 10:07 AM