综采纯水介质液压系统成套技术及装备运用

Complete set technology and equipment application of fully-mechanized mining pure water medium hydraulic system

近年来,随着我国智能制造水平的不断进步,煤炭产业的发展不断创新,大胆引进先进的新材料、新技术和新工艺。液压支架是井下综采工作面最主要的生产设备之一,其乳化液作为传统液压系统的工作介质,因工作面液压管路存在跑、冒、滴、漏等问题导致乳化油融入地下水,造成严重的水体污染和土壤油质化。为积极响应国家煤炭资源绿色开采的发展理念,探索以纯水系统代替乳化液的成套技术,重点攻克了纯水制备装置、纯水高压泵站和纯水支架等装备在选材、密封、防腐、控制等方面的关键技术,并运用到井下生产实践。综采纯水液压系统运行以来,2套制水设备均衡运行,每套日均运行7~8 h水质各项指标符合要求,纯水利用率在30%~45%之间。经测算液压支架使用纯水的吨煤成本为0.184元/t,较使用乳化液节约成本0.179元/t,不仅降低了生产成本,而且实现了绿色采煤,解决了地下水体污染和土壤油质化问题。同时提出立柱压力自卸、纯水制备二次污染、回液清污分离等问题的解决方案,为煤炭行业推广该项技术积累经验。

In recent years,with the continuous progress of China’s intelligent manufacturing level,the development of the coal industry is constantly innovative,the bold introduction of advanced new materials,new technologies and new processes.As the working medium of the traditional hydraulic system,the emulsion of the hydraulic support,which is one of the most important production equipments in the fully-mechanized coal mining face underground,causes the emulsified oil to melt into the underground water because of the problems such as running,flowing,dripping and leaking of the hydraulic pipeline in the working face,it causes serious water pollution and soil oil pollution.In order to actively respond to the development concept of green mining of national coal resources,the complete set of technologies of substituting pure water system for emulsion are explored,the key technologies in material selection,sealing,anti-corrosion and control of pure water preparation equipment,high-pressure pump station and pure water support are emphasized and applied to underground production.Since the fully mechanized coal mining pure water hydraulic system runs,two sets of water making equipment run in balance,each set runs 7-8 hours per day,each water quality index meets the requirements,the pure water utilization ratio is between 30%and 45%.It is estimated that the cost of using pure water per ton of coal in hydraulic support is 0.184 Yuan/ton,compared with 0.179 Yuan/ton using emulsion,which not only reduces the production cost,but also realizes green coal mining,the invention solves the problems of groundwater pollution and soil oil quality.At the same time,the solutions of column pressure self-dumping,secondary pollution of pure water preparation and separation of return liquid are put forward to accumulate experience for coal industry to popularize this technology.