Experimental research and energy analysis of a new type of dry ice powder pneumatic rock breaking technology

When the traditional drill and blast method is applied to rock crushing projects,it has strong vibration,loud noise and dust pollution,so it cannot be used in densely populated areas such as urban public works.We developed a supercritical CO_(2)true triaxial pneumatic rock-breaking experimental system,and conducted laboratory and field tests of dry ice powder pneumatic rock-breaking.The characteristics of the blast-induced vibration velocity waveform and the evolution of the vibration velocity and frequency with the focal distance were analyzed and discussed.The fracturing mechanism of dry ice powder pneumatic rock breaking is studied.The research results show that:(1)The vibration velocity induced by dry ice powder pneumatic rock breaking decays as a power function with the increase of the focal distance;(2)The vibration frequency caused by dry ice powder pneumatic rock breaking is mainly distributed in 1–120 Hz.Due to the dispersion effect,the dominant frequency of 10–30 Hz appears abnormally attenuated;(3)The traditional CO_(2)phase change fracturing energy calculation formula is also applicable to dry ice pneumatic rock breaking technology,and the trinitrotoluene(TNT)equivalent of fracturing energy is applicable to the Sadovsky formula;(4)Dry ice powder pneumatic rock breaking is shock wave and highenergy gas acting together to fracture rock,which can be divided into three stages,among which the gas wedge action of high-energy gas plays a dominant role in rock mass damage.

Rock breaking performance of the newly proposed unsubmerged cavitating abrasive waterjet

To improve the rock breaking ability, cavitating waterjet and abrasive waterjet are combined by using a coaxial low-speed waterjet generated around the periphery of a high-speed abrasive waterjet, and a new type of waterjet called unsubmerged cavitating abrasive waterjet(UCAWJ) is thus produced. The rock breaking performance of UCAWJ was compared with submerged cavitating abrasive waterjet(SCAWJ)and unsubmerged abrasive waterjet(UAWJ) by impinging sandstone specimens. Moreover, the effects of jet pressure, standoff distance, abrasive flow rate and concentration were studied by evaluating the specific energy consumption, and the area, depth, and mass loss of the eroded specimen. The results show that the artificially generated submerged environment in UCAWJ is able to enhance the rock breaking performance under the same operating parameters. Furthermore, the rock breaking performance of UCAWJ is much better at higher jet pressures and smaller standoff distances when compared with UAWJ. The greatest rock breaking ability of UCAWJ appears at jet pressure of 50 MPa and standoff distance of 32 mm, with the mass loss of sandstone increased by 370.6% and the energy dissipation decreased by 75.8%. In addition, under the experimental conditions the optimal abrasive flow rate and concentration are 76.5 m L/min and 3%, respectively.

Factor analysis and numerical simulation of rock breaking efficiency of TBM deep rock mass based on orthogonal design

This study investigates the factors affecting the rock-breaking efficiency of the TBM disc cutter in deep rock excavation,including confining pressure,penetration,cutter spacing,and revolution speed.The finite element method is employed to formulate a rock-breaking model of the rotary disc cutters and a numerical simulation is also implemented.The rock breaking effect,rock breaking volume,and rock breaking specific energy consumption under different combinations of the factors are investigated.An orthogonal test of four factors at four levels was constructed.Based on the test results and range analysis in the process of deep rock mass breaking,the order of sensitivity of each influencing factor with respect to the rock breaking specific energy for the disc cutter is cutter spacing>revolution speed>penetration>confining pressure.By constructing a numerical simulation comparison scheme,the orthogonal test results are analyzed and corroborated,and the rock breaking law and rock breaking efficiency under different influencing factors are derived.Finally,the sensitivity of different influencing factors on the rock-breaking efficiency is verified.

The rock breaking and ROP increase mechanisms for single-tooth torsional impact cutting using DEM

Torsional impact drilling is a new technology which has the advantages of high rock-breaking efficiency and a high rate of penetration(ROP).So far,there is no in-depth understanding of the rock-breaking mechanism for the ROP increase from torsional impact tools.Therefore,it has practical engineering significance to study the rock-breaking mechanism of torsional impact.In this paper,discrete element method(DEM)software(PFC2 D)is used to compare granite breaking under the steady and torsional impacting conditions.Meanwhile,the energy consumption to break rock,microscopic crushing process and chip characteristics as well as the relationship among these three factors for granite under different impacting frequencies and amplitudes are discussed.It is found that the average cutting force is smaller in the case of torsional impact cutting(TIC)than that in the case of steady loading.The mechanical specific energy(MSE)and the ratio of brittle energy consumption to total energy are negatively correlated;rock-breaking efficiency is related to the mode of action between the cutting tooth and rock.Furthermore,the ROP increase mechanism of torsional impact drilling technology is that the ratio of brittle energy consumption under the TIC condition is larger than that under a steady load;the degree of repeated fragmentation of rock chips under the TIC condition is lower than that under the steady load,and the TIC load promotes the formation of a transverse cracking network near the free surface and inhibits the formation of a deep longitudinal cracking network.

Numerical and experimental investigation of rock breaking method under free surface by TBM disc cutter

To study the rock breaking method under the free surface induced by disc cutter,the rock breaking simulations were first conducted based on the discrete element method,and the dynamic process of rock breaking under the free surface was studied including stressed zone,crush zone,crack initiation and propagation.Then the crack propagation conditions,specific energy,etc.under different free surface distance(S)were also investigated combined with linear cutting experiments.The results show that the rock breaking process under the free surface induced by disc cutter is dominated by tension failure mode.There exists a critical S to promote crack propagation to free surface effectively.And this rock breaking method can improve the rock breaking force and breaking efficiency significantly when proper.

Rock Breaking Performance of a Pick Assisted by High-pressure Water Jet under Different Configuration Modes

In the process of rock breaking, the conical pick bears great cutting force and wear, as a result, high-pressure water jet technology is used to assist with cutting. However, the effect of the water jet position has not been studied for rock breaking using a pick. Therefore, the models of rock breaking with different configuration modes of the water jet are established based on SPH combined with FEM. The effect of the water jet pressure, distance between the jet and the pick bit, and cutting depth on the rock breaking performance as well as a comparison of the tension and compression stress are studied via simulation; the simulation results are verified by experiments. The numerical and experimental results indicate that the decrease in the rates of the pick force obviously increases from 25 MPa to 40 MPa, but slowly after 40 MPa, and the optimal distance between the jet and the pick bit is 2 mm under the JFP and JSP modes. The JCP mode is proved the best, followed by the modes of JRP and JFP, and the worst mode is JSP. The decrease in the rates of the pick force of the JCP, JRP, JFP, and JSP modes are up to 30.96%, 28.96%, 33.46%, 28.17%, and 25.42%, respectively, in experiment. Moreover, the JSP mode can be regarded as a special JFP model when the distance between the pick-tip and the jet impact point is 0 mm. This paper has a dominant capability in introducing new numerical and experimental method for the study of rock breaking assisted by water jet and electing the best water jet position from four different configuration modes.

Differentiation and analysis on rock breaking characteristics of TBM disc cutter at different rock temperatures

In order to study rock breaking characteristics of tunnel boring machine(TBM) disc cutter at different rock temperatures,thermodynamic rock breaking mathematical model of TBM disc cutter was established on the basis of rock temperature change by using particle flow code theory and the influence law of interaction mechanism between disc cutter and rock was also numerically simulated.Furthermore,by using the linear cutting experiment platform,rock breaking process of TBM disc cutter at different rock temperatures was well verified by the experiments.Finally,rock breaking characteristics of TBM disc cutter were differentiated and analyzed from microscale perspective.The results indicate the follows.1) When rock temperature increases,the mechanical properties of rock such as hardness,and strength,were greatly reduced,simultaneously the microcracks rapidly grow with the cracks number increasing,which leads to rock breaking load decreasing and improves rock breaking efficiency for TBM disc cutter.2) The higher the rock temperature,the lower the rock internal stress.The stress distribution rules coincide with the Buzin Neske stress circle rules: the maximum stress value is below the cutting edge region and then gradually decreases radiant around; stress distribution is symmetrical and the total stress of rock becomes smaller.3) The higher the rock temperature is,the more the numbers of micro,tensile and shear cracks produced are by rock as well as the easier the rock intrusion,along with shear failure mode mainly showing.4) With rock temperature increasing,the resistance intrusive coefficients of rock and intrusion power decrease obviously,so the specific energy consumption that TBM disc cutter achieves leaping broken also decreases subsequently.5) The acoustic emission frequency remarkably increases along with the temperature increasing,which improves the rock breaking efficiency.

Effect of the number of irradiation holes on rock breaking under constant laser energy

The use of mechanical drilling in accessing energy resources stored in deep and hard rock formations is becoming increasingly challenging.Thus,laser irradiation has emerged as a novel drilling method with considerable in this context.This study examines the variation of rock fracture length,fracture tortuosity,hole size,and rock breaking efficiency for a different number of holes and laser power,based on the constant total energy of laser irradiation.As indicated by the results,increasing the laser power increases the laser intensity,which helps increase the hole diameter and depth.Moreover,for the same laser power,increasing the number of irradiated holes reduces the laser energy absorbed by each hole,which is not conducive to increasing the hole depth.As the number of holes increases,the mass loss of the rock also increases,while both specific energy(SE)and modified specific energy(MSE)decrease.When the number of holes remains the same,the mass of the shale removed by low power is less than that removed by high power,while SE and MSE have an inverse relation with power.Therefore,high laser power and multiple-hole irradiation are more conducive to rock breaking.Besides,the fracture length and fracture tortuosity of the rock irradiated by the low laser power will increase first and then decrease with the increase in the number of holes,and reach the peak value when the irradiation takes place through three holes.When a high-power laser irradiates the rock,the fracture length and tortuosity will increase with the increase in the number of irradiation holes.This is because a rock irradiated by low power dissipates more energy,with the result that the energy absorbed by the sample with four irradiation holes is not enough to break the rock quickly.This study is expected to provide some guidance to break rock for drilling deep reservoirs and hard rock formations using laser irradiation.

Analysis of the Flow Field Characteristics Associated with the Dynamic Rock Breaking Process Induced by a Multi-Hole Combined External Rotary Bit

The characteristics of the flow field associated with a multi-hole combined external rotary bit have been studied by means of numerical simulation in the framework of an RNG k-εturbulence model,and compared with the results of dedicated rock breaking drilling experiments.The numerical results show that the nozzle velocity and dynamic pressure of the nozzle decrease with an increase in the jet distance,and the axial velocity of the nozzle decays regularly with an increase in the dimensionless jet distance.Moreover,the axial velocity related to the nozzle with inclination angle 20°and 30°can produce a higher hole depth,while the radial velocity of the nozzle with 60°inclination can enlarge the hole diameter.The outcomes of the CFD simulations are consistent with the actual dynamic rock breaking and pore forming process,which lends credence to the present results and indicates that they could be used as a reference for the future optimization of systems based on the multi-hole combined external rotary bit technology.

Numerical Study on Rock Breaking Mechanism of Supercritical CO_(2)Jet Based on Smoothed Particle Hydrodynamics

Supercritical carbon dioxide(Sc-CO_(2))jet rock breaking is a nonlinear impact dynamics problem involving many factors.Considering the complexity of the physical properties of the Sc-CO_(2)jet and the mesh distortion problem in dealing with large deformation problems using the finite element method,the smoothed particle hydrodynamics(SPH)method is used to simulate and analyze the rock breaking process by Sc-CO_(2)jet based on the derivation of the jet velocity-density evolution mathematical model.The results indicate that there exists an optimal rock breaking temperature by Sc-CO_(2).The volume and length of the rock fracture increase with the rising of the jet temperature but falls when the jet temperature exceeds 340 K.With more complicated perforation shapes and larger fracture volumes,the Sc-CO_(2)jet can yield a rock breaking more effectively than water jet,The stress analysis shows that the Sc-CO_(2)rock fracturing process could be reasonably divided into three stages,namely the fracture accumulation stage,the rapid failure stage,and the breaking stabilization stage.The high diffusivity of Sc-CO_(2)is identified as the primary cause of the stress fluctuation and W-shaped fracture morphology.The simulated and calculated results are generally in conformity with the published experimental data.This study provides theoretical guidance for further study on Sc-CO_(2)fracturing mechanism and rock breaking efficiency.

AN EXPERIMENTAL STUDY ON THE MECHANISM AND PROCESS OF ROCK BREAKAGE WITH THE PLANETARY CUTTER HEAD

Based on the kinematic features of the Planetary Cutter Head (PCH),this paper deals with specificity of rock breakage with PCH, and the basic laws of this process are presented. The study shows that the axial force acting on the drilling face by a single cutter and the uniaxial com-pressive strength of the drilled rock have the marked influence on the penetrating depth of the cutter ,and the breakage of the drilling face with the PCH has two forms,the cyclical and the noncyclical. The major reason why the PCH has higher drilling efficiency than other cutter heads is that the PCH can make more free faces on the drilling face.

Comparative Study of the Rock-breaking Mechanism of a Disc Cutter and Wedge Tooth Cutter by Discrete Element Modelling

The operation of a shield tunnel boring machine(TBM)in a high-strength hard rock stratum results in significant cutter damage,adversely affecting the thrust and torque of the cutter head.Therefore,it is very important to carry out the research on the stress characteristics and optimize the cutter parameters of cutters break high-strength hard rock.In this paper,the rock-breaking performance of cutters in an andesite stratum in the tunnel of Qingdao Metro Line No.8 was investigated using the discrete element method and theoretical analysis.The rock-breaking processes of a disc cutter and wedge tooth cutter were simulated by software particle flow code PFC^(3D),and the rock-breaking degree,stress of the cutter,and rock-breaking specific energy were analyzed.The rock damage caused by the cutter in a specific section was divided into three stages:the advanced influence,crushing,and stabilizing stages.The rock-breaking degree and the tangential and normal forces of the wedge tooth cutter are larger than that of the disc cutter under the same conditions.The disc cutter(wedge tooth cutter)has the highest rock-breaking efficiency at a cutter spacing of 100 mm(110 mm)and a penetration depth of 8 mm(10 mm),and the rock-breaking specific energy is 11.48 MJ/m^(3)(12.05 MJ/m^(3)).Therefore,two types of cutters with different penetration depths or cutter spacing should be considered.The number of teeth of wedge tooth cutters can be increased in hard strata to improve the rock-breaking efficiency of the shield.The research results provide a reference for shield cutterhead selection and cutter layout in similar projects.

A review of rock macro-indentation:Theories,experiments,simulations,and applications

Rock macro-indentation plays a fundamental role in mechanical rock breaking for various rock engineering application,such as drilling,tunneling,cutting,and sawing.Over the past decades,extensive research has been conducted to understand the indentation mechanisms and responses through various approaches.This review aims to provide an overview of the current status and recent advancements in theories,experiments,numerical simulations,and applications of macro-indentation in rock engineering.It starts with elaborating on the mechanisms of macro-indentation,followed by a discussion of the merits and limitations of commonly used models.Influence factors and their effects on indentation test results are then summarized.Various numerical simulation methods for rock macro-indentation are highlighted,along with their advantages and disadvantages.Subsequently,the applications of indentation tests and indentation indices in characterizing rock properties are explored.It reveals that compression-tension,compression-shear,and composite models are widely employed in rock macroindentation.While the compression-tension model is straightforward to use,it may overlook the anisotropic properties of rocks.On the other hand,the composite model provides a more comprehensive description of rock indentation but requires complex calculations.Additionally,factors,such as indentation rate,indenter geometry,rock type,specimen size,and confining pressure,can significantly influence the indentation results.Simulation methods for macro-indentation encompass continuous medium,discontinuous medium,and continuous-discontinuous medium methods,with selection based on their differences in principle.Furthermore,rock macro-indentation can be practically applied to mining engineering,tunneling engineering,and petroleum drilling engineering.Indentation indices serve as valuable tools for characterizing rock strength,brittleness,and drillability.This review sheds light on the development of rock macro-indentation and its extensive application in engineering practice.Specialists in the field can gain a comprehensive understanding of the indentation process and its potential in various rock engineering endeavors.

EXPERIMENTAL STUDY OF ROCK BREAKING EFFECT OF STEEL PARTICLES

Particle impact drilling is an efficient drilling technology for deep-well hard formation, With this technology, the rock is cut mainly by high-speed spherical particle impact under hydraulic action. In this article, the influence of jet flow factors, hydraulic factors and abrasive factors on rock breaking is studied through indoor experiments of impact by steel particles. The results indicate that the particle water jet has an optimal standoff distance and particle concentration; the rock breaking effect declines with the increase of the confining pressure and the decrease of the pump pressure and particle diameter. This study will provide some food of thought for the development of particle impact drilling technology.

A swirling jet from a nozzle with tangential inlets and its characteristics in breaking-up rocks

In order to apply a swirling jet to a PDC drill bit, the nozzle performance influenced by nozzle inlet geometric parameters and rock breaking tests under submerged conditions were studied. Numerical simulation was used to study the influence of the nozzle structure on the swirling intensity and nozzle discharge coefficient. Simulation results indicate that spreading angle of the swirling jet is greater than that of＂ the non-swirling jet, and the swirling intensity of the jet is strongly influenced by the length of the nozzle body but weakly by the number of tangential inlets. Rock breaking tests were conducted to evaluate the performance of the swirling jet. It is found that the swirling jet shows a lower threshold pressure to break the rock samples and could break rock more efficiently compared with the non-swirling jet.

Flow structure and rock-breaking feature of the self-rotating nozzle for radial jet drilling

For improving the hole-enlarging capability,roundness and rock-breaking efficiency of the nozzle in radial jet drilling,a new structure of self-rotating nozzle was put forward.The flow structure and rock-breaking features of the self-rotating nozzle were investigated with sliding mesh model and labortary tests and also compared with the straight and the swirling integrated nozzle and multi-orifice nozzle which have been applied in radial jet drilling.The results show that the self-rotating jet is energy concentrated,has longer effective distance,better hole-enlarging capability and roundness and impacts larger circular area at the bottom of the drilling hole,compared with the other two nozzles.Forward jet flow generated from the nozzle is peak shaped,and the jet velocity attenuates slowly at the outer edge.Due to periodic rotary percussion,the pressure fluctuates periodically on rock surface,improving shear and tensile failures on the rock matrix and thereby enhancing rock-breaking efficiency.The numerical simulation results of the flow structure of the nozzle are consistent with the experiments.This study provides an innovative approach for radial jet drilling technology in the petroleum industry.

New Method for Studying Rock-Breaking Mechanism by Disc Cutters

Gaining a thorough understanding of the theoretical principles of rock breaking with a disc cutter is a critical issue in tunnel boring machine (TBM) technology. To fully consider the complexity and importance of the basic principles of rock breaking during tunnel excavation, in this paper we use a new method, the smooth particle hydrodynamics (SPH), to study the rock-breaking mechanism and verify its accuracy and feasibility. Using the SPH method, we induce the rock fragmentation process with two cutters in synchronous and sequential orders. The results show that when the cutters act on rock sequentially, the second indentation influences the crack evolution of the first indentation. With increased cutter spacing, the second crack gradually becomes independent of the first crack. Under synchronous action of the two cutters, a bursiform nucleus is generated beneath the cutters and the area of the nucleus increases with increased cutter spacing. Whether the cutters act on the rock sequentially or synchronously, we found the optimum cutter spacing of our chosen rock type to be 60 mm. Our analyses results show that the efficiency of sequential rock cutting is superior to synchronous cutting, both with respect to crack evolution and cutter force. © 2017, Tianjin University and Springer-Verlag Berlin Heidelberg.

Vibrating-Rocking Motion of Caisson Breakwater Under Breaking Wave Impact

The possible motions of a caisson breakwater under dynamic load excitation include vibrating, vibrating-sliding and vibrating- rocking motions. The models of vibrating motion and vibrating-sliding motion have been proposed in an early paper. In this paper, a model of vibrating- rocking motion of caisson breakwaters under breaking wave impact is presented, which can be used to simulate the histories of vibrating-rocking motion of caisson breakwaters. The effect of rocking motion on the displacement, rotation, sliding force and overturning moment of breakwaters is investigated, In case the overturning moment exceeds the stability moment of a caisson, the caisson may only rock. The caisson overturns only in case the rocking angle exceeds the critical angle, It is shown that the sliding force and overturning moment of breakwaters can be reduced effectively due to the rocking motion, It is proposed that some rocking motion should be allowed in breakwater design.

非刀具破岩理论与技术研究进展与趋势

随着我国深地战略的逐步实施,深部资源开采和地下空间建设迎来新的机遇,但也面临诸多挑战,高地应力、高地温和坚硬岩体等极端地质条件层出不穷。岩石破碎技术是所有资源开采和地下空间建设的主要工程活动,是决定施工工艺和工程效率的主要因素。在极端地质条件下,以刀具为基础的岩石破碎技术由于刀具磨损快、岩石破碎效率低,已成为遏制深地战略顺利实施的关键技术瓶颈,为解决深地岩石高效破碎难题,保障深地战略的顺利实施,迫切需求革命性的岩石破碎技术。无刀具破岩技术作为刀具破岩技术的重要补充,是突破刀具破岩技术瓶颈的可行性思路。为此,将无刀具破岩技术归纳为冲击破岩、热应力破岩和冲蚀磨损破岩3类技术体系,系统分析了水射流、激光和磨料空气射流等16种岩石破碎技术,总结了每种技术的发展历史和技术原理,分析了其破岩优势和技术瓶颈。得出,目前非刀具破岩技术没有在资源开采和地下空间建设中广泛应用的主要原因为破岩能耗高、适用较差和技术装备复杂等。相比刀具破岩,非刀具破岩技术破岩能量利用率较低,水射流破岩比能耗为刀具的40~70倍。微波、激光和等离子体等技术对施工环境要求较高,无法适用于钻井、隧道掘进等受限和恶劣环境。为解决极端地质条件岩石破碎难题,提出多种非刀具破岩技术协同破岩的思路,充分发挥每一种非刀具破岩的技术优势,构建了以射流切缝卸除高地应力、粒子冲击体积破碎坚硬岩体的破岩理念,最大限度降低岩石破碎能耗,简化系统装备,为岩石破碎技术向非刀具化发展提供理论支撑。

冲击破岩钻井提速技术研究现状与发展建议

提高钻井速度不仅是提高我国油气效益开发及深地勘探等方面的重要技术手段,同时对保障国家能源安全意义重大。冲击破岩钻井技术在国内外油田现场应用并获得了良好的提速效果,持续开展此类技术攻关有望攻克当下我国深地高温高压硬岩地层进尺低、提速难的技术痛点。介绍和分析了轴向冲击、扭力冲击和轴-扭耦合冲击辅助钻头破岩钻进技术方面的实践及发展动态。结合冲击破岩钻井技术现状,阐明了冲击辅助钻头破岩力学原理是冲击破岩钻井提速技术的关键问题,综述了国内外研究学者在冲击辅助钻头破岩物理实验、理论模型和数值模拟等研究方法上取得的科学进展。针对冲击破岩钻井提速技术的发展提出了相关建议,即加强在材料结构优化设计、智能化控制、多元技术融合和井场应用优化等方面的研究力度,为我国能源高效开发做出贡献。