Longwall Top-Coal Caving in Thinner Thick-Seam and Research on Light Hydraulic Support

The application of light hydraulic support highlights the advantages of longwall top-coal caving (LTC) in thinner thick-seams (3. 0~ 5. 0 m). Considering the problems in practice, the developing of its new series will promote the mining of LTC with light hydraulic supports. Some relevant technical problems of the caving technology and the future of this series of supports are analyzed in this paper with several new opinions.

Key technologies and equipment for a fully mechanized top-coal caving operation with a large mining height at ultra-thick coal seams

Thick and ultra-thick coal seams are main coal seams for high production rate and high efficiency in Chinese coal mines, which accounts for 44 % of the total minable coal reserve. A fully mechanized top-coal caving mining method is a main underground coal extraction method for ultra-thick coal seams. The coal extraction technologies for coal seams less than 14 m thick were extensively used in China. However, for coal seams with thickness greater than 14 m, there have been no reported cases in the world for underground mechanical extraction with safe performance, high efficiency and high coal recovery ratio. To deal with this case, China Coal Technology ＆ Engineering Group, Datong Coal Mine Group, and other 15 organizations in China launched a fundamental and big project to develop coal mining technologies and equipment for coal seams with thicknesses greater than 14 m. After the completion of the project, a coal extraction method was developed for top-coal caving with a large mining height, as well as a ground control theory for ultra-thick coal seams. In addition, the mining technology for top-coal caving with a large mining height, the ground support technology for roadway in coal seams with a large cross-section, and the prevention and control technology for gas and fire hazards were developed and applied. Furthermore, a hydraulic support with a mining height of 5.2 m, a shearer with high reliability, and auxiliary equipment were developed and manufactured. Practical implication on the technologies and equipment developed was successfully completed at the No. 8105 coal face in the Tashan coal mine, Datong, China. The major achievements of the project are summarized as follows： 1. A top-coal caving method for ultra-thick coal seams is proposed with a cutting height of 5 m and a top-coal caving height of 15 m. A structural mechanical model of overlying strata called cantilever beam-articulated rock beam is established. Based on the model, the load resistance of the hydraulic support with a large mining height for top-coal caving method is determined. With the analysis, the movement characteristics of the top coal and above strata are evaluated during top-coal caving operation at the coal face with a large mining height. Furthermore, there is successful development of comprehensive technologies for preventing and controlling spalling of the coal wall, and the top-coal caving technology with high efficiency and high recovery at the top-coal caving face with a large mining height. This means that the technologies developed have overcome the difficulties in strata control, top-coal caving with high efficiency and high coal recovery, and enabled to achieve a production rate of more than 10 Mtpa at a single top-coal caving face with a large mining height in ultra-thick coal seams; 2. A hydraulic support with 5.2 m supporting height and anti-rockburst capacity, a shearer with high reliability, a scraper conveyor with a large power at the back of face, and a large load and long distance headgate belt conveyor have been successfully developed for a top-coal caving face with large mining height. The study has developed the key technologies for improving the reliability of equipment at the coal face and has overcome the challenges in equipping the top-coal caving face with a large mining height in ultra-thick coal seams; 3. The deformation characteristics of a large cross-section roadway in ultra-thick coal seams are discovered. Based on the findings above, a series of bolt materials with a high yielding strength of 500-830 MPa and a high extension ratio, and cable bolt material with a 1 × 19 structure, large tonnage and high extension ratio are developed. In addition, in order to achieve a safe roadway and a fast face advance, installation equipment for high pre-tension bolt is developed to solve the problems with the support of roadway in coal seams for top-coal caving operation with a large mining height; 4. The characteristics of gas distribution and uneven emission at top-coal caving face with large mining height in ultra-thick coal seams are evaluated. With the application of the technologies of gas drainage in the roof, the difficulties in gas control for high intensive top-coal caving mining operations, known as ＂low gas content, high gas emission＂, are solved. In addition, large flow-rate underground mobile equipment for making nitrogen are developed to solve the problems with fire prevention and safe mining at a top-coal caving face with large mining height and production rate of more than 10 Mtpa. A case study to apply the developed technologies has been conducted at the No. 8105 face, the Tashan coal mine in Datong, China. The case study demonstrates that the three units of equipment, i.e., the support, shearer and scraper conveyor, are rationally equipped. Average equipment usage at the coal face is 92.1%. The coal recovery ratio at the coal face is up to 88.9 %. In 2011, the coal production at the No. 8105 face reached 10.849 Mtpa, exceeding the target of 10 Mtpa for a topcoal caving operation with large mining height performed by Chinese-made mining equipment. The technologies and equipment developed provide a way for extracting ultra-thick coal seams. Currently, the technologies and equipment are used in 13 mining areas in China including Datong, Pingshuo, Shendong and Xinjiang. With the exploitation of coal resources in Western China, there is great potential for the application of the technologies and equipment developed.

Ground pressure and overlying strata structure for a repeated mining face of residual coal after room and pillar mining

To investigate the abnormal ground pressures and roof control problem in fully mechanized repeated mining of residual coal after room and pillar mining, the roof fracture structural model and mechanical model were developed using numerical simulation and theoretical analysis. The roof fracture characteristics of a repeated mining face were revealed and the ground pressure law and roof supporting condi- tions of the repeated mining face were obtained. The results indicate that when the repeated mining face passes the residual pillars, the sudden instability causes fracturing in the main roof above the old goal and forms an extra-large rock block above the mining face. A relatively stable ＂Voussoir beam＂ structure is formed after the advance fracturing of the main roof. When the repeated mining face passes the old goaf, as the large rock block revolves and touches gangue, the rock block will break secondarily under overburden rock loads. An example calculation was performed involving an integrated mine in Shanxi province, results showed that minimum working resistance values of support determined to be reason- able were respectively 11,412 kN and 10,743 kN when repeated mining face passed through residual pillar and goaf. On-site ground pressure monitoring results indicated that the mechanical model and support resistance calculation were reasonable.

6~10 m厚煤层超大采高液压支架及其工作面系统自适应智能耦合控制

厚煤层储量及产量占我国原煤总储量及产量的一半,通过梳理厚煤层开采历史沿革,总结了我国厚煤层开采40年来的技术及装备研发实践,系统分析了以高端大采高液压支架及围岩智能耦合理论为代表的6~10 m大采高综采高效智能化综采技术及装备研究进展,提出了大采高支护理论及围岩智能耦合控制的突破是厚煤层一次开采高度突破的首要因素,完善的感知体系建立是液压支架自适应支护的前提,数字技术的应用为大采高工作面高效推进及装备智能协同控制提供了新的技术途径;阐明了大采高综放液压支架与围岩耦合关系,剖析了采高增加对硬煤层冒放性的有利影响,提出了基于煤矸识别、放煤机构控制的“纯煤段记忆放煤+煤岩分界模糊段人工反馈式干预放煤”的智能放煤控制策略;分析了大采高开采“采–运”协同智能耦合控制关键技术,构建了基于采煤机牵引速度与刮板输送机链速间联动调节的工作面装备间多机异构耦合自适应协同控制模型;研发了厚煤层开采中10 m超大采高液压支架,分析了厚煤层开采不断突破开采高度极限的新认识,从开采装备、控制系统等方面提出厚煤层一次开采高度的突破的研发方向。

煤矿综放工作面矿压显现规律与切顶压架预警指标分析

煤矿特厚煤层综放开采时受技术装备等条件限制,放顶煤时由于顶板松散程度较高难以形成稳定结构,导致工作面顶板更容易大面积切落,瞬间冲击支架,损坏液压支架结构,严重影响矿井安全高效生产。以不连沟煤矿F6218综放工作面为工程背景,通过实测数据分析了工作面支架初撑力、安全阀开启情况及工作阻力频率等支架基本工况,揭示了工作面矿压显现规律,建立了适合该矿的切顶压架灾害预警指标体系。结果表明:不连沟煤矿预警指标界限分别为循环增阻率40 kN/min、安全阀开启率50%、动载系数1.4、活柱下缩量500 mm、支架前柱不低于25 MPa,前柱合格率不低于90%;后柱不低于20 MPa,后柱合格率不低于90%。

综放端头支架与后部输送机配套形式及空间探讨

智能化无人开采是实现煤矿安全高效开采的技术途径,各种设备的自动化及相互间的配套影响着工作面的智能化程度,合理的配套形式及空间是提高开采自动化率的保障。随着工作面开采设备能力的提高,相关配套设备特别是刮板输送机两端的驱动部体积和占用空间不断增大,受设备配套和设备尺寸制约,给工作面的自动化运行与控制带来挑战。对于综放工作面,两端头的端头支架与后部输送机的配套非常关键。为了解决端头支架尾柱与后部输送机电动机间相对位置观察不便、难于控制、发生碰撞损坏电动机、需要人工干预的痛点,通过端头支架底座与后部输送机间限位装置的研究和毫米波雷达的应用,从机械、控制、监测等方面形成了综放工作面两端头后部狭窄空间的设备安全解决方案,此方案的实施,取得了较好的应用效果。

综放巷内充填原位沿空留巷充填体支护阻力研究

在综放巷内充填原位沿空留巷技术基础上,根据岩层控制的关键层理论,建立综放巷内充填原位沿空留巷围岩结构力学模型,推导出不同地质条件下巷内充填体的支护阻力计算公式,并对围岩与巷内充填体之间的相互作用机制进行深入分析。研究结果表明,留巷围岩的稳定性与充填体的支护阻力和巷内支护方法密切相关。采用锚梁网索巷内支护技术结合及时巷内充填和加强临时支护等工艺措施,可形成良好的充填体-围岩共同承载体系,能充分发挥留巷围岩的自承能力,增强巷道整体性,有效减小需由充填体来平衡的围岩载荷。现场工业性试验表明,该项技术的应用是成功而有效的,综放巷内充填原位沿空留巷围岩结构力学模型和支护阻力计算公式是合理的,可在类似条件的综放工作面中推广应用。

浅埋深综放工作面矿压规律及支架工作阻力确定

针对浅埋深综放工作面矿压显现剧烈、安全阀开启频繁的问题,对平朔井工三矿39107浅埋深综放工作面支架工作状况进行分析研究。采用矿压监测系统现场实测液压支架工作阻力,得到工作面基本顶初次来压步距为33.7 m,平均周期来压步距20.7 m,周期来压期间液压支架循环末阻力平均为9 700 kN,安全阀开启率平均为3.7%,工作面液压支架初撑力水平整体较低,分析表明液压支架存在3种不合理工作状态:安全阀调定压力不合理,前后立柱受力不均衡,部分支架串液。结合现场实测数据进行理论计算,得出39107工作面支架合理工作阻力应不低于12 000 kN。

大采高综放开采几个理论问题的研究

提出大采高综放开采的概念,对大采高综放开采主要基础理论问题如:大采高综放开采工作面参数的确定、煤壁片帮冒顶机理与防治、提高工作面煤炭采出率、大断面高煤帮巷道支护、围岩活动规律与特种综放支架研发进行了探讨,以期推动这一技术的发展.

综放开采煤层支承压力分布规律现场实测分析

依据谢桥矿1151(3)综放面开采地质及技术条件,采用钻孔应力计对工作面回采过程中煤柱和工作面煤层及巷帮侧向实体煤的应力进行观测。研究分析表明,在非对称开采条件,回采期间工作面及巷道周围煤层应力分布规律明显不同,煤柱和工作面煤层沿走向在工作面前方存在支承压力峰值,但巷帮侧向实体煤沿走向在工作面前方并不存在应力峰值,其峰值在采空区后方,而煤柱和巷帮侧向实体煤沿倾向均存在应力峰值,邻近工作面煤柱及工作面煤层应力均处于降低区。

综放开采端面顶板稳定性的数值模拟研究

由于直接顶 (含顶煤 )厚度的成倍增加 ,综放采场顶板下沉量与支架工作阻力并不存在类双曲线关系。因此用顶板最大下沉量判断直接顶 (含顶煤 )稳定性已失去意义。应用 U DEC程序分析了综放开采端面顶板稳定性与支架工作阻力及端面距的关系 ,得到当端面距在一定范围之内时 ,端面顶板冒落情况与支架工作阻力及支护角度密切相关 ,支架工作阻力 P和端面顶板下沉量Δ ld呈类双曲线关系。在此基础上提出综放支架工作阻力新的确定方法。

特厚煤层大采高综放工作面矿压及顶板破断特征

针对大采高综放工作面覆岩活动空间大、开采扰动强烈的特点,以不连沟煤矿特厚煤层大采高综放开采为背景,采用现场实测和理论分析等方法对大采高综放采场矿压及顶板运移破断特征进行分析,建立了大采高综放采场周期来压岩层破断的力学模型,得出了液压支架工作阻力的计算方法。结果表明:大采高综放工作面来压时安全阀开启频繁、顶板快速下沉,额定工作阻力13 800 kN的液压支架不能满足顶板控制的需要;开采空间的增大、直接顶厚度增大,低位基本顶转化为直接顶成为悬臂结构、高位基本顶形成砌体梁,二者形成"上位砌体梁-下位倒台阶组合悬臂结构";工作面来压强烈、动载明显、持续时间短的矿压现象是由于高位砌体梁结构滑落失稳造成的,据其力学特征确定了液压支架的工作阻力。

两柱大采高强力放顶煤支架的特点与创新发展

介绍了放顶煤液压支架的现状和发展趋势,通过与四柱放顶煤液压支架进行对比分析,认为两柱式放顶煤液压支架前端支顶力大,控制煤壁片帮和架前冒顶能力强;顶梁位态调整幅度大,适应外载变化和自身调节能力强;易于实现自动化控制;同等宽度支架可达到的工作阻力低。阐述了两柱放顶煤支架近几年创新发展的新成果:提高两柱式放顶煤液压支架的极限工作阻力;开发自动化放煤系统;提升钢板性能,降低液压支架质量;认为两柱式大采高强力放顶煤支架将成为大采高自动化综放工作面的首选架型。

两柱及四柱放顶煤支架适应性对比分析

通过现场实测及理论计算,分别给出了两柱掩护式及四柱支撑掩护式综放支架立柱受力及支架合力作用点位置的对比分析。分析认为:两柱掩护式综放支架支护时,其支架左、右立柱受力分布均衡,支架支护性能得到了有效的发挥,支护效率较高;支架外载荷合力作用点分布范围更集中,距离工作面煤壁更近,有利于端面顶煤的稳定及减少工作面煤壁的片帮冒顶现象;在煤层条件适宜的情况下选用两柱式放顶煤支架更具有优势。

综放工作面沿空留巷支护阻力研究

为了计算综放工作面沿空留巷支护阻力,以结构力学理论为基础,分析综放工作面沿空留巷支护阻力计算模型,建立沿空留巷围岩和支护体的结构力学模型,应用超静定结构和静定结构分析支护体与沿空留巷围岩相互作用机制,推导出巷旁支护阻力的计算公式。结果表明,进行沿空留巷支护阻力力学分析时,要考虑顶板极限断裂前和断裂后两种状态下的受力情况,支护阻力与岩层厚度、容重、煤体极限平衡区宽度、跨距、支护体宽度和巷道宽度等因素密切相关。工业性试验表明,该技术的应用是成功而有效的。因此,综放巷内沿空留巷围岩结构力学模型和支护阻力计算公式是合理的,可在类似条件的综放工作面中应用。

综放工作面回采巷道锚杆支护解除机理与实践

为了防止顶板初次垮落步距加大和工作面端头较大范围悬顶,基于潞安矿业(集团)公司漳村矿2203工作面安全高效生产的重要性,采用理论分析、数值模拟和现场试验的方法,分析了锚杆支护解除前后回采巷道顶板状态、煤柱支承压力分布、煤柱屈服区宽度、邻近巷道围岩移动破坏等变化情况,研究了回采巷道锚杆、锚索支护解除机理、方法及工艺过程。结果表明:实施锚杆支护解除可以减小初次垮落步距,增加初采放煤量,减小煤柱压力,改变工作面邻近煤柱的受力状态,提高煤柱整体强度,可以回收锚杆、锚索及组合构件。2203工作面成功回收90%以上的可回收锚杆,不可回收锚杆(索)的托盘及钢带等基本回收,初采垮落步距减小了8 m,增加初采放煤量7 311 t。

浅埋综放工作面矿压特征及支护强度实测研究

为了解上覆松软覆岩浅埋深综放工作面的矿压特征并确定其支护强度,以路天煤矿16号煤层1603综放工作面为例,研究了上覆松软覆岩浅埋深综放工作面的顶板垮落步距和支架载荷特征。研究结果表明:浅埋深条件下顶板仍有初次来压与周期来压现象,来压期间载荷增大系数为1.01~2.07,平均1.20,并且载荷增大系数随埋深的增加而减小;浅埋深条件下的1603综放工作面支架支护强度为442~802 k N/m2;支架载荷的平均值随开采深度的增加而增大,且支架循环末工作阻力随初撑力的增大线性增加。据研究结果可得开采深度60~110 m、上覆松软覆岩浅埋深综放工作面支架支护强度计算式,能简单快捷得到该类似条件下综采工作面支架支护强度。

特厚煤层大采高综放自动化开采技术与装备

针对我国西部矿区坚硬特厚煤层综放自动化开采技术难题,研究了大采高综放工作面液压支架与围岩耦合作用关系,分析了坚硬特厚煤层顶煤冒放结构及液压支架合理工作阻力确定方法,研发了液压支架与围岩智能耦合控制系统及自动化放顶煤控制系统,实现了大采高综放工作面自动化开采。基于坚硬特厚煤层大采高综放液压支架与围岩耦合作用关系,建立了坚硬顶煤冒放的"悬臂梁"模型及顶板岩层结构失稳的"组合悬臂梁"模型,揭示了大采高综放工作面合理机采高度确定方法及合理液压支架工作阻力确定方法。通过分析两柱强力液压支架的承载特性,创新设计了大采高综放液压支架三级高效强扰动放煤机构,研发了综放液压支架智能耦合控制系统,实现了对液压支架姿态与受力状态的实时监测。基于大采高综放工作面分段多窗口多轮放煤工艺的时序控制自动化放煤逻辑关系,研发了自动化放煤控制装置,实现了坚硬特厚煤层大采高综放工作面安全、高效、高回采率自动化开采。

放顶煤液压支架的创新与发展

回顾我国放顶煤技术的发展历程,介绍了我国放顶煤液压支架的创新成果,着重阐述我国放顶煤液压支架的最新发展、大采高放顶煤液压支架的应用及其采用的关键技术,如:专利技术新型双四连杆中通式大空间支架稳定机构、抗冲击立柱、支架稳定性措施及煤壁片帮控制措施等。分析了新型分体组合式直线型放顶煤液压支架的特点及其适应性和稳定性,并提出放顶煤液压支架发展的方向应为:发展两柱放顶煤液压支架、轻型放顶煤液压支架、大采高放顶煤支架、浅埋深厚煤层放顶煤液压支架和深部矿井厚煤层放顶煤液压支架等。

特厚煤层综放工作面大断面切眼支护技术

为了解决塔山煤矿综放工作面跨度10 m切眼的支护难题,采用理论分析、数值计算方法确定了大跨度切眼的支护形式为高强度锚杆、组合锚索、W钢带、金属网、混凝土联合支护,以形成群锚封闭效应,维护切眼巷道围岩的稳定性和安全性。试验中锚索锚固力达140~160 kN,锚固区内顶板最大离层值7 mm,顶底板移近量最大值38 mm,试验结果表明,设计提出的锚杆-组合锚索-混凝土支护提高了支护结构的整体承载力,有效控制了切眼巷道围岩的变形,保证了大断面切眼的安全使用。