Stability analysis of longwall top-coal caving face in extra-thick coal seams based on an innovative numerical hydraulic support model

The relationship between support and surrounding rock is of great significance to the control of surrounding rock in mining process.In view of the fact that most of the existing numerical simulation methods construct virtual elements and stress servo control to approximately replace the hydraulic support problem,this paper establishes a new numerical model of hydraulic support with the same working characteristics as the actual hydraulic support by integrating numerical simulation software Rhino,Griddle and FLAC3D,which can realize the simulation of different working conditions.Based on this model,the influence mechanism of the supporting strength of hydraulic support on surrounding rock stress regulation and coal stability in front of the top coal caving face in extra thick coal seam were researched.Firstly,under different support intensity,the abutment pressure of the bearing coal and the coal in front of it presents the “three-stage”evolution characteristics.The influence range of support intensity is 15%–30%.Secondly,1.5 MPa is the upper limit of impact that the support strength can have on the front coal failure area.Thirdly,within a displacement range of 2.76 m from the coal wall,a support strength of1.5 MPa provides optimal control of the horizontal displacement of the coal.

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.

Deformation mechanism of surrounding rocks and key control technology for a roadway driven along goaf in fully mechanized top-coal caving face

The variation of the stress in the bolted surrounding rocks structure of the roadway driven along goaf in a fully mechanized top coal caving face with moderate stable conditions are studied by using numerical calculation. The essential deformation characteristics of the surrounding rocks in this kind of roadway are obtained and the key technology of bolting support used under these conditions is put forward.

Study on destressing technology for a roadway driven along goaf in a fully mechanized top-coal caving face

Based on the deformation characteristics of the roadways driven along goaf in fully mechanized top coal caving faces, the author considers that it is the key to ensure the stability of surrounding rocks of roadway driven along goaf to control the deformation during the period affected by mining. Considering the characteristics of the roadway layout in fully mechanized top coal caving faces, a technical scheme of destressing is put forward and the destressing effect is analyzed by using the software of Universal Distinct Element Code 3 0(UDEC 3 0).

Statistic constitutive equation of top-coal damage for fully mechanized coal face with sublevel caving

Under the action of abutment pressure in front of fully mechanized coal face with sublevel caving(CFSC),top-coal over CFSC deformed.In the process of whole de- formation of top-coal,it changed from continuum elastic mass to non-continuum plastic mass contained fissures,become a loose body.According to its bearing characteristics and mechanical properties,top-coal mass can be divided into four deformation zones along the winning direction of CFSC,i.e.initial stress zone,elastic zone,plastic zone and loose zone.Top-coal in plastic zone located in the post-peak zone of the stress-strain curve for top-coal.With equivalent strain principle of damage mechanics and mathemati- cal theory of statistic,combining the movement law of top-coal,set up a constitutive equa- tion with damage statistics for top-coal in different position in CFSC.The equation illus- trated the mathematical relationship among top-coal bearing capacity,horizontal confining pressure along the winning direction of CFSC and mechanical properties of top-coal mate- rial.The conclusions not only provide a basis for numerical computer simulations on damage deformation and failure mechanism for top-coal,but also further promote the ap- plication of damage mechanics in CFSC.

Underground pressure appearance laws analysis for fully mechanized top coal slice caving on high-dipping thick coal seams

Taking Adaohai Coal Mine as the example, underground pressure appearance laws of fully mechanized top coal slice caving on high-dipping and thick coal seams. Through site visit, theoretical analysis and discrete element calculation, the research shows that, as the mining deepens, underground stress of lower sublevels is more obvious and higher than that of upper sublevels and is higher in the air return roadway than that in the air intake roadway in the area that is near to the top coal. Because the top coal is thick and gangue is caved above the support, underground pressure to the working face is relatively gentle. Immediate roof will mainly fall down along the floor. Main roof and the rock bed above the main roof will move to the mined out area along the fault in the early stage and then fall down with the mined out area later. In addition, roof pressure mainly periodically appears in two directions along the trend and the dip.

Reliability analysis of the velocity matching of coal cutting and caving in fully mechanized top-coal caving face

The matching relationship between coal cutting and caving in fully mechanized top-coal caving face is analyzed in detail from the angle of reliability. The coupling equation of reliability is established correspondingly, and the mathematical equation of the coefficient of velocity matching of coal cutting and caving is obtained, which meets a certain reliability demand for making the working procedure of coal caving not influence coal cutting of coal-cutter. The results show that the relationship between the coefficient of the velocity matching and the reliability of coal cutting and caving system is linear on the whole when R <0.9. It is pointed out that different numerical value should be selected for different coal face according to different demand for reliability.

Back-and-forth mining for hard and thick coal seams—research about the mining technology for fully mechanized caving working face of Datong Mine

The article introduced the key technology, mining process, and back-and-forth mining method for the caving working face of hard-thick coal seams in Datong mine, and researched this innovations process, optimized the systemic design and working face out-play, tried to perfect the caving mining technology of hard-thick coal seams further.

Study of mechanical principle of floor heave of roadway driving along next goaf in fully mechanized sub-level caving face

Abstract On the basis of analyzing floor strata mechanical circumstance of the roadway, the mechanical model was established. The relative displacement of roadway floor, narrow pillar floor coal mass and floor strata was calculated, the results showed that the high abutment pressure on coal mass beside the roadway was the main reason to lead to relative displacement of floor strata. And the roadway floor heave come mainly from three aspects. Firstly, the roadway floor strata is easily fractured by the stretch stress. Secondly, because the high abutment pressure is greater than the uniaxial compressive strength of floor strata, when the roadway floor strata are fractured, the coal mass floor strata at the same depth will be fractured, and broken rock will fluid into the open roadway. Thirdly, comparing with the coal mass floor, the roadway floor is relative ascending.

Top-coal deformation control of gob-side entry with narrow pillars and its application for fully mechanized mining face

A mechanical model to control the top-coal deformation is established in accordance with the structural characters of the gob-side entry surrounding rock for the fully-mechanic top-coal caving; the analytical solution of top coal roof-sag curve is deduced with Winkler elastic foundation beam model. By means of a calculating and analytic program, the top coal roof-sag values are calculated under the conditions of different supporting intensities, widths of narrow pillars and stiffness of top coal; meanwhile, the relationship between the roof-sag values and supporting intensity, width of narrow pillars and stiffness of top coal is analyzed as well. With the actual situation of the gob-side entry taken into consideration, the parameters of top-coal control are determined and a supporting plan is proposed for the top-coal control,which is proved to be reliable and effective by on-site verification. Some theoretical guidance and advice are put forward for the top-coal deformation control in gob-side entry for fully mechanized top-coal caving face.

Analysis and key control technologies to prevent spontaneous coal combustion occurring at a fully mechanized caving face with large obliquity in deep mines

In order to prevent spontaneous coal combustion occurring at a fully mechanized caving face with large obliquity in deep mines in China, we have analyzed the characteristics of spontaneous coal combustion and explain theoretically the factors affecting spontaneous coal combustion, such as rock bursts, high temperatures, high ventilation resistance, slow advancing speed and large obliquity mining. Key technologies to prevent spontaneous combustion occurring in sharply inclined seams in deep mines are pro- posed; these include pouring water, stopping leakage in upper and lower comers of the working face, choking off the goaf and cov- eting the coal. CO concentrations were controlled within two years to less than 15×10^-6 at the upper comer by applying these tech- nologies at the 1410 working face of the Huafeng coal mine. Our method has significant theoretical value and is of practical impor- tance in controlling spontaneous coal combustion occurring at a fully mechanized caving face with large obliquity in deep mines.

Hydraulic support stability control of fully mechanized top coal caving face with steep coal seams based on instable critical angle

Analyzed the support instable mode of sliding,tripping,and so on,and believed the key point of the support stability control of fully mechanized coal caving face with steep coal seams was to maintain that the seam true angle was less than the hydraulic support instability critical angle.Through the layout of oblique face,the improvement of support setting load,the control of mining height and nonskid platform,the group support system of end face,the advance optimization of conveyor and support,and the other control tech- nical measures,the true angle of the seam is reduced and the instable critical angle of the support is increased,the hydraulic support stability of fully mechanized coal caving face with steep coal seams is effectively controlled.

Analysis of factors of top coal caving in fully mechanized sublevel caving face in soft coal and control

According to the analysis of the mechanism of top coal caving, the caving condition was pointed out, and many factors of caving were also determined. Then the relationship between factors and caving was studied. Based on the above research, one effective method by using field monitoring was brought forward to determine the controlling factor. Then some related key technologies were provided, such as keeping the integrality of the top-coal, raising the horizontal resistance of supports and decreasing the real end-face distance etc.. At last one application of this method was presented, and it was proved to be an effective method.

Development and prospect on fully mechanized mining in Chinese coal mines

Fully mechanized mining(FMM)technology has been applied in Chinese coal mines for more than 40 years.At present,the output of a FMM face has reached 10-million tons with Chinese-made equipment.In this study,the new developments in FMM technology and equipment in Chinese coal mines during past decades are introduced.The automatic FMM technology for thin seams,complete sets of FMM technology with ultra large shear height of 7 m for thick seams,complete sets of fully mechanized top coal caving technology with large shear height for ultra-thick seams of 20 m,complete sets of FMM technology for complex and difficult seams,including steeply inclined seams,soft coal seams with large inclination angle,and the mechanized filling mining technology and equipment are presented.Some typical case studies are also introduced.Finally,the existing problems with the FMM technology are discussed,and prospect of FMM technology and equipment applied in Chinese coal mines is put forward.

特厚煤层综放工作面煤-架受力演化特征及其承载机理

为了研究特厚煤层综放工作面煤-架结构及其承载机理,以塔山矿8216工作面为背景,根据煤体与支架的位置关系将其分为架前顶煤、架上顶煤和承载煤体,采用FLAC3D数值模拟软件分析了煤-架结构应力演化特征及煤体失稳破坏规律。结果表明:工作面超前支承压力峰值位于煤壁斜上方的架前顶煤中,顶煤破坏深度与超前支承压力峰值的超前距离基本相当,向控顶区侧呈“弧形”破坏形态。确定了煤-架结构对顶板来压承载能力的排序依次为架前顶煤>承载煤体>液压支架>架上顶煤。承载煤体在围岩应力拱和顶煤的保护下破坏深度始终保持在近煤壁侧3 m内,已破坏煤体应力基本不受推进距离与支架工作阻力变化的影响。架上顶煤在顶煤冒放前后承载特性不同,进而引起整个煤-架结构承载特性的改变。放煤前后煤壁破坏深度分别为3 m和2 m,顶煤破坏深度分别为7 m和12 m。架前顶煤的失稳是发生端面冒顶的主要原因,煤壁侧承载煤体的破坏是煤壁片帮的直接原因。在围岩应力拱的作用下,顶板以架前顶煤为轴做回转运动并伴随着顶板、支架及超前煤体应力的动态变化,但煤-架结构的承载特性不会改变。研究结果可为特厚煤层综放工作面矿压灾害防控提供有益参考。

“截割-放落”煤体瓦斯解吸粒度效应及动态预测模型

为了进一步探究综放开采落煤瓦斯涌出规律,通过理论分析、物理实验和现场测试,分析了截落和放落煤体粒度分布特征,揭示了落煤瓦斯涌出强度变化特征,构建了综放开采落煤瓦斯涌出动态预测模型,并对模型进行了验证。结果表明:王家岭矿12302综放工作面落煤粒度分布主要集中在2~20 mm及40 mm以上,占比总和达到60%以上;随着煤体粒度减小,瓦斯解吸强度增高,达到解吸平衡的速度增快;构建的截落和放落煤瓦斯涌出动态预测模型平均误差不大于10%,能够较好地表征现场实际落煤瓦斯涌出规律,为综放开采条件下瓦斯涌出预测及防控提供了可靠基础支撑。

Mating model on production capacity for the system of cutting coal and drawing top-coal in FMMSC

Being a safe and highly-efficient mining method, fully mechanized mining with sublevel caving （FMMSC） was extensively employed in Chinese coal mines with thick seam. In order to make drawing top-coal furthest to parallel work with shearer cutting coal, decrease failure ratio of rear scraper conveyor and increase safe production capacity of equipments, based on production technology, set up the mating model of safe production capacity of equipments for the system of drawing top-coal and shearer cutting coal in coal face with sublevel caving. It is mean capability of drawing top-coal adapted to the capability of shearer cutting coal in a working circle in the coal face that was deduced. The type selection of equipment of rear scraper conveyor can be tackled with this mating model. The model was applied in FMMSC in Yangcun Coal Mine, Yima Coal Group of China. With the mating light-equipments, the coal output in coal face attained 1.05 Mt in 2004. It gained better technical-economic benefit.

Experiment Research of Application of FMCCT in Complex-Condition Coal Seams

The fully-mechanized caving coal technique (FMCCT) is a great technique progress of mining method in thick coal seams in China, and it has succeeded in some suitable condition mines. This paper introduces some technical measures and achieved outcomes in gas and fire precaution and support selection for the use of the fully-mechanized caving coal technique in the complex-condition coal seams based on the practice of Weijiadi Coal Mine, in which the technique is used in the gently inclined extremelythick soft coal seam with the dangers of coal and gas outburst and spontaneous combustion.

基于改进Faster R-CNN的综放煤矸混合放出状态识别方法

放煤量的智能监测技术是智能化综放开采发展的方向之一。针对厚煤层综放开采混合介质下落过程煤矸智能识别现有方法存在适用范围窄、误判率高等问题,提出一种基于实时区域卷积神经网络(Faster R-CNN)改进的CBAM Faster R-CNN煤矸混合放出状态分析识别方法。该方法以综放开采工作面煤矸石下落状态为背景,将注意力机制算法(CBAM)融入ResNet50特征提取网络,研究了注意力机制融合于ResNet50主干特征提取网络的融合优化方法,确定了以煤矸石下落状态检测为目标的最佳融合位置,增加了提取煤与矸石权重信息的能力,使得特征提取过程重点关注煤矸运动状态参量;构建了粉尘环境下综放开采煤矸混合放出状态试验平台,对高速摄像机所采集的煤矸原始运动图像进行暗通道去雾与模糊集增强预处理操作,分析识别不同工况下静态图像,定量研究了模型权重优化以及粉尘环境预处理对煤矸混合放出状态识别的影响。研究结果表明:基于CBAM Faster R-CNN模型的预处理图像识别精确率较原始图像提升了8.84%,召回率提升了6.68%;模型优化效果方面,CBAM Faster R-CNN模型平均查准率和召回率分别为82.63%,86.53%,高于经典模型的74.69%,79.93%;F_(1)-score值较经典模型提升了7%。因此,基于“预处理+CBAM Faster R-CNN”的图像识别方法为实现粉尘环境下综放开采放煤量的精准辨识提供了可靠的理论支撑。

特厚煤层综放煤-矸-岩放落流动的时序规律及识别方法

综放工作面放煤工艺中的煤矸智能识别是智能化综放开采的瓶颈,经过十几年的不断探索研究,基于煤层的沉积环境和岩性赋存特征,提出了煤岩层低水平自然γ射线辐射高精度实时探测方法和煤矸自动识别原理,为综放工作面放煤工序的煤矸智能识别控制奠定了基础。根据特厚煤层含多层夹矸的复杂结构特征,以提高煤矸识别的精准性为目的,分析了特厚煤层夹矸的赋存特点及自然辐射特性;开展了煤-矸(夹矸)-岩(直接顶岩石)放落流动的时序规律研究,得出顶煤中夹矸的层位、间距、层数等因素会影响放落流动时序,且呈现不同的时序状态,据此进行了放落流动时序分区;相应地不同时序区的混矸率会呈现不同的特征:当夹矸无时序放出时,混矸率在一固定的范围内波动,当煤-夹矸渐次放出时,混矸率呈现上升—稳定—连续台阶式上升的特征,直接顶矸石的混入,使得混矸率呈线性增加;基于煤-矸-岩放落流动的时序特征,得出了不同时序条件下自然射线的辐射变化特征,确定了自然射线辐射强度台阶式变化与夹矸赋存参数的影响关系,区分了放煤流中含有夹矸和直接顶矸石混入的辐射特征,确定了不同煤-矸-岩放落时序区的辐射强度范围,提出了以自然射线辐射强度作为煤-矸-岩自动识别的主要参数和2种不同关窗方式的识别方法;在同煤集团塔山煤矿进行了现场测试,测试结果与研究结果得到了很好的印证,达到了预期效果,为智能放煤的现场应用奠定了基础。