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.

Mining pressure monitoring and analysis in fully mechanized backfilling coal mining face-A case study in Zhai Zhen Coal Mine

Fully mechanized solid backfill mining(FMSBM) technology adopts dense backfill body to support the roof. Based on the distinguishing characteristics and mine pressure control principle in this technology, the basic principles and methods for mining pressure monitoring were analyzed and established. And the characteristics of overburden strata movement were analyzed by monitoring the support resistance of hydraulic support, the dynamic subsidence of immediate roof, the stress of backfill body, the front abutment pressure, and the mass ratio of cut coal to backfilled materials. On-site strata behavior measurements of 7403 W solid backfilling working face in Zhai Zhen Coal Mine show that the backfill body can effectively support the overburden load, obviously control the overburden strata movement, and weaken the strata behaviors distinctly. Specific performances are as follows. The support resistance decreases obviously; the dynamic subsidence of immediate roof keeps consistent to the variation of backfill body stress, and tends to be stable after the face retreating to 120-150 m away from the cut. The peak value of front abutment pressure arises at 5-12 m before the operating face, and mass ratio is greater than the designed value of 1.15, which effectively ensures the control of strata movement. The research results are bases for intensively studying basic theories of solid backfill mining strata behaviors and its control, and provide theoretical guidance for engineering design in FMSBM.

STUDY ON PRODUCTION SYSTEM OPERATION REGULARITY OF FULLY MECHANIZED SUBLEVEL CAVING MINING AND SEQUENTIAL OPERATION

According to a lot of practical data in Liujialiang Mine and reliability theory and result of computer simulation, operation regularity of fully mechanized sublevel caving mining production system in the condition of gently inclined complicated geological structure and production shortcomings are found out and reliability of system and output of the working face are predicted finally.

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.

Fracture mechanics model of fully mechanized top coal caving of shallow coal seams and its application

Based on break characteristics of roofs in fully mechanized top-coal mining of thick shallow coal seams, a fracture mechanics model was built, and the criterion of crack propagation in the main roof was derived using the fracture mechanics theory. The relationships between the fracture length of the roof and the working resistance of the supports were discovered, and the correlations between the load on the overlying strata and the ratio of the crack's length to the thickness of the roof were obtained. Using a working face of Jindi Coal Mine, Xing county Shanxi province as an example, the relationships between the fracture length of the roof and the working resistance of the supports were analysed in detail. The results give a design basis in hydraulic top coal caving supports, which could provide useful references in the practical application. On-site experiment proves that the periodic weighting step interval of the caving face is 15–16 m, which is basically consistent with the theoretical analysis results, and indicates that the mechanized caving hydraulic support is capable of meeting the support requirements in the mining of a super-thick but shallowly buried coal seam.

Application of deep borehole blasting on fully mechanized hard top-coal pre-splitting and gas extraction in the special thick seam

In order to solve the problems of top-coal inadequate destruction and large amounts of gas emission in mining extra thick and hard coal seam,this study investigated the pre-splitting for deep borehole blasting and gas pre-draining technologies on top coal.The mechanism of the technologies was systematically expounded based on hard top-coal cracks development obtained by numerical simulation and theoretical analysis.The results show that explosive blasting in the hard rock results in a large number of cracks and large displacement in the rock mass due to the effect of explosion stress.Meanwhile,the thick top-coal caves,and desorbing gas flows along the cracks improve gas extraction.Finally,the pre-splitting for deep borehole blasting and gas pre-draining technologies was applied in No.3802 working face of Shui Liandong Coal Mine,which increases monthly output in the face to 67.34 kt and the drained gas concentration to 86.2%.The drained gas average concentration from each borehole reaches 40%,and the effect is remarkable.

Effect of suppressing dust by multi-direction whirling air curtain on fully mechanized mining face

A combined method of numerical simulation and field testing was adopted in this study in the interest of solving the problem of hard to control high concentrate dusts on a fully mechanized mining face. In addi- tion, the dust suppression effect of a multi-direction whirling air curtain was studied in this paper. Under the influence of the wall attachment effect, the compressed air which blows out from the two-phase or three-phase radial outlets on the generator of the air curtain can form a multi-direction whirling air curtain, which can cover the whole roadway section of a fully mechanized mining face. The traditional method of controlling dust is a forcing system with exhaust overlap which has the major disadvantage of lacking a jet effect and consequently results in poor dust control. It is difficult to form the air flow field within the range of Lp ≤ 5√S. However, due to the effect of this novel system, the radial airflow can be turned into axial airflow allowing fresh air to flow through the length of the heading. The air flow field which is good at controlling dust diffusion can be formed 12.8 m from the heading face. Furthermore, the field measurement results show that before the application of a multi-direction whirling air curtain, the dust concentration is 348.6 mg/m^3 and 271.4 mg/m^3 respectively at the roadway cross-section measurement points which are 5 m and 10 m from the heading face. However, after the application of the multi-direction whirling air curtain, the dust concentration is only 61.2 mg/m3 and 14.8 mg/m^3, respectively. Therefore, the dust control effect of a multi-direction whirling air curtain is obvious.

Similar material simulation research on movement law of roof over-lying strata in stope of fully mechanized caving face with large mining height

Similar material simulation test W9-15 101 fully mechanized caving face with was carried out in a geological model of large mining height in the Liuhuanggou Colliery, in Xinjiang Uigur Autonomous Region. The roof overlying strata movement law in the stope of a fully mechanized caving face with large mining height was studied and show that the roof overlying strata in the stope of a fully mechanized caving face with large mining height can be formed into a stable arch structure; the fracture rock beam is formed resembling a ＂bond beam＂, but it has essentially the structure of ＂multi-span beams＂ under the big structure of the stable arch. The roof overlying strata movement law in the stope of a fully mechanized caving face with large mining height is similar to that of the common, fully mechanized caving stope, which is determined by the deformation and instability of the structure of ＂multi-span beams＂. But because of the differences between the mining heights, the peak pressure in the stope of a fully mechanized caving face with large mining height is smaller while the affected area of abutment pressure is wider in the front of the working face; this is the obvious difference in abutment pressure between the stope of a fully mechanized caving face with large mining height and that of the common.

Technological optimization of fully mechanized caving mining face with large mining heights

Fully mechanized cave mining with large mining height is a new mining method, due to its large mining thickness and lower roadway excavation, the technology has been widely used in China＇s thick seam mining. In order to improve the top-coal recovery ratio of fully mechanized cave mining with large mining height, a study was conducted on optimizing the caving process, based on the mechanized caving face 1302N in Longgu Coal Mine. This was achieved by improving the PFC numerical calculation methods, and establishing a more accurate model system. On this basis, the recovery ratio of the top coal in different drawing intervals and technologies was investigated in order to achieve a reasonable caving process. The top-coal tracking system was used for practical surveying of the recovery ratio of top coal.

Study on dangers of methane in the gob of fully mechanized caving mining

Divided the gob gas in different types according to falling structure and spatial patterns of gob of the fully mechanized caving mining and analyzed its main form of harm. This passage preliminarily studied the law of unusual gush of gob gas of the fully mechanized caving mining. According to the basic condition for the gas explosion, made comprehensive analysis and appraisal about the oxygen condition, gas concentration distribute and fire source conditions. And find that there is the dangerous district of gas explosion in a certain area of the producing gob and give the three zone theory of gob gas explosion.

Research on Robotized Advance Support and Supporting Time for Deep Fully Mechanized Excavation Roadway

To keep coal workers away from the hazardous area with frequent accidents such as the roof fall and rib spalling in an underground coalmine,we put forward the solution with robotized self-moving anchor-supporting unit.The existing research shows that the surrounding rock of the roadway has self-stability,and the early or late support is not conducive to the safe and reliable support of the roadway,so there is a problem of support opportunity.In order to study the supporting effect and the optimal supporting time of the above solution,we established the mechanical coupling model of surrounding rock and advance support,and investigated the surrounding rock deformation and advance support pressure distribution under different reserved roof subsidence by using the numerical simulation software FLAC3D.The results show that the deformation of surrounding rock increases and finally tends to a stable level with the increase of pre settlement of roadway roof,and when the pre settlement of roof is between 8-15 mm,the vertical pressure of the top beam of advance support reaches the minimum value,about 0.58 MPa.Based on the above research,we put forward the optimum supporting time in roadway excavation,and summarized the evaluation method based on the mechanical coupling model of surrounding rock-advance support.

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.

Developing Technology of Fully Mechanized Mining with Sublevel Caving Posititvely and Reasonably

ＤｅｖｅｌｏｐｉｎｇＴｅｃｈｎｏｌｏｇｙｏｆＦｕｌｌｙＭｅｃｈａｎｉｚｅｄＭｉｎｉｎｇｗｉｔｈＳｕｂｌｅｖｅｌＣａｖｉｎｇＰｏｓｉｔｉｔｖｅｌｙａｎｄＲｅａｓｏｎａｂｌｙ￥ＬｉｕＸｉｕｙｕｏｎ１Ｄｅｖｅｌｏｐｍｅｎｔａｎｄｐｒｃｓｅｎｔｓｉｔｕａｔｉ...

Vertical transportation system of solid material for backfilling coal mining technology

For transportation of solid backfill material such as waste and fly ash from the surface to the bottom of the shaft in a fully mechanized backfilling coal backfilling coal mining technology, we developed a new vertical transportation system to transport this type of solid backfill material. Given the demands imposed on safely in feeding this material, we also investigated the structure and basic parameter of this system. For a mine in the Xingtai mining area the results show that: (1) a vertical transportation system should include three main parts, i.e., a feeding borehole, a maintenance chamber and a storage silo; (2) we determined that 486 mm is a suitable diameter for bore holes, the diameter of the storage silo is 6 m and its height 30 m in this vertical transportation system; (3) a conical buffer was developed to absorb the impact during the feeding process. To ensure normal implementation of fully mechanized backfilling coal mining technology and the safety of underground personnel, we propose a series of security technologies for anti-blockage, storage silo cleaning, high pressure air release and aspiration. This vertical transporting system has been applied in one this particular mine, which has fed about 4 million tons solid material with a feeding depth of 350 m and safely exploited 3 million tons of coal.

我国大倾角煤层开采技术变革与展望

大倾角煤层是我国煤炭资源的主要赋存样式之一。在地域分布上呈现出广泛性与区域性,据不完全统计,全国25个省、自治区、直辖市均涉及该类煤层开采,在中西部地区储量丰富、产量大、生产集中程度高。在赋存条件上呈现出多样性与复杂性,不同区域成煤时期不一,构造控煤过程迥异,形成了多样且复杂的开采条件,催生了不同的开采技术要求。大倾角煤层开采的技术难度大。煤层倾角导致采场围岩运动破坏呈现非对称性显现特征,支护系统稳定性控制与“三机”配套与协同、采准巷道布置与支护、工作面“人-机”环境安全保障等工作的难度显著加剧,严重制约了矿井安全高效开采。大倾角煤层开采的区域经济需求强,该类煤层赋存与生产较集中的区域多见以煤炭工业为主的资源型城市,经济结构相对单一,煤炭资源安全高效开发利用对区域能源保供、民生保障、经济保稳具有兜底作用。长期以来,大倾角煤层开采技术变革聚焦于解决“难”与“需”的矛盾,在采煤方法与工艺、岩层控制理论与技术、成套装备研制与应用3个方面不断完善、创新、发展,实现了由非机械化向机械化开采的转变,安全产效水平大幅提升,人员劳动强度大幅下降,作业环境显著改善。20世纪90年代中期,川煤集团绿水洞煤矿首次成功实现了大倾角中厚煤层长壁综采,冲破了大倾角煤层机械化开采技术“禁区”。在此示范作用下,大倾角厚煤层长壁综放开采、大采高综采、薄煤层伪俯斜长壁综采三项首创性工程实践先后取得成功。这一过程中创新了工作面非线性限位布置与调斜方式,确立了“支架-围岩”系统稳定性多维交互控制模式,研发了工作面成套装备,取得良好收效,综合机械化开采技术适用范围进一步拓宽。与此同时,大倾角煤层开采仍存在许多亟待突破的关键科学问题与技术瓶颈,导致自动化、智能化水平提升与近水平/缓倾斜煤层相较仍存在较大差距。需进一步强化倾斜层状煤系地层煤岩体采动力学行为研究,揭示其对采场围岩灾变的控制机制,并实现量化表征;需进一步阐明岩体承载结构-采场装备群组系统间的多维动态作用过程与规律,完善装备与围岩多维动态多目标协同控制理论与技术基础,实现技术转化应用。在科学问题取得突破的基础上进行采煤方法、回采工艺、岩层控制、成套装备的系统性技术创新与研发,破解大倾角煤层开采安全-产效双提升的制约技术瓶颈,使大倾角煤层综合机械化开采倾角上限在有可靠技术保障的前提下向上延伸(扩展),为实现自动化、智能化开采奠定基础。

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.

综掘面风流调控下的瓦斯与粉尘浓度双目标预测模型研究

针对综掘面瓦斯和粉尘浓度预测能力不足,导致瓦斯粉尘积聚难以提前解决,造成风筒出风口风流调控降尘排瓦效果不佳的问题,采用层次分析法确定了瓦斯和粉尘浓度分布的关键影响因素,建立了7-11-3结构的双目标预测神经网络模型,并进行出风口距端头5 m和10 m工况下的应用测试,结果表明:模型误差率最大9.85%,最小0.27%。瓦斯浓度最高降低了45%,粉尘浓度最高降低了40%,有效预防了瓦斯和粉尘浓度的积聚问题。

岩巷综掘面抽尘参数影响粉尘污染扩散规律研究

抽尘系统是岩巷综掘面长压短抽通风方式中控除粉尘污染的重要组成部分,而确定适宜的抽尘参数是实现有效除尘的关键。利用Solidworks软件对某矿632岩巷综掘面进行了物理建模,并进行了ICEM-CFD网格划分,通过网格无关性检验确认了后续所用的网格模型,运用FLUENT计算流体力学软件对不同抽尘位置Dn(n分别为0、1/4、1/2、3/4、1)与抽风量(300~350 m^(3)/min)影响粉尘污染扩散状况进行了数值模拟,并通过仿真试验验证了数值模拟结果的准确性。结果表明:抽尘位置为D0、D1/4、D1/2、D3/4时,巷道内风流整体均处于较为紊乱的状态,粉尘污染经风流运载最终均扩散至整个巷道;抽尘位置为D1时,在抽风与压风协同作用下,距迎头4.6~6 m范围内形成了风向指向迎头、流动均匀且覆盖巷道全断面的有效控尘风幕,粉尘污染被风幕控制在掘进机司机与迎头之间的封闭空间内。抽风量在330 m^(3)/min及以上时,在司机处均形成了有效控尘风幕。为了在有效控尘的前提下尽可能降低能耗,最优抽风量选取最小值330 m^(3)/min。

综掘工作面混合式风流调控下的粉尘沉降研究

煤矿掘进过程中粉尘聚集严重,目前针对综掘工作面混合式风流调控下粉尘沉降规律及优化的研究还不够深入。基于混合式风流调控系统,依托陕煤集团神木柠条塔矿业有限公司综掘工作面,分析了压风口距工作面距离、压风口右偏角度、压风口口径、抽风口距工作面距离和压抽比等混合式风流调控参数对粉尘沉降规律的影响:随着压风口距工作面距离增加,司机处和回风侧行人呼吸带截面大颗粒粉尘占比先增后减再增,小颗粒粉尘占比增加;随着压风口右偏角度增加,司机处和回风侧行人呼吸带截面大颗粒粉尘占比变化明显;随着压风口口径增加,司机处截面小颗粒粉尘占比先增后减再增,回风侧行人呼吸带截面大颗粒粉尘占比先增后减;随着抽风口距工作面距离增加,司机处截面大颗粒粉尘占比先增后减,小颗粒粉尘占比先增后减再增,回风侧行人呼吸带截面粉尘粒径分布变化不大;随着压抽比增大,司机处和回风侧行人呼吸带截面小颗粒粉尘占比减小。以上述风流调控各参数为自变量,回风侧行人呼吸带全尘平均浓度和司机处呼尘平均浓度最低为优化目标,建立了粉尘沉降优化回归模型,利用粒子群优化算法求解模型,得到最优风流调控方案:压风口距工作面距离为8.9 m,压风口右偏角度为14.8°,压风口口径为0.9 m,抽风口距工作面距离为4.3 m,压抽比为1.1。搭建了风流调控下粉尘沉降实验平台,实验结果表明:测试值与粉尘沉降优化回归模型的模拟值误差在13%以内,验证了模型的准确性;优化后粒径为71~100μm的粉尘受风流调控参数影响明显,沉降在掘进机前方;优化后回风侧行人呼吸带全尘平均浓度和司机处呼尘平均浓度分别降低了47.4%和42.4%,降尘效果明显。

基于双曲嵌入的露天矿区暗光环境下道路多目标检测模型

露天矿环境特殊,道路场景复杂多变,在光照不足时会导致矿区道路多目标识别不清、定位不准,进而影响检测效果,给矿区无人矿用卡车的安全行驶带来严重安全隐患。目前的道路障碍物检测模型不能有效解决矿区暗光环境对模型检测效果的影响,同时对矿区小目标障碍物的识别也有较大误差,不适用于矿区特殊环境下障碍物的检测与识别。针对上述问题,提出了一种基于双曲嵌入的露天矿区暗光环境下多目标检测模型。首先,在模型的图像预处理阶段引入卷积神经网路Retinex-Net对暗图像进行增强,提高图像清晰度;然后,针对数据集中特征过多而无重点偏好的问题,在加强特征提取部分添加全局注意力机制,聚集3个维度上更关键的特征信息;最后,在检测模型预测阶段引入双曲全连接层,以减少特征丢失,并防止过拟合现象。实验结果表明:(1)基于双曲嵌入的露天矿区暗光环境下道路多目标检测模型不仅对露天矿区暗光环境下的大尺度目标具有较高的分类与定位精度,对矿用卡车及较远距离的小尺度目标即行人也可准确检测与定位,能够满足无人矿用卡车在矿区特殊环境下驾驶的安全需求。(2)模型的检测准确率达98.6%,检测速度为51.52帧/s,较SSD、YOLOv4、YOLOv5、YOLOx、YOLOv7分别提高20.31%,18.51%,10.53%,8.39%,13.24%,对于矿区道路上的行人、矿用卡车及挖机的检测精度达97%以上。