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.

Analysis of the Risk of Water Breakout in the Bottom Plate of High-Intensity Mining of Extra-Thick Coal Seams

In order to clarify the danger of water breakout in the bottom plate of extra-thick coal seam mining, 2202 working face of a mine in the west is taken as the research object, and it is proposed to use the on-site monitoring means combining borehole peeping and microseismic monitoring, combined with the theoretical analysis to analyze the danger of water breakout in the bottom plate. The results show that: 1) the theoretically calculated maximum damage depth of the bottom plate is 27.5 m, and its layer is located above the Austrian ash aquifer, which has the danger of water breakout;2) the drill hole peeping at the bottom plate of the working face shows that the depth of the bottom plate fissure development reaches 26 m, and the integrity of the water barrier layer has been damaged, so there is the risk of water breakout;3) for the microseismic monitoring of the anomalous area, the bottom plate of the return air downstream channel occurs in the field with a one-week lag, which shows that microseismic monitoring events may reflect the water breakout of the underground. This shows that the microseismic monitoring events can reflect the changes of the underground flow field, which can provide a reference basis for the early warning of water breakout. The research results can provide reference for the prediction of sudden water hazard.

Study on Filling Cross-Roadway in Fully-Mechanized Coal Faces with High Water-Content Material

A new method using high water content material to mechanically fill cross roadways to form artificial bottom for coal faces was introduced. The reasonable determination of filling range, the optimization of the compounding ratio of high water content material, and the filling technique were discussed in detail. This new method has been spread after industrial testing in Baodian Colliery. Compared with the traditional method, the manual wooden chock method, the new one decreases about 40% of the filling range and cost in dealing every one set of cross roadway in the testing condition.

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.

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.

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.

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.

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。

王洼煤矿水库坝体下工作面安全开采高度研究

为解决水库坝体下开采安全性,提高煤炭资源回收率,以王洼煤矿水库坝体下110505工作面为研究背景,通过物理仿真模拟、数值模拟及理论分析等方法对覆岩裂隙发育规律及导水裂隙带高度展开研究。为避免矿井开采对地表水坝与水体破坏,针对导水裂隙带高度分析结果,提出了110505工作面限高开采方案。结果表明:工作面开采后地表形成“凹”型盆地,并产生拉伸裂隙,致使地表水位下降78%;现场实测导水裂隙高度为170.76 m,物理仿真模拟试验、数值计算、传统经验公式得出三者的导水裂隙带高度分别为162,164 m和120.57 m;方差修正系数对经验公式做出修正后,反推出限高开采的安全开采高度为2.6 m。研究揭示了工作面覆岩导水裂隙带高度发育规律及水库水体受采动影响的规律,为王洼煤矿后续此类条件下安全措施的制定提供了依据。

煤矿井下非均匀照度图像去噪研究

煤矿综采工作面空间小、照明环境复杂多变,采煤过程中伴随着大量的粉尘、大雾,导致采集的图像出现曝光、细节特征减弱等问题,难以对井下照明区域光照强度过大的图像进行有效的特征提取。针对上述问题,提出了一种煤矿井下非均匀照度图像去噪算法。首先,将视频截取为图像,判断图像是否需要进行光照抑制,将需要进行光照抑制的RGB图像拆分通道,并计算每个通道的光照调节因子,实现图像的整体光照调节;然后,将未进行整体光照抑制的图像和经整体光照抑制的图像进行反射分量提取,即将输入的图像转换为HSV空间图像,使用单尺度Retinex(SSR)算法对V通道图像中的光照分量进行单独处理,将V分量中的入射分量去除,保留反射分量,并对反射分量使用直方图均衡算法实现光照均衡化处理;最后,使用基于引导滤波的暗通道先验算法对经过光照处理后的图像进行去雾处理,并使用伽马校正函数重新调节亮度不均的图像。主观评价结果表明:提出的煤矿井下非均匀照度图像去噪算法有效抑制了因光照导致整体亮度较高的问题,且由于大雾、粉尘等因素导致图像模糊的部分更加清晰,图像的细节特征更加突出。采用信息熵、均值、标准差、空间频率4种评价指标对提出的算法效果进行客观评价,结果表明,提出的算法在信息熵、均值、标准差、空间频率上较多尺度Retinex(MSR)算法分别平均提升了21.87%,-56.06%,153.43%,294.45%,较基于颜色保持的多尺度视网膜增强(MSRCP)算法分别平均提升了1.18%,-39.56%,33.29%,-4.71%,较带色彩恢复的多尺度视网膜增强(MSRCR)算法分别平均提升了38.06%,-55.27%,462.10%,300.96%,说明提出的算法能更有效地增加图像信息量、抑制光照强度、提升边缘信息及图像清晰度。

厚煤层大采高综放工作面覆岩断裂演化规律研究

大采高综放开采易形成强烈的矿压显现,上覆岩层的断裂演化规律对工作面安全生产至关重要。以羊场湾煤矿160206工作面为工程背景,运用相似模拟试验、数值模拟和理论分析的综合研究方法,对大采高综放工作面覆岩的断裂过程与覆岩运移规律进行系统研究。研究表明:导水裂隙带内岩层随工作面推进表现为“台阶下沉”,同层岩层下沉趋势沿走向表现为“急剧下降—稳定(最大值)—快速上升—稳定(最小值)”。工作面覆岩运动场由两区分布(加速下沉区、缓慢下沉区)演化为三区分布(加速下沉区、缓慢下沉区、稳定区)。对离层演化与地表下沉规律进行了定量描述,运用理论计算表达式深入地剖析了地表的动态下沉机理及其相关因素。结合相似模拟与数值模拟的试验结果,提出了覆岩断裂演化的形态变化特征:覆岩断裂形态由“单等腰梯形”演化为“双等腰梯形”,表土层影响区由“矩形”演化为“倒梯形”。分析了覆岩中垮落区、离层区、压实区、裂隙富集区的动态演化过程:垮落区逐渐增大至一定程度,高度小幅度降低并趋于稳定,离层区由下至上逐渐发育并随工作面向前移动,离层区逐渐闭合形成压实区,且压实区逐渐增大并最终保持稳定,裂隙富集区位于采空区前后端部并随工作面向前移动。

综放工作面围岩控制与智能化放煤技术现状及展望

分析了厚及特厚煤层智能化综放工作面围岩控制技术与智能化放顶煤技术发展现状及存在的问题,从巷道围岩高效支护、工作面超前支护、坚硬特厚顶煤冒放性、液压支架位姿监测及智能化放顶煤5个方面提出了工程实际需求。针对综放工作面实现安全、高效、智能化开采存在的技术难题与工程需求,对综放工作面围岩控制技术、智能化放煤技术进行了研究:构建了坚硬特厚煤层顶煤悬臂梁力学模型,研发了提高顶煤冒放性及放出率关键技术,实现了坚硬特厚煤层超大采高综放开采;研发了单元式超前液压支架顶梁可旋转自复位装置,实现了液压支架顶梁根据巷道顶板倾斜角度自动旋转支护,有效提高了单元式超前液压支架对巷道顶底板的适应性;提出了采用巷道支护液压支架替代传统锚网支护结构的思路,具有支护效率高、成本低、节省工作面超前支护等优点;开发了基于立柱与尾梁千斤顶行程的综放液压支架支护姿态监测装置与算法,提高了液压支架支护姿态解算效率与精度;提出了基于透明地质模型、煤量监测装置与煤矸识别装置融合的智能放煤控制方法,可有效解决多夹矸层特厚顶煤智能化放煤技术难题。提出智能地质保障技术、机器视觉精准测量与智能感知技术、综放工作面设备智能精准自适应控制技术、综放工作面数字孪生技术等是智能化综放开采技术与装备的发展趋势。

综采面坚硬顶板超深孔预裂爆破远场解危控制技术

工程实践表明,顶板事故在煤矿各类事故中占首要位置,已严重制约了我国现代化矿井安全高效开采。为了实现煤矿综采面坚硬顶板的安全治理,亟需形成综采面坚硬顶板超深孔预裂爆破远场解危控制技术以有效解决因工作面大空间坚硬顶板垮落而影响安全生产的重大难题。基于此,通过自主创新和联合攻关,面向深部矿井坚硬顶板,开展了综采面坚硬顶板超深孔预裂爆破远场解危技术研究;研发了高威力三级煤矿许用水胶炸药、填塞材料等技术与装备,形成了成熟的深孔爆破工艺,突破了厚硬顶板爆破中煤矿许用炸药威力与安全度的矛盾,解决了超深孔爆破中炸药可靠起爆等技术瓶颈问题;通过构建大空间采场覆岩-支架-围岩系统力学模型,揭示了采场大小周期来压及强矿压作用机理,提出了大空间采场厚硬覆岩多层位精准定位爆破弱化控制原理和基于爆破损伤的综采工作面厚硬顶板深孔爆破参数设计方法,形成了综采工作面厚硬顶板超前深孔卸压控制技术。研究成果在全国近百个综采面进行工程应用,未发生一起顶板事故,避免了综采面厚硬顶板发生压架、形成飓风、矿震等重大安全事故的风险,保障了综采面的安全高效生产,为综采面坚硬顶板远场解危的设计提供了理论依据并为现场施工提供了指导作用。

基于残差优化的综采工作面煤壁点云补全方法

煤矿综采工作面巷道的数字化三维重建过程中需要完整且密集的煤壁点云数据。受遮挡、视角限制等因素影响,采集的综采工作面煤壁点云数据往往不完整且稀疏,影响下游任务,需进行煤壁点云修复和补全。目前缺少针对井下点云补全任务的数据集和网络模型,现有模型用于煤壁点云补全时存在点云密度分布不均匀、点云特征信息丢失等情况。针对上述问题,设计了一种基于残差优化的煤壁点云补全网络模型,采用监督学习方式学习点云特征信息,通过最小化密度采样和残差网络迭代优化输出完整点云。采集煤矿井下真实综采工作面煤壁点云数据,预处理后筛选可用数据,通过模拟随机空洞制作煤壁点云缺失数据集,并用缺失数据集训练基于残差优化的煤壁点云补全网络模型。实验结果表明:与经典的FoldingNet,TopNet,AtlasNet,PCN,3D-Capsule点云补全网络模型相比,基于残差优化的煤壁点云补全网络模型针对构造的缺失煤壁点云和稀疏煤壁点云补全的倒角距离、地移距离及F1分数均能达到最优水平,整体补全效果最佳;针对实际缺失的煤壁点云,该模型能够实现有效补全。

特厚煤层工作面煤厚变化电磁波透视响应特征

目的为掌握煤厚变化对特厚煤层工作面电磁波透视探测的影响,以准确圈定地质异常区,保障工作面安全高效生产。方法根据煤层工作面地质条件,利用三维仿真软件,对煤厚变化进行了电磁波透视数值模拟,并结合工作面探查实例进行了分析。结果0~20m煤厚范围,随煤厚减小,电磁波透视场强值呈抛物线下降趋势,可分为缓慢降低(煤厚≥9m)、明显降低(9m>煤厚≥5m)和快速降低(煤厚<5m)3个范围。煤厚10m以上的工作面适合于依据相对煤层变薄程度和变薄区煤厚来分析透视电磁波响应:变薄程度>1/3正常煤厚且煤厚<8m的薄煤区有明显响应,变薄区煤厚越小,透视电磁波场强降低越显著。煤厚10m以下的工作面,可以仅依据相对煤层变薄程度分析透视电磁波响应:变薄程度>1/4正常煤厚的薄煤区有明显响应,变薄程度越大,透视电磁波场强降低越显著。陕西金源招贤矿业有限公司特厚煤层1304工作面探测实例表明:正常煤厚变化及薄煤区的电磁波响应特征与数值模拟结果一致;工作面物探圈定的落差1m以上断层及薄煤区范围,与实际揭露范围相吻合。结论利用煤厚变化电磁波响应特征能够可靠地探查特厚煤层工作面地质异常区范围。

多频雷达融合的顶煤结构精准探测技术

顶煤结构的准确探测是实现综放智能化开采的重要依据,然而我国煤层结构复杂且内部常含多层夹矸,易影响综放智能化开采的水平。为此,提出一种多频雷达融合的顶煤结构精准探测方法,可提高雷达天线探测深度内的浅部探测精度,同时对顶煤内部的结构信息进行解释。主要研究步骤如下:首先,对不同频率的雷达数据进行预处理和空间对齐,建立不同频率雷达数据之间的空间对应关系;其次,利用滑动窗口与小波变换加权融合方法对多频率雷达数据进行处理,根据窗口内各分段小波信号的能量占比确定各频率信号的时变权重值,并引入边缘检测算法来提高小波变换对雷达数据的融合效率,实现多频雷达数据有效融合;最后,根据煤-矸-岩的介电常数差异和电磁波传播的衰减特性,建立顶煤内部回波强度模型,并利用分层识别方法计算出顶煤内部煤-矸-岩之间的界面信息,进而反演出顶煤内部结构(包括顶煤厚度、夹矸厚度及层数、夹矸层间距等)。试验结果表明:所提出的方法能有效地将不同频率雷达数据进行融合,并能有效地探测出顶煤内部结构特征,且顶煤厚度、夹矸厚度和夹矸层间距的探测误差均小于10%。该方法有助于实现顶煤结构的精准探测,为综放智能化开采提供理论技术支撑。

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。

深部特厚煤层综放沿空掘巷煤柱优化及巷道支护

为研究深部大采高综放工作面窄煤柱沿空掘巷巷道矿压控制问题,以国能宁煤集团枣泉煤矿2^(-2)特厚煤层130203大采高综放工作面回风巷道为背景,基于实用矿山压力理论,建立了巷道围岩内、外应力场动态结构力学模型,运用理论计算和数值计算针对不同尺寸煤柱煤体应力对比分析,将原留设15 m护巷煤柱缩小至5 m进行了煤柱优化。结果表明:在稳定的内应力场掘巷有利于巷道的稳定性,避免了顶板事故及冲击地压相关灾害的发生,现场5 m小煤柱护巷工程应用中,130203回风巷道小煤柱侧变形量为1050 mm,实体煤帮变形量为400 mm,两帮呈现不对称性变形,底板局部底鼓量为1400 mm;深部特厚煤层综放开采沿空掘巷采用5 m小煤柱护巷方案设计正确,极大改善了巷道围岩的应力环境,整体设计满足生产要求,现场应用良好。130203工作面小煤柱沿空掘巷技术成功应用,为矿井开采提供了可靠的科学依据。