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.

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.

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.

Hydraulic fracture initiation theory for a horizontal well in a coal seam

A series of experiments were pertbrmed to determine rock mechanical parameters related to hydraulic fracturing of coal. The effect of confining pressure and pore pressure on the strength of coal was stt, died. Experimental results show that the coal seam in the study areas has a relatively low elastic modulus, high Poisson＇s ratio, high fragility and is easily broken and compressed. The coal seam is considered as a transversely isotropic medium, since the physical properties in the direction of bedding plane and orthogonal to the bedding plane vary markedly. Based on the generalized plane strain model, stress distribution for an arbitrarily orientated wellbore in the coal seam was determined. In a horizontal well, hydraulic fracturing was lbund to initiate in the coal seam mass due to tensile failure, or from cleats due to shear or tensile failure. For those coal seams with abundant natural cleats, hydraulic fracture initiation can be induced by any of these mechanisms. In this study, hydraulic fracture initiation criteria tbr a horizontal well in a coal seam were established.

The impact of cleats on hydraulic fracture initiation and propagation in coal seams

Cleats are systematic, natural fractures in coal seams. They account for most of the permeability and much of the porosity of coalbed methane reservoirs and can have a significant effect on the success of hydraulic fracturing stimulation. Laboratory hydraulic fracturing experiments were conducted on coal blocks under true tri-axial stress to simulate fracturing stimulation of coal seams. Fractures were initiated by injecting a water gel with luminous yellow fluorescent dye into an open hole section of a wellbore. The impact of cleats on initiation and propagation of hydraulic fractures in coal seams is discussed. Three types of hydraulic fracture initiation and propagation pattern were observed in this study： 1） The hydraulic fracture initiated and then grew along the cleat. 2） The hydraulic fracture initiated along a butt cleat or a fracture （natural or induced by drilling） oriented roughly in the minimum horizontal stress direction, then turned to propagate along the first face cleat that it encountered or gradually turned towards the maximum horizontal stress direction. 3） The hydraulic fracture initiated perpendicular to the minimum stress and, when it encountered a face cleat, tended to propagate along the cleats if the extension direction does not deviate greatly （〈20° as determined in this paper） from the maximum horizontal stress direction. When a coal seam is hydraulically fractured, the resulting fracture network is controlled by the combined effect of several factors： cleats determine the initiation and extension path of the fracture, the in-situ stress state dominates the main direction of the fracture zone and bedding planes impede fracture height growth.

Phenomenon of methane driven caused by hydraulic fracturing in methane-bearing coal seams

The methane concentration of the return current will always be enhanced to a certain degree when hydraulic fracturing with bedding drilling is implemented to a gassy coal seam in an underground coal mine. The methane in coal seam is driven out by hydraulic fracturing. Thus, the phenomenon is named as methane driven effect of hydraulic fracturing. After deep-hole hydraulic fracturing at the tunneling face of the gassy coal seam, the coal methane content exhibits a ‘‘low-high-low" distribution along excavation direction in the following advancing process, verifying the existence of methane driven caused by hydraulic fracturing in methane-bearing coal seam. Hydraulic fracturing causes the change of pore-water and methane pressure in surrounding coal. The uneven distribution of the pore pressure forms a pore pressure gradient. The free methane migrates from the position of high pore(methane) pressure to the position of low pore(methane) pressure. The methane pressure gradient is the fundamental driving force for methane-driven coal seam hydraulic fracturing. The uneven hydraulic crack propagation and the effect of time(as some processes need time to complete and are not completed instantaneously) will result in uneven methane driven. Therefore, an even hydraulic fracturing technique should be used to avoid the negative effects of methane driven; on the other hand, by taking fully advantage of methane driven, two technologies are presented.

Reasonable location of stopping line in close‑distance underlying coal seam and partition support of large cross‑section roadway

Close-distance coal seams are widely distributed over China,and the coal pillars left by the overlying coal seams afect the retracement channel of the underlying coal seam in the stopping stage.Based on the engineering background of close-distance seam mining in a coal mine,the reasonable position of the underlying coal seam's stopping line and the support method of the large section roadway during stopping are investigated using feld measurements,similar simulation experiments,and numerical simulations.There are three types of location relationships between the stopping line of the underlying coal seam and the stopping line of the overlying coal seam:"externally staggered with the upper stopping line"(ESUL,stops mining under the overlying goaf),"overlapped with upper stopping line"(OUL),and"internally staggered with the upper stopping line"(ISUL,ISUL-SD for shorter internal staggered distances,ISUL-LD for longer ones).There are diferent stress arch structures in the overlying strata of the above three positions,and the stress arch evolution process exists in the process of ESUL→OUL→ISUL-SD→ISUL-LD:a front and rear double stress arch structure→the front arch gradually decreases→the front arch dies out,and the double arch synthesizes the single arch→the single-arch range expands→the nested double arch.The relationship between the stress arch structure and the position of the stopping line is evaluated as follows:(1)ESUL:the stress concentration in the roof plate of the retracement channel of the underlying coal seam is the highest,because the overburden block of the extensive collapse zone acts directly on the roof plate of the retracement channel,resulting in relative difculties in roof support.(2)OUL:although the retracement channel roof pressure is minimal,the overlying rock structure has the potential for rotation or slippage instability.(3)ISUL-SD:the pressure on the roof of the retracement channel is small and the overburden structure is stable,which is conducive to the safe retraction of the support and not limited by the width of the end-mining coal pillar.(4)ISUL-LD:it is basically the same as the condition of stopping under the non-goaf;however,it has a limitation on the width of the end-mining coal pillar.The location of the stopping line is selected as ISUL-SD,and the retraction process of the self-excavating retraction channel was adopted.A partition asymmetric support scheme which is proven by feld practice is proposed,through a comprehensive analysis of the pre-stress feld simulation of the support scheme,based on the diferent control requirements of the roof above the support and the roof of the retracement channel in the stopping area.This method realizes safe and smooth withdrawal of the support.

Soft–strong supporting mechanism of gob-side entry retaining in deep coal seams threatened by rockburst

When gob-side entry retaining is implemented in deep coal seams threatened by rockburst, the cementbased supporting body beside roadway will bear greater roof pressure and strong impact load. Then the supporting body may easily deform and fail because of its low strength in the early stage. This paper established the roadside support mechanical model of gob-side entry retaining. Based on this model,we proposed and used the soft–strong supporting body as roadside support in the gob-side entry retaining. In the early stage of roof movement, the soft–strong supporting body has a better compressibility, which can not only relieve roof pressure and strong impact load, but also reduce the supporting resistance and prevent the supporting body from being crushed. In the later stage, with the increase of the strength of the supporting body, it can better support the overlying roof. The numerical simulation results and industrial test show that the soft–strong supporting body as roadside support can be better applied into the gob-side entry retaining in deep coal seams threatened by rockburst.

Experimental investigation on behaviors of bolt-supported rock strata surrounding an entry in large dip coal seam

In order to investigate the behaviors and stability of rock strata surrounding an entry with bolt supporting in large dip coal seams (LDCSs) dipping from 25° to 45°, a self-developed rotatable experimental frame for similar material simulation test was used to build the model with the dip of 30°, based on analyses of geological and technological conditions in Huainan mine area, Anhui, China. The strata behaviors, such as extracting- and mining-induced stresses development, deformation and failure modes, were synthetically integrated during working face advancing. Results show that the development characteristics of mining-induced stress and deformation are asymmetrical in the roadway. The strata behaviors are totally different in different sections of the roadway. Because of asymmetrically geometrical structure influenced by increasing dip, strata dislocating, rock falling and breaking occur in roof. Then, squeezing, collapsing and caving of coal happen in upper- and lower-rib due to shearing action caused by asymmetrical roof bending and dislocating. Owing to the absence of supporting, floor heaving is very violent and usually the zone of floor heaving develops from the lower-rib to upper-rib. Engineering practices show that, due to the asymmetrical characteristics of rock pressure and roadway configuration, it is more difficult to implement bolt supporting system to control rock stability of roadways in LDCSs. The upper-rib and roof of entries are the key sections. Consequently, it is reliable to use asymmetrical bolt-mesh-cable supporting system to control rock stability of roadways based on the asymmetrical characteristics of roadway configuration and strata behaviors.

Hydraulic support crushed mechanism for the shallow seam mining face under the roadway pillars of room mining goaf

While the fully-mechanized longwall mining technology was employed in a shallow seam under a room mining goaf and overlained by thin bedrock and thick loose sands, the roadway pillars in the abandoned room mining goaf were in a stress-concentrated state, which may cause abnormal roof weighting, violent ground pressure behaviours, even roof fall and hydraulic support crushed(HSC) accidents. In this case,longwall mining safety and efficiency were seriously challenged. Based on the HSC accidents occurred during the longwall mining of 3-1-2 seam, which locates under the intersection zone of roadway pillars in the room mining goaf of 3-1-1 seam, this paper employed ground rock mechanics to analyse the overlying strata structure movement rules and presented the main influence factors and determination methods for the hydraulic support working resistance. The FLAC3 D software was used to simulate the overlying strata stress and plastic zone distribution characteristics. Field observation was implemented to contrastively analyse the hydraulic support working resistance distribution rules under the roadway pillars in strike direction, normal room mining goaf, roadway pillars in dip direction and intersection zone of roadway pillars. The results indicate that the key strata break along with rotations and reactions of the coal pillars deliver a larger concentrated load to the hydraulic support under intersection zone of roadway pillars than other conditions. The ‘‘overburden strata-key strata-roadway pillars-immediate roof" integrated load has exceeded the yield load that leads to HSC accidents. Findings in HSC mechanism provide a reasonable basis for shallow seam mining, and have important significance for the implementation of safe and efficient mining.

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.

Mechanism and control technology of strong ground pressure behaviour induced by high-position hard roofs in extra-thick coal seam mining

This work aimed at revealing the mechanism of strong ground pressure behaviour(SGPB)induced by high-position hard roof(HHR).Based on the supporting structures model of HHR,a modified voussoir beam mechanical model for HHR was established by considering the gangue support coefficient,through which the modified expressions of limit breaking span and breaking energy of HHR were deduced.Combined with the relationship between the dynamic-static loading stress of supporting body(hydraulic support and coal wall)and its comprehensive supporting strength,the criteria of ground pressure behaviour(GPB)induced by HHR were discussed.The types of Ⅰ_(1),Ⅰ_(2),Ⅱ_(1),andⅡ_(2) of GPB were interpreted.Results showed that types Ⅰ_(1) and Ⅰ_(2) were the main forms of SGPB in extra-thick coal seam mining.The main manifestation of SGPB was static stress,which was mainly derived from the instability of HHR rather than fracture.Accordingly,an innovative control technology was proposed,which can weaken static load by vertical-well separated fracturing HHR.The research results have been successfully applied to the 8101 working face in Tashan coal mine,Shanxi Province,China.The results of a digital borehole camera observation and stress monitoring proved the rationality of the GPB criteria.The control technology was successful,paving the way for new possibilities to HHR control for safety mining.

Mechanisms and Kinematics of Hydraulic Support for Top-Coal Caving

The structure and characteristic of new type of hydraulic support for top coal caving were discussed. The mechanism and kinematics of the hydraulic support were analyzed. The formulas were deduced to calculate the velocity and acceleration of top beam, shield beam, front and back legs, which give the solution to the design and research for hydraulic support.

Roadway failure and support in a coal seam underlying a previously mined coal seam

The influence of an upper,mined coal seam on the stability of rock surrounding a roadway in a lower coal seam is examined.The technical problems of roadway control are discussed based on the geological conditions existing in the Liyazhuang Mine No.2 coal seam.The stress distribution and floor failure in the lower works after mining the upper coal is studied through numerical simulations.The failure mechanism of the roof and walls of a roadway located in the lower coal seam is described.The predicted deformation and failure of the roadway for different distances between the two coal seams are used to design two ways of supporting the lower structure.One is a combined support consisting of anchors with a joist steel tent and a combined anchor truss.A field test of the design was performed to good effect.The results have significance for the design of supports for roadways located in similar conditions.

A case study of multi-seam coal mine entry stability analysis with strength reduction method

In this paper,the advantage of using numerical models with the strength reduction method(SRM) to evaluate entry stability in complex multiple-seam conditions is demonstrated.A coal mine under variable topography from the Central Appalachian region is used as a case study.At this mine,unexpected roof conditions were encountered during development below previously mined panels.Stress mapping and observation of ground conditions were used to quantify the success of entry support systems in three room-and-pillar panels.Numerical model analyses were initially conducted to estimate the stresses induced by the multiple-seam mining at the locations of the affected entries.The SRM was used to quantify the stability factor of the supported roof of the entries at selected locations.The SRM-calculated stability factors were compared with observations made during the site visits,and the results demonstrate that the SRM adequately identifies the unexpected roof conditions in this complex case.It is concluded that the SRM can be used to effectively evaluate the likely success of roof supports and the stability condition of entries in coal mines.

Current status and technical challenges of C_(2)storage in coal seams and enhanced coalbed methane recovery:an overview

In the past two decades,research on C_(2)storage in coal seams and simultaneously enhanced coalbed methane recovery(ECBM)has attracted a lot of attention due to its win–win effect between greenhouse gas(C_(2))emission reduction and coalbed methane recovery enhancement.This paper presents an overview on the current status of research on C_(2)-ECBM in the past two decades,which involves C_(2)storage capacity evaluations,laboratory investigations,modelings and pilot tests.The current status shows that we have made great progress in the ECBM technology study,especially in the understanding of the ECBM mechanisms.However,there still have many technical challenges,such as the definition of unmineable coal seams for C_(2)storage capacity evaluation and storage site characterization,methods for C_(2)injectivity enhancement,etc.The low injectivity of coal seams and injectivity loss with C_(2)injection are the major technique challenges of ECBM.We also search several ways to promote the advancement of ECBM technology in the present stage,such as integrating ECBM with hydraulic fracturing,using a gas mixture instead of pure C_(2)for injection into coal seams and the application of ECBM to underground coal mines.

Test and application of hydraulic expansion bolts in a roadway under goaf with ultra-close separation

The roof of a roadway under goal with ultra-close separation consists of thin rock strata and rocks caving in upper goal. Influenced by the mining of the upper coal seam, the roof is loose and broken, and its integ- rity is poor. Resin anchored bolts cannot provide an effective anchoring force in such roof conditions. By conducting free expansion tests and field pull-out tests on a hydraulic expansion bolt, this study has ana- lyzed the influencing factors and laws of radial expansion and anchoring force changes in the rod body. This has revealed the anchoring mechanism of such bolts, and has obtained reasonable water injection pressures and suitable drilling diameters （which are 20-25 MPa and 32-35 mm respectively） for the hydraulic expansion bolt （cR28 mm） used in these tests. Based on pull-out tests at different interlayer spacing, the applicability of hydraulic expansion bolts had been verified for controlling the roof of road- ways under goal with ultra-close distance. Combined with the deformation and failure characteristics of the test roadway roof, this paper proposes a united roof-control technology based on the use of hydraulic expansion bolts and advancing intubation for the roof. Engineering practice indicated that the roof of the test roadway did not generate leaking and caving phenomenon, and the amount of roof deformation was controlled to within 150 mm. Maintenance of the roadway roof has been improved significantly, which ensures safe mining in coal seams with ultra-close separation.

Plastic zone analysis and support optimization of shallow roadway with weakly cemented soft strata

Based on a shallow roadway with weakly cemented soft strata in western China, this paper studies the range and degree of plastic zones in soft strata roadways with weak cementation. Geological radars were used to monitor the loose range and level of surrounding rocks. A mechanical model of weakly cemented roadway was established, including granular material based on the measured results. The model was then used to determine the plastic zone radium. The predicted results agree well with measured results which provide valuable theoretical references for the analysis of surrounding rock stability and support reinforcing design of weakly cemented roadways. Finally, a combined supporting scheme of whole section bolting and grouting was proposed based on the original supporting scheme. It is proved that this support plan can effectively control the deformation and plastic zone expansion of the roadway surrounding rock and thus ensure the long-term stable and safe mining.

极近距离煤层开采无煤柱自成巷控制方法研究

极近距离煤层传统长壁开采,受上层遗留煤柱和采空区垮落等因素的影响,下煤层开采过程中应力环境复杂、矿压显现剧烈,易诱发巷道围岩大变形。为解决上述问题,提出了极近距离条件下巷道定向切顶–约束高强支护无煤柱自成巷控制方法。通过顶板定向预裂切顶,主动改变顶板悬臂结构,切断采空区向巷道顶板的应力传递。充分利用矿山压力和岩体碎胀特性,取消煤柱留设,结合高强支护加强巷道顶板整体性,共同实现切顶自成巷。建立了极近距离煤层开采覆岩结构模型,计算了下煤层切顶自成巷巷旁支护阻力。以典型极近距离煤层为工程背景,开展了不同开采方法的数值试验对比研究,结果表明,提出的自成巷控制方法使巷道围岩应力降低59.8%,巷道顶板变形减少70.8%,并明确了极近距离煤层开采无煤柱自成巷控制机理。在此基础上,开展了典型极近距离煤层工程设计及现场应用研究,结果表明该方法有效降低了矿压显现程度,保证了自成巷的安全稳定控制。

特厚煤层小煤柱沿空掘巷支护技术研究

小煤柱沿空掘巷过程中易出现巷道围岩变形大、局部鼓出等现象,针对这一问题,采用理论分析、数值模拟、工程类比的方法,对巷道基本顶破断方式进行了判断,并采用数值模拟分析不同宽度下煤柱的应力及位移变化规律,初步确定了煤柱留设宽度为8 m;对比邻近矿井的沿空掘巷案例,采用工程类比法最终确定了煤柱宽度,并对巷道支护方案进行设计,现场应用效果良好。