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.

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.

Theoretical description of drawing body shape in an inclined seam with longwall top coal caving mining

Understanding the characteristics of drawing body shape is essential for optimization of drawing parameters in longwall top coal caving mining.In this study,both physical experiments and theoretical analysis are employed to investigate these characteristics and derive a theoretical equation for the drawing body shape along the working face in an inclined seam.By analyzing the initial positions of drawn marked particles,the characteristics of the drawing body shape for different seam dip angles are obtained.It is shown that the drawing body of the top coal exhibits a shape-difference and volume-symmetry characteristic,on taking a vertical line through the center of support opening as the axis of symmetry,the shapes of the drawing body on the two sides of this axis are clearly different,but their volumes are equal.By establishing theoretical models of the drawing body in the initial drawing stage and the normal drawing stage,a theoretical equation for the drawing body in an inclined seam is proposed,which can accurately describe the characteristics of the drawing body shape.The shape characteristics and volume symmetry of the drawing body are further analyzed by comparing the results of theoretical calculations and numerical simulations.It is shown that one side of the drawing body is divided into two parts by an inflection point,with the lower part being a variation development area.This variation development area increases gradually with increasing seam dip angle,resulting in an asymmetry of the drawing body shape.However,the volume symmetry coefficient fluctuates around 1 for all values of the seam dip angle variation,and the volumes of the drawing body on the two sides are more or less equal as the variation development volume is more or less equal to the cut volume.Both theoretical calculations and numerical simulations confirm that the drawing body of the top coal exhibits the shape-difference and volume-symmetry characteristic.

Top coal caving mining technique in thick coal seam beneath the earth dam

It is important to study the mining technology under structures for raising the coal resources recovery ratio. Based on the geological and mining conditions, the top coal caving harmonic mining technique in thick coal seam beneath the earth dam was put forward and studied. The 5 factors such as the panel mining direction, panel size, panel location, panel mining sequence and panel advance velocity were taken into account in this technique. The dam movement and deformation were predicted after the thick coal seam mining and the effects of mining on the dam were studied. By setting up the surveying stations on the dam, the movement and deformation of the dam were observed during mining. By taking some protective measures on the dam, the top coal caving mining technique in thick coal seam beneath the earth dam was carried out successfully. The study demonstrates that harmonic mining in thick coal seam is feasible under the dam. The safety of the earth dam after mining was ensured and the coal resources recovery ratio was improved.

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.

麻家梁矿9号煤层煤质特征及其沉积环境分析

为探讨石炭系太原组煤层的煤质特征及其成煤古环境,研究收集了麻家梁矿9号煤层煤样,从煤样的物理性质、煤岩特征、煤样的化学性质和工艺性能等方面进行分析研究,确定其成煤时的沉积环境。研究结果表明:9号煤层位于石炭系太原组,其煤层厚度为0.79~20.53 m,平均厚度为11.49 m;其宏观煤岩类型以半暗型煤为主,其次为半亮型煤,暗淡型煤少量;显微煤岩组分以镜质组及惰质组为主,其次为半镜质组和壳质组。分析显微组分中镜质组含量与惰质组含量的关系,硫分中有机硫和无机硫(硫化铁硫和硫酸盐硫)含量的多少,煤灰成分中灰成分指数(K)、m(100*MgO/Al_(2)O_(3))及n[CaO/(CaO+Fe_(2)O_(3))]的大小,判定其沉积环境为受海水影响的泥潭沼泽的强还原性环境。

特厚煤层8.8 m超大采高综采面切眼放顶技术

上湾煤矿特厚煤层8.8 m超大采高12403综采面顶板不易自然垮落,在工作面初采阶段,易导致顶板初次垮落步距较大,在顶板大面积瞬间垮落时会产生强烈的强矿压和飓风现象,从而导致人员伤亡及设备损坏等。为了保证工作面初采阶段的安全生产工作,上湾煤矿通过引进井下定向长钻孔水力压裂工艺技术对切眼顶板进行预裂,同时配合切眼三角区强放技术,对特厚煤层8.8 m超大采高综采面切眼进行了初采放顶工作。实践表明:通过在上湾煤矿12403工作面进行煤层顶板定向长钻孔分段水力压裂工程施工,有效降低了顶板强度,缩小了初次放顶步距,为矿井安全高效回采提供技术保障,同时为大采高工作面初次放顶提供了治理经验。

提高8405综放工作面回采率途径探讨

为了解决厚煤层综放工作面开采过程中,顶煤冒放性差、回收率低等问题,通过分析北辛窑煤矿8405工作面放顶煤机理以及回采过程中煤炭损失原因,提出了8405工作面回采率提升的具体措施,并在现场应用,有效提高煤炭资源回收率。

宁正矿区新庄煤矿首采区侏罗系延安组8号煤层顶板涌(突)水危险性评价

针对新庄矿井水文地质条件特别是矿井水的涌(突)水水源和机理认识不清,直接影响新庄煤矿的安全、高效、绿色开采这一问题,通过水质分析和计算导水裂隙带发育高度,判定新庄矿井8号煤层顶板涌(突)水水源;同时在含水层的厚度、单位涌水量、物探含水层富水异常区、钻孔消耗量、岩芯采取率、地层脆塑性比6个主控因素的含水层富水性分析和综放开采条件下冒裂安全性分析基础上,通过多结果叠合对首采区8号煤层顶板涌(突)水危险性进行评价。结果表明:矿井顶板涌(突)水水源为下白垩统志丹群洛河组砂岩孔隙−裂隙含水层和中侏罗统直罗组、延安组上、中部(煤8层顶板以上)砂岩复合承压含水层,其中下白垩统志丹群洛河组砂岩孔隙−裂隙含水层是主要致灾水源。首采区内8号煤层导水裂隙带发育高度均能沟通洛河组砂岩含水层,首采区全区域为冒裂危险区。8号煤层顶板涌(突)水危险区中Ⅰ区主要分布在首采区的北部及中西部,Ⅱ区主要分布在首采区的中部及中西部,Ⅲ区主要分布在首采区的中东部及南部,Ⅳ区主要分布在首采区的东部及南部。

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。

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。

东欢坨矿8煤瓦斯异常的地质因素

运用压汞法和等温吸附法对开滦矿区东欢坨矿8煤储层特征进行研究,结合矿井实测瓦斯涌出量数据,分析了控制东欢坨矿8煤瓦斯异常涌出的地质因素。结果表明:瓦斯异常主控地质因素为地质构造及水文地质特征,东欢坨矿"水大瓦斯小,水小瓦斯大"的赋存规律明显。矿井瓦斯赋存形式主要为游离态,表现出在压性断层带时,瓦斯涌出量较小;在未导通煤系含水层情况下,张性断层带往往煤体破碎、孔裂隙相对发育,瓦斯涌出量显著增大,而在断层导通煤系含水层的水文异常区,瓦斯涌出量有明显减小的趋势。东欢坨矿瓦斯涌出量受多种因素的控制,筛选出煤层埋深、煤层厚度、煤层顶板含泥率和断层数作为主要控制因素,建立了具有较好相关性的瓦斯涌出量多变量数学预测模型;并通过灰色系统理论建模软件对瓦斯涌出量和各影响因子之间的关联度进行分析,得到断层数是瓦斯涌出量的最主要影响因素。

急倾斜中厚煤层单一巷道放顶煤采煤方法研究与应用

为解决某矿急倾斜中厚煤层倾角及厚度变化大的开采问题,提出了“急倾斜中厚煤层单一巷道放顶煤采煤方法”。该采煤方法是沿急倾斜煤层倾斜方向划分为若干区段,每个区段沿急倾斜煤层走向仅布置1条巷道。此巷道服务于1个采煤区段,担负工作面通风、运输和行人等任务。对单一巷道放顶煤采煤方法的巷道布置、综放工艺和沿空留巷方法进行了探讨。实践表明,该采煤方法使采煤工作面形成全负压通风,避免了巷道与采空区窜风,杜绝了采空区瓦斯积聚和遗煤自燃,实现了采煤机械化,提高了急倾斜中厚煤层的开采效率和煤炭回收率。单一巷道放顶煤采煤法为类似急倾斜煤层安全、高效开采提供了技术支撑。

近直立特厚煤层分段开采覆岩垮落规律研究

近直立特厚煤层由于其特殊开采方式,导致采空区的覆岩垮落与裂隙发育规律较水平煤层不同。利用相似材料模拟试验研究了近直立煤层采空区覆岩垮落规律,然后利用PFC^(3D)软件模拟了不同水平分段开采稳定后的地表沉降和裂隙发育情况,分析了空隙率演化规律,并进一步探究了地表沉降规律。相似材料模拟试验发现,随着分段开采的进行,上覆岩层逐渐垮落,首先形成“U”形区域,最终形成“V”形的垮落结构;随着开采的进行,采空区两端所留的少量空间逐渐消失,采空区裂隙与地表连通,形成采空区漏风通道;采空区的空隙率稳定在0.30~0.65,顶、底板侧裂隙的空隙率逐渐增加,最终稳定在0.30左右;垮落后地表沉降范围宽度由92.93 m缓慢增加至100.16 m,深度由27.85 m大幅增加,最终稳定在101.63 m。研究结果可为近直立煤层的开采设计及安全生产提供参考。

汪家寨矿C409复杂难采厚煤层开采方法选择及建议

针对汪家寨矿C409复杂难采厚煤层合理开采方法选择进行了研究。首先,为进一步增加开采方法选择的直观性,就三种厚煤层开采方法一般适用条件及选择原则以表格形式进行了总结;其次,具体分析了C409复杂难采厚煤层开采需着重考虑的不利因素。在此基础上,进行了C409厚煤层开采方法选择对比分析和适应性综合评价。结果表明,在现有开采技术条件下,C409厚煤层采用放顶煤开采较合理,这与矿井目前实际采用的开采方法是一致的。最后,针对C409复杂难采厚煤层放顶煤开采可能遇到的问题,给出了具体建议,以指导其安全高效开采。

开采4～8m急倾斜煤层运输设备选型及布置方案探讨

开采4～8m急斜煤层,采用F3200/17.5/27F型放顶煤液压支架。根据工作面开采方法,依据支架宽度、煤层厚度、支架数量以及顺槽输送机安放位置,对扩巷工作面及放顶煤工作面上输送机选型及布置方案进行了探讨。

ZZF5200/19/32S型坚硬特厚煤层放顶煤液压支架的研制

该支架是针对靖远矿务局红会一矿坚硬、特厚煤层综放开采技术的需要研制而成的。试用结果表明,支架的结构合理,支护性能良好,与其它设备配套性能良好。

近距煤层合层综放工作面矿压显现规律研究

针对近距煤层合层综放开采覆岩移动破坏与矿压显现规律等问题,以涡北煤矿842首采综放工作面为工程背景,采用相似模拟试验和数值分析手段对工作面开采过程进行研究。结果表明:相似模拟试验下覆岩冒落带高度为38 m,开切眼附近裂隙带的高度为103.8 m,停采线附近裂隙带的高度为95.4 m,基本顶初次来压步距为28 m,周期来压步距为17.5 m。由数值分析得到采场围岩位移场与应力场的变化颇为相似,分析采场前方支承压力分布特征与相似模拟试验的结果相吻合。研究结果可为近距煤层合层综放工作面煤柱宽度、工作面支护参数设计提供技术指导。

煤岩物性及地质因素对嘉乐泉煤矿8号煤层瓦斯的耦合控制

瓦斯突出是影响矿井安全生产的主要灾害之一,厘清其赋存规律是矿井开采的必要条件。为厘清西山煤田嘉乐泉煤矿8号煤层瓦斯地质特征及赋存规律,基于研究区钻孔录井信息绘制了瓦斯含量等值线图,并探讨了地质因素和煤岩物性对瓦斯含量的影响。结果表明:8号煤层瓦斯含量整体偏低,为低瓦斯矿井,其含量南北向呈带状分布,东西向集中连片分布,整体呈现北低南高特征;断裂不发育的宽缓单斜利于瓦斯富集;煤层埋深、上覆盖层厚度和顶底板封闭性顶底板岩性控制瓦斯含量的关键;岩溶陷落柱也为瓦斯提供了重要的富集空间。此外,煤层厚度和煤岩物性对8号煤层瓦斯含量也有一定影响,但体现的相关性较弱。研究结果对嘉乐泉煤矿8号煤层瓦斯防治工作有一定的参考意义。

近直立煤层群水平分段综放开采充填卸压防冲研究

目前近直立煤层开采冲击地压防治措施主要有爆破、水压致裂、建立保护层等,或破坏层间岩柱和顶底板,或难以解决大采深情况下的层间岩柱应力集中问题,且会导致较大的地表沉降。以乌东煤矿为工程背景,针对近直立煤层群水平分段综放开采方法,提出了充填采空区技术,以支护层间岩柱及顶底板,降低开采分段周围煤岩体的应力集中现象。设计了3种充填方案:方案1为第一开采分段采空区使用高强度材料充填,其余分段采用普通材料充填;方案2为第一开采分段采空区使用高强度材料充填,其余分段交替采用高强度材料和普通材料充填;方案3为每一分段采空区均使用高强度材料充填。通过数值模拟研究了3种充填方案的卸压防冲效果,结果表明:与未充填相比,3种充填方案下层间岩柱最大垂直应力分别下降25.07%,26.57%,29.23%,下一分段煤体最大水平应力分别下降10.63%,10.79%,12.34%。综合考虑卸压效果和经济效益,优选间隔充填的方案3。指出可结合高应力区域实时智能监测技术,及时支撑层间岩柱,减少层间岩柱及下分段煤体的应力集中,防止冲击地压发生。