The influence of inter-band rock on rib spalling in longwall panel with large mining height

In order to improve rib stability,failure criteria and instability mode of a thick coal seam with inter-band rock layer are analysed in this study.A three-dimensional mechanical model is established for the rib by considering the rock layer.A safety factor is defined foy the rib,and it is observed that the safety factor exhibits a positive correlation with the thickness and strength of the inter-band rock.A calculation method for determining critical parameters of the rock layer is presented to ensure the rib stability.It is revealed that incomplete propagation of the fracture at the hard rock constitutes a fundamental prerequisite for ensuring the rib stability.The influence of the position of the inter-band rock in the coal seam on failure mechanism of the rib was thoroughly investigated by developing a series of physical models for the rib at the face area.The best position for the inter-band rock in the coal seam is at a height of 1.5 m away from the roof line,which tends to provide a good stability state for the rib.For different inter-band rock positions,two ways of controlling rib by increasing supports stiffness and flexible grouting reinforcement are proposed.

Measurement and numerical analysis of influence of key stratum breakage on mine pressure in top-coal caving face with super great mining height

To analyze the influence of movement in shallow-buried working faces with large mining heights on mine pressure manifestation, the key stratum at a working face was categorised using the 1313 top-coal caving face with super great mining height under cover as a case study. The research combined theoretical analysis, field measurement, and numerical simulation to analyze the influencing mechanism of key stratum. Moreover, the research results were verified by numerical simulation and indicate that the sub-key stratum is prone to be broken to form a "cantilever beam" structure rather than a stable hinged structure during the excavation of working faces with super great mining heights. When the "cantilever beam" structure is unstable, a low pressure will occur on the working face, and the overlying strata will subside simultaneously with the sub-key stratum to induce the breakage of the primary key stratum: the breakage will further trigger the periodic breakage of sub-key stratum, causing a greater load on the working face. Finally, steps, and strength of weighting in the working face vary to be great or small alternatively. This is the main reason explaining why the 1313 working face shows strong mine pressure manifestation. The results provide theoretical and practical experience for forecasting and controlling mine pressure manifestation.

Subsidence prediction method based on equivalent mining height theory for solid backfilling mining

Based on the characteristics of strata movement of solid backfilling mining technology, the surface subsidence prediction method based on the equivalent mining height theory was proposed, and the parameters selection guideline of this method was also described. While comparing the parameters of caving mining with equivalent height, the subsidence efficient can be calculated according to the mining height and bulk factor of sagging zone and fracture zone, the tangent of main influence angle of solid backfilling mining is reduced by 0.2-0.5（while it cannot be less than 1.0）. For sake of safety, offset of the inflection point is set to zero, and other parameters, such as horizontal movement coefficient and main propagation angle are equal to the corresponding parameters of caving mining with equivalent height. In the last part, a case study of solid backfilling mining subsidence prediction was described. The results show the applicability of this method and the difference of the maximum subsidence point between the prediction and the observation is less than 5%.

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.

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.

Experimental investigation into stress-relief characteristics with upward large height and upward mining under hard thick roof

According to geological conditions of No. 3 and No. 4 coal seams （namely A3 and B4） of the Pan＇er coal mine and the parameters of panels 11223, 11224, and 11124 with fully-mechanical coal mining, we built 2D similar material simulation and FLAC3D numerical simulation models to investigate the development of mining-induced stress and the extraction effect of pressure-relief gas with large height and upward mining. Based on a comprehensive analysis of experimental data and observations, we obtained the deformation and breakage characteristics of strata overlying the coal seam, the development patterns of the mining-induced stress and fracture, and the size of the stress-relief area. The stress-relief effect was investigated and analyzed in consideration with mining height and three thick hard strata. Because of the group of three hard thick strata located in the main roof and the residual stress of mined panel 11124, the deformation, breakage, mining-induced stress and fracture development, and the stress-relief coefficient were discontinuous and asymmetrical. The breakage angle of the overlying strata, and the compressive and expansive zones of coal deformation were mainly controlled by the number, thickness, and strength of the hard stratum. Compared with the value of breakage angle derived by the traditional empirical method, the experimental value was lower than the traditional results by 3°-4°below the hard thick strata group, and by 13°-19° above the hard thick strata group. The amount of gas extracted from floor drainage roadway of B4 over 17 months was variable and the amount of gas per month differed considerably, being much smaller when panel 11223 influenced the area of the three hard thick strata. Generally, the stress-relief zone of No. 4 coal seam was small under the influence of the hard thick strata located in the main roof, which played an important role in delaying the breakage time and increasing the breakage space. In this study we gained understanding of the stress-relief mechanism influenced by the hard thick roof. The research results and engineering practice show that the main roof of the multiple hard thick strata is a critical factor in the design of panel layout and roadways for integrated coal exploitation and gas extraction, provides a theoretical basis for safe and high-efficient mining of coal resources.

Energy method and numerical simulation of critical backfillheight in non-pillar continuous mining

Non-pillar continuous mining(NPCM) is regarded as a high-efficient, high-level and one-step mining technology, which can be divided into two substopes. Back fill stability status in substope I, which directly influence the loss rate and dilution rate, etc, will determine whether the experimental research is successful or not. By employing energy method of limit analysis and finite element numerical simulation method, the critical backfill height was determined under the prerequisite condition of its stability, which put forward theoretical basis for reasonable and correct selection of backfill’s parameters. The result showed that the first backfill could not keep stable for NPCM, while the other was able to.

Height of fractured zone inside overlying strata under high-intensity mining in China

The height of fractured zone(HFZ) at the high-intensity longwall mining panel plays a vital role in the safety analysis of coal mining under bodies of water. This paper described definitions of the highintensity mining. The processes of overburden failure transfer(OFT) were analyzed, which were divided into the development stage and the termination stage. Through theoretical analysis, the limited suspension-distance and the limited overhanging distance were proposed to judge the damage of each stratum. Mechanical models of strata suspended integrity and overhanging stability were established.A theoretical method to predict the HFZ at the high-intensity longwall mining panel was put forward based on the processes of OFT. Taking a high-intensity longwall mining panel(No. 11915 panel) as an example, the theoretical method proposed, the engineering analogy and the empirical formulas in the Regulation were used to predict the HFZ. The results show that the theoretical result is consistent with the engineering analogies' result and empirical formulas' result. The rationality and reliability of the theoretical method proposed is verified.

Formation mechanism and height calculation of the caved zone and water-conducting fracture zone in solid backfill mining

To study the heights of the caved zone and water-conducting fracture zone in backfill mining,the failure mechanism of strata during backfill mining was analyzed,and a method for determining the heights of the two zones was proposed based on key strata theory.The movement and failure regularity of the strata above the backfilling panel were revealed through numerical simulation.Considering the geologic conditions of the CT101 backfilling panel,the height of the fracture zone was determined using the proposed method along with empirical calculation,numerical simulation,and borehole detection.The results of the new calculation method were similar to in situ measurements.The traditional empirical formula,which is based on the equivalent mining height model,resulted in large errors during calculation.The findings indicate the reliability of the new method and demonstrate its significance for creating reference data for related studies.

Technical parameters of drawing and coal-gangue field movements of a fully mechanized large mining height top coal caving working face

Under fully mechanized, large mining height top coal caving conditions, the shield beam slope angle of the support increases due to the enlargement of the top coal breaking and caving space. This results in a change of the caving window location and dimensions and, therefore, the granular coal-gangue movement and flows provide new characteristics during top coal caving. The main inferences we draw are as follows. Firstly, after shifting the supports, the caved top coal layer line and the coal gangue boundary line become steeper and are clearly larger than those under common mining heights. Secondly, during the top coal caving procedure, the speed of the coal-gangue flow increases and at the same drawing interval, the distance between the coal-gangue boundary line and the top beam end is reduced. Thirdly, affected by the drawing ratio, the slope angle of the shield beam and the dimensions of the caving window, it is easy to mix the gangue. A rational drawing interval will cause the coal-gangue boundary line to be slightly behind the down tail boom lower boundary. This rational drawing interval under conditions of large mining heights has been analyzed and determined.

Mode of overlying rock roofing structure in large mining height coal face and analysis of support resistance

The mining space of large mining height coal face is large,the range of movement and caving of rock strata is large and the stability of supports at coal face is low and damage rate of supports is high,which significantly affects the safe and efficient production of coal mines.By similar simulation experiment and theoretical analysis,the mode of fractured roofing structure of large mining height coal face and the method of determination of reasonable support resistance of the support was evaluated.Analysis shows that the structural mode of "combined cantilever beam – non-hinged roofing – hinged roofing" of the large mining height coal face appears at the roofing of large mining height coal face.The supporting factor of caved gangue at the gob is introduced,the calculating equations of the fractured step distance of roofing were derived and conventional calculating method of caved height of roofing was corrected and the method of determination of the length and height of each structural area of the roofing was provided.With reference to the excavating conditions at Jinhuagong coal mine in Datong minefield,the dimensions of structural areas of the roofing of the coal face were determined and analyzed,and reasonable support resistance of the height coal face was acquired.By selecting Model ZZ13000/28/60 support and with procedures of advanced pre-cracking blasting,the safe production of large mining height coal face was assured.

Suitable retention and recovery technology of floor coal at ends of fully mechanized face with great mining heights

Gateways at faces of great mining heights are mostly driven along the roof of coal seams.For gateway height restrictions,a 1-3 m floor coal is retained,leaving a triangular floor coal at the face ends,causing a loss of coal.In order to improve coal recovery rates and to ensure efficiency of equipment at coal mining faces,we investigated suitable retention methods and recovery technology of floor coal at face ends.The upper floor coal can directly be recovered by a shearer with floor dinting.The lower floor coal is recovered by shearer with floor dinting after advanced floor dinting and retaining a step for protecting coal sides in a haulage gateway.Field practice shows that this method can improve the coal recovery rates at fully mechanized working faces with great mining heights.

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.

Stress field evolution law of mining environment reconstructing structure with change of filling height

For improving global stability of mining environment reconstructing structure,the stress field evolution law of the structure with the filling height change of low-grade backfill was studied by ADINA finite element analysis code.Three kinds of filling schemes were designed and calculated,in which the filling heights were 2,4,and 7 m,separately.The results show that there are some rules in the stress field with the increase of the filling height as follows:(1) the maximum value of tension stress of the roof decreases gradually,and stress conditions are improved gradually;(2) the tension stress status in the vertical pillar is transformed into the compressive stress status,and the carrying capacity is improved gradually;however,when the filling height is beyond 2.8 m,the carrying capacity of the vertical pillar grows very slowly,so,there is little significance to continue to fill the low-grade backfill;(3) the bottom pillar suffers the squeezing action from the vertical pillars at first and then the gravity action of the low-grade backfill,and the maximum value of tension stress of the bottom pillar firstly increases and then decreases.Considering the economic factor,security and other factors,the low-grade backfill has the most reasonable height(2.8 m) in the scope of all filling height.

Numerical simulation study on the relationship between mining heights and shield resistance in longwall panel

A numerical model based on a Continuum-based Distinct Element Method(CDEM) was used to carry out a dynamic simulation of the interaction between shield and rock strata movement in longwall mining. In Northern China, the Ordos coal field geological conditions and operational characteristics were used as a case example. The CDEM was constructed on Ordos coal field shield's operation characteristics and geological conditions. Numerical modelling was carried out to investigate the effects of different mining heights on the caving process, movement characteristics, equilibrium and stability conditions of overburden as the interaction between shield and surrounding rocks. With the numerical model, the internal factors for changes in shield resistance under different mining heights was found. The quantitative relationship between mining heights and shield resistance was also obtained by the numerical simulation.

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.

A method for predicting the water-flowing fractured zone height based on an improved key stratum theory

In the process of using the original key stratum theory to predict the height of a water-flowing fractured zone(WFZ),the influence of rock strata outside the calculation range on the rock strata within the calculation range as well as the fact that the shape of the overburden deformation area will change with the excavation length are ignored.In this paper,an improved key stratum theory(IKS theory)was proposed by fixing these two shortcomings.Then,a WFZ height prediction method based on IKS theory was established and applied.First,the range of overburden involved in the analysis was determined according to the tensile stress distribution range above the goaf.Second,the key stratum in the overburden involved in the analysis was identified through IKS theory.Finally,the tendency of the WFZ to develop upward was determined by judging whether or not the identified key stratum will break.The proposed method was applied and verified in a mining case study,and the reasons for the differences in the development patterns between the WFZs in coalfields in Northwest and East China were also fully explained by this method.

An analysis on the effect of mining height and floor lithology on pressure relief of upper protective layers

In order to understand the effect of mining height and floor lithology at the upper protective layer face on the pressure relief of protected coal seams, this paper uses a numerical simulation method to model the pressure changes at protected coal seam during mining upper protective layer. The results show that the taller the mining height at the upper protective layer face, the greater the protection on protected coal seam due to the higher level of pressure release; the upper protective layer face with hard rock floor impedes the pressure release at the protected coal seam, which affects the overall effect of the pressure release at protected coal seam using the protective layer mining method.

Study on the characteristics of ground pressure behaviors in working face with great mining height at different advance speeds by similarity model experiment

Presently most of research results on strata behaviors were concluded under the normal （moderate） advance rate conditions. Comparing with normal advance rate, fast advance rate and slow advance rate may cause some new changes of strata behaviors. The characteristics of ground pressure behaviors in working face with great mining height at different forward speeds were studied by similarity model experiment in laboratory. Its conclusion provides a theoretic basis for ground pressure controlling.

Analysis and control of hydraulic support stability in fully-mechanized longwall face to the dip with great mining height

The working condition of the hydraulic support in working face can be divided into three kinds of situations in the following： roof fall and col,lapse with cavity, advancing support and supporting. Took single support with four-pole in Iongwall face to the dip as research object, control method was studied to avoid support instability in three situations mentioned above. Based on these researches, the major factors of influencing on support stability and its controlling measures were put forward. According to specific conditions of working face 1215（3）, which is fully-mechanized and Iongwall face to the dip with great mining height in Zhangji Coal Mine, Huainan Mining Group, the effective measures was taken to control supports stability..