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.

Surface Movement Regularity of Super-Wide Mining Face With Top-Coal Caving

No.4326 super-wide panel of Wangzhuang Coal Mine ( in which the fully-mechanized top-coal caving longwall mining method was used) was monitored for dynamic characteristic of surface movement. The dynamic surface movement in and after mining was predicted by using the Mining Subsidence Prediction System. The results indicate that after mining, the surface above the super-wide panel reaches a state of full subsidence, making the No.309 national highway above the panel be located on the flat bottom of the subsidence basin so that the influence of mining activity in both sides of 4326 panel on the national highway is the smallest.

Analysis on air-leakage law of goal in condition of ascending mining for top-coal caving

Using the Jisan Coalmine's top-coal caving for the 3down coal seam with ascending mining as the project background, the air-leakage characteristics of the goaf wasanalyzed. Through data fitting of the in situ observation, the models of gas seepage, diffusion and air-leakage in the goaf were established in ascending mining. The ComputationFluid Dynamics software Fluent was used to simulate the air-leakage law of the goaf. Theresults of the numerical simulation provide a basis for the use of the technology of ventilation and fire prevention in the working face of an ascending mining, which ensures thesafety in production in the working face of the top-coal caving for 3_down coal seam in theJisan Coalmine.

Numerical investigation of the effectiveness of radon control measures in cave mines

Ventilation is one of the radon control measures in an underground working environment.However,the dynamics related to the cave mining methods particularly in block/panel cave mines,complicate the design of effective ventilation system,and implementation.Events such as hang ups(in the drawbells),leakage from old workings,and changes in cave porosity lead to differing response of an existing ventilation designs.However,it is difficult to investigate these conditions at the mine or with a laboratory scale study.Therefore,this study develops a discrete model to investigate the impact of different radon control measures in cave mines using computational fluid dynamics techniques.We considered two ventilation conditions for a fully developed cave:with and without the undercut ventilation.For each of the two conditions,we studied four parameters:airflow distribution through the production drifts,radon distribution through the production drifts,the effect of increasing airflow on radon concentration,and the effect of a cave top negative pressure on radon distribution.The results show that:the undercut ventilation significantly increases the radon concentration in the production drift;the growth of radon concentration through the production drift is nonlinear(oscillating pattern);maintaining a negative pressure on top of the cave is more effective at mitigating radon exposure,when the undercut ventilation is active;and increase in air volume flow rate decreases radon concentration in most regions,however,there might be regions with significant radon accumulation due to pressure variation across the drifts.These findings provide vital information for designing an effective ventilation system and for proactive implementation of radon control measures in cave mines.

Prediction of airway resistance in panel cave mines using a discrete and continuum model

The configuration of an airway(or production drift)in panel cave mines is different from the typical(straight)mine airway designs.The drawpoints are connected to the airway(cross-cuts),which allows airflow from the cave into the airway or air loss from the airway into the cave due to the ventilation approach and cave porosity.These affect airflow in the production drifts,but it is difficult to investigate these conditions from field or laboratory scaled studies.Therefore,this study develops discrete and continuum computational fluid dynamics(CFD)models to study the effects of the ventilation approach and cave porosity on the airway resistance.Our findings show that:with active undercut ventilation,a unique resistance model is required for the airway in panel cave mines;and an increase in cave porosity decreases the drift’s resistance.These findings provide essential tools for a panel cave ventilation design.

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.

SAFETY PROBLEMS IN FULLY-MECHANIZED TOP-COAL CAVING LONGWALL FACES

The thick-san top-ctal catrig technology has been in use in China for over a decade,and has given rise to siguscant economic efficiendes. Eftorts in reeent years to extend its applica tion to more complex mining conditions, mostly high-gas seams , with or without proneness ofspontaneous combustion. have brought about new safety problems This paper will highlight thefcatures and problems retared with thick-seam top-coal caving systems, compared with conventionai, fully-mecbanized longwall systems , particularly issues retated to methane, spontaneous combustion and dust,and disam the methods and measures to ded with them.

基于3Dmine的采空区治理工程实践

通过对某金矿采空区资料收集及现场调查,利用3Dmine软件建立了该金矿采空区+巷道三维数字模型,准确获得了各中段采空区的实际边界和采空区形态等相关信息。针对采空区情况,结合矿区生产实际,经综合分析研究,提出了采空区治理方案,即:对矿区已经贯通连成一体的采空区群/塌陷坑(四中段以上)采用地表废石充填,四中段未贯通的采空区采用中深孔强制崩落顶板,将上部自地表“灌入”的废石充填到采空区,同时采取密闭隔离的方式联合治理;对于其余地段的采空区,已经结束回采且无法进入的区域采取在中段石门密闭隔离的方式进行治理,尚在开采的其他采空区采取施工措施工程进行坑内毛石回填并密闭隔离方式治理。通过多项措施的综合运用,彻底消除了发生大面积地压活动并引起地面塌陷的隐患,为井下正常生产作业创造了良好的条件。

Analysis of factors of top coal caving in fully mechanized sublevel caving face in soft coal and control

According to the analysis of the mechanism of top coal caving, the caving condition was pointed out, and many factors of caving were also determined. Then the relationship between factors and caving was studied. Based on the above research, one effective method by using field monitoring was brought forward to determine the controlling factor. Then some related key technologies were provided, such as keeping the integrality of the top-coal, raising the horizontal resistance of supports and decreasing the real end-face distance etc.. At last one application of this method was presented, and it was proved to be an effective method.

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.

有限回采空间内贫矿资源无底柱分段崩落法低贫损开采方案研究

做好无底柱分段崩落法的贫损控制对于矿山经济效益及环境保护具有重要意义,但当矿床开采条件复杂、矿石品位较低时,矿石贫损控制难度将会大幅增加,在此条件下如何做好矿石贫损控制一直是崩落法开采方向的重要关注点。金川龙首矿西二采区无底柱分段崩落法采场仅可布置4个分段,回采空间十分有限,不利于矿石的贫损控制,加之西二采区矿石品位较低但经济价值较高,因此在开采过程中需要严格控制矿石贫损。针对西二采区的复杂开采条件及贫损控制需求,提出了一种“首采分段总量控制出矿、中间分段低贫化出矿、最末分段低贫化出矿+辅助进路回收残留矿石”的组合式低贫损回采方案。以西二采区为工程背景,设计并制作了一种高仿真度的物理放矿模型并对该方案展开了试验研究。结果表明:即便是在暂时不考虑回收最末分段残留矿石的情况下,该方案可使西二采区崩落法采场的矿石回收率达到75.6%,而废石混入率仅为6.0%,在确保矿石回收率的基础上显著降低了矿石贫化。该方案在现场应用后,实际的矿石回收指标与试验结果基本接近,表明该方案在西二采区有限回采空间内实现了贫矿资源低成本、高质量回收的总体目标。

基于FLAC3D与无人机航测的全部垮落法采煤塌陷分析

内蒙古串草圪旦煤矿位于黄河中游上段,其全部垮落法采煤导致大面积塌陷,地表生态和环境问题频发。为研究采空区地表裂缝发育规律及塌陷应力与位移场演化特征以串草圪旦煤矿6102工作面为研究对象,利用无人机航测查清了地表裂缝分布范围及规律,构建了FLAC3D数值模型并计算分析了采空区围岩应力及位移变化,将分析结果与无人机航测结果进行了相互验证。结果表明:(1)塌陷主要以地裂缝为表现形式,主要分布于矿区西北部及中西部。工作面发育2类地裂缝,一类为弧形阶梯式裂缝群,呈平行分布且以间隔5~20 m出现,大部分形成阶梯式高度为15~130 cm的错台,裂缝以3°~5°的偏角垂直工作面推进方向发育;另一类为直线型边缘裂缝带,拉张破坏严重,平行工作面外围呈带状发育,少数可展布于工作面内部,最外围裂缝至工作面的距离分别为38,53 m。(2)由于地下煤层开挖,采空区顶板出现明显的“马鞍状”拉应力集中区,且随着开挖的推进地表集中区拉应力先增大后减小,最大值为0.181 MPa;(3)采空区顶部完全垮塌,地表垂直位移最大值在采空区正中间,最大值约5.5 m;地表水平位移最大值位于采空区煤柱正上方,最大值1.93 m。(4)数值模拟计算的沉降量、裂缝角与无人机航测数据基本一致。研究成果可为煤层开采带来的生态环境问题解决方案提供参考依据。

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。

自然崩落法矿山矿岩赋存特征精细调查与辅助致裂崩落效果研究

自然崩落法采矿技术对矿岩赋存特征要求严苛,矿岩崩落特性直接影响自然崩落法矿山矿岩崩落速率及出矿块度。通过人工辅助致裂增加矿岩体内部裂隙发育程度实现矿岩预处理,是当前国外自然崩落法矿山生产过程的重要技术手段。本文以我国首座自然崩落法矿山铜矿峪矿向深部转移首采区开采工程为背景,开展了矿岩赋存特征精细调查与水压致裂矿岩预处理试验研究。结果表明:铜矿峪矿410 m中段5号矿体首采区矿岩坚硬、中等完整~较完整,岩体质量等级为Ⅱ~Ⅲ类,矿岩中等可崩~难崩,矿岩崩落破碎特性为中等破碎~大块较多;岩体赋存特征精细调查对于深入了解矿岩崩落特性意义重大;通过钻孔摄像技术获取了水压致裂矿岩预处理试验前后钻孔孔壁图像并揭示了水压致裂过程产生的新裂隙,有效改善了矿岩结构面发育程度;通过对崩落顶板监测及出矿口块度统计分析显示首采区生产期崩落速率提高了3倍多、出矿口大块率降低了58.3%,为铜矿峪矿转深部开采过渡期产能平稳衔接提供了坚实保障;初步形成了水压致裂矿岩预处理技术及装备体系,可支撑我国现代自然崩落法采矿技术进一步推广应用。

铜矿峪矿530m中段4~#EE矿体开采技术方案研究

受矿体形态、赋存条件和矿岩可崩性等因素影响,金属矿床地下开采须经过科学严谨的论证,选择安全性高、可行性强、经济效益好的开采方案。铜矿峪矿主要采用自然崩落法开采,为充分回收矿产资源,主矿体开采范围以外的530中段4~#EE矿体,根据矿体赋存条件,充分论证比较后选择了“上部‘预摘’+下部自然崩落法+侧翼有底柱分段崩落法”的联合开采技术方案。本方案兼顾了不同崩落法采矿工艺的优点,降低了矿体形态复杂、规模相对较小,以及可崩性差等不利因素影响,技术可靠性大幅提升,回采率显著提高,经济效益大幅提升,实现了安全、经济、高效开采。本次联合开采技术方案的成功运用,对于类似特点的金属矿体地下开采具有很强的借鉴意义,并且文中提到的“预摘、预裂爆破、废石分出”等扩大自然崩落法适用范围的技术措施值得推广和借鉴。

浅孔诱导落矿小分段空场采矿法在某金矿的应用

针对某金矿矿岩节理裂隙发育、矿体稳固性差、采准工程掘进与支护困难、回采安全性差等问题,在局部矿体破碎区域开展了浅孔诱导落矿小分段空场采矿法试验研究,利用矿岩本身的力学特性和受人为工程控制的崩落应力场来崩落破碎矿石。详细介绍了该方法的采场结构参数,采切工程布置、拉底切割和落矿等工艺。现场应用表明:采用该方法开采,采场生产能力达127 t/d,采矿损失率为9.2%,矿石贫化率为14.6%,取得了较好的效果,对于该类矿体的安全高效回采具有一定的借鉴意义。

崩落法转充填法中存窿矿石回收方法研究与实践

龙桥铁矿无底柱分段崩落法转充填法过程中,原采场存在大量的存窿矿石资源,主要包括覆盖矿石层和下盘三角矿柱。为安全有效地回收该部分资源,分析采空区及存窿矿石分布状况及技术条件,确定了合理的回收原则,提出了分区回收方案。存窿矿石回收全过程在基于采空区稳定性及监测监控下进行,并顺利实施,充分解决了崩落法转充填采矿法所遗留的资源损失问题,延长矿山服务年限,同时又能对采空区进行安全处理。

龙岩市非煤矿山顶板事故分析与管理措施

顶板事故在非煤地下矿山事故中占比最多,顶板管理是非煤地下矿山安全管理的重点和难点。统计分析龙岩市2008—2023年共15a的顶板事故情况,总结非煤矿山顶板事故的特点。研究得出,矿井爆破工艺技术水平低及在大暴露空间下进行作业是顶板事故原因。提出改善措施,将中深孔爆破分段崩落采矿法代替空场法,但受到矿石价格影响,该方法成本高,当前可行性低;通过推广应用凿岩台车、撬毛台车等机械工具,严格控制井下采掘作业空间宽度和高度等措施,加强顶板管理,努力实现顶板零事故。

铜矿峪矿深部矿岩赋存特征研究对自然崩落法开采的指导意义

本文通过对铜矿峪矿深部矿岩赋存特征及其物理力学特性研究,探讨深部矿岩可崩性,为矿山深部自然崩落法开采提供重要的指导意义。研究表明:4^(#)、5^(#)矿体岩体中存在倾向为北西向和南东向的两组优势节理组,节理面陡倾;岩石坚固程度属坚硬岩~较坚硬岩;岩体质量属Ⅱ~Ⅲ级,破碎特性为中等大块~大块较多,可崩性属难崩~中等可崩。为改善深部矿岩可崩性,在深部开采时还应积极引用水压预裂矿岩预处理技术,合理规划首采区拉底部位、确定拉底推进方向、控制拉底速率,并辅以适当的预裂、割帮等诱导工程,以实现自然崩落法的成功开采。

白家庄煤矿垮落法残采区上行开采相似模拟实验研究

针对白家庄煤矿垮落法残采区上覆煤层开采问题,通过室内相似模拟实验研究发现,受两次采动影响,上行开采层间岩层出现了裂隙产生、扩展甚至贯通的过程,导致其层间岩层发生了结构性变化。掌握了垮落法残采区上行开采层间岩层的应力传递规律,再现了垮落法残采区上行开采层间岩层受两层煤开采共同影响作用下的移动变形全过程和岩层结构演化过程,揭示了垮落法残采区上行开采层间岩层存在块体梁-半拱结构控制层的结构机理与其力学特性。