超大采高工作面厚硬顶板压裂卸压技术研究及应用

Research and application of pressure relief technology for fracturing thick hard roof in super-high mining face

  • 摘要: 针对超大采高厚硬顶板综采工作面面临的超大开采空间、强矿压显现及超高煤壁稳定性控制等难题,以世界首个10 m超大采高综采工作面——曹家滩煤矿122104工作面为研究背景,系统开展了厚硬顶板压裂卸压机制、真三轴水力压裂裂缝重构试验、三维裂缝扩展流固耦合数值模拟、大流量复合压裂技术与工艺、水力压裂效果监测与评价等方面的研究。研究结果表明:厚硬顶板水力压裂卸压作用机制主要体现在结构调控、应力转移、能量释放、强度劣化等方面;延安组相较于直罗组脆性矿物含量更高,易形成复杂裂缝网络;排量由1 m3/min增至5 m3/min,裂缝平均半径由21.9 m增至32.5 m,增幅约为48.40%,排量越大水力裂缝尺度越大。研发了井下厚硬顶板水力压裂卸压技术及大流量压裂装备,开发了磨料射流预切缝与5 m3/min大流量复合压裂技术工艺,提出了一种井下长水平钻孔定向水力压裂“一场一策”分区设计理念,形成了一种动态更新压裂层位和压裂方案的井下长水平钻孔定向水力压裂方法,并在曹家滩煤矿开展了工程应用试验,实现了10 m超大采高工作面矿压显现的科学有效防控。通过地面微震实时监测技术实时捕捉缝网扩展轨迹,有效指导了水力压裂方案的优化,并获得了顶板水力裂缝空间展布特征。开展了水力压裂实施效果的多因素综合评价,对液压支架工作阻力、工作面周期来压步距和持续距离、来压动载系数、微震事件及能量等进行综合分析,综合评价了水力压裂效果。井下试验结果表明:曹家滩煤矿井下水力裂缝以水平裂缝为主,沿钻孔两侧扩展平均距离约为80 m,有效弱化了工作面范围内上覆厚硬、完整顶板,实现了区域顶板结构有效调控;通过区域压裂技术将厚硬岩层组提前预裂,减小了来压步距和动载系数,保障了10 m超大采高工作面安全高效生产。

     

    Abstract: Aiming at the problems of super-large mining space, strong ore pressure and ultra-high coal wall stability control faced by full-mechanized mining face with ultra-large mining height and thick hard roof, this paper takes the 122104 working face of Caojiatan Coal Mine, the world’s first ultra-10 m super-mechanized mining face, as the research background. Systematic research on pressure relief mechanism of heavy hard roof fracturing, true triaxial hydraulic fracturing fracture reconstruction experiment, three-dimensional fracture propagation fluid-structure coupling numerical simulation, high-flow composite fracturing technology and process, hydraulic fracturing effect monitoring and evaluation are carried out. The results show that the pressure relief mechanism of hydraulic fracturing of thick hard roof is mainly embodied in structural regulation, stress transfer, energy release, strength deterioration and so on. Compared with Zhiluo formation, Yan’an Formation has a higher content of brittle minerals and is easy to form complex fracture network. The average fracture radius increases from 21.9 m to 32.5 m with the displacement increasing from 1 m3/min to 5 m3/min, an increase of about 48.40%. The larger the displacement, the larger the hydraulic fracture scale. The hydraulic fracturing pressure relief technology and high-flow fracturing equipment for thick hard roof have been developed. The composite fracturing technology of abrasive jet pre-cut slit and 5 m3/min large flow rate was developed, and a “one game, one policy” zoning design concept of directional hydraulic fracturing for long horizontal drilling was proposed. A set of directional hydraulic fracturing methods for long horizontal drilling with dynamic update of fracturing zones and fracturing plans was formed, and engineering application tests were carried out in Caojiatan Coal Mine. It has realized scientific and effective prevention and control of ore pressure in 10 m super-high working face. The surface microseismic real-time monitoring technology captures the spread track of the fracture network in real time, effectively guides the adjustment of hydraulic fracturing scheme, and obtains the spatial distribution characteristics of roof hydraulic fractures. The multi-factor comprehensive evaluation of hydraulic fracturing effect is carried out, and the working resistance of hydraulic support, the pressing step distance and continuous distance of working face cycle, the dynamic load coefficient, microseismic events and energy are comprehensively analyzed to evaluate the hydraulic fracturing effect. The underground test results show that the underground hydraulic cracks in Caojiatan Coal mine are mainly horizontal cracks, and the average spreading distance along both sides of the borehole is about 80m, which effectively weakens the overlying thick and complete roof within the working face, and realizes the effective control of regional roof structure. By using zone fracturing technology, the thick hard rock group is pre-fractured in advance, reducing the pressure step and dynamic load coefficient, and ensuring the safe and efficient production of 10 m super-high mining face.

     

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