特厚煤层10 m超大采高综采关键技术及装备

Key technology and equipment for fully mechanized mining with extra-large shearing height of 10 m in extra-thick coal seam

  • 摘要: 超大采高综采技术是我国6~10 m特厚煤层实现高产、高效、高回收率开采的有效途径。在分析国内超大采高综采技术及装备研究现状的基础上,围绕陕煤集团曹家滩煤矿10 m特厚煤层超大采高工作面开采地质条件,从超大采高采场围岩控制、关键开采装备、智能协同控制3个方面分析了存在的难题,并提出了解决路径。经过5 a的技术攻关,取得一系列创新成果:① 提出“主动强力支撑与防护+区域压裂弱化卸压”的支─卸协同超大采高工作面围岩控制策略,研发出5 m3/min大流量井下水力压裂成套技术与设备,实现了超大采高工作面强矿压的有效防控。② 研发出10 m超大采高强力液压支架,创新设计了“双层伸缩梁+三级护帮”机构,实现了超大采高工作面顶板和超高煤壁的安全防控;采煤机分区润滑与分布式冷却方案提高了大仰角长摇臂采煤机截割可靠性;高可靠中部槽、下链道悬链及慢变动力启动提高了超大运量刮板输送机对超大采高工作面煤流运输的适应性。系统集成世界首套特厚煤层10 m超大采高综采成套装备。③ 提出10 m超大采高液压支架运行状态智能控制策略,采煤机自动控制策略,通过应用粗糙神经网络技术,构建了超大采高采煤机与刮板输送机的协调控制系统。形成了超大采高重型开采装备群智能控制模式及控制逻辑。④ 构建了基于“微震−岩层移动−应力−水文”的超大采高工作面多场多参量协同监测融合分析系统,实现了工作面覆岩破坏、地表移动变形、地下水流场和矿压显现间的多元异构数据融合分析。研究成果在曹家滩煤矿得到成功应用,实现了10 m特厚煤层高产、高效、高回收率开采,取得了显著经济效益,引领了国内外特厚煤层高效智能开采技术的发展方向。

     

    Abstract: Fully mechanized mining technology with extra-large shearing height is the optimal technical approach to achieve high-yield, high-efficiency and high-recovery mining for 6-10 m ultra-thick coal seam in Chinese coal mines. Based on the analysis of the current status of fully mechanized mining technology and equipment with extra-large shearing height at home, focusing on the geological condition of fully mechanized working face with ultra-large shearing height of 10 m in extra-thick coal seam in the Caojiatan Coal Mine, Shaanxi Coal and Chemical Industry Group Co., Ltd., the existing technical problems were analyzed and the associated solutions were given from three aspects: surrounding rock control, key mining equipment and intelligent collaborative control. After nearly five years of scientific research, a series of innovative achievements have been achieved: ① The surrounding rock control strategy with coordination of support and destressing for ultra-large shearing height working faces, namely "active strong support and protection + regional hydraulic fracturing weakening and stress relief", was proposed, a complete set of underground hydraulic fracturing technology and equipment with large flow of 5 m3/min was developed. Effective prevention and control of strong mining-induced activities in ultra-large shearing height working face has been realized. ② The strong hydraulic shields with ultra-large shearing height of 10 m were developed, and the "double-layer telescopic beam + three-level side guard" mechanism was innovatively designed to achieve safe protection of working face roof and ultra-high coal wall; the zoned lubrication and distributed cooling scheme improves the cutting reliability of the shearer with large angle of elevation and long rocker; the high-reliability middle trough, lower chain catenary and slow-changing power start-up improve the adaptability of the ultra-large capacity scraper conveyor to the coal flow transportation of the working face with ultra-large shearing height. The systematic integration has formed the global first set of comprehensive mining equipment with extra-large shearing height of 10 m. ③ An innovative intelligent control strategy for the operation status of the hydraulic shields with 10 m ultra-large shearing height, and the automatic control strategy for the shearer were proposed. A coordinated control system for the shearer with ultra-large shearing height and the scraper conveyor was constructed by applying the rough neural network technology. An intelligent control mode and control logic for heavy equipment groups with ultra-large shearing height were formed. ④ A multi-field and multi-parameter collaborative monitoring and integrated analysis system for the working face with ultra-large shearing height based on "microseism-rock movement-stress-hydrology" was constructed, realizing the multivariate heterogeneous data integrated analysis among damage of overburden rock above working face, surface movement and deformation, groundwater flow field and mining-induced activities. The research results were successfully applied in the in Caojiatan Coal Mine, achieving high-yield, high-efficiency and high-recovery mining in 10 m ultra-thick coal seam, getting significant economic benefits, and leading the development direction of high-efficiency and intelligent mining for extra-thick coal seam at home and abroad.

     

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