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极薄煤层智能高效开采关键技术装备研发与应用

Research and application on key technologies and equipment for intelligent high-efficiency mining of extremely thin coal seams

  • 摘要: 针对我国0.7~1.0 m极薄煤层开采作业空间狭小、装备适配性差、智能化水平低、资源回收率不足等难题,以黑龙江东部矿区极薄煤层工作面为研究对象,系统开展极薄煤层智能高效开采关键技术装备研发与应用。开发了基于地质特征与多源煤岩感知信息的地质模型动态修正方法,融合巷道素描、钻孔探测、槽波勘探与图像识别等数据,实现了煤层顶底板起伏、断层构造等地质信息的动态更新与透明化展示,进而构建了"感知−决策−调控"全闭环智能通风管控系统,实现工作面风量动态精准调控,形成地质与通风协同保障技术体系。针对极薄煤层狭小空间工况约束,研发了过桥式矮机身采煤机、分体式弹性连接顶梁液压支架、永磁变频一体刮板输送机、带犁煤铲清浮煤功能的智能拖缆装置等成套装备,优化了滚筒螺旋升角、转速等关键运行参数,解决了极薄煤层装煤效率低、电缆拖拽卡阻等难题。构建了基于双DSP架构的采煤机自动化控制系统与CAN/Modbus TCP实时工业以太网总线的电液控制系统,实现了采煤机记忆截割、液压支架自动跟机、三机协同联动等功能,搭建了融合透明地质模型、智能通风管控的极薄煤层智能开采综合管控平台。在双阳煤矿开展工程示范,应用结果表明:示范工作面实现了“无人跟机、有人巡视、远程集控”的智能化开采模式,月单产稳定达到3万t以上,回采工效提升300%,综采设备开机率提升至85%以上,煤炭资源回收率提高至95%以上,吨煤直接生产成本降低32.8%,吨煤电耗降低15.1%,井下单班作业人员减少67%。研究构建了一套可复制、可推广的极薄煤层智能开采技术装备体系,可为我国同类煤炭资源的安全高效开发提供理论依据与工程示范。

     

    Abstract: Aiming at the challenges associated with 0.7–1.0 m extremely thin coal seam mining in China, including restricted working space, poor equipment adaptability, limited intelligent mining capability, and inadequate resource recovery, this study takes an extremely thin coal seam working face in the eastern Heilongjiang mining area as the engineering background and investigates the key technologies and equipment for intelligent high-efficiency mining. A dynamic updating method for the geological model was developed by integrating geological characteristics with multi-source coal–rock interface sensing information, integrating roadway sketching, borehole detection, in-seam seismic exploration and image recognition data, to realize dynamic updating and transparent display of geological information such as coal seam roof-floor fluctuation and fault structures. On this basis, a full closed-loop intelligent ventilation control system featuring “perception-decision-regulation” was constructed to realize dynamic and precise air volume regulation at the working face, forming a collaborative guarantee technology system integrating geology and ventilation. Targeting the narrow space constraints of extremely thin coal seams, a complete set of mining equipment suitable for extremely thin coal seam conditions was developed, including bridge-type low-profile shearer, hydraulic supports with split elastic connecting top beams, permanent-magnet variable-frequency-drive scraper conveyor and intelligent cable towing device with coal-ploughing float coal cleaning function. Key operating parameters such as drum helix angle and rotation speed were optimized, addressing challenges such as low coal loading efficiency and cable jamming during dragging in extremely thin coal seams. A shearer automatic control system based on a dual-DSP architecture and an electro-hydraulic control system based on CAN/Modbus TCP industrial Ethernet were established, implementing core functions such as shearer memory cutting, automatic hydraulic support following, and coordinated operation of the three machines. In addition, an integrated intelligent mining management and control platform incorporating a transparent geological model and intelligent ventilation control was constructed. An engineering demonstration was carried out at Shuangyang Coal Mine. The field application results show that the demonstration working face realized an intelligent mining mode featuring no personnel following the shearer, on-site patrol inspection, and remote centralized control. The monthly output remained above 30000 tons, the longwall extraction efficiency increased by 300%, the fully mechanized equipment operation rate increased to over 85%, the coal recovery rate exceeded 95%, and the direct production cost per tonne of coal decreased by 32.8%, the electricity consumption per tonne of coal decreased by 15.1%, and the number of underground workers per shift reduced by 67%. The developed replicable and scalable technology and equipment system provides an integrated technical approach for intelligent mining of extremely thin coal seams and offers an engineering reference for the safe and efficient extraction of coal resources under similar geological and mining conditions.

     

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