从离层注浆到覆岩隔离注浆充填的创新与发展

Innovation and development from bedding separation grouting to overburden isolated grouting

  • 摘要: 建筑物压煤开采一直是困扰煤矿的重大技术难题,为了解决我国建筑物压煤开采问题,20世纪80年代开始在近10个煤矿开展了离层注浆减沉试验,取得了一定效果,但由于其实际减沉率达不到建筑物保护的要求,通过离层注浆开采建筑物压煤的技术可行性受到质疑而逐渐被弃用。基于岩层控制的关键层理论和全柱状学术思想研发的覆岩隔离注浆充填技术,2009年率先在淮北矿区成功应用,解决了建筑物压煤开采的难题,应用范围、规模、领域不断扩大。当前,覆岩隔离注浆充填热度有增无减,为促进行业技术健康发展,有必要科学回顾、全面审视发展历程,清晰厘定理论、技术层面的差异,系统论述覆岩隔离注浆充填在理论、技术、实践等方面的创新。在原理层面,鲜明地将技术实质由离层注浆的“寻找离层”扭转到隔离注浆的“压实注浆”,坚定了正确的指导思想与理论方向。从采动覆岩卸荷膨胀累积效应审视发现,离层受到抑制作用,最大量通常小于采高的10%,有些条件下甚至没有,离层注浆将重心放在“离层空间”并加以灌注,实践证明其充填量少、注采比小,难以阻止关键层破断下沉,这是离层注浆减沉效果不及预期的根本原因。覆岩隔离注浆的压实注浆方法,变被动“寻找离层”为主动“挖掘空间”,通过注浆压力的“托上压下”作用,在关键层破断前将其下部卸荷膨胀岩层重新压实,从而产生可注浆充填空间,大幅提高注采比,在采空区中部形成压实支撑体,对关键层结构产生支撑并保持长期稳定性。在原理创新的基础上,从技术层面攻克了往哪注、注多少、怎么注等3方面难题,将压实注浆由抽象理论转化为工艺方法。在注浆层位方面,创新提出了主层位概念,从根本上确保了注浆充填的控沉效果;通过基于关键层位置的裂隙带高度预计等理论方法的运用,确保了注浆充填隔离层的安全性;尤其是在全柱状学术思想的指导下,针对薄基岩厚松散层条件下覆岩结构由基岩关键层向松散层拱结构转移,覆岩隔离注浆的层位也由基岩进化到松散层底界,并取得了实践创新。围绕充填量与注采比的关键技术问题,从理论上阐明了充填物料由固相浆材到液态浆体再到压实固结的过程,进而根据岩层移动规律确定了充填体在空间上呈梯台状的赋存形态,并提出了考虑岩体碎胀与地表沉陷的注采比计算式,回答了能够注多少以及需要注多少的问题,彻底颠覆了以离层量预计充填量的认知。进而,提出了以注采匹配为核心的注浆控制技术,使压实注浆转化为可控的导向注浆,从源头保障了减沉效果;加之注浆钻孔布置等系列设计方法,以及钻孔压力、密度、流量参数监测调控的运用,实现了采动黑箱地层中钻孔注浆的长周期健康运行,以及地表沉陷控制效果的稳定性。在系列理论与关键技术支撑下,覆岩隔离注浆将注采比提高到50%以上,地表下沉系数控制在0.1以下,满足了建筑物保护的要求,实现了村庄不搬迁开采(减沉),以及百万吨级煤基固废的综合利用(减排)、含水层保护(减漏)和矿震防治(减震)。发展方向是,针对煤矿固废充填材料不足和“双碳”目标,将CO2作为注浆充填材料,达到减沉、减排、减漏、减震、减碳的“一注五减”效果,实现煤炭资源绿色开采与低碳利用。

     

    Abstract: The mining of coal under buildings has always been a major technical challenge for coal mines. To address this issue in China, the bedding separation grouting subsidence reduction experiments were carried out from the 1980s in about 10 coal mines, achieving certain results. However, since the actual subsidence reduction rate did not meet the requirements for building protection, the technical feasibility of mining coal under buildings through bedding separation grouting was questioned and gradually abandoned. Based on the key stratum theory of strata control and the full-stratigraphy academic thought, the overburden isolated grouting technology was developed. It was first successfully applied in Huaibei mining area in 2009, solving the problem of mining coal under buildings. Its application scope, scale, and fields have been continuously expanding. Currently, the enthusiasm for overburden isolated grouting is on the rise. To promote the healthy development of the industry’s technology, it is necessary to scientifically review and comprehensively examine the development process, and clearly define the differences at the theoretical and technical levels. This innovations of overburden isolated grouting in theory, technology, and practice are systematically discussed. At the principle level, it clearly shifts the technical essence from the “searching for bedding separation” of bedding separation grouting to the “compaction grouting” of isolated grouting, firmly establishing the correct guiding ideology and theoretical direction. From the perspective of the cumulative effect of unloading and expansion of the overburden due to mining, it is found that the bedding separation is suppressed, and the maximum amount is usually less than 10% of the mining height. In some conditions, there is even no bedding separation. Bedding separation grouting focuses on the “bedding separation space” and fills it, which has been proven to have a small filling volume and a low grouting-to-mining ratio, and is difficult to prevent the key stratum from breaking and sinking. This is the fundamental reason why the subsidence reduction effect of bedding separation grouting is not as expected. The compaction grouting method of overburden isolated grouting changes the passive “searching for bedding separation” to the active “creating space”. Through the “lifting up and pressing down” effect of grouting pressure, the unloading and expansion strata below the key stratum are re-pressed before its breakage and sinking, thereby generating a grouting space, significantly increasing the grouting-to-mining ratio, and forming a compacted support structure in the middle of the goaf, which provides support to the key stratum structure and maintains long-term stability. Based on the principle innovation, the technical level has overcome three major problems: where to grout, how much to grout, and how to grout, transforming the abstract theory of compaction grouting into a process method. In terms of grouting layers, the concept of the main layer position was innovatively proposed, fundamentally ensuring the subsidence control effect of grouting. Through the application of theoretical methods such as the prediction of the height of the fracture zone based on the position of the key stratum, the isolated layer and safety of grouting were ensured. Especially under the guidance of the full-stratigraphy academic thought, in the condition of thin bedrock and thick unconsolidated layer, the overburden structure shifts from the key stratum of the bedrock to the arch structure of the unconsolidated layer, the grouting layer of overburden isolated grouting has evolved from the bedrock to the bottom boundary of the unconsolidated layer, and practical innovations have been achieved. Focusing on the key technical issues of filling volume and grouting-to-mining ratio, the theory clarifies the process from solid slurry to liquid slurry and then to compacted consolidation of filling materials, and determines the spatial trapezoidal state of the filling body based on the movement law of strata. A formula for calculating the grouting-to-mining ratio considering rock mass expansion and surface subsidence is proposed, fundamentally answering the questions of how much can be grouted and how much needs to be grouted, and completely overturning the cognition of estimating the filling volume based on the bedding separation volume. Furthermore, a grouting control technology centered on grouting-to-mining matching is proposed, transforming compaction grouting into controllable guided grouting, ensuring the subsidence reduction effect from the source. Coupled with a series of design methods for grouting borehole layout and the application of monitoring and regulation of parameters such as grouting pressure, density, and flow rate, the long-term healthy operation of grouting through boreholes in the mining-induced black box strata and the stability of surface subsidence control effects have been achieved. Supported by a series of theories and key technologies, overburden isolated grouting has increased the grouting-to-mining ratio to over 50%, and controlled the surface subsidence coefficient below 0.1, meeting the requirements for buildings protection. It has achieved the mining without relocation of villages (subsidence reduction), the comprehensive utilization of millions of tons of coal-based solid waste (emission reduction), the protection of aquifers (leakage reduction), and the prevention of mine earthquakes (vibration reduction). The development direction is to address the shortage of solid waste filling materials in coal mines and the “dual carbon” goals by using CO2 as grouting material to achieve the “one injection, five reductions” effect of subsidence reduction, emission reduction, leakage reduction, vibration reduction, and carbon reduction, and realize green mining and low-carbon utilization of coal resources.

     

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