Feart 11 1196898
Feart 11 1196898
KEYWORDS
1 Introduction
With the decrease in the shallow coal seam, coal mining has begun to move to deep
mining (Chun et al., 2023) and the mine environment will certainly become more
complex. The environment of the deep roadway excavation face is very complex, has
high ground pressure (Fan et al., 2019) (Liang et al., 2022) (Fan et al., 2020a), high
ground temperature (Zhang et al., 2017), high gas (Fan et al., 2020b), high confined
water (Guo et al., 2019), and soft rock, and other disasters are full of roadway. The
traditional roadway excavation construction technology has not been well qualified for
the excavation work under complex geological conditions in deep mines (Yuan and
Zhang, 2023). The excavation construction technology of the mining industry needs to
2.2 TBM technical problems The roadway of the Gaojiapu Coal Mine was designed to have four
main roadways in the east and west areas, respectively. The length of
The Gaojiapu Coal Mine has the characteristics of complex roadway development in the east area was 30,000 m, the length of
geological conditions and multiple coupling of disasters. The roadway development in the west area was 31,800 m, and the length of
following problems need to be considered when using the open the unexplored roadway in the east and west areas was 56,930 m. In
TBM in this mine. summary, the Gaojiapu Coal Mine has the characteristics of long
roadway distance, large excavation workload, and large amount of
(1) The roadway space is limited, and the open TBM has problems waste slag. However, the open TBM is comprehensive equipment that
such as difficult entry, difficult loading and unloading, and integrates multiple technologies and can quickly complete rock
difficult turning. breaking, support, slag removal, and other operations. The amount
of roadway development in the Gaojiapu Coal Mine is large, and the
The Gaojiapu Coal Mine has the characteristics of large coal seam open TBM will produce a large amount of waste slag and congest the
depth, small roadway section, and limited roadway space. In addition, road during the construction process, resulting in the difficulty of the
the size of the auxiliary shaft cage in the Gaojiapu Coal Mine is 5.8 m open TBM advancement. In addition, the Gaojiapu Mine has soft strata
long, 2.5 m wide, and 3.8 m high. The maximum lifting load of the cage and the open TBM in the construction process will inevitably encounter
is only 37 t. The size of the flat car in the roadway of the mine is 4.5 m roof fall, spalling, and other emergencies, making the waste slag directly
long and 1.8 m wide, and the maximum bearing capacity is only 40 t. fall on the main beam of the open TBM or through the finger shield gap
Because the existing open TBM systems and their supporting to the main beam. As a result, the accumulation of waste slag in the
equipment have the disadvantages of large size, weight, and turning inner cavity of the main beam affects the normal operation of the belt
radius, and high difficulty in loading and unloading in the mine, it is not conveyor. In severe cases, it will squeeze the main beam to produce
suitable for direct use in the Gaojiapu Coal Mine. If it is put into the deformation and damage the main beam structure. Therefore, the open
Gaojiapu Coal Mine without technical improvement, there will be TBM used in the Gaojiapu Coal Mine must have the function of rapid
problems such as difficult entry, difficult loading and unloading, and slag removal; otherwise, a large amount of waste accumulation will
difficult turning. Therefore, in order to solve the aforementioned inevitably affect the normal operation of the TBM.
problems, it is necessary to simplify the existing open TBM system
and supporting equipment in the market so that the open TBM can
better adapt to the working environment of the Gaojiapu Coal Mine. 3 Improvement of the open TBM
system and supporting equipment
(2) The lithology changes greatly, the roadway formation is poor,
and the open TBM has problems such as untimely support and Usually the TBM consists of systems for excavation, support, slag
easy jamming. discharge, ventilation, dust removal, anti-impact, explosion-proof, and
other systems (Zhang et al., 2021) and is equipped with a cutterhead,
The stratum structure of the Gaojiapu Coal Mine is complex and main drive, shield, gripper, trailer, and other supporting equipment
changeable. The open TBM excavation inevitably passes through soft (Wang et al., 2014). Due to the complexity of the open TBM system and
strata such as sandstone, sandy mudstone, and coal seam. When the supporting equipment, it is easy to cause the disadvantages of large size,
open TBM passes through the soft strata, due to the soft rock strata of weight, and turning radius, which is not suitable for the Gaojiapu Coal
the roof and floor of the roadway and the excessive deformation of the Mine with a small roadway section and limited roadway space.
surrounding rock, it is prone to collapse accidents such as roof fall and Therefore, the Shaanxi Zhengtong Coal Industry is based on the
spalling, which leads to open TBM jamming (Ding et al., 2022a; Fan existing open TBM; combined with the actual working environment
et al., 2021; Chen et al., 2014; Ding et al., 2022b; Liu et al., 2019; Ma of the Gaojiapu Mine, the existing open TBM is improved to better
et al., 2022). In order to solve the problem of TBM jamming, the adapt to the actual working environment of the Gaojiapu Mine.
existing open TBM generally installs a shield device to reduce the
TBM jamming problem through the protective effect of the shield.
However, some of the existing shields cannot freely expand and 3.1 Streamlined open TBM system and
contract, and other expansion ranges are limited, which cannot supporting equipment
play a supporting role in time and effectively when the weak
surrounding rock is broken. In addition, the existing support In order to solve the problems of difficult entry, difficult loading
technology of the open TBM needs to be supported manually, and unloading, and difficult turning of the open TBM, first, the open
which has the disadvantages of slow support speed and high risk TBM system and supporting equipment were simplified, and then, the
(Song et al., 2023) (Chen et al., 2022). If the open TBM is not redundant rear-supporting trailer was removed. Only four trailers
supported in time, it will seriously threaten the safety of staff and were retained, and each trailer was connected by the universal joint.
equipment. Therefore, the open TBM used in the Gaojiapu Coal Mine The first trailer was equipped with automatic jumbolters to anchor the
needs to have the functions of timely support and preventing monorail suspension equipment, and the idle position could be used
equipment jamming. to stack materials; the second trailer was equipped with a cooler and
dust collector; the third trailer was equipped with a dust collector, a
(3) The excavation distance of the roadway is long, the amount of fan, and a wind storage tube, and a position reserved for the auxiliary
waste slag is large, and the open TBM has the problem of gripper. On both sides of the fourth trailer, jumbolters were installed
untimely slag removal. as the bottom angle support rigs, which are responsible for 1–2 bolts
FIGURE 2
Automatic correction device.
FIGURE 3
Unsimplified open TBM.
below the waist line. Second, according to the actual situation of the determined according to the size of the cage. The assembly method of
mine, the connection bridge and sprayed concrete system in the the pulley was relatively simple. It only needed to be hoisted to the
supporting equipment were canceled (practice found that it was not monorail crane beam and then connected with the ball hinge, without
necessary). Third, an automatic correction device was added to the the need for a cumbersome assembly and splicing. Each pulley was
first wheel of each trailer (Figure 2). The automatic correction device equipped with independent pipelines and cables, which could be
can adjust the wheel direction of the trailer through the oil cylinder, quickly installed and evacuated by connecting pipelines and cables.
thereby assisting the TBM to successfully complete the turning work. This not only removes unnecessary devices in the open TBM system
Finally, 15 suspension vehicles were equipped on the open TBM, and and the supporting equipment but also reduces the assembly difficulty
some supporting systems and equipment were suspended on the right of the TBM system and supporting equipment. It also greatly reduces
monorail through the suspension vehicle. The size of each pulley was the workload of the assembly chamber layout and saved the
FIGURE 4
Simplified open TBM.
cutterhead was shortened (Figure 5), and then, the top part of
the shield was replaced with a finger shield capable of secondary
expansion (Figure 6). The finger shield can use the oil cylinder to
expand up and down, to achieve the purpose of timely support,
reducing TBM jamming and ensuring roof safety. Second, the
main beam of the open TBM was shortened to 14 m, and a
movable support platform was arranged on the upper part of the
main beam (Figure 7), which is not only conducive to the support
work of the open TBM but also reduces the turning radius of the
TBM. The specific methods are as follows: a large support
platform was set on the upper part of the main beam in front
of the gripper. The large support platform was welded by multiple
steel plates and steel frame structures, and the steel frame
structure was bolted to both sides of the main beam 1 and
fixed with the large support platform. A multi-level partition
support platform was arranged on the upper part of the main
beam behind the gripper. By setting up a large support platform
and a multi-level partition support platform, it is convenient for
workers to complete the support work on the support platform. A
propulsion cylinder was arranged under the large support
FIGURE 5
platform to push the support platform for displacement, and
Shortened shield. the maximum distance of the platform forward was 1.2 m. When
the TBM is excavating, by promoting the support platform, the
jumbolters on the platform were supported, and the two could
work together to improve the support efficiency. Third, eight
jumbolter systems were set up on the support platform of the
preparation time before the TBM work. Figures 3, 4 show the open TBM main beam (Figure 8), and the encoder was arranged
schematic diagrams of the open TBM system and supporting at the bottom of the jumbolter. In this way, it can not only
equipment before and after simplification. The total length of the support the top, shoulder, and two sides of the roadway
unsimplified open TBM is 167 m, and the total length of the simplified synchronously and quickly to significantly improve the
open TBM is only 75 m. support efficiency of open TBM but also accurately control the
jumbolter to support the bolt and anchor cable at the designated
position of the roadway surrounding rock to effectively improve
3.2 Improved open TBM support system and the safety factors of underground work. Finally, in order to save
supporting equipment manpower and improve the safety factors of underground work,
the jumbolter was installed at the bottom of the fourth trailer to
In order to solve the problems of untimely support and support the bolt and anchor cable at the bottom of the roadway to
jamming of the open TBM shield when the surrounding rock increase the support strength of the roadway and improve its
is broken, first, the length of the shield connected to the safety.
FIGURE 6
Scalable finger shield.
FIGURE 7
Supporting platform.
3.3 Improved open TBM slag discharge TBM to further clean up the falling rocks on the road. Third,
system and supporting equipment multiple circular holes were added to the main beam of the open
TBM (Figure 10). The belt conveyor was directly below the
In order to solve the problem of untimely cleaning of waste circular holes to facilitate the timely cleaning of the waste
slag by the open TBM, first, a slag cleaning bucket wheel machine slag. Each circular hole was equipped with a corresponding
with a speed of 1r/min was set between the open TBM main beam cover, which can be sealed when not in use to maintain the
and the first trailer (Figure 9), which is used to clean up the waste internal ventilation of the main beam. This not only facilitates the
slag on the track in front of the trailer and transport it to the belt cleaning and maintenance of the internal equipment of the main
conveyor. The slag cleaning bucket wheel machine could be lifted beam but also reduces the weight of the main beam and saves the
by a lifting cylinder up to 300 mm. Second, the slag-skimming manpower and material resources consumed in the assembly. It
device was installed on the second wheel of the four trailers of the can also stack materials on the circular holes after the upper cover
FIGURE 8
Jumbolter layout.
FIGURE 9
Slag cleaning bucket wheel machine.
of the main beam to improve the space utilization rate. The problem of waste slag accumulation on the main beam, four
specific practices are as follows: Figure 10 shows that the main circular holes 1–4 were arranged on the main beam 1, in which
beam was designed as a split structure, and the main beam 1 was the circular holes 3 and 4 were located directly below the circular
connected to the main beam 2 by bolts. In order to solve the holes 1 and 2, respectively, and the main beam 1 was penetrated.
FIGURE 10
Main beam with circular holes.
FIGURE 11
Main beam reserved for the slag collecting port.
There were six circular holes 5–10 on the main beam 2, in which had corresponding covers, which were connected with circular
the circular holes 8–10 were located directly behind the circular holes by hinges. Figure 11 shows that circular holes 1 and 2 are
holes 5–7, and the main beam 2 was penetrated. All circular holes used to collect automatically dropped waste slag or manually
A: rock roadway general excavation; B: rock roadway comprehensive excavation; C: open TBM.
clean the waste slag to the hole, and then let the waste slag pass TBM according to the working conditions of the mining site is
through the main beam and fall on the belt from circular holes conducive to improving the adaptability of the open TBM to the
3 and 4. In addition, the lower circular holes 3 and 4 can also be environment of the roadway excavation face.
used to repair the equipment in the main beam and clean up the
waste slag falling into the main beam. Side circular holes 5–10 are
also used to repair the piece of equipment in the main beam and 5 Conclusion
clean up the waste. Finally, a slag-cleaning guide plate device was
set up on the upper part of the main beam of the open TBM, (1) By removing the redundant rear-supporting trailer and
which can automatically collect the falling waste slag from the installing the automatic correction device on the wheels of
finger shield gap. the remaining trailer, the problems of difficult entry, difficult
loading and unloading, and difficult turning of the open TBM
can be solved.
4 Engineering practice application (2) By improving the open TBM shield, shortening the main beam
effects and arranging the mobile support platform on the main beam,
and then setting the anchor jumbolter system on the support
Table 1 is the statistical table of the footage level after different platform, the problems of untimely support and easy jamming
excavation–construction techniques are adopted in the Gaojiapu of the open TBM can be solved.
Coal Mine from January to August 2021. Table 1 shows that the (3) By opening circular holes on the main beam of the open TBM,
total amount of the footage level of different tunneling installing a slag-cleaning guide plate, and adding a slag-cleaning
construction technologies is in the order of the open TBM > bucket wheel machine between the main beam and the trailer,
rock roadway comprehensive excavation > rock roadway general the problem of untimely slag cleaning of the open TBM can be
excavation. According to the calculation of actual working solved.
months, it is found that the monthly average footage level of (4) Compared with the ordinary excavation construction
rock roadway general excavation and rock roadway technology, the improved open TBM can well adapt to the
comprehensive excavation is 79.17 m and 187.71 m, environment of the excavation face and significantly improve
respectively. However, after the construction of the improved the tunneling speed, which can alleviate the tension of the mine
open TBM, the monthly average footage level is as high as production connection.
300.88 m. In addition, after further detailed calculation, it is
found that the average daily footage levels of rock roadway
general excavation and rock roadway comprehensive Data availability statement
excavation are 2.62 m and 6.24 m, respectively, while the
average daily footage level is 9.91 m after the improved open The original contributions presented in the study are included in
TBM construction. Compared with rock roadway general the article/Supplementary Material; further inquiries can be directed
excavation and rock roadway comprehensive excavation, the to the corresponding author.
monthly average footage level of the open TBM is nearly four
times (3.8 times) and nearly two times (1.6 times) the
construction speed of rock roadway general excavation and Author contributions
rock roadway comprehensive excavation, respectively. This
shows that the improved open TBM in the Gaojiapu Coal YL: conceptualization, supervision, and writing—original draft. DR:
Mine can adapt well to the environment of the roadway methodology, writing—review and editing, and data curation. CZ:
excavation face, significantly improve the excavation speed, validation, resources, investigation, and formal analysis. ZD and HQ:
and effectively alleviate the tension of production connection validation and formal analysis. CL: review and editing. All authors
in the Gaojiapu Coal Mine. It also shows that improving the open contributed to the article and approved the submitted version.
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