千米竖井硬岩全断面掘进机凿井关键技术与研究路径探析

Analysis of key technology and research path of full section boring machine for 1 000 m vertical shaft with hard rock strata

  • 摘要: 机械破岩为代表的非爆破破岩技术是现阶段竖井凿井技术发展的重要方向,是解决现有钻孔爆破凿井井下作业人员多、工序复杂、职业伤害严重和环境污染等问题的可行技术途径。目前,已形成适用松软地层条件的竖井钻机钻井和适用井筒下部存在通道的反井钻机钻井,适用条件受到限制且未突破千米难关,竖井硬岩全断面掘进机凿井技术与装备依然处于研发起步阶段。竖井机械破岩凿井重大装备不仅是国家高端装备制造新兴产业发展的需求,也是千米竖井凿井技术变革的重要支撑。梳理了竖井掘进机发展历程与现状,分析了千米竖井多变地层稳定和高压涌水控制、坚硬岩石破碎、克服重力排渣、与支护相适应的井筒断面变化4个方面的难题,提出了地层预改性“干井掘进”、坚硬岩石“组合破岩”、克服重力“协同排渣”、掘-支协同“智能变径”等硬岩全断面掘进机凿井的核心功能需求。为满足复杂环境和工况下竖井掘进机高效可靠服役的需求,凝练了拟攻克的3个关键科学问题和8个关键技术问题,其中科学问题包括:1)基于千米地层原位状态探识的竖井掘进机凿井围岩分级理论,2)硬岩大断面多刀协同与射流辅助破岩机理,3)大直径破岩掘进面岩渣分布与运移规律及垂直输送机制;关键技术问题包括:1)千米地层原位探测、风险识别与改性技术,2)大断面硬岩镶齿滚刀-盘形滚刀联合与水射流辅助高效破岩技术,3)大直径刀盘机械与流体组合排渣技术,4)竖井掘进机姿态调控与整机集中控制技术,5)竖井掘进机系统耦合动力学分析及优化,6)时空关系协同的竖井掘进机掘进与地层改性平行作业,7)基于竖井掘进机凿井的井筒空间断面优化布置,8)竖井掘进机前置高韧性薄喷临时支护与掘-支协同永久支护技术。最后根据科学问题和技术问题,面向工程示范制定了5项攻关任务,包括:竖井掘进机凿井工艺及工程适应性,2)千米竖井地层原位精细化探测、岩性识别与地层预改性关键技术,3)千米竖井大体积破岩、垂直排渣与掘支协同关键技术,4)千米竖井硬岩全断面掘进机研制,5)千米级井筒竖井掘进机凿井工程示范,并明确了攻关任务之间的逻辑关系。基于以上内容,初步构建了千米竖井硬岩全断面掘进机凿井技术体系和研发路径,以期为我国千米竖井安全、高效、绿色、智能建设提供基础参考。

     

    Abstract: At present, the drilling and blasting method in vertical shaft sinking has many problems, such as too many workers required, complicated working procedures, serious occupational injury and environmental pollution. Mechanical rock breaking is non blasting rock breaking, which is an important development direction of shaft sinking technology. Currently, there are vertical drilling rig suitable for soft formation conditions and reverse drilling rig for a passage in the lower part of wellbore. Both technologies have limited applicability, and neither penetrates beyond 1 000 meters. The drilling technology and equipment of a full section boring machine for 1 000 m deep hard rock shaft are still in the initial stage of research and development. The hard rock full section boring machine for kilometer deep vertical shaft is not only the demand of national high end equipment manufacturing, but also an important support of a step change in kilometer deep shaft sinking technology. In this paper, the development course and the present situation of shaft boring machine are described. The paper analyzes four problems of hard rock full section boring machine, such as variable formation stability of kilometer deep shaft and control of high pressure water gushing, efficient crushing of hard rock, overcoming gravity slag discharge, and change of shaft section corresponding to support. The core functional requirements of hard rock full section boring machine are put forward, such as “dry shaft boring” of formation pre modification, “combined rock breaking” of hard rock, “cooperative slag discharge” of overcoming gravity, and “intelligent diameter changing” of excavation support. Three key scientific and eight key technical problems are summarized in view of the high efficiency and reliable service requirements of the shaft boring machine under complex environment and working conditions. Among them, the scientific problems include: ① The theory of surrounding rock classification based on the in situ exploration of kilometer deep strata;② The mechanism of rock fragmentation assisted by multi knife cooperation and jet flow in large section of hard rock;③ The distribution, migration and vertical transport mechanism of rock slag in large diameter rock fragmentation face. Key technical issues include: ① The kilometers formation in situ detection, risk identification and modification technology;② The big cross section hard rock with disc cutter hob combined with water jet assisted rock technology efficiently;③ The combination of big diameter cutter machinery and fluid slag discharge technology;④ The shaft machine attitude regulation and whole machine centralized control technology;⑤ The shaft machine system coupling dynamics analysis and optimization;⑥ The parallel operation of the boring and formation modification of the shaft boring machine based on the coordination of time and space relationship;⑦ The optimal layout of the spatial cross section of the shaft based on the boring of the shaft boring machine;⑧ The temporary support with high toughness and thin injection in front of the shaft boring machine and the collaborative permanent support with excavation support. Finally, according to the scientific and technical problems, five key tasks for engineering demonstration are formulated including:① Machine shaft sinking technology and engineering adaptability;② Kilometers shaft formation in situ detection, formation lithology recognition and modification of key technologies;③ The kilometers large volume of broken rock, vertical shaft discharge with digging the key technology;④ The development of kilometer deep full cross section hard rock shaft boring mathine completely;⑤ The engineering demonstration with shaft boring machine drilling, and clearing the logical relationship among the tasks. Based on the above mentioned, the shaft boring technological system, and research and development path for 1 000 m deep hard rock full section shaft boring machine are preliminarily formulated in order to provide a reference for the safe, efficient, green and intelligent construction of kilometer deep vertical shaft in China in the future.

     

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