金属矿深井充填系统的安全评价与失效控制方法研究
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摘要
基于人们对矿产资源的强烈需求和安全环保的开采理念,使得深部开采的基础和应用研究成了矿业科技进步的主要研究方向,国家自然科学基金重大项目课题—深部多相多场耦合作用及其灾害发生机理与防治(编号:50490274)就是由此原因提出的。该课题的启动,在对传统采矿工艺提出新要求的同时,也为传统工艺注入了新的活力,带来了新的发展契机,增加了新的研究内容。充填技术作为贵金属矿和难采矿床开采中的重要技术手段,不可避免地成了深井开采研究中具有重大理论和实用价值的研究对象。
鉴于目前我国矿山充填体质量难以保证、胶凝材料浪费严重、系统运行故障率高、充填事故频发以及对充填系统可靠性缺乏系统研究的现状。作者基于填充技术面临的问题,结合填充技术的研究现状,在参与国内多个矿山管道自流输送充填系统的技术改造基础上,应用安全系统工程理论、可靠性理论和模糊评判原理,完成了对管道自流输送充填系统的可靠性评价方法研究,提出了提高充填系统可靠性的策略。论文的主要研究内容和结论如下:
1、提出深部多场耦合作用下,开挖工程多因素安全评价方法,揭示充填系统可靠性与工程评价的关系。分级方法以国际认可的“DOW”法为纲,综合深部岩体多场耦合作用的研究成果、岩石和开挖工程分析测试成果、岩体稳定性分级方法中的Q法和RMR法,通过从宏观影响出发确定各因素的危险性取值和权重,得到了开挖工程的危险性评定指数。
2、建立深井充填系统评价的理论框架。以白银有色金属公司小铁山矿、湖北三鑫金铜股份公司和凤凰山铜矿充填试验研究为依据,从大量研究数据中揭示充填系统的内在规律,将深井充填系统层次划分为三个相互关联的层次,并确立层间和层内各要素的逻辑关系,揭示各层次部件的随机不确定性,阐明对系统应用可靠性理论评价的客观必要性,提出评价的方法和重点。
3、针对目前充填系统设计和评价中缺少目标失效概率的难题,结合长距离管道输送和油气管道系统的研究成果,将深井充填系统失效界定在可能发生到不可能发生之间,并提出以模糊综合评判方法计算不同系统的可接受失效概率的方法。应用FMEA、FTA、故障影响
For strong demand of mineral resources and through consideration of the safety and environmental protection during mining activities, fundamental and applied research topics toward deep-level ore deposits have become the active research directions to make progress in the mining science and technology. For this reason, the research project "Multi-Phase & Multi-Field Coupling and Disaster Mechanism and its Prevention in Deep Level Rock Mass (No. 50490274)" was brought forward and was supported as a key project by the national nature science fund. The investigation of this project will greatly influence on the traditional mining techniques and will produce a new demand and new progress to mining activities. Backfill is an important technology that is often used in noble metal mines and the mines of which ore deposits are difficult to exploitation. Therefore, the backfill technology becomes an important research topic and is very significant both in theory and application for deep level mining of ore bodies.However, there are many existing problems at present in the backfill technology in Chinese mines, such as low strength of filling mass, high consumption of cement material, poor reliability of the backfill system which causes many accidents. Meanwhile, few investigations were conducted by researchers in reliability of the backfill system. After considering the presented problems of the backfill technology and the research status in the area, and based on the data collected from many technical improvement cases of pipeline backfill system with gravity in Chinese mines, the author completed a series of reliability analysis and assessment for the pipeline system with gravity and put forward the correspondent strategies for improving the system reliability with the help of safety system engineering, theories of reliability and fuzzy evaluation approach. The main research contents and results in the dissertation are as follows:1. A complete risk assessment system considering multi-factors was put forward for evaluating the excavation engineering under deep level with multi-field coupling conditions and for explaining the relationship between the reliability and the backfill system. In the assessing process, the noble risk assessment system of DOW's Chemical Company was integrated with the existing research results in deep rock mass with multi-field coupling, the testing results in rock excavation engineering and Q method and RMR method in rock mass stability classifications. In the assessing system, risk assessment indexes of the underground excavation engineering were given by determining each hazard index and its weight in the model from considering macro reaction.
2. Based on the data collected from Xiaotieshan Mine of Baiyin Nonferrous Metals Corporation, Hubei Sanxin Gold & Copper Limited Company and Fenghuangshan Copper Mine, the theoretical framework for evaluation of a backfill system was established and the internal reaction regulations in the backfill system was discovered. A deep level backfill system is divided into three parts, and the connection among the parts and the logic relationship among all elements within each part are deduced. The objective necessary for evaluation of the system with reliability theory was addressed, and correspondingly the method and its emphasis for the evaluation of the backfill system were put forward.3. With reference of the research fruits of long distance slurry transportation system and oil-gas pipeline system, the deep level backfill system failure from possibility to impossibility was set up to resolve the presented puzzle that appears in the design and the evaluation of the backfill system. A method for calculation of fault probability in different backfill systems was brought forward with fuzzy comprehensive evaluation method. The logic relationships among the factors which influence on the deep level backfill system failure were established systematically, with the application of FMEA, FTA, fault effect propagation diagraph and fuzzy probability. It is shown that the main system failure reasons are the high frequency of filling process, bad quality of filling materials and slurry loss. The calculation of probability value of basic events has been conducted through the conversion from fuzzy probability estimation of basic event failure probability to probability estimation calculation. The quantitative puzzle is resolved without the failure database, the degree of reliability can be judged through the comparison of occurrence probability and project failure probability which are calculated by fault tree.4. The model for a pipeline backfill system has been established and analyzed, the utmost state function for bearing capacity has been established which is used for the analysis of failure possibility of the pipe. Hence it is concluded that residual head and slurry flow are the main factors which influence the reliability of deep level backfill system. The reliability analysis of in-service pipeline with defect which is a puzzle for years is resolved with the model for supply and demand. By analyzing the influence of density, concentration, flux of slurry on the effective slurry height of deep level pipe and by analyzing the effective mean value and standard value for slurry highness and the means of central-point method (mean value), that is Taylor series expansion method, the reliability of the designed pipe height can be calculated with the application of the reliability index as a result. It is demonstrated that the reliability of the system with 93% and 99% can be insured when the height of slurry is increased with 10 mm and 20 mm on the designed
height. However, the reliability with only 50% can be insured if the design is conducted under mean condition.5. The scheme for improving the backfill system reliability was based on the modifications in technology and filling material. In respect of the technology, variable diameter pipe for dissipated energy and isometric flow distribution technology which can improve the reliability of operation and the quality of the backfill material are recommended. In respect of the backfill materials, flocculants settlement approach was successfully conducted, and the quality of the filling materials is improved, and the improvement of dewatering effect is obtained. Applied multi-factor classification method, a solution to the subjective weight, objective weight and decision-making priority was found. The effect of the non-clinker blast furnace slag cementing material in the mining filling is good, which illustrates that the strategy method is correct, so more reliable cementing materials can be supplied to deep mines.
鉴于目前我国矿山充填体质量难以保证、胶凝材料浪费严重、系统运行故障率高、充填事故频发以及对充填系统可靠性缺乏系统研究的现状。作者基于填充技术面临的问题,结合填充技术的研究现状,在参与国内多个矿山管道自流输送充填系统的技术改造基础上,应用安全系统工程理论、可靠性理论和模糊评判原理,完成了对管道自流输送充填系统的可靠性评价方法研究,提出了提高充填系统可靠性的策略。论文的主要研究内容和结论如下:
1、提出深部多场耦合作用下,开挖工程多因素安全评价方法,揭示充填系统可靠性与工程评价的关系。分级方法以国际认可的“DOW”法为纲,综合深部岩体多场耦合作用的研究成果、岩石和开挖工程分析测试成果、岩体稳定性分级方法中的Q法和RMR法,通过从宏观影响出发确定各因素的危险性取值和权重,得到了开挖工程的危险性评定指数。
2、建立深井充填系统评价的理论框架。以白银有色金属公司小铁山矿、湖北三鑫金铜股份公司和凤凰山铜矿充填试验研究为依据,从大量研究数据中揭示充填系统的内在规律,将深井充填系统层次划分为三个相互关联的层次,并确立层间和层内各要素的逻辑关系,揭示各层次部件的随机不确定性,阐明对系统应用可靠性理论评价的客观必要性,提出评价的方法和重点。
3、针对目前充填系统设计和评价中缺少目标失效概率的难题,结合长距离管道输送和油气管道系统的研究成果,将深井充填系统失效界定在可能发生到不可能发生之间,并提出以模糊综合评判方法计算不同系统的可接受失效概率的方法。应用FMEA、FTA、故障影响
For strong demand of mineral resources and through consideration of the safety and environmental protection during mining activities, fundamental and applied research topics toward deep-level ore deposits have become the active research directions to make progress in the mining science and technology. For this reason, the research project "Multi-Phase & Multi-Field Coupling and Disaster Mechanism and its Prevention in Deep Level Rock Mass (No. 50490274)" was brought forward and was supported as a key project by the national nature science fund. The investigation of this project will greatly influence on the traditional mining techniques and will produce a new demand and new progress to mining activities. Backfill is an important technology that is often used in noble metal mines and the mines of which ore deposits are difficult to exploitation. Therefore, the backfill technology becomes an important research topic and is very significant both in theory and application for deep level mining of ore bodies.However, there are many existing problems at present in the backfill technology in Chinese mines, such as low strength of filling mass, high consumption of cement material, poor reliability of the backfill system which causes many accidents. Meanwhile, few investigations were conducted by researchers in reliability of the backfill system. After considering the presented problems of the backfill technology and the research status in the area, and based on the data collected from many technical improvement cases of pipeline backfill system with gravity in Chinese mines, the author completed a series of reliability analysis and assessment for the pipeline system with gravity and put forward the correspondent strategies for improving the system reliability with the help of safety system engineering, theories of reliability and fuzzy evaluation approach. The main research contents and results in the dissertation are as follows:1. A complete risk assessment system considering multi-factors was put forward for evaluating the excavation engineering under deep level with multi-field coupling conditions and for explaining the relationship between the reliability and the backfill system. In the assessing process, the noble risk assessment system of DOW's Chemical Company was integrated with the existing research results in deep rock mass with multi-field coupling, the testing results in rock excavation engineering and Q method and RMR method in rock mass stability classifications. In the assessing system, risk assessment indexes of the underground excavation engineering were given by determining each hazard index and its weight in the model from considering macro reaction.
2. Based on the data collected from Xiaotieshan Mine of Baiyin Nonferrous Metals Corporation, Hubei Sanxin Gold & Copper Limited Company and Fenghuangshan Copper Mine, the theoretical framework for evaluation of a backfill system was established and the internal reaction regulations in the backfill system was discovered. A deep level backfill system is divided into three parts, and the connection among the parts and the logic relationship among all elements within each part are deduced. The objective necessary for evaluation of the system with reliability theory was addressed, and correspondingly the method and its emphasis for the evaluation of the backfill system were put forward.3. With reference of the research fruits of long distance slurry transportation system and oil-gas pipeline system, the deep level backfill system failure from possibility to impossibility was set up to resolve the presented puzzle that appears in the design and the evaluation of the backfill system. A method for calculation of fault probability in different backfill systems was brought forward with fuzzy comprehensive evaluation method. The logic relationships among the factors which influence on the deep level backfill system failure were established systematically, with the application of FMEA, FTA, fault effect propagation diagraph and fuzzy probability. It is shown that the main system failure reasons are the high frequency of filling process, bad quality of filling materials and slurry loss. The calculation of probability value of basic events has been conducted through the conversion from fuzzy probability estimation of basic event failure probability to probability estimation calculation. The quantitative puzzle is resolved without the failure database, the degree of reliability can be judged through the comparison of occurrence probability and project failure probability which are calculated by fault tree.4. The model for a pipeline backfill system has been established and analyzed, the utmost state function for bearing capacity has been established which is used for the analysis of failure possibility of the pipe. Hence it is concluded that residual head and slurry flow are the main factors which influence the reliability of deep level backfill system. The reliability analysis of in-service pipeline with defect which is a puzzle for years is resolved with the model for supply and demand. By analyzing the influence of density, concentration, flux of slurry on the effective slurry height of deep level pipe and by analyzing the effective mean value and standard value for slurry highness and the means of central-point method (mean value), that is Taylor series expansion method, the reliability of the designed pipe height can be calculated with the application of the reliability index as a result. It is demonstrated that the reliability of the system with 93% and 99% can be insured when the height of slurry is increased with 10 mm and 20 mm on the designed
height. However, the reliability with only 50% can be insured if the design is conducted under mean condition.5. The scheme for improving the backfill system reliability was based on the modifications in technology and filling material. In respect of the technology, variable diameter pipe for dissipated energy and isometric flow distribution technology which can improve the reliability of operation and the quality of the backfill material are recommended. In respect of the backfill materials, flocculants settlement approach was successfully conducted, and the quality of the filling materials is improved, and the improvement of dewatering effect is obtained. Applied multi-factor classification method, a solution to the subjective weight, objective weight and decision-making priority was found. The effect of the non-clinker blast furnace slag cementing material in the mining filling is good, which illustrates that the strategy method is correct, so more reliable cementing materials can be supplied to deep mines.
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