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英文原文High performance longwall extraction in large depthH.C.WKnissel & H. MischoTechnical University of Clausthal, Institute for Mining, Clausthal-Zellerfeld, GermanyABSTRACT: Stagnation of coal prices to a low level on the international coal trading markets reduces profits and pressured the German hardcoal companies to reduce the mining costs by increasing of the face output and at the same time by reducing the numbers of working points. This concentration could be achieved by the insertion of high performance longwall operations.The success of longwall operations is.dependent upon key points like Geology, equipment and the mine layout. This paper discusses the definition of high performance longwall extraction in large depths and introduces the standard parameters of the equipment and the typical coefficients of these longwall operations as well.Keywords: high performance; longwall; large depth1 INTRODUCTIONThe economic conditions for the German hardcoal mining industry have changed significantly in recent years. The German hardcoal industry had until the early 1990s a secure selling market. The ,Jahrhundertvertrag” guaranteed the purchase of German hardcoal by heavy industry and steel and energy providers. In the last few years the development of the European Union and a sweeping liberalization of the energy markets lead to heavy European and international rivalry. This increasing competition, caused by the import of inexpensive hardcoal from overseas, pressured the German hardcoal industry to react. It was necessary to concentrate the extraction on the most profitable collieries and to excavate only the most suitable parts of the deposits. Until recently it was required to mine the entire deposit. Although the number the mining operations decreased from 147 in 1990 to 64 in 1997 a 56 % decrease, the coal output decreased by only 32 % to 47 mu, tons. This concentration will continue. Additionally, a reduction of the costs of production and an increase in productivity required thedevelopment of new and innovative techniques and face equipment. The goal of these developments is to compensate for the competitive disadvantage due to the great depth of the German hardcoal deposits with the most modern technology and mining methods.Hard coal mining in Germany is based on a century-old tradition. Figure 1 shows the German hardcoal basins.Even 500 years ago only the out-crop of the coal seams was mined. Since the mid-i 9th century, the Industrial Revolution and the resulting need for energy promoted the recovery of the deposits and the extraction in ever-increasing depths. Since 1920 the average mining depth has increased from 330 m to 648 m in 1959 and lies today at 1,006 m (1997). Some longwaU operations have reached depths of around 1,450 m.Figure 1: German hardcoal basinsFigure 2: Sinking of the seam-bearing strata in the Ruhr-area in the northern directionAn additional problem is the increasing coverage of the remaining hardcoal deposits. Figure 2 shows the sinking of the seam-bearing strata in the Ruhr-area in the northern direction.The new working areas and hardcoal mines, which open up the deposits in great depth, are attached without exception to the existing old coal mines. The main problem is to improve these existing mines, originally designed for much smaller working point capacity, to handle high performance longwall operations and to transport the entire conveyance discharge through the old mine to the coal preparation plant.2 HIGH PERFORMANCE LONGWALL OPERATIONSIn Germany the term “high performance longwall operation” is not clearly defined. Usually we describe it as the longwall which extract a net amount of over 16,000 t high quality coal per day. That means 30,000 t run-of-mine coal per day. These operations can be roughly described by the following simple guidelines (1). Net production (effective delivery):Over 16,000 t high quality coal from great depths 1,000m Gross Production (total delivery):Up to 1.6 times the net production, 30,000 t run-of-mine coal/d Face length:Up to 480 m (600 m are planned) Power consumption:Up to 4,500 kW at the longwall Working length:Several kilometers Area increment of face advance:Over 16 m2/min up to 25 m2/min Supporting Performance:At least 1.2 times the area increment of face advance, up to 30 m2/min Productivity in the longwall:Over 200 t v.F.IMS (European record: 452 t v.F./MS in Ensdorf Colliery) Goaf treatment:Roof-fall exploitation Development design:With parallel headings and inclinesIn order to integrate the high performance longwall operations in the existing collieries, it was necessary to carry out adaptation measures. The first measure was to optimize the development design and orientation of the new working areas and attached mines.2.1 Demands on the mine layoutThe great depth, in which the German hardcoal deposits lie, has a large influence on the mine layout. Each roadway must, therefore, be lined with extensive and expensive sliding roadway arch supports regardless if it is a main transport drift or only a short-term parallel gate. The construction costs reach up to DM 15,000 ($US 9,000 ) per meter roadway. Attempts to replace the sliding roadway arch supports with bolted supports or to develop the roadway in a rectangular rather than arch profile, did not achieve all desired results to stabilize the roadway or reduce the development costs.The mine layout connected to the high performance longwall must fulfill the following requirements:- Suitable infrastructure for the efficient transport of material to the longwall Short traveling time for the workers for a long effective working time Fast transport of workers with passenger lifts and belt riding Transport of large cross-sections, for example transport of complete shield units Efficient material transport, maximal 3 h from storage depot over the surface to the longwall- Suitable infrastructure for product extraction: Sufficient dimensional analysis of the belt conveyor If possible, inclines to avoid vertical conveyance If necessary, storage bunkers for homogenization of the conveyance discharge- Adequate ventilation area Control of the climatic conditions, for example formation and mining product temperature, waste heat of the mining machinery Control of the gas emission- Adequate energy supply Electrical energy Compressed air and hydraulics Water for cooling water, consolidation and nozzle reception Cooling capacity and air conditioningSince the above-mentioned requirements were, in many cases, taken into consideration in the planning and development of new fields and connecting mines, they are capable of economical and trouble-free high performance longwall operations today.dust consolidation and nozzle reception Cooling capacity and air conditioningSince the above-mentioned requirements were, in many cases, taken into consideration in the planning and development of new fields and connecting mines, they are capable of economical and trouble-free high performance longwall operations today.2.2 Connection of the high performance longwall to the mining layoutThe layout of the fields and the connection of the longwall operations to the mining layout is intimately associated with the development of the mining layout itself. The following requirements should, therefore, be considered (1):- Development of the connecting mine and the working areas in the coal seam with inclines even in great depth Delivery with belt conveyors: no junctions from horizontal to vertical haulage No junctions from horizontal to vertical haulage in transport and carriage roads- Parallel headings should be directly connected with a main deliveiy or transport road if possible Linear product extraction from the longwall Faster material transport to the longwall, reduction of the transport time Short travelling time, extension of the effective working time Short ventilation circuitsUnder certain circumstances a homogenization of the conveyance discharge may be necessary. In particular for the continuous operation of the small belt conveyors in the old parts of the mines and a continuous preparation in particular, a homogenous conveyance discharge is necessary.2.3 Design of the longwallIn order to operate high performance longwalls under the difficult geologic and climatic conditions prevalent in depths greater than 1,000 meters, aspecial longwall design is needed. These longwalLs are generally cut as retreating faces to the main haulage road. This has the advantage of obtaining information about the seam, for example coal gas content, before starting the excavation.With gas rich longwalls, in particular, a preliminary degassing can be undertaken before the extraction begins. Due to the high overburden pressure at great depths, a significant expenditure is necessary to prepare and maintain the parallel extraction and transport roads. To limit this expenditure the parallel gates are abandoned after passage of the face. There are no coordination problems between the longwall operation and the drifting as well, and there is no additional material handling in the parallel mining heading with building and support material. An additional argument for retreating longwalls is the shortening of the conveyance distance and the constant optimization of the conveyance over the running time of the working panel.Until the early l990s face lengths of only up to 270 m were technically possible and allowed at great depths. Today the new high performance longwalls are designed as double longwall systems with two 350 m face lengths or as single longwalls with up to480 m face lengths. Greater face lengths are not practical at this time because the layout of the face conveyor reaches its limits. At present the length of the face conveyor and the resulting vibrations create significant problems for durability. The maximal possible power consumption of the face conveyor limits the loading rate and, therewith, the total length of the face conveyor length of the escape way exceeds the regulated length. Another significant problem is the air cooling.The maximal seam pitch in the longwall is generally reported to be 40 gon. Steeper deposit sections are not suitable for economically profitable recovery using standing high performance longwall techniques. A gently declining mining direction through the strike has proven to be useful in increasing the stability of the wall and avoiding the flaking of the seam through the tipped coal face.2.4 Safety RegulationsDue to the slow escape speeds in the longwall, a long face increases the duration of a possible escape over the acceptable and allowed limits. In order to confront this problem several measures were implemented. Care was taken when selecting and constructing the individualshield supports in order to attain comfortable and sufficiently wide gangway. In addition it became necessary to equip the face workers with the most modern filter self-rescuers. These filter self-rescuers guarantee lower inhalation resistance at significantly reduced temperatures of the breathable air (65C). The organization of the escape routes was also reorganized. Medical examinations show that regular short pauses regulated by specially-trained escape leaders strongly reduce the physical burden of the individual miner during the escape without significantly increasing the escape time. Moreover, it may be necessary to employ selected, physically fit miners at steep faces. When calculating the length of the escape ways, according to the German hardcoal mining regulations, only the speed traveled by foot is taken into account. Passenger lifts, which would increase the escape speed and would usually be used, are not included in the calculation (2).The introduction of high performance longwall operations and the planning of overly long faces also creates new problems for explosion protection. The German hardcoal mining industry requires the erection of explosion water barriers with 200 1 water/rn2 roadway cross-section at 400 m intervals to extinguish the beginnings of methane gas explosions. These requirements are clearly exceeded by the introduced great face lengths with a distance of up to 120 m from the face end to the nearest barrier. Two different methods to meet the latent danger of a methane explosion were developed. The entrance of fresh air through the lower section of the shield column and the abandoned belt road is drastically reduced by consequent sealing of the gate end using Figure 3：GROUTING side packs and flue dust insertion piping for the prevention of air leakage in the abandoned workingsgrouting side packs and piping of flue dust against this grouting side pack. The goal is to reduce air leakage and to avoid the formation of an explosive gas mixture behind the shield column. Figure 3 shows the arrangement of the grouting side packs and flue dust in the abandoned workings.In order to limit the starting length of a methane explosion, a mobile explosion water barrier (Saar-Ex 2000) was developed. This system is based on the active Tremonia barriers which, sensor-controlled, produce and distribute a fine water mist throughout the roadway cross section before the explosion wave can continue. ThisSaar-Ex 2000 explosion water barrier reduces the distance fromthe face end to the first barrier to a constant 30 m.2.5 New developments of longwall techniquesThe desired high face output could not be achieved using the formerly applied face equipment. It was, therefore, necessary to modernize and, if need be, redevelop the individual components of the face equipment for the demands of a high performance longwall. (I)These demands to achieve a high face output are summarized as follows: High coal output of the longwall machine with a power consumption up to 500 kW per drum Application of point attack bits with a necessary high bit cutting depth of 8-10 cm even by lower drum rotational speeds; this is necessary for an effective reduction of the dust production Effective pie track flushing to avoid Hot-Spots and to consolidate the dust。 Large drum cutting depth, up to 1,000 mm Optimized drum loading capacity by the use of cowls and Globoid-drums High winning speed, speed over 13 mlmin needs a powerful wheel-rackatrack haulage system High technical availabilityThe shearer loaders SL from the company Eickhoff which fulfill the above-mentioned criteria, are most commonly used in German high performance longwall operations. It was then necessary to switch from the previously used I kVtechnology in the longwall, present in most mines, to a 3 or 5 kV power supply. Figure 4 shows a shearer loader SL.The armored flexible face conveyors in the longwall area were equipped to reach high chain speed and manage large loaded cross sections in order to handle the expected increase in tonnage.Much effort has been placed in the face support in order to continue the development of the longwall technique. The newly developed two-leg lemniscate powered face supports are used today without exception with the IFS (immediate forward support). The yield support resistances are suited for the high demands of great depths and amount up to 5,700 kN (yield load density of 600 kN/m2). An additional demand on the shield support was the necessity for high supporting performance of up to 30 m2/min in connection with short cycle times and quick roof support through the use of extensible canopies. The large cutting depth of the drum shearer requires a maximum advance distance for the shearer and the support of 1,200 mm. The operating range of this support should make heights of 1.80 to 4 m possible.In order to optimize the longwall face move, the transport dimensions and weight were limited to make complete transport under ground possible. Within the framework of the new developments in longwall techniques, the system width was increased from the customary spacing of 1.50 m to 1.75 m for the longwall conveyor as well as the shield support. This enlargement of the system width primarily serves the purpose of minimizing the number of possible trouble sources in the longwall.An analysis in the late-eighties and nineties showed that great expenditure was required to control the face-end zone and the belt entry. It was not possible to use the common face suport in the parallel mining roadways due to the lining of the mining parallel headings with TH-sliding roadway arches. Moreover, several meters between the parallel mining roadway and the first shield had to be built up conventionally using single legs and strike beams. Only after the development of the new face end shields and prop drawer shields for the parallel mining roadways was it possible to use high performance longwall technology to support the face end zone and the belt entry with modem powered supports (3).Figure 4: Shearer loader SL from EickhoffTo control the longwall face-end it was necessary to develop new power support systems as seen above. There was, however, no need for new side discharge technology. The direct side discharges used in the Ruhr area and the free side discharges with discharge pan used in the Saar area were able to handle even the great output of high performance longwalls.The DSK (Deutsche Steinkohle AG) has realized the above-mentioned concept in different high performance longwall operations. One of these operations is described below.3 HIGH PERFORMANCE LONGWALL EXTRACTION “LONG WALL 2000” AT THE ENSDORF COLLIERYThe Ensdorf colliery was one of the first to introduce high performance longwall operations to the German hardcoal mining industry in 1995 under the concept “Longwall 2000”. The goal of this trial was to install a longwall system that could guarantee the daily output of 12,000 t of the Ensdorf mine out of a single longwall. Based on the positive results, the idea was then taken over by the other mines in the Saar deposit.The Ensdorf colliery mines the northem section of the Saar hardcoal deposit on the Schwalbach coal seam (Coal seam 930) and the Wahlschied coal seam (Coal seam 950). The underlying Grangeleisen coal seam (Coal seam 970) is developed as a reserve. The mining done in this colliery, formed from the formerly independent Griesborn, Schwalbach and Ensdorf mines, concentrated on the southern deposits in shallow depths up to the 1950s. The mine concessions Ostfeld and Nordfeld were also mined later. Because the minable deposits were limited here, the Dilsburg field with the north shaft for material transport, man haulage and downcast ventilation shaft as well as the south upcast ventilation shaft were connected to the mining layout in the 1 970s with the main haulage road on the fourteenth floor. Today the Primsmulde field is joined with the Dilsburg field as an additional reserve.As can be seen in Figure 5, the Dilsburg field is developed with centered inclines and cross-cuts. The parallel mining headings are directly connected with the inclining main haulage roads. These transport requirements were ideally met using a suitable infrastructure for material transport and haulage. Both are processed over the Nordschacht. Using a powerful shaft haulage layout it was possible to transport complete shield units and machinery up to 35 tons, or up to 160 persons per haul. The travelling from the 201h level to the face entrance proceeds by belt riding over particular haulage and level belt conveyors under ground. Figure 6 shows the vertical sections of the mine. The bed inclination to the north is clearly recognizable.The material transport is processed over the 18th level. The pieces to be transported are transferred directly from the cage to the transport site using locomotive haulage. At this point the material is transferred to the flat top track cable ways which carries it to the longwall. These track cable ways can also be used for face moves and transport up to 3 complete shield units at a time. Ideally the material transport from the storage depot on the surface to the longwall can be completed in 2 hours. All roadways in the working panel must have a cross-section of 23.5 m2 to guarantee the necessary transport and ventilation diameters (4).The product transport from the parallel gate continues on the conveyor belts in the inclines. Using additional conveyor belts, the raw coal is raised to the 14th level and carried over a lateral road on the 14th level to the old Duhamel Collieiy. There it is raised through the Barbara drift over a length of 3.500 m and a vertical interval of 650 m to the surface. The material is then processed by the Duhamel shaft plant. Due to the generous design of the conveyor belts, at least 1,400 mm wide and a speed of up to 3.5 m/s, and a number of interposed field bunkers to homogenize the conveyance discharge, up to 3,200 t/h can be hauled to the surface. The total length of the conveyor belts connected in series amounts to up to 17 km. The use of conveyor belts to the surface enabled higher output than the discontinuous skip hoisting.Since the energy supply of the Dilsburg field comes through the Nordschacht, it was no problem to hang up the additional 5 kV lines needed for the high performance longwalls in the shaft.When planning the layout of the high performance longwalls, the double longwall systems tried and proved in Ensdorf were used. Figure 7 shows the layout for the first double longwall using the high performance longwall technique. It ran from the beginning of 1996 to the middle of 1997.When using the double longwall system, two longwall operations in neighboring panels are run simultaneously, using the same center gate. Both longwalls are layed out as retreating faces to the coal seam. The upper longwall hauls over the center gate, which also serves for ventilation and the lower longwall hauls over lower gate. The face length of the individual longwalls is 310 m, the panel length around 2,850 m. The direction of face advance is slightly inclined out of the drift into the dip in order to prevent the running out of the coal from the wall face. Fresh air flows in through the lower and the center gate. The upper gate serves as a return air road.Figure 5: Mine plan of the Ensdorf collieryFigure 6: Vertical section of the Ensdorf collieryFigure 7: Layout of the high performance longwall in the Ensdorf collieryThe Eickhoff SL 500 is used as the standard shearer loader. Figure 8 shows this shearer with labeled transport units.A total performance of 1,240 kW was installed in this shearer loader. Each drum has 500 kW (5kV) and each of the two winches has 60 kW (1kV) to its disposal. With a maximal speed of 13 mlmin during the extraction and a cutting depth of up to 1,000 nun for both Globoid drums, up to 39 m3 coal per minute can be extracted from a 3 m thick coal seam.To be able to extract these amount, a armored face chain conveyor RB 1000 280 V with a engagement width of 1,000 mm and a maximal drive power of 615 kW was installed in the longwall. The chain speed of the 34 x 102 double center chain can be increased to up to 1.61 mIs. In this case the speed had previously been restricted to 0.93 m/s. It was necessary to develop new racks to fulfill the input requirements of the wheel rackatrack system. The transfer to the 1,000 mm gate chain conveyor width with. a conveyor belt speed of 1.5 rn/s proceeds by the means of unbound side discharge. The conveyor hauls on a 1,200 mm wide conveyor belt, with a speed of 3.2 m/s, and a haulage capacity of 2,200 t/h, the limits of the capacity of the longwall system. Through the use of overhanged loading sections of the stage loader and belt storage, the shortening of the belts was no longer coupled with the face advance.The newly developed Saartech-Ecker Shield16 - 18/40 was introduced for face support. This shield support with its small transport height of1,650 mm, large operating range froml,800 to4,000 mm, and large support resistance of, 700 kN (507 kN on the front tip of the canopy and a load density of 574 kN/m2) corresponded exactly to the demands of a face support at great depths. Based on the modem concept of a carriage road shifted into the shield, a large support advance, and an earlier roof support through the use of forepole canopy, this shield type has proved to be useful for other new longwalls in the Saar area and worldwide. Figure 9 shows a cross-section of the longwall system. Clearly identifiable are the generous dimensions of the longwall as well as the operator friendly and safe Location of the carriage road in the shield.Figure 8: Shearer loader Eickhoff SL 500Figure 9: Cross-section of the Longwall 2000Figure 10: Longwall 2000Figure 10 takes a look into the longwall during the extraction. The size of this high performance longwall equipment is clearly seen when compared with the shearer operator.The shield column could be extended into the top as well as into the bottom road using the new gate shields first used in this double longwall. The personnel and time intensive conventional single leg support of the belt-entry could be forgone.For the continuous performance trials with these high performance longwalls in 1997, each individual longwall ran a daily output of over 18,500 t which corresponds to a gross output of about 27,000 t. The goal of guaranteeing a daily output of 12,000 t from a longwall was achieved. In the meantime, a record daily output of 23,700 t was set inEurope by the new panel 8.6 West on the Ensdorf colliery.4 OUTLOOKIn recent years, the German hardcoal industry has put great effort in attempting to provide a secure future for German coal in spite of significant competition from inexpensive coal importers. In particular, the introduction of the most modem extraction technology has allowed for reduction of production costs almost to the levels of the world markets. Due to the great depths of the deposits, special demands set put on the layout of the longwall operations and the development of newer equipment. The positive results from the introduction of the first high performance longwall operations in Germany have lead to the standard use of this technology for the extraction of deposits at very great depths. The constant development of the installed technology and the adaptation of the winning method to the particular demands of these depths increases the possibility for the German hardcoal industry to offer hardcoal to the German economy at competitive prices into the future.中文译文极深条件下的高效长壁采煤H.C.W.克尼希尔与H.密斯高（德国克劳斯茨尔矿业大学，克劳斯茨尔-策勒菲特尔矿业学院）摘要：国际煤炭交易市场上的煤炭价格在低水平上的低迷使得德国的硬煤生产企业利润减少，因此，这些企业不得不通过提高工作面的产出量，同时减少工作面的数量来降低开采成本。这种集约化生产可以通过引入高效长壁采煤法来实现。长壁采煤法的成功之处在于依靠了关键因素如地质条件、设备和采区布置。本论文论述的是在深井中使用高效长壁采煤法采煤，同时介绍设备的标准参数和长壁采煤工艺的系数。关键词：高效；长壁；极深1 概述德国硬煤采掘工业的经济条件最近几年有很明显的改变。1990年以前德国的硬煤采掘工业 有一个有保证的销售市场。“Jahrhundertvertrag”公司获得了重工业、钢铁行业以及能源供应商们的买单。最近几年欧盟的发展和能源市场的普遍自由化导致欧洲和世界范围内的竞争加剧。这种由于国外进口硬煤的价格低廉而使得激烈程度不断上升的竞争，迫使德国的硬煤工业予以回应。虽然煤炭企业的数量从1990年的147家减少到1997年的64家，降低了56%，但是煤炭的产出量此时减少了4 700万t，降低了32%。这种生产厂家的集中仍然会继续。另外，生产费用的降低和生产效率的提高要求采煤技术的创新和工作面的设备得到发展。这些发展的目标是补偿因为使用相当先进的现代技术和采煤方法所带来的竞争性的弊端。硬煤开采在德国已经具有百年的历史了。图1显示了德国的硬煤盆地。500年以前只有每层的露头部分进行开采。从19世纪中期开始，工业革命及其导致对能源的需求量使得储量的面积不断增加并且使得开采深度不断加深。从1920年开始，平均采掘深度已经从333m增加到1959年的648m，现今已达到1000m。一些长壁工作面的深度接近1450m。同时带来的一个问题就是不断增加的残留储量。图2显示了鲁尔工业区北部的煤层下沉状况。在深部储量上开设新的工业广场和煤矿，进行深部储量的开采，并和老煤矿来把运出的煤炭运到选煤厂。这里主要的问题是提高这些存在的起初是为小容量而设计的工作面来实现高效长壁工作面。图1 德国硬煤盆地图2 鲁尔区北部煤层的下沉状况2 高效长壁采煤作业在德语中，对于“高效长壁采煤法”没有明确的定义。通常我们这样来描述：该长壁工作面日净产量几乎在16 000 t高质量煤炭。这意味着预计原煤日产量将要达到30 000 t。这些方法可以用以下的简单指标来概述。l 净产量（有效产量）：从大于1000 m的极深条件下开采出16 000 t高品质煤l 总产量（总的产量）：约为于净产量的1.6倍l 日产30,000t原煤l 工作面长度：接近480 m（计划600 m）l 电力消耗：长壁工作面接近4,500 kWl 工作长度：数公里l 工作面推进空顶面积增量：约16 m2/min至25 m2/minl 支护能力：至少是工作面推进空顶面积增量的1.2倍，接近30 m2/minl 长壁工作面的生产率：大于200 t v.F./MS（欧洲纪录：Ensdorf矿的452 t v.F./MS）l 采空区处理：顶板垮落开采l 开拓设计：使用盘区巷道和斜巷为了在现有的矿井重引进高效长壁工作面，有必要采取一些修改措施。首先是要优化新工作面和附加矿井的开拓设计和新工作面的定位并于老矿井相联系。2.1 矿井设计的要求德国煤炭储量的埋藏的极深条件对煤矿的设计有很大的影响。因此，每条巷道，不管是运输大巷还是短期使用平巷都要用可延伸并且昂贵的巷道片帮拱形支护来建造。每米巷道的建造费用已接近15,000德国马克（9,000美元）。试图重置巷道片帮拱形支护或者将巷道建成矩形断面而不是拱形断面，都不会达到稳定巷道或者是减少建设费用等所有预期目的。与长壁工作面有关的煤矿设计需满足以下的要求：与长壁工作面有效的物料运输相适应的基础设施l 为长时间有效率的工作缩短工人的行走时间l 用运人机车和胶带运输快速运送工人l 大断面的运输，例如输送整套的支架设备l 高效的物料运输，从地表仓库到长壁工作面最长时间为3小时与采煤相适应的基础设施l 充分的输送胶带尺寸性分析l 如果可能，用斜面运输以避免垂直运输l 如果需要，贮料仓为运输卸货的单一化足够的通风区域l 气候环境的控制，例如采掘时岩层和采落煤炭的温度，采煤机的废热l 瓦斯泄漏的控制足够的能源供给l 电力l 高压气体和高压水l 冷却，降尘和疏通喷嘴所用的水l 制冷能力和空气调节一旦上述的要求都满足，很大的情况下，若今后要考虑设计和发展新的煤田和相联的矿井时，就可以将其设计成为有经济能力和没有困扰因素的高效长壁工作面。2.2 高效长壁工作面和采区设计的关系煤田设计和矿井长壁采煤方法设计的关系与采煤设计本身的发展有着紧密地联系。因此，以下的有求是必须考虑的（1）：极深条件下用斜井连接矿井和煤层工作面的进行开拓l 胶带输送机输送：从水平到立井没有交叉点l 从水平到立井的运输巷和轨巷没有交叉点可能的话，平行端头用运输大巷直接连接l 从长壁中一次性采出煤炭l 到长壁工作面更快的物料运输，以减少运输时间l 减少步行时间，延长有效工作时间l 减少通风环流在一定环境下，均衡运输量是很有必要的。特别要注意矿井中老区域的运输能力较小的胶带输送机的连续运行和准备，均衡运输量是必要的。2.3 长壁工作面的设计在超过1000 m的深度下，要在恶劣的地质和气候环境下实现高效长壁工作面采煤，就需要特殊的长壁工作面设计。这些长壁到运输大巷通常被分割为几个回采工作面。这样做的优点在于，在煤炭开采以前，就能知道煤层的状况。例如煤层瓦斯含量。富含瓦斯的长壁工作面，在开采以前可以进行瓦斯气体的释放。因为在极深条件下有着很大的地压。在回采巷道和运输巷道的准备和维护上需要一笔很大的费用来维持平行开采和运输巷道。为了减少这笔费用，采取平行顺槽在工作面采完后就报废。同时，在采煤和巷道掘进中没有协调的困难，而且在平巷中没有另外的支护材料。另外一个观点认为长壁工作面回采能减少运输距离和工作面搬迁时间。直到90年代早期，在极深条件下，技术上可行并且允许的工作面长度只是刚接近270 m。如今，新的高效长壁工作面已经被设计成350 m长的双长壁系统或者是接近480 m的单长壁系统。在这个时候，更长的工作面长度是不切实际的，因为工作面的设计运输能力已经达到了它的极限。现今工作面输送机的长度及其因此产生的震动给耐用性带来了一些问题。工作面输送机最大功耗限制了装载的速度，随其而来的是，工作面输送机的总长度和避灾路线的长度超出了规定的长度。另外一个显著的问题就是空气降温。通常认为长壁开采中最大倾角可以达到40。使用普通的高效长壁采煤方法开采极倾斜的煤层是不经济的。采掘方向向垮落方向略微倾斜，在增加煤壁的稳定性和避免煤炭在工作面前端垮落方面，这种方法被证明是很有用的。2.4 安全措施由于长壁的回采速度慢，在可允许和接受的限制内，使长壁工作面增加了可能撤离持续的时间。为了解决这个问题，很多方法已经实现了。要注意在选择和安设单个掩护支架时获得一个有效并且宽敞的通道。此外，给工作面人们配备了最先进的过滤自救器显得很有必要。这些过滤自救器降低吸气阻力，能显著降低可吸入空气的温度(65)。避灾路线也需要重新布置。医疗研究表明，在撤离时，由特别训练过的回采班的班长带领，进行有规律的短暂停顿可以明显减少单个矿工的体力负担，而不增加撤离时间。而且，在难采工作面选用精干的、体力充沛的矿工，也是很有必要的。根据德国硬煤安全规程，当预测回采巷道的长度时，只有步行的速度需要考虑。提高撤离速度并且通常会使用的人员机车运输速度不计算在内。 引入高效长壁采煤工序的和设置过多的长壁工作面也给隔爆水棚的保护带来许多的新问题。德国煤炭行业要求隔爆水棚的设置为每隔400 m，每平方米的巷道断面有200升的水来扑灭瓦斯气体的爆炸。引入长壁工作面后，从工作面到最近的水棚的距离约为120 m，明显超出了这些要求。因此发明了两种不同的方法用来解决瓦斯爆炸的隐患。使用灌浆侧部充填和烟道尘管道使得支架支柱低位处和报废胶带巷道的新鲜空气的进口明显减少。这样做的目的是减少空气的泄漏和避免掩护支架后的爆炸气体混合的形成。图3 显示的是在采空区用灌浆侧部充填和烟道尘管道的工序。图3 采空区灌浆侧部充填和烟道尘管道布置为了减少瓦斯爆炸的起始长度，发明了一种可移动的隔爆水棚（萨尔-Ex 2000）。这种系统的原型是Tremonia水棚，该水棚是用传感器控制，在爆炸气流开始以前，在整个巷道断面中产生并散布适量的水雾。这种萨尔-Ex 2000 隔爆水棚减少从工作面到最近的水棚的距离约30 m。2.5长壁采煤技术的新发展使用以往的工作面设备，高效工作面的预期产量无法实现，因此，有必要使工作面设备中单个组成部分现代化，需要的话使其更新换代，以满足高效工作面的需要。(1)这些为了实现高效工作面产量的要求总结如下：l 工作面采煤机煤炭的高产需要每个滚筒的功率约为500 kWl 使用点接触的截齿，其截深在滚筒低转速的情况下为8-10 cm，这对减少粉尘非常有效l 有效的轨道冲刷以减少热点并结固粉尘l 约1000 mm截深的大滚筒l 通过使用壳套和Globoid滚筒来优化滚筒的装载能力l 高速采煤速度，需要一个马力足够的齿轨牵引使机构速度超过13 m/minl 高度的技术可选性Eickhoff公司制造的满足上述要求的SL型滚筒采煤机，在德国高效长壁工作面中得到广泛使用，但必须将目前在大多数矿井的长壁工作面使用的1 kV动力源转变为3 kV或5 kV。图4显示的是SL型滚筒采煤机。图4 Eickhoff公司SL型滚筒采煤机在长壁工作面配备铠装可弯曲刮板输送机，可以提高链牵引速度并增大装载断面面积，以实现预期产量的增加。为了不断发展长壁采煤工艺，在工作面支护做出了很多的研究。现今使用的是新研究的没有及时向前临时支护的加强型工作面双腿铰接顶梁。掩护式液压支架的支撑力满足极深环境下的高要求，并可以达到5,700 kN（屈服载荷密度为600 kN/m2）。关系到缩短采煤循环的时间，还有必要使掩护式支架支撑能力达到30 m2/min，并用可延伸的前探顶梁加快顶板支护。采煤机滚筒的大截深要求给采煤机和支架提供一个最大的约为1,200 mm超前距离。这种支架的可伸缩高度范围应该在1.80 m至4 m。为了优化工作面的搬迁，输送机的尺寸和重量应限制在能进行地下整套搬迁的可能上。在长壁采煤工艺新发展的框架下，因为长壁输送机，同时也因为掩护式支架，系统的宽度由通常的1.50 m增加到1.70 m。系统宽度的增加是为了减少长壁工作面中困扰因素。80年代早期到90年代的分析表明工作面端头和胶带机平巷控制需要很高的费用。由于平行巷道的设置是用TH滑行拱支护的，在平巷中使用普通的工作面支架是不可能的。而且，平巷和第一个掩护支架之间的数米距离一般必须使用单体支架和破碎煤层来支护。只有新的工作面而且平巷中的支架准备完后，才有可能用先进的液压支架，运用高效长壁工作面工艺来支护工作面端头和胶带机平巷。（3）为了控制长壁工作面的端头，有必要研制上述的液压支护系统，但不需要新的侧部排料工艺。鲁尔区使用的正侧部排料和萨尔区使用的通过卸载溜槽进行自由排料都能实现高效长壁工作面的高产排料。DSK（Deutsche Steinkohle AG）已经认识到在不同的高校长壁采煤工艺的上述概念，以下叙述其中的一种。3 Ensdorf煤矿的高效长壁回采工作面“长壁2000”Ensdorf煤矿于1995年按照长壁20