A quick-setting thin-film spray support material for mining, its preparation method, application, and spraying equipment.

Abstract

This invention relates to the field of mine roadway support preparation, specifically disclosing a mine-use rapid-setting thin-spray support material, its preparation method, application, and spraying equipment. It includes combination A and combination B. Combination A comprises sulfoaluminate binder, VAE emulsion, and water, while combination B comprises gypsum and silicate solution. The rapidly setting thin-spray support material designed here can solidify quickly during spraying, forming a support layer with a certain strength and flexibility in a very short time. This enables rapid support of the roadway, accelerating roadway support speed, shortening the construction cycle, improving roadway support efficiency, saving manpower and material resources, and reducing roadway support construction costs.

Description

Technical Field

[0001] This invention relates to the field of mine roadway support preparation, and in particular to a mine-use rapid-setting thin-spray support material, its preparation method, application, and spraying equipment. Background Technology

[0002] The geological conditions of coal mine tunneling faces are complex. Some tunnels have loose and easily broken rock strata on the roof and sides. During drilling and anchor bolt installation, mechanical vibration can easily cause the surrounding rock to break and fall, damaging the anchor bolt holes and making it difficult to support the surrounding rock of the tunnel. To address this, the current support method is to use concrete, anchor bolts and mesh, and then concrete support. The purpose of the initial shotcrete support is to reinforce the loose and easily broken rock strata. The shotcrete layer forms a continuous whole with the rock strata, thereby preventing it from breaking and falling due to external vibration, which is conducive to the drilling of anchor bolts. Currently, the primary shotcrete material is shotcrete, and dry shotcrete is used for construction. The construction equipment is inexpensive and easy to operate.

[0003] However, some shortcomings of shotcrete have been found in long-term application. First, the concrete material has a long curing time, and it takes a long time to reach the strength required for temporary support, resulting in a long construction cycle. Second, the hardened concrete material is brittle and cracks and breaks after being subjected to external forces, so it cannot play a good role in the initial spraying of temporary support. At the same time, the concrete spraying process generates a lot of dust pollution, which can easily lead to silicosis and affect the health of workers. In addition, the high rebound rate of the concrete spraying process can easily cause serious material waste, which in turn increases the overall construction cost. Summary of the Invention

[0004] The purpose of this invention is to provide a rapid-setting thin-film sprayed support material for mining, its preparation method, application, and spraying equipment. This aims to address several shortcomings of existing sprayed concrete technologies discovered during long-term application. Firstly, the concrete material has a long curing time, reaching the required strength for temporary support relatively slowly, resulting in a long construction cycle. Secondly, the hardened concrete material is brittle and prone to cracking and breakage under external forces, failing to effectively serve its purpose as initial temporary support. Furthermore, the spraying process generates significant dust pollution, potentially leading to silicosis and impacting worker health. Additionally, the high rebound rate during spraying results in substantial material waste, further increasing overall construction costs.

[0005] To achieve the above objectives, the present invention employs a mine-use rapid-setting thin-spray support material, comprising combination A and combination B. Combination A comprises sulfoaluminate binder, VAE emulsion and water, and combination B comprises gypsum and silicate solution.

[0006] The composition includes 50-70 parts of sulfoaluminate binder, 10-20 parts of VAE emulsion, 10-40 parts of water, 60-75 parts of gypsum, and 25-40 parts of silicate solution.

[0007] This invention also provides a method for preparing a quick-setting thin-film sprayed support material for mining, which is applied to the aforementioned quick-setting thin-film sprayed support material for mining, comprising the following steps:

[0008] The sulfoaluminate binder, VAE emulsion, and water are mixed and stirred for 3–5 minutes to obtain combination A.

[0009] Mix the gypsum and silicate solution and stir for 3-5 minutes to obtain combination B;

[0010] Finally, combination A and combination B are mixed and sprayed using a spraying device to obtain a fast-setting support material.

[0011] The mass ratio of combination A to combination B is 1:1 to 2.

[0012] The sulfoaluminate binder is one of sulfoaluminate cement or sulfoaluminate cement clinker.

[0013] The gypsum is either anhydrous gypsum or hemihydrate gypsum.

[0014] The silicate solution is one of potassium silicate solution, sodium silicate solution, or silica sol.

[0015] The glass transition temperature of the VAE emulsion is between 0 and 10°C.

[0016] The aforementioned rapid-setting thin-spray support material for mining is applied to surface spraying in mining applications.

[0017] The pneumatic dual-liquid spraying equipment includes a dual-tube spray gun, a first diaphragm pump, a second diaphragm pump, and a main body. The dual-tube spray gun is provided with a first liquid inlet and a second liquid inlet. The dual-tube spray gun can spray a mist in an atomized fan shape, and the atomized fan shape is mixed outside the gun. The outlet end of the first diaphragm pump is connected to a first high-pressure liquid outlet hose, and the first high-pressure liquid outlet hose is connected to the dual-tube spray gun and located at the first liquid inlet. The inlet end of the first diaphragm pump is connected to a first suction pipe, and one end of the first suction pipe is provided with a first distribution tank. The outlet end of the second diaphragm pump is connected to a second high-pressure liquid outlet hose, and the second high-pressure liquid outlet hose is connected to the dual-tube spray gun and located at the second liquid inlet. The inlet end of the second diaphragm pump is connected to a second suction pipe, and the other end of the second suction pipe is provided with a second distribution tank. The first diaphragm pump and the second diaphragm pump are respectively symmetrically arranged on the main body of the equipment.

[0018] This invention discloses a rapid-setting thin-film sprayed support material for mining, its preparation method, application, and spraying equipment. The material includes combination A and combination B. Combination A comprises sulfoaluminate binder, VAE emulsion, and water. Combination B comprises gypsum and silicate solution. This designed rapid-setting thin-film sprayed support material can solidify quickly during spraying, forming a support layer with certain strength and flexibility in a very short time. It can provide rapid support for roadways, accelerating roadway support speed, shortening the construction cycle, improving roadway support efficiency, saving manpower and material resources, and reducing roadway support construction costs. This effectively solves the problem of long-term application... During the process, several shortcomings of shotcrete were discovered. First, the concrete material has a long curing time, reaching the strength required for temporary support relatively slowly, resulting in a long construction cycle. Second, the hardened concrete material is quite brittle, and cracks and breaks after being subjected to external forces, failing to effectively serve its purpose as initial temporary support. Furthermore, the shotcrete process generates a large amount of dust pollution, which can easily lead to silicosis and affect the health of workers. Additionally, the high rebound rate during shotcrete application leads to significant material waste, further increasing overall construction costs. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a flowchart of the steps involved in preparing a rapid-setting thin-spray support material for mining according to the present invention.

[0021] Figure 2 This is a schematic diagram of the pneumatic dual-liquid spraying equipment in this invention.

[0022] 1-First dispensing bucket, 2-Second dispensing bucket, 3-First suction pipe, 4-Second suction pipe, 5-Second diaphragm pump, 6-First diaphragm pump, 7-Second high-pressure outlet hose, 8-First high-pressure outlet hose, 9-Dual-pipe spray gun, 10-Atomized fan-shaped spray. Detailed Implementation

[0023] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0024] Please see Figures 1-2 The present invention provides a quick-setting thin-spray support material for mining, comprising combination A and combination B. Combination A comprises sulfoaluminate binder, VAE emulsion and water, and combination B comprises gypsum and silicate solution.

[0025] The composition includes 50-70 parts of sulfoaluminate binder, 10-20 parts of VAE emulsion, 10-40 parts of water, 60-75 parts of gypsum, and 25-40 parts of silicate solution.

[0026] This invention also provides a method for preparing a quick-setting thin-film sprayed support material for mining, which is applied to the aforementioned quick-setting thin-film sprayed support material for mining, comprising the following steps:

[0027] The sulfoaluminate binder, VAE emulsion, and water are mixed and stirred for 3–5 minutes to obtain combination A.

[0028] Mix the gypsum and silicate solution and stir for 3-5 minutes to obtain combination B;

[0029] Finally, combination A and combination B are mixed and sprayed using a spraying device to obtain a fast-setting support material.

[0030] Furthermore, the sulfoaluminate binder is one of sulfoaluminate cement or sulfoaluminate cement clinker.

[0031] Furthermore, the gypsum is one of anhydrous gypsum or hemihydrate gypsum.

[0032] Furthermore, the silicate solution is one of potassium silicate solution, sodium silicate solution, or silica sol.

[0033] Furthermore, the glass transition temperature of the VAE emulsion is between 0 and 10°C.

[0034] Furthermore, the aforementioned rapid-setting thin-spray support material for mining is applied to surface spraying in mining applications.

[0035] Further, the pneumatic dual-liquid spraying equipment includes a dual-tube spray gun 9, a first diaphragm pump 6, a second diaphragm pump 5, and an equipment body. The dual-tube spray gun 9 is provided with a first liquid inlet and a second liquid inlet. The dual-tube spray gun 9 can spray a mist 10 in an atomized fan shape, and the atomized fan-shaped mist 10 is mixed outside the gun. The outlet end of the first diaphragm pump 6 is connected to a first high-pressure outlet hose 8, and the first high-pressure outlet hose 8 is connected to the dual-tube spray gun 9 and located at the first liquid inlet. The inlet end of the diaphragm pump 6 is connected to the first suction pipe 3, and one end of the first suction pipe 3 is provided with the first distribution tank 1. The outlet end of the second diaphragm pump 5 is connected to the second high-pressure outlet hose 7, and the second high-pressure outlet hose 7 is connected to the dual-pipe spray gun 9 and is located at the second inlet. The inlet end of the second diaphragm pump 5 is connected to the second suction pipe 4, and the other end of the second suction pipe 4 is provided with the second distribution tank 2. The first diaphragm pump 6 and the second diaphragm pump 5 are respectively symmetrically arranged on the equipment body.

[0036] In this invention, the first suction pipe 3 and the second suction pipe 4 are respectively inserted into the first distribution bucket 1 and the second distribution bucket 2 after being stirred by the pneumatic dual-liquid spraying equipment. The A combination and the B combination are atomized and sprayed in a fan shape by the two nozzles of the dual-pipe spray gun 9. The A combination and the B combination are mixed at high speed by the included angle formed by the two spray gun pipes of the dual-pipe spray gun 9 and then uniformly sprayed onto the surface of the surrounding rock of the tunnel, forming a 5-10 mm spray layer on the surface of the surrounding rock.

[0037] In summary, the present invention provides a mine-use rapid-setting thin-film sprayed support material, its preparation method, application, and spraying equipment. Compared with existing technologies, the rapid-setting sprayed support material of the present invention overcomes the shortcomings of shotcrete materials, such as slow hardening speed, high brittleness, thick spray layer, high pollution, and high rebound. While achieving rapid support for roadways, the material is environmentally friendly, requires less material, has high early strength, and possesses a certain degree of toughness without cracking. It can quickly provide support and load-bearing for loose and easily broken surrounding rock in roadways, improving construction efficiency and support safety. Furthermore, this rapid-setting sprayed support material has the characteristics of fast curing time, high early strength, low heat release, no rebound during spraying, no dripping, and thin spray layer. It can quickly and effectively seal loose and easily broken surrounding rock in roadways, providing rapid support and load-bearing for the surrounding rock, thereby improving roadway safety and construction efficiency.

[0038] In this invention, adjustments can be made according to actual site requirements and surrounding rock conditions. Specifically, the proportions of each component in the quick-setting sprayed support material, the selection of construction equipment, and parameters such as spraying pressure can be adjusted to achieve the best rapid support effect.

[0039] In this invention, embodiments relating to the combination A are also provided.

[0040] Furthermore, the A combination has the following eight embodiments,

[0041] The first embodiment consists of 50 parts of sulfoaluminate cement, 10 parts of VAE emulsion, and 40 parts of water.

[0042] The second embodiment consists of 50 parts of sulfoaluminate cement clinker, 10 parts of VAE emulsion, and 40 parts of water.

[0043] The third embodiment consists of 50 parts of sulfoaluminate cement, 20 parts of VAE emulsion, and 30 parts of water.

[0044] The fourth embodiment consists of 50 parts of sulfoaluminate cement clinker, 20 parts of VAE emulsion, and 30 parts of water.

[0045] The fifth embodiment consists of 50 parts of sulfoaluminate cement, 10 parts of VAE emulsion, and 20 parts of water.

[0046] The sixth embodiment consists of 70 parts of sulfoaluminate cement clinker, 10 parts of VAE emulsion, and 20 parts of water.

[0047] The seventh embodiment consists of 70 parts of sulfoaluminate cement, 20 parts of VAE emulsion, and 10 parts of water.

[0048] The eighth embodiment consists of 70 parts of sulfoaluminate cement clinker, 20 parts of VAE emulsion, and 10 parts of water; please refer to the table below for details.

[0049]

[0050]

[0051] In this invention, embodiments relating to the B combination are also provided.

[0052] Furthermore, the B combination has the following eight embodiments, wherein 60 parts of anhydrous gypsum and 40 parts of potassium silicate solution are the first embodiment;

[0053] The second embodiment contains 60 parts hemihydrate gypsum and 40 parts potassium silicate solution.

[0054] The third embodiment contains 60 parts of anhydrous gypsum and 40 parts of silica sol.

[0055] The fourth embodiment contains 60 parts hemihydrate gypsum and 40 parts silica sol.

[0056] The fifth embodiment contains 75 parts anhydrous gypsum and 25 parts potassium silicate solution.

[0057] The sixth embodiment contains 75 parts hemihydrate gypsum and 25 parts potassium silicate solution.

[0058] The seventh embodiment contains 75 parts anhydrous gypsum and 25 parts silica sol.

[0059] The eighth embodiment contains 75 parts hemihydrate gypsum and 25 parts silica sol; please refer to the table below for details.

[0060]

[0061] In this invention, various data regarding the use of the A combination and the B combination are also provided.

[0062] Furthermore, the specific data are provided in eight embodiments, wherein the initial setting time is 45s and the final setting time is 6min when the combination A is 50 parts and the combination B is 50 parts, the maximum reaction temperature is less than 35℃, the tensile strength is 1.9MPa, the compressive strength at 1h is 7MPa, and the compressive strength at 24h is 15MPa, which is the first embodiment.

[0063] The first embodiment has 50 parts of combination A and 50 parts of combination B, with an initial setting time of 38s, a final setting time of 5min, a maximum reaction temperature of less than 35℃, a tensile strength of 2.2MPa, a 1h compressive strength of 8MPa, and a 24h compressive strength of 19MPa.

[0064] The third embodiment has 50 parts of combination A and 50 parts of combination B, with an initial setting time of 42s, a final setting time of 6min, a maximum reaction temperature of less than 35℃, a tensile strength of 1.8MPa, a 1h compressive strength of 7MPa, and a 24h compressive strength of 16MPa.

[0065] The fourth embodiment has 50 parts of combination A and 50 parts of combination B, with an initial setting time of 36s, a final setting time of 6min, a maximum reaction temperature of less than 35℃, a tensile strength of 2.3MPa, a 1h compressive strength of 7MPa, and a 24h compressive strength of 18MPa.

[0066] The fifth embodiment has the following characteristics: Combination A consists of 33 parts and Combination B consists of 67 parts; the initial setting time is 20s, the final setting time is 3min, the maximum reaction temperature is less than 35℃, the tensile strength is 2.9MPa, the 1h compressive strength is 11MPa, and the 24h compressive strength is 20MPa.

[0067] The initial setting time is 25s when combination A is 33 parts and combination B is 67 parts, the final setting time is 4min, the maximum reaction temperature is less than 35℃, the tensile strength is 2.7MPa, the compressive strength at 1h is 9MPa, and the compressive strength at 24h is 18MPa, which is the sixth embodiment.

[0068] The initial setting time is 26s when combination A is 33 parts and combination B is 67 parts, the final setting time is 4min, the maximum reaction temperature is less than 35℃, the tensile strength is 2.5MPa, the compressive strength at 1h is 9MPa, and the compressive strength at 24h is 19MPa, which is the seventh embodiment.

[0069] The eighth embodiment has the following characteristics: Combination A consists of 33 parts and Combination B consists of 67 parts. The initial setting time is 21 seconds, the final setting time is 3 minutes, the maximum reaction temperature is less than 35°C, the tensile strength is 2.8 MPa, the compressive strength at 1 hour is 10 MPa, and the compressive strength at 24 hours is 20 MPa. For details, please refer to the table below.

[0070]

[0071]

[0072] The data above demonstrates that the rapid-setting thin-film sprayed support material of this invention possesses excellent mechanical properties. It forms a film quickly during spraying, exhibits rapid setting and early strength, and demonstrates good adhesion to the underlying rock wall. The material exhibits high strength and flexibility after film formation, making it resistant to cracking. It provides excellent reinforcement and support for loose and easily fractured surrounding rock, indicating that the rapid-setting thin-film sprayed support material of this invention can effectively and quickly provide support and load-bearing capacity for loose and easily fractured surrounding rock in roadways. This facilitates subsequent anchor bolt drilling, improving construction efficiency and support safety.

[0073] The above description discloses only one preferred embodiment of the present invention, and should not be construed as limiting the scope of the present invention. Those skilled in the art will understand that all or part of the processes of the above embodiments can be implemented, and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A mine-use rapid-setting thin-film sprayed support material, characterized in that, The mixture includes combination A and combination B, wherein the mass ratio of combination A to combination B is 1:1~2. Combination A includes sulfoaluminate binder, VAE emulsion and water. The sulfoaluminate binder is one of sulfoaluminate cement and sulfoaluminate cement clinker. Combination B includes gypsum and silicate solution. The silicate solution is one of potassium silicate solution, sodium silicate solution and silica sol. The composition includes 50-70 parts of sulfoaluminate binder, 10-20 parts of VAE emulsion, 10-40 parts of water, 60-75 parts of gypsum, and 25-40 parts of silicate solution.

2. A method for preparing a mine-use rapid-setting thin-film sprayed support material, applied to the mine-use rapid-setting thin-film sprayed support material as described in claim 1, characterized in that, Includes the following steps: Sulfoaluminate binder, VAE emulsion and water are mixed and stirred for 3-5 minutes to obtain combination A; Mix the gypsum and silicate solution and stir for 3-5 minutes to obtain combination B; Finally, combination A and combination B are mixed and sprayed using a spraying device to obtain a fast-setting support material.

3. The method for preparing a mine-use rapid-setting thin-spray support material as described in claim 2, characterized in that, The gypsum is one of anhydrous gypsum or hemihydrate gypsum.

4. The method for preparing a mine-use rapid-setting thin-spray support material as described in claim 3, characterized in that, The glass transition temperature of the VAE emulsion is 0~10℃.

5. The application of the mine rapid-setting thin-film sprayed support material as described in claim 1, characterized in that, The rapid-setting thin-spray support material for mining is applied to surface spraying in mining applications.

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