矿渣基胶凝材料充填配比响应面优化及工业应用研究

    Response Surface Optimization of Slag-based Cementitious Backfill Mix Ratio and Its Industrial Application

    • 摘要: 为降低煤矿充填开采成本,以山东省某矿综合机械化单元密实充填开采为背景,针对充填体28 d单轴抗压强度不低于4.5 MPa的设计要求,系统开展了矿粉替代水泥的配比优化研究。通过原材料特性试验与坍落度、单轴抗压强度试验,确定了料浆质量浓度(72%~76%)、矿粉掺量(占胶凝材料总质量,40%~60%)和胶矸比(胶凝材料质量与煤矸石质量比,0.20~0.24)的合理范围。基于响应面法设计27组配比试验,构建了充填体3、7、28 d单轴抗压强度的回归预测模型,解析了各因素间的交互作用规律。结果表明,矿粉最优掺量为50%,三因素对强度的增益存在协同增效窗口,并非线性叠加。综合技术与经济分析,确定最优配比:料浆质量浓度74%、矿粉掺量50%、胶矸比0.20、粉矸比(粉煤灰质量与矸石质量比)0.18。现场工业应用实测充填体28 d单轴抗压强度达5.92 MPa,满足设计要求;单位充填材料成本由71.42元/m3降至46.17元/m3,降幅达35%,年节约成本超400万元,同时实现了工业固废的资源化利用。

       

      Abstract: To reduce the cost of coal mine backfill mining, this study was conducted against the background of fully mechanized unit dense backfill mining at a mine in Shandong Province. Aiming at the design requirement that the 28-day uniaxial compressive strength (UCS) of the backfill should be no less than 4.5 MPa, a systematic investigation was carried out on the mix proportion optimization of slag powder replacing cement. Through raw material property tests, slump tests, and UCS tests, the reasonable ranges of the slurry mass concentration (72%~76%), slag powder content (percentage of the total mass of cementitious materials, i.e., cement + slag powder, 40%~60%), and binder-to-gangue ratio (mass ratio of cementitious materials to coal gangue, 0.20~0.24) were determined. Based on the response surface methodology (RSM), 27 sets of mix proportion experiments were designed. Regression prediction models for the UCS of the backfill at 3 days, 7 days, and 28 days were established, and the interaction effects among the factors were analyzed. The results showed that the optimal slag powder content was 50%, and the three factors exhibited a synergistic enhancement window for strength gain rather than a linear superposition. Through comprehensive technical and economic analysis, the optimal mix proportion was determined as follows: slurry mass concentration 74%, slag powder content 50%, binder-to-gangue ratio 0.20, and fly ash-to-gangue ratio (mass ratio of fly ash to coal gangue) 0.18. In field industrial application, the measured 28-day UCS of the backfill reached 5.92 MPa, satisfying the design requirement. The unit cost of filling materials was reduced from 71.42CNY/m3to 46.17CNY/m3, a decrease of 35%, saving over 4 million yuan annually. Meanwhile, the resource utilization of industrial solid waste was realized.

       

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