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Analysis of Ultra-High-Reach Pumping Technology for Mining Wet-Spraying Bogies
Release time:
2026-04-09
Source:
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Summary:
During ultra-high-rise pumping operations, mine-used wet-mix shotcrete boom pumps face challenges such as high pumping pressure, severe pipeline wear, and a tendency for concrete segregation. However, through appropriate equipment configuration, process optimization, and operational control, these difficulties can be effectively mitigated, thereby ensuring the smooth execution of high-rise pumping operations.
I. Specialized Configuration of the Equipment System
High-pressure pumping system
The core of ultra-high-rise pumping lies in having sufficient pumping pressure and a stable hydraulic system.
A high-pressure pumping system shall be used, with pumping pressure sufficient to overcome the gravitational force acting on the concrete in vertical pipelines and the frictional resistance of the pipeline.
The hydraulic system must be stable and reliable; for example, it can be configured with an electro-hydraulic proportional relief valve and a high-pressure, high-flow variable-displacement pump to achieve electro-hydraulic proportional pressure control with no overflow losses, thereby reducing power loss and improving efficiency.
The pumping system should feature low energy consumption, high operational efficiency, a low failure rate, and few wear parts to ensure the stability of high-rise pumping.
High-Power Power System
Ultra-high-rise pumping operations are highly intensive and place stringent demands on equipment power.
High-power engines are typically required to provide sufficient power.
Depending on the specific operating conditions, a higher-power main motor may also be selected as the power source.
High-Efficiency Jetting Robotic Arm
High-rise operations place higher demands on the coverage and flexibility of robotic spray arms.
A multi-degree-of-freedom hydraulically driven spray boom shall be provided to enable the main boom to extend and retract, rotate, pitch, and perform grouting operations, thereby covering a wider working range.
The boom can be designed as a folding and telescoping structure to increase the working height.
II. Key Control Points in Pumping Operations
Pump Pressure Control
In ultra-high-rise pumping, control of pumping pressure is critical.
Pumping pressure must be precisely calculated and set based on pumping height, pipe diameter, concrete properties, and other factors to ensure smooth delivery of concrete to the designated elevation.
During the pumping process, the changes in working pressure should be monitored at all times and adjusted promptly. For example, the concrete outlet pressure of some wet-mix shotcrete boom trucks can reach 63bar。
Concrete Mix Proportion Optimization
The properties of concrete directly affect the effectiveness and success of pumping in super-tall buildings.
Concrete shall exhibit good pumpability, with its slump controlled within an appropriate range.
Optimize the aggregate gradation of concrete, control the maximum aggregate size, and ensure good cohesion and workability to reduce the risk of segregation and pipe blockage.
Precise addition of accelerating agent
The addition of accelerators has a significant impact on the early strength and rebound rate of shotcrete.
Screw-type rapid-setting agent pumps and other equipment shall be used, and Programmable Logic Controller Control is implemented to enable the accelerating agent to adjust its output flow proportionally and in synchronization with changes in the concrete flow rate.
The addition of the accelerating agent shall be continuously adjustable and capable of stepless regulation in accordance with the shotcrete output.
III. Optimized Layout of the Piping System
High-Pressure Piping Design
Ultra-high-rise pumping places extremely stringent demands on the pressure-bearing capacity and reliability of the conveying pipeline system.
High-pressure dedicated conveyance pipelines with high pressure-bearing capacity must be used.
Pipeline layout should be optimized by minimizing unnecessary bends and using large-radius bends to reduce pipeline resistance.
Multiple sets of three-way valves, safety valves, pressure sensors, and other devices can be installed in the conveying pipeline system to facilitate monitoring of the concrete pumping status, pipeline cleaning, and troubleshooting of pipe blockages.
Anti-blocking measures
Pipe blockage is a critical issue that must be rigorously prevented in ultra-high-rise pumping operations.
By optimizing the pumping system—such as upgrading the pump and refining the pipeline configuration—it is possible to achieve high pumping speeds while maintaining material versatility.
Hydraulic-driven equipment for wet-mix shotcrete rigs typically employs a hydraulic-cylinder–driven plunger-type concrete delivery pump to convey concrete, a system that features automatic overload protection and high reliability.
During the spraying process, if pipe blockage occurs, it must be addressed promptly: first shut off the high-pressure air supply and carefully control the nozzle to prevent residual air from causing injury; then use high-pressure air to thoroughly purge the spray hose.
IV. Operation and Safety Control
Intelligent Control System
Modern wet-mix shotcrete rigs for mining are typically equipped with intelligent control systems to enhance operational efficiency and safety.
Adopt Programmable Logic Controller (Programmable Logic Controller) performs intelligent control, such as precisely proportioning the addition of rapid-setting agents.
Electro-hydraulic control technology is employed to enable remote control and stepless remote adjustment of pumping capacity, among other functions.
Advanced equipment is also equipped with an arm collision-avoidance system that monitors the spray orientation of the boom to prevent collisions and interferences.
Remote Control Operating System
Operation is performed using a dual remote control system that supports both wired and wireless modes, offering flexible and convenient control. This allows operators to stay away from high-risk work areas, thereby enhancing safety.
Security Monitoring and Protection
The equipment shall feature robust braking performance, such as by incorporating a dual-circuit braking system to enhance braking reliability, or by being equipped with wet-disc axles and pressure-loss-protected brakes.
Operators must undergo training and pass the examination before being authorized to work.
During the spraying process, it is essential to continuously monitor changes in working pressure and make timely adjustments as needed.
V. Key Points for Maintenance and Upkeep
Hydraulic System Maintenance
The hydraulic system is the core of the wet-spray trolley and requires meticulous maintenance.
The hydraulic oil must be kept clean; regularly check the oil level and quality, and replace the oil as needed.
Regularly inspect all components of the hydraulic system to ensure there are no leaks and that it is operating properly.
Pumping System Inspection
Regularly inspect and maintain the pumping system, and promptly replace worn components such as the wear plate and cutting ring.
An automatic lubrication system is employed for the primary sealing areas, with automated control of grease quantity and injection timing to extend the service life of wear-prone components.
Pipeline System Maintenance
After each operation, the spray pipe must be thoroughly blown clean with high-pressure air, and the carriage and spray pipe should be washed with water if necessary.
Inspect the conveying pipelines regularly, and replace any severely worn sections promptly.
Conclusion
The safe and efficient ultra-high-rise pumping of mining wet-spray boom trucks is a systems engineering endeavor that requires close coordination among equipment, processes, operations, and maintenance. With technological advancements, intelligent remote control, more efficient pumping systems, and the trend toward larger-scale, specialized equipment will be key development directions for mining wet-spray boom trucks to achieve even greater pumping heights in the future.
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