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Journal of Loss Prevention in the Process Industries 46 (2017) 45e53

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Journal of Loss Prevention in the Process Industries

journal homepage: www.elsevier .com/locate/ j lp

Unsteady simulation for optimal arrangement of dedusting airduct incoal mine heading face

Guoqing Shi a, b, *, Maoxi Liu a, Zhixiong Guo b, **, Fangkun Hu a, Deming Wang a

a College of Safety Engineering, China University of Mine Technology, Jiangsu, 221008, Chinab Department of Mechanical and Aerospace Engineering, Rutgers, The State University of New Jersey, Piscataway, NJ 08854, USA

a r t i c l e i n f o

Article history:Received 2 November 2015Received in revised form3 November 2016Accepted 9 January 2017Available online 11 January 2017

Keywords:DedustingAirductVentilationHeading faceDust explosionATEX

* Corresponding author. College of Safety EngineerTechnology, Jiangsu, 221008, China.** Corresponding author. 98 Brett Road, Piscataway,

E-mail addresses: shiguoqing2001@163.com (G(Z. Guo).

http://dx.doi.org/10.1016/j.jlp.2017.01.0110950-4230/© 2017 Published by Elsevier Ltd.

a b s t r a c t

To optimize dedusting efficiency in coal mines, a model of dust movement in heading roadway with far-pressing-near-absorption ventilation system was built. The empirical drag force model was applied intothe unsteady inter phase coupling modeling of air and dust flow. The Discrete Phase Modeling in Fluentwas employed to solve the problem and unstructured grids were utilized to mesh the complex 3-Droadway with different airduct allocations. Results show that the dedusting efficiency with thededusting fan in the air return side is obviously better than that with the fan in the middle of the headingmachine. The dedusting efficiency decreases within creasing distance between air inlet and headingsection. When this distance is 2.0mwith airduct in the air return side, it has the best dedusting efficiency;in which the dust concentration in the front of roadway after 60 s of digging and cutting decreases from1150 mg/m3 to 365 mg/m3; the average dust concentration in roadway decreases from 597 mg/m3 to144 mg/m3; and the total dedusting efficiency reaches up to 75.88%.

© 2017 Published by Elsevier Ltd.

1. Introduction

Dust has become a serious problem in coal industry worldwide,causing pneumoconiosis in coal workers and coal dust explosionsin mines (Wang et al., 2017; Du et al., 2010). Themost common dustexplosion occurs in underground coal mines. In coal mine tunnel,coal dust explosion is usually caused by gas explosion. Moving atthe speed of sound, pressure wave resulting from gas explosion liftsthe deposited coal dust in the air. Then gas flame reaches the coaldust causing a dust explosion that is severer than the first one(Beidaghy Dizaji et al., 2014; Bidabadi et al., 2014a, b; Bidabadi et al.,2013; Soltaninejad et al., 2015). In China, over 85% of undergroundmines face the risk of coal dust explosions, and there were 103recorded coal dust explosion accidents in China between the yearsof 1949 and 2007, resulting in 4613 casualties (Zheng et al., 2009).Pneumoconiosis caused by dust threatens human health. Accordingto statistics, pneumoconiosis caused approximately 69,377 deathsamong U.S. underground coal mineworkers from 1970 to 2004, and

ing, China University of Mine

NJ 08854, USA.. Shi), guo@jove.rutgers.edu

over $39B was paid to compensate these workers (Colinet, 2010).Heading faces in underground coal mines possess the charac-

teristics of highly density of dust and relatively narrow space(Kissell, 2003; Qin et al., 2011). High concentration of dust affectsnormal operation because it may block workers’ sights, leading toaccidents. It may also cause dust explosion. How to effectivelycontrol coal mine dust has become a key issue (Wang et al., 2015).

Ventilation dedusting technology has been widely used for dustcontrolling. However, inproper dedusting may increase the risk ofdust explosion (ATEX 1999/92/EC, 1999; Going and Lombardo,2007; Robert Zalosh, 2015). During the dedusting process, localconcentration of dust may increase to a level higher than the lowerexplosion limit. Thus, it is critical to control ignition source toprevent dust explosion. Potential ignition sources in dedustinginclude static electricity caused by airduct, heat accumulation byrunning machine, etc.

Ignition sources can be present and active when combustibledusts are processed. These can be related to static electricity build-up and discharge, hot electrical and mechanical parts, sparksgenerated by electrical and non-electrical equipment, friction ef-fects of components. In order to minimize the occurrence and theeffectiveness of these ignition source, the dedusting system designshall be carried out in accordance with international ISO, IEC andEN standards covering ignition source control of ELECTRICAL and

Nomenclature

Ca Average dust concentration in roadway, kg/m3

CD Drag coefficientdP Diameter of particle,m

F!

Force, Ng! Vector of gravity, ms-2L Distance between the airflow inlet and the heading

section, mL1 Length of roadway,mL2 Distance between pressing airduct and the heading

section, mmtotal Total mass of dust produced by heading in roadway, kgP Pressure, N/m2

Re Reynolds numbert Time,su Velocity vector of air, m/suP Velocity vector of particle, m/suvw Velocity components, m/sV Volume, m3W Width of roadway, mx, y, z Coordinates, m

Greek symbolsm Kinetic viscosity of air, m2/sr Density of air in roadway, kg/m3rP Density of particle (skeletal density), kg/m3htotal Total dedusting efficiency

G. Shi et al. / Journal of Loss Prevention in the Process Industries 46 (2017) 45e5346

NON ELECTRICAL equipment.Airduct ventilation dedusting technology has been popularly

adopted for removing dust in coal mine heading face, and itsdedusting efficiency is significantly influenced by the location ofthe dedusting airduct. In order to design optimal processes fordedusting, dust concentration and its distribution for differentdedusting airduct allocations should be understood. CFD simula-tion techniques have the traits of light workload, short time-consumption, and highly repeatability. Compared with field mea-surement, the results of CFD simulation can reflect the movementprocess and distribution of dust intuitively and comprehensively.Wang et al. (2006, 2007) established the face model of coalroadway heading and compared the steady state distributions ofdust under the condition of forced ventilation and exhaust venti-lation. Ren and Balusu (2010) established a three-dimensional (3-D) model of coal face and researched on the movement and dis-tribution of dust in coal face. Wang et al. (2011) modeled a far-pressing-near-absorption ventilation heading face, compared thedistribution of steady state under different pressure extraction ra-tios, and specified the optimal pressure extraction ratio between 1.1and 1.3. CFD simulation techniques have avoided the limitations ofpoor lighting underground and difficult observation and beenwidely applied. Previous simulation of dust movement in headingface mainly assumed steady state, which could reflect the dustdistribution status after infinite longtime of working (Hu et al.,2012).

In fact, there is no steady distribution of dust in heading face,since digging and cutting process is always interrupted by workingcondition and driving procedure. Digging and cutting process willbe ceased before the distribution of dust concentration has reacheda steady state. Moreover, under complex ventilation conditions likefar-pressing-near-absorption ventilation, the airflow could beeasily interfered by moving items such as heading machine andother equipment, so that unsteady state physical phenomenon likeKarman vortex street flow is more suitable for dust simulation inheading face. Unsteady state simulation can intuitively reflect themovement history of dust and investigate the time developmentand distribution in addition to the three spatial dimensions (Huet al., 2013).

In this paper, we take the heading face scene of whole rock inTangshan Donghuan Coal Mine as an example to establish oursimulation model. Unsteady state model of far-pressing-near-absorption ventilation heading face is considered, and solved toinvestigate the history of movement and distribution of dust duringdigging and cutting process. This study aims to compare ventilatorarrangements for optimal dust prevention in far-pressing-near-

absorption heading roadway.

2. Far-pressing-near-absorption ventilation roadway model

2.1. Simulation model and meshing

Fig. 1(a) shows the simulation domain of a heading roadwaywithout dedusting fan. The dimension of the model is similar to theheading face scene of whole rock in Tangshan Donghuan Coal Mine,China. There are two common arrangements for dust-preventingabsorbing airduct: 1) the absorbing airduct is located in the mid-dle of roadway, as showed in Fig. 1(b); or 2) the absorbing airduct islocated on the air return side of roadway, as shown in Fig. 1(c). Wecompared the non-dedusting case (Fig. 1(a)) with 6 dedustingmodels via varying distance, L, between the airflow inlet(Inlet ofabsorbing airduct) and the heading section. For Fig. 1 (b) arrange-ment, L ¼ 2.0, 3.5, and 5.0 m, respectively; for Fig. 1 (c), L ¼ 2.0, 3.0,and 4.0 m, respectively. Other dimensions are defined as: L1 is thelength of roadway and its value is 50 m; the section is semi-archedwith the upper semi-circle's radius of 2.75 m and lower rectangle'sradius of 1.05 m; the body of heading machine is simplified as acuboid with outer dimensions of 10 m � 3.6 m � 1.8 m(length � width � height). Distance between the heading machineand the heading section is about 5 m.The pressing airduct withdiameter of 0.8 m is simplified as a hollow cylinder that is hangedon the side of roadway. Its distance from road floor is 2.5 m anddistance from side wall is 0.2 m. It exits at 7 m away from thesection (L2 in Fig. 1 (b)). The pressing airduct installed in the middle

Fig. 1. Heading roadway models of different airduct arrangements.

G. Shi et al. / Journal of Loss Prevention in the Process Industries 46 (2017) 45e53 47

of roadway is usually designed as a rectangle, with a size of1.2 m � 0.8 m (length � height); The size of the absorbing airductinstalled in the wide return side of roadway is same as the pressingairduct, i.e., 0.8 m in diameter. Its distance from roadway floor is2.5 m and from the side wall is 0.2 m.

Because of the irregularity and complexity of roadway, un-structured meshes were used to divide the 3-D simulation domain.The grid cells were designed as tetrahedral elements. To discuss theinfluence of meshes, we considered 5 different mesh densities, i.e.,522,479, 476,868, 390,336, 317,005, and 247,829 grid cells, respec-tively. Fig. 2 (a) and (b) show typical meshes (476,868 cells)generated on the roadway surface and inside, respectively; inwhich the biggest grid cell was 2.938609 � 10�2 m3, and thesmallest cell was 3.617841 � 10�5 m3.

2.2. Governing equations

During the digging and cutting process of a heading machine,the movement of dust with airflow is in unsteady state. Dusts aregenerated from the digging and cutting location and dispersed withairflow. Hence, dust moving state and concentration distributionchangewith time. The governing equations for transient airflow aredescribed by the Navier-Stokes equations as (Wang, 2004):

vðrÞvt

þ rV,ðuÞ ¼ 0 (1)

r

�vuvt

þ ðu,VÞu�

¼ �V,P þ m,�V2u

�þ r g! (2)

whereuis the velocity vector of air; mis the kinetic viscosity of air;risthe density of air;P is pressure; t is time; and g!is the vector ofgravity.

The continuous discrete interaction between airflow and dustparticles can be described through interphase force or drag force.Since the interaction between airflow and dust particles is rela-tively complicated, drag force between airflow and dust particles isusually calculated with an empirical model or semi-empiricalmodel (Wen and Yu, 1966; Huang et al., 2008; Kang and Guo,2006); in which, the motion of individual particles is completelydetermined by Newton's second law of motion. Force balanceequation of particles is (Wang, 2004; ANSYS Inc, 2013):

dup

dt¼ FD

�u� up

�þ g!�rp � r

�rp

þ F!

(3)

In which,FDðu� upÞ is the unit mass drag force of particles (ANSYSInc, 2013); F

!is the resultant force of other forces acting on dust

particles, which is neglected in the present study.upis the velocityvector of particles. rpis the density of particles (skeletal density).

Fig. 2. Typical unstructured meshes generated.

The expression of FD is:

FD ¼ 18mrPd

2P

CDRe24

(4)

In which, dP is the average diameter of particles; and Re is therelative Reynolds number, defined as (Wang, 2004):

Re ¼ rdp��up � u

��m

(5)

Drag coefficientCD is expressed as (Kang et al., 2008):

CD ¼24

�1þ 0:15Re0:687

�Re

0:43(6)

2.3. Boundary conditions

The following simplifications were assumed in establishing thepresent model.

(1) The influences of collision, bond and recrushing betweendust particles inflow field were ignored.

(2) The influence of temperature change in roadway wasignored.

(3) The dedusting fan could completely dispose the dust absor-bed in the airflow, and the fresh airflow in air outlet did notcontain dust.

This simulation was carried out by commercial software Fluentwith its Discrete Phase Model (DPM). The attributes of the DMP inthis study are described as follows. The entrance and exit ofventilator and the terminal export of the roadway are treated asEscape, and so as the solution domain of the dust's entering into theinlet of dedusting fan or free spreading out of terminal roadway.Heading machine, airduct, side wall and roof support are treated asReflect, in order to describe the continuous existence of dust in thesolution domain after the bounce of dust between the surface ofheading machine, airduct, side wall and roof support. There doesnot exist a trap wall surface in our simulation, i.e., the dust can onlyescape from the solution domain in two ways: being collected bythe exhaust inlet or freely flowing off the distal export of roadway.Thereby, the exhaust effect of dedusting fan under the single forcecan be fully investigated.

The time step used in the present unsteady solution was 0.05s.The explicit scheme in Fluent was adopted. Other calculation con-ditions are as follows: gravity is 9.8 m/s2; the compressed air vol-ume was 300 m3/min; the purity volume of dedusting fan was240 m3/min; and the mass flow of dust was 0.008 kg/s.

The study aims to simulate heading procedure, in which venti-lation equipment started before coal digging and cutting, then thedispersed phase of dust was introduced into the roadway airflow.Continuous phase and dispersed phase are constantly revisedduring the solving process. Iterative computations were precededuntil convergence in each time step.

3. Results and discussion

For mesh-independency test, the dust concentrations at loca-tions (0, 5, 0) and (0, 10, 0) and time instants of 12 and 24 s arecompared in Fig. 3 for the five different sets of meshes. It is seenthat increasing mesh density beyond 476,868 cells had little impacton the calculation. Therefore, the meshing scheme of 476,868 cells

200 250 300 350 400 450 500 550

0.0008

0.0012

0.0016

0.0020

0.0024

0.0028

0.0032

location (0,5,0), t=24s location (0,5,0), t=12s location (0,10,0), t=24s location(0,10,0), t=12s

Dus

t con

cent

ratio

n (k

g/m

3 )

Count of meshes (Thousand)

Fig. 3. Influence of grids on dust concentration.

G. Shi et al. / Journal of Loss Prevention in the Process Industries 46 (2017) 45e5348

was employed for all calculations thereafter.The velocity vector diagrams of airflow in the heading roadway

when the airduct is located at different positions are shown inFig. 4. It is seen that most airflow impacts the heading section inrelatively high speed after flowing out from the pressing airduct.Thereafter the air carried dust flow toward the rear of roadway viathe narrow space beside the heading machine with a rapid speed,and then the airflow speed decreases quickly. Meanwhile, thereexists a range of recirculating airflow in the front of roadway; itflows along the air return side of the roadway-top and in the rear ofheading machine-wind pressing side of the roadway.

Fig. 5 shows dust circulating history in the front of roadway.When the absorbing airduct is located in themiddle of roadway, thestrength of circulating airflow enhances significantly. The range ofcirculating airflow extends, so that more dust will accumulate nearthe headingmachine andmove through the location of the driver ofthe heading machine via the back and side. In such a situation, thehealth of the driver and normal operationwill be affected.Whereas,when the absorbing airduct is arranged in the air return side of theroadway, the strength of this circulating airflow weakens signifi-cantly. The volume of dust flowing through the driver is effectivelydecreased. It is evident that locating the absorbing airduct in the airreturn side is more beneficial to decrease the volume of dust

Fig. 4. Velocity vector diagrams of airflow

flowing through the driver.Fig. 6 compares air velocity vector and dust concentration pic-

tures between the absorbing airduct in the middle of roadway andon the air return side. From Fig. 6(a) and (c), we can find that thereis a vortex area generated between the heading section and theheading machine. Correspondingly, the dust concentration isgreater in the vortex area because of strong flow of air as shown inFig. 6(b) and (d).

Fig. 7 shows the dust movement history for different airductlocations. It is found that after the starting of dedusting fan, thedust concentration in the rear of roadway is evidently decreased ascompared with the case of no dedusting fan (Nie et al., 2011; Chenget al., 2011). The air after dust separation flowed towards the rearroadway at speed of 240 m3/min, it diluted the dust in the roadwayand carried dust towards further roadway at a relative high speed.On awhole, the dispersion of dust movement is accelerated and theconcentration of dust is significantly decreased.

From the comparison, it is evident that the position of airductaffects the dust movement pattern in the front of roadway. Whenthe absorbing airduct is located in the middle of roadway, the dustproduced by digging and cutting immediately moves towards theair return side under wind pressure and will not be collecteddirectly by the absorbing airduct. The intensification of circulatingairflow in the front makes the dust being collected by the absorbingairduct only after the circulation along the air return side, the top ofheadingmachine and the air pressing side. As shown in Fig. 7(bed),the air circulation causes relatively high concentration of dust nearthe heading machine. Moreover, with increasing distance L, theeffective suction distance will deviate further from the dust-produced position, i.e., the digging and cutting point. Therefore,just like the condition of no dedusting fan, dust concentration willincrease in the front of heading machine, and the dedusting wouldbe ineffective. Whereas, when the absorbing airduct is located inthe air return side of roadway, the circulating airflow on the top ofheading machine is effectively decreased, and the volume of dustthat moves towards the position of heading machine driver de-creases too. Most dust will enter the absorbing airduct along the airreturn side, which is beneficial for direct collection of dust. Thededusting effect is obviously better. Comparing the 7 cases in Fig. 7,the scenario shown in Fig. 7(e), when the absorbing airduct islocated in the air return side of roadway with L ¼ 2.0 m, illustratesminimum dust distribution in the roadway, and its environment isthe best.

with different airduct arrangements.

Fig. 5. Circulating history of dust in the front of roadway.

G. Shi et al. / Journal of Loss Prevention in the Process Industries 46 (2017) 45e53 49

Dedusting effect can be compared from two perspectives: one isthe variation of average dust concentration in different sections ofthe roadway and the other is the total dedusting efficiency in theroadway. Fig. 8 shows the histogram of the variation of average dustconcentration in different roadway sections, which reflect dustmovement and accumulation process in space and time. It is seenthat the average dust concentration in different roadway sectionsincreases with the extension of digging and cutting procedure.Without dedusting fan, lot of dust will move circularly in the frontof roadway; the dispersion process of dust towards the rearroadway is rather slow, resulting in relative high concentration ofdust in the front of heading roadway. After 60 s of digging and

cutting, the average dust concentration in the roadway reaches upto 1150mg/m3e a very high value that would cause great hazard toworkers in the roadway.

Comparing the 6 cases (Fig. 8(beg)) with dedusting fan, the ratioof dust precipitation is much higher when the absorbing airduct islocated in the air return side thanwhen it is located in themiddle ofroadway. Furthermore, the dust precipitation effect decreases withthe increase of L. As shown in Fig. 8(e), when the absorbing airductis located in air return side with L ¼ 2.0 m, the average concen-tration of dust in the front roadway after 60 s digging and cutting is365 mg/m3, just 31.7% of the value without dedusting fan, i.e., dustin the front roadway is decreased by 68.3%. When the absorbing

Fig. 6. Comparison of air velocity vector diagrams and dust mass concentrations.

Fig. 7. Dust movement history in the roadway under different airduct positions.

G. Shi et al. / Journal of Loss Prevention in the Process Industries 46 (2017) 45e5350

airduct is located in the middle of roadway with L ¼ 2.0 m, theaverage concentration of dust in the front roadway after 60 s dig-ging and cutting is 712 mg/m3, about 61.9% of the value withoutdedusting fan. It means that the dust concentration in the frontroadway is still rather high.

The total dedusting efficiency (htotal) is defined as:

htotal ¼ 1� Ca,Vmtotal

(7)

where Cais the averagemass concentration in roadway; mtotal is thetotal mass of dust produced by the heading machine; and V is thevolume of laneway.

Fig. 8. Comparison of average dust concentration history in different roadway sections among different airduct allocations.

G. Shi et al. / Journal of Loss Prevention in the Process Industries 46 (2017) 45e53 51

Fig. 9 shows the comparison of the total dedusting efficiency fordifferent airduct allocations. Fig. 9(a) is the changing curve of theaverage concentration with time of digging and cutting in the 50 mlong roadway; Fig. 9(b) is the corresponding dedusting efficiency.From Fig. 9(b), it is observed that although the movement of dusthas not reached steady state, the total dedusting efficiency after oneminute of digging and cutting tends to be steady. Among all thepresent cases investigated, when the dedusting fan is located in airreturn side with L ¼ 2.0 m, the dedusting effect is the optimal; inwhich, the average dust concentration in the roadway is only

144 mg/m3, the lowest value. In comparison with the average dustconcentration of 597 mg/m3 in the roadway without dedusting, theratio of dust precipitation when the dedusting fan is located in airreturn side with L ¼ 2.0 m is about 75.88%.

4. Conclusions

With unsteady DPM model, the airflow, dust movement, anddedusting effects for rock dust were simulated. The influence ofairduct location in far-pressing-near-absorption ventilation

Fig. 9. Comparison of dedusting efficiency for different airduct allocations.

G. Shi et al. / Journal of Loss Prevention in the Process Industries 46 (2017) 45e5352

heading roadway was investigated. The following conclusions canbe drawn:

(1) Dust in the heading roadway is not evenly distributed inspace and time. It cannot achieve steady state within a fewminutes of heading machine's digging and cutting proced-ure; and thus, unsteady simulation is more suitable.

(2) There is circulating airflow along air return side, top of theheading machine and wind pressing side in the front ofheading roadway, resulting in themovement of dust with theairflow through the position of the driver via back and side.When the absorbing airduct is located in the middle ofroadway, the circulating airflow enhances and more dustsmove through the driver, which not only threatens driver'shealth, but also affects normal operation. When theabsorbing airduct is located in the air return side, the circu-lating airflow weakens, and the dust moving through theposition of the drover decreases. It is beneficial for directcollection of dust.

(3) The dedusting effect with the dedusting fan being located inthe air return side is obviously better than when it is locatedin the middle of roadway on top of heading machine.Moreover, the simulation results show that the dust con-centration in the front of roadway after 60 s of digging andcutting is decreased from 1150 mg/m3 to 365 mg/m3; theaverage dust concentration in the roadway decreases from597 mg/m3 to 144 mg/m3; and the total dedusting efficiencycan reach up to 75.88%.

Acknowledgments

This research was supported by the National Natural ScienceFoundation of China (Grant No. 51676206, No. U1361213), Newcentury excellent talents in support of Ministry of education plan(NCET-13-1021), and CUMT Innovation and Entrepreneurship Fundfor Undergraduates (201403 & 201503).

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