Research on Eddy Air-Curtain Dust Controlled Flow Field in Hard

Research on Eddy Air-Curtain Dust Controlled Flow Field in Hard Rock Mechanized Driving

Face

Wei-min Cheng1, 2, Wen Nie1, 2, Gang Zhou 1, 2, Jun-lei Yang 1. College of Resource and Environmental Engineering Shandong University of Science and Technology, Qingdao,

China

1, 2

2. Key Laboratory of Mining Disaster Prevention and Control, Ministry of Education Shandong University of Science and Technology, Qingdao, China

Email: [email protected], [email protected], [email protected]

Abstract—The mathematical model of single-phase flow of gas was established based on the k-ε two-equation model and numerically simulated the eddy air-curtain dust controlled flow field in hard rock mechanized driving face with the help of FLUENT software on account of the collocated grid SIMPLE algorithm. The result showed that, after all the pressure ventilation blown out by the radial clearance of mural cylinder, a full-face eddy air-curtain flow field is formed at the roadway section and with the help of the exhausting cylinder, it keeps pushing toward the tunneling place, forming the air-curtain dust controlled flow field that presses the tunneling place equally in front of the driver of road header. After the application of the development of new light polymer materials radial cylinder eddy air-curtain dust controlled system was adopted in hard rock mechanized driving face of north conveyor main roadway, the average settlement rate of total dust and repairable dust have reached to 97.4% and 96.8% respectively, reducing the local dust concentration effectively. Index Terms—hard rock mechanized driving face, mural cylinder, eddy air-curtain, dust control, k-ε model

I. INTRODUCTION

Hard rock mechanized driving face is a new and high-efficiency tunneling method and is gradually adopted in our country [1, 2]. But compared with the traditional blasting driving face and mechanized driving face [3, 4], its dust producing amount has increased dramatically [5, 6]. What’s worse is that the higher SiO2

Recent study [11, 12] shows that, it is impossible to control and prevent the dust’s drift and diffusion fundamentally in the traditional dedusting way, but to control and capture dust absorption with the eddy air-curtain and the suction flow formed by the dust purification equipment is an effective way to control the spread of dust [13]. Eddy air-curtain dust controlled flow field in hard rock mechanized driving face is a very complex flow process. There are too many influencing

factors and they are not easy to obtain through model experiment and field measurement, so numerical simulation is very important to research of this flow field [14, 15]. At the present stage, the most of simulations to eddy air-curtain dust controlled flow field in heading face is two-dimension and the three-dimensional simulation is limited to the simpler form [16, 17]. It can’t accurately reflect the diffusion rule of eddy air-curtain dust controlled flow field in working face [18, 19, 20].

content in rock dust results in a serious threat to underground workers’ health [7, 8], and causes great harm to the safety, efficient production of mine [19, 10].

In this paper, we discussed numerical simulation research of the diffusion rule of eddy air-curtain dust controlled flow field in hard rock mechanized driving face and developed an eddy air-curtain dust controlled system in hard rock mechanized driving. The mathematical model of single-phase flow of gas was established based on the k-ε two-equation model and numerically simulated the eddy air-curtain dust controlled flow field in hard rock mechanized driving face with the help of FLUENT software on account of the collocated grid SIMPLE algorithm. The result showed that, after all the pressure ventilation blown out by the radial clearance of mural cylinder, a full-face eddy air-curtain flow field is formed at the roadway section and with the help of the exhausting cylinder, it keeps pushing toward the tunneling place, forming the air-curtain dust controlled flow field that presses the tunneling place equally in front of the driver of road header.

II. NUMERICAL SIMULATION OF EDDY AIR-CURTAIN DUST CONTROLLED FLOW FIELD

A. Physical Model Using preprocess software GAMBIT together with

FLUENT to build an equal-scale model of hybrid ventilation system in conveyor main roadway with mural cylinder of north LongGu mine. The tunnel is a semicircle arch area with the length of 35m, the width of 5.7m and the height of 4.87m; the total length of the roadheader is 11m. The fuselage is a cuboid with the length of 7m, the width of 3m and the height of 2.5m; the diameters of the forced cylinder and exhaust cylinder which are arranged in different sides of the roadway are

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© 2013 ACADEMY PUBLISHERdoi:10.4304/jnw.8.2.453-460

1m and 0.8m, 0.4 m away from the nearest tunnel wall and the axis of cylinder is 3.5m away from the ground. The forced cylinder is 5 m away from the tunneling place. The mural cylinder whose total length is 5 m is arranged in the middle of the forced cylinder and 27m away from the tunneling place, opening a radial clearance with the length of 2m and the width of 0.15m along with mural cylinder per meter and the total number is 2. The exhausting cylinder whose total length is 34 m is 1m away from the tunneling place. The established model was further mesh-divided by GAMBIT and the mesh Interval size (400) of this model was hexahedral. Figure 1 is the diagram of physical model before and after the mesh was divided.

(a) Before the mesh was divided

(b) After the mesh was divided

Figure 1. Physical Model

B. Mathematical Model Long pressure-short pumping type ventilation in

whole-rock fully mechanized workface is actually turbulent jet ventilation. There are two different models that describe the turbulent flow in whole-rock fully mechanized workface, these models are classified as zero equation model, one-equation model, two-equation model, reynolds stress model and direct numerical simulation model. k-ε model is one of the most commonly used models, it is the typical mathematical model of Eulerian Model. turbulent kinetic energy k equation and energy dissipation rate ε equation are intrduced in k-ε model, and it has been widely used in resolving turbulent flow process under various conditions successfully, governing equations of local ventilation working face k-ε model include: mass conservation equation that describe fluid pressure p, or continuity equation, velocity component u, v and w Navier-Stocks equation, turbulent energy k equation, energy dissipation rate ε equation, there are altogether six equations. These equations provide sufficient information that determines air flow field solutions. They can be described basic coupling partial differential equation which govern fluid flow [18-20]:

0)()()(=

∂∂

+∂

∂+

∂∂

+∂∂

zw

yu

xu

tρρρρ (1)

xp

zu

z

yu

yxu

x

zuw

yuv

xuu

tu

t

tt

∂∂

−∂∂

+∂∂

+∂∂

+∂∂

+∂∂

+∂∂

=∂

∂+

∂∂

+∂

∂+

∂∂

)(

)()(

)()()()(

µµ

µµµµ

ρρρρ

(2)

xp

zv

z

yv

yxv

x

zvw

yvv

xvu

tv

t

tt

∂∂

−∂∂

+∂∂

+∂∂

+∂∂

+∂∂

+∂∂

=∂

∂+

∂∂

+∂

∂+

∂∂

)(

)()(

)()()()(

µµ

µµµµ

ρρρρ

(3)

xp

zw

z

yw

yxw

x

zww

ywv

xwu

tw

t

tt

∂∂

−∂∂

+∂∂

+∂∂

+∂∂

+∂∂

+∂∂

=∂

∂+

∂∂

+∂

∂+

∂∂

)(

)()(

)()()()(

µµ

µµµµ

ρρρρ

(4)

)(

)()()()(

εσµ

µ

σµ

µσµ

µ

ρρρρ

−+∂∂

=∂∂

+∂∂

=∂∂

+∂∂

=∂∂

=∂

∂+

∂∂

+∂

∂+

∂∂

kk

t

k

t

k

t

Gzk

z

yk

yxk

x

zkw

ykv

xku

tk

(5)

kc

kGc

zz

yyxx

zw

yv

xu

t

kt

tt

2

21

)()()()(

ερεεσµ

µ

εσµ

µεσµ

µ

ρερερερε

ε

εε

−+∂∂

=∂∂

+∂∂

=∂∂

+∂∂

=∂∂

=∂

∂+

∂∂

+∂

∂+

∂∂

(6)

Among them, P is pressure, Pa; u, v, w: velocity component, m/s; k: turbulent kinetic energy, m2/s2; ε: energy dissipation rate, m2/s2; t: time, s; μ: kinetic viscosity, Pa·s; ρ: fluid density, kg/m3; μ t: turbulent dynamic viscosity coefficient, and as the formula (7) shows:

∂=

2kDCt ρµ (7)

Gk is turbulent energy generation rate, as the formula (8) shows:

222

222

2

zu

xw

yw

zv

xv

yu

zw

yv

xuG tk

∂∂

+∂∂

+∂∂

+∂∂

+∂∂

+∂∂

+∂∂

+∂∂

+∂∂

= µ

(8)

Among them, CD, C1, C2, σk, σε

TABLE I.

: experimental constant, as the table I shows:

THE EXPERIMENTAL CONSTANT

C σD σk Cε C1 0.09

2 1.0 1.3 1.44 1.92

All independent variables obey one common conservation law. If ϕ is independent variable, the general form of differential equation is:

Sut）（

+Γ=+∂

∂ )grad(div)(div ϕϕρρϕ (9)

Among them, Γ: diffusion coefficient; S: production term of volume rate.

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© 2013 ACADEMY PUBLISHER

The value of Γ and S depends on variables mean, different variables of Γ and S is shown as table II.

TABLE II. THE VALUE OF Γ AND S IN DIFFERENT VARIABLES MEANING

Variables Γ S

u tµµ + xBxp+

∂∂

v tµµ + yByp+

∂∂

w tµµ + zBzp+

∂∂

k k

tσµ

µ + ρε−KG

ε εσµ

µ t+ k

ck

Gc k2

21ερε

−

In table II, Bx, By, Bz: volume force component; u=uin=constant; v=w=0; k=kin=0.005;

( )RkC inDin 03.0/23

== εε , among of them, R: water conservancy radius of fan drum; subscript “in”: the parameters of section air flow in fan drum outlet. In the wall of roadway: u=0, v=0, w=0, k=0, ε=0.

In order to master the action mechanism of closed dust control of eddy air-curtain formed by mural cylinder, the mathematical model

(1) Hypothesis: 1) ventilation flow is shown as incompressible fluid, the heat of dissipation that caused by fluid viscous force do work can be ignored, meanwhile, the wall surface adiabatic and isothermal ventilation were fixed; 2) turbulence viscous of fluid has isotropic, turbulence viscous coefficient μt can be shown as scalar; 3) flow is steady turbulent, and it satisfy Boussinesq assumptions.

of closed dust control mural cylinder air flow system was set up [21-25].

(2) Mathematical model: Based up on the above assumptions, single end tunnel ventilation can be described by time-averaged equations of turbulent flow mathematical model, tensor expressions are represented as shown below.

1) Continuity equation:

0=∂∂

i

i

xv

i=1, 2, 3 (10) 2) Momentum equation (N-S equation):

])[[(

)32()(

i

iit

i

iji

i

xv

xjv

x

kpx

vvx

∂∂

+∂∂

+∂∂

++∂∂

−=∂∂

µµ

ρρ (11)

3) Turbulent flow energy equation:

( ) ii

i i r i i p

T qv Tx x P x c

µµρσ

∂ ∂ ∂= − + + ∂ ∂ ∂

i=1, 2, 3 (12) 4) Turbulent pulsation kinetic energy equation (k

equation):

ρεεσµρ −+

∂∂

∂∂

−=∂∂ G

xxkv

x ik

i

ii

i)(

i=1, 2, 3 (13) 5) Turbulent pulsation kinetic energy dissipation rate

equation (ε equation):

kcGc

xxv

x i

i

ii

i

ερεεσµερε

)()( 21 −+

∂∂

∂∂

−=∂∂

i=1, 2, 3 (14) Among them, G: generation item of turbulent pulsation

kinetic energy; cp: air specific heat at constant pressure, KJ/ (kg·K); Pi; pr number when made full of turbulent; q; heat flux, W/m3; T; fluid temperature, K; v i: velocity component (x direction: i=1, y direction: i=2, z direction: i=3), m/s; μ i

The essence of the model is to use transport equation of turbulent second orderrelated factors and “gradient simulation assumption” was used in the simulation. Meanwhile, the two differential equations of turbulent flow energy and turbulent kinetic energy dissipation rate, thus providing added equations for turbulent flow time-averaged equations, and they could be closed equations of mathematics at last.

: turbulent kinetic viscosity, Pa·s.

C. Boundary Condition. The author imports the physical model into FLUENT

and sets boundary conditions. The entrance boundary type is VELOCITY_INLET. The forced air volume is 400m3/min. All winds blow through radial clearance of mural cylinder, with a speed of 11.66667m/s. The wind speed of forced cylinder is 9.28875m/s and the exhaust air volume is 550m3/min. The wind speed of exhaust cylinder is 18.2365m/s. The turbulent kinetic energy is 0.8m2/s2. The turbulent diffusion ratio is 0.8m2/s3

D. The analysis of Simulated Result.

. The exit boundary type is outflow.

After the above model was completed, discredited the partial differential equations by the hybrid difference scheme based on finite volume method, then solved the eddy air-curtain dust controlled flow in hard rock mechanized driving face by the hybrid difference scheme and collocated grid SIMPLE algorithm and showed the flow law of the working face with vector graph of wind speed. The total simulated results of wind velocity vector along x, y, z axis are showed in figure 2. In order to show the wind velocity vector at different cross section clearly, lists the wind velocity vector of different cross section which x equal to 30m, 11m, 5m and 3m are listed, as shown in figure 3. Units of figure 2 and 3 are all “m/s”.

(a) x axis



(b) y axis

(c) z axis

Figure 2. The total simulated result of wind velocity vector along x, y, z axis

(a) x=30m

(b) x=11m

(c) x=5m

(d) x=3m

Figure 3. Definite dust concentration simulated result of cross-section at different locations which X equal to 30m, 11m, 5m

and 3m

(1) After the mural cylinder was used in north conveyor main roadway in fully rock mechanized excavation face, in the region of x respect from 27m to 31.3m, all forced air blows through the radial clearance of mural cylinder. The maximum wind speed is 11.8m/s, formed a full-face eddy Air-curtain at the lockable roadway section. For example, a full-face eddy Air-curtain flow field at the lockable roadway section is formed in the cross section which x is equal to 30m. In this flow field, wind speed near the tunnel wall is within the range from 2.08m/s to 11.8m/s. While the wind speed of roadway center is around 0.00637m/s to 0.699m/s.

(2) In the location of x=3m, x=5m and x=11m, direction of the wind speed arrow heads are pointing to tunneling place and the speed are basically same. The slight difference only exists when there are road-header and other obstructions. This shows that: under the influence of exhaust cylinder, the formation of eddy Air-curtain flow field continue to promote to the tunneling place and make the pressure air flow evenly spread in the roadway section, gradually forming an air-curtain dust controlled flow field that presses to the tunneling place in front of the workers including driver of the roadheader.

III. DEVELOPMENT OF EDDY AIR-CURTAIN DUST CONTROLLED SYSTEM IN HARD ROCK MECHANIZED

DRIVING FACE

Based on the above simulated results and physical condition of hard rock mechanized driving face, the author developed the eddy air-curtain generator mural cylinder and formed the new eddy air-curtain dust controlled system in hard rock mechanized driving face with the combination of the smoke dust purification equipment which is shown in figure 4.

A. Mural Cylinder The rotating duct is designed in the side wall of hard

material cylinder in the development of the light polymer material radial cylinder, and this cylinder is designed with rotating damper. The damper is closed at work, so the air flow can only flow from the rotating duct, forming a rotating air flow. This mural cylinder can ensure that all forced air flow through the rotating duct, forming a thick and dense air curtain. The new mural cylinder is formed by one cylinder memory whose length is 1.2m, one cylinder with the rotating damper whose length is 1.2m



and two cylinders with radial clearance whose length is 2.3m. The total length is 7m. In contrast, the traditional mural cylinder is made of the steel material which is heavy, inconvenient to move underground. In order to improve mine workers’ labor efficiency, the developed light polymer material radial cylinder is made of a new high molecular material whose composition is aliphatic resin while the main component of polyester is resin. The basic parameters of these materials are listed as follows: Fire-protection rating: B1; Density: 100kg/m3

; High-

temperature resistance: 170℃; Low-temperature

resistance: -30℃; Compressive strength: greater than 200KPa; Water absorption: less than 3%; Thermal conductivity: less than 0.018 W/ (m·K). The total weight of light polymer material radial cylinder is less than 50 Kg, 5 to 10 percent lighter of an ordinary iron or steel cylinder, which greatly reduces the miners' labor strength. Figure 5 is the structure diagram of light polymer material radial cylinder

Air-curtain

Dedusting Fan

Exhaust Cylinder

Forced Cylinder

Roadheader

Light Polymer Materials Radial Cylinder

Figure 4. Structure diagram of eddy Air-curtain dust controlled system

Cylinder Memory Ventilation Blown Out By Radial Clearance Rotating Damper Ventilation Blown Out By Radial Clearance

Cylinder Body Rotating Damper Switch Cylinder Body Figure 5. Structure diagram of light polymer material radial cylinder

B. Overall Layout of the Dust Control System According to the actual situation of north conveyor

main roadway in fully rock mechanized excavation face and numerical simulated result of eddy Air-curtain dust controlled flow field, we put the exhaust cylinder whose diameter is 0.8m in the side of the roadway in opposition to the driver. The distance from the suction exit to the tunneling place is less than 1.25m while the distances between the axis of the cylinder and the ground and the nearest tunnel wall are 3.5m and 0.4m respectively. The exhaust cylinder and dedusting fan are suspended in the monorail crane of tunnel roof, with the dedusting fan adopting the slip mode. Forced cylinder whose diameter is 0.8m is arranged in the driver’s side which is paralleled with the exhaust cylinder. As has been mentioned above, the distances between the axis of the cylinder and the ground and the nearest tunnel wall are 3.5m and 0.4m respectively. And the distance from the press tuyere to the tunneling place is about 5m. Mural cylinder is installed in the middle of forced cylinder. In order to ensure the diffusion of eddy air-curtain in the roadway to be full and uniform, we design the distance of air inlet

and air outlet to be bigger than 5 S (S is area of roadway), while the actual distance is from 26m to 35m. When rock-cutting is done by the roadheader, it is designed to rotate the damper of rotating mural cylinder and make all press-in air blows through radial clearance thus forming the eddy air-curtain and blocking the outward diffusion of dust effectively. In order to avoid the influence of winds to wet dust electromotor, the distance of light polymer material radial cylinder’s end and air outlet of dust electromotor is designed to be 1 to 2 times of the S , while the actual distance is from 5m to 10m.

IV. ANALYSIS OF APPLICATION EFFECT IN FIELD

This eddy air-curtain dust controlled system in hard rock mechanized driving face was used in mechanized driving face of north conveyor main roadway. The roadheader is EBH315 roadheader, figure 6 is the EBH315 roadheader. The main dust is hard sandstone (short-form Hd. sd.) whose coefficient of hardness f is from 9 to 13. The absolute emission of toxic and harmful gases CO2 is 0.15m3/min and CH4 is 0.1m3/min. The



absolute production of toxic or harmful gas is extremely low. Even if recirculating air of which exhaust air volume is greater than the amount of forced air volume, there will not be the accumulation of toxic and harmful gases in tunneling place. The forced air volume in working face is 400m3/min. When cutting the rock, all press-in air blows through radial clearance of the mural cylinder. The selected dedusting fan is HCN600/1 wet dust electromotor of which the exhaust air volume is about 550m3/min and the dust suppression rate is above 99%. Figure 7 is the HCN600/1 wet dust electromotor. Table Ⅲ shows the measurement of the dust concentration of hard rock mechanized driving face in north conveyor main roadway before and after of the eddy air-curtain dust controlled system was adopted.

Figure 6. EBH315 roadheader

Figure 7. HCN600/1 wet dust electromotor

TABLE III. DUST CONCENTRATION BEFORE AND AFTER EDDY AIR-CURTAIN DUST CONTROLLED SYSTEM WAS ADOPTED.

Measuring point position Dust characteristics

Before (mg/ m3 After (mg/ m) 3 Dust suppression rate (%) ) Total dust

Espirable dust

Total dust

Espirable dust

Total dust

Espirable dust

Tunneling place Hd.sd. 1538.4 768.2 175.4 88.6 97.6 87.3 Drivers Hd.sd. 986.3 497.5 21.7 97.8 13.9 97.2 Downwind of loader Hd.sd. 847.2 413.6 21.2 97.5 13.2 96.8 Downwind of telescopic belt conveyor Hd.sd. 811.5 387.9 19.5 97.6 11.2 97.1 100m away from the tunneling place Hd.sd. 698.7 324.8 18.9 97.3 10.7 96.7 200m away from the tunneling place Hd.sd. 542.9 259.1 16.8 96.9 9.8 96.2

Average dust suppression rate (%) 97.4 96.8

After the eddy air-curtain dust controlled system was used in hard rock mechanized driving face of north conveyor main roadway, the dust-fall rate of the dust concentration at the working face is significant and the average settlement rate of the of total dust and respirable dust have reached to 97.4% and 96.8% in working face. At the location of the driver of roadheader where the dust concentration is the highest, the concentration of total dust and espirable dust is only 21.7mg/m3 and 13.9mg/m3

V. CONCLUSION

. The highest concentration of dust is still at the tunneling place. But the average settlement rate of the total dust and respirable dust were only 88.6% and 87.3%, the minimum number among the six measured stations. This indicates that the developed new light polyeaster materials radial cylinder eddy air-curtain dust controlled system can produce eddy air-curtain dust controlled flow field, playing a significant role in controlling dust

especially in controlling effectively the dust within the tunneling place inside of air-curtain so as to do the concentrated dedust.

(1) From the numerical simulated result of eddy air-curtain dust controlled flow field, we know that, after all forced air blow through the radial clearance of mural cylinder, a full-face eddy air-curtain at the lockable roadway section is formed. With the help of the exhaust cylinder, this formed eddy air-curtain flow field continues to move forward to the tunneling place, forming an air-curtain dust controlled flow field that presses to the tunneling place in front of the driver of roadheader.

(2) Based on the simulated results and physical condition of hard rock mechanized driving face, after the



developed new light polymer materials radial cylinder eddy air-curtain dust controlled system was adopted in hard rock mechanized driving face of north conveyor main roadway, the average settlement rate of total dust and respirable dust have reached to 91.6% and 90.5%, and the dust concentration was reduced effectively.

ACKNOWLEDGMENT

The authors wish to thank Natural Science Foundation of China (51074100), the Natural Science Foundation of Shandong Province (ZR2010EM016), the Natural Science Foundation of Shandong Province (ZR2011EEQ009), the National Colleges and Universities Specialized Research Fund for the Doctoral Program of China (20113718110005), the Postgraduate Science and Technology Innovation Funding of Shandong University of Science and Technology (YCA120102) and the Science Research Innovative Group of Shandong University of Science and Technology (2010KYTD106). This work was supported in part by a grant from them.

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Wei-min Cheng, male, was born in Caoxian, Shandong Province, September 1966. The author got the postdoctoral of explosion and control state key laboratories weapons and science major in Beijing Institute of Technology in November 2001.

He is the VICE PRESIENT of College of Resources and Environmental Engineering in Shandong University of Science and Technology, DIRECTOR of mine ventilation and security research institute and DOCTRAL SUPERVISOR. Dr.Cheng is the fifth council member of COSHA, the member of the national production safety experts and got the third prize of national production safety scientific and technological achievements in 2011.

Wen Nie, male, was born in Taian, Shandong Province, September 1985. The author has been studying for doctorate degree of safety technology and engineering since September 2010 in Shandong University of Science and Technology.

He is a doctoral student of College of Resources and Environmental Engineering in Shandong University of Science and Technology. His research interests include Mine ventilation and dust control and mine disaster prevention and control technology research.

Dr. Nie got the third prize of Technology progress of China National Coal Association in 2011.



Documents

Research on Eddy Air-Curtain Dust Controlled Flow Field in Hard