Computational Fluid Dynamics (CFD) Modeling of Free-Surfaces and Particle Capture in a Vortecone Scrubber System Scaled for Installation on Continuous Miners

"Continuous miners are often equipped with a flooded-bed dust scrubber to clean the air from close to an active underground coal mining face. However, its impingement screen is prone to clogging due to an accumulation of dust, thereby lowering the scrubber’s efficiency and potentially exposing the mine workers to higher levels of dust. Fans can compensate for the increased resistance by varying their operating parameters, but the scrubber screen needs significant maintenance which leads to downtime. The authors have proposed a suitably sized Vortecone as an alternative to the conventional flooded-bed dust scrubber system. Water is used as the filter medium, which is replaced and recycled continuously. Preliminary CFD investigations of Vortecone scrubbers have indicated higher cleaning efficacies, especially in the respirable range. This paper presents the results including the flow characteristics and capture efficacies of a full-scale Vortecone. Multi-phase flows, including free-surface modeling and particle tracking methods, have been adopted. ACKNOWLEDGEMENT The authors acknowledge the National Institute for Occupational Safety and Health (NIOSH) for funding this research project. This research is being developed with the support of a NIOSH Grant 200-2014-59922- ‘Coal Mine Dust Mitigation through Novel Scrubber Development and Numerical Modeling’. The views expressed in this paper are those of the authors and do not necessarily reflect those of NIOSH. This project is aimed at designing novel and efficient scrubbing systems for underground mining operations. The authors acknowledge Dr. Thomas Novak of the Department of Mining Engineering, the University of Kentucky for his support and encouragement. The authors also thank Dr. Sunil Vytala, CFD engineer at Cradle CFD for his invaluable inputs to the numerical models.INTRODUCTION Continuous miners are the main production machines deployed in room and pillar mining operations. These miners extract coal by the shearing action of the wethead cutting drums. Strategically placed water sprays on the drum not only cool the bits extending their useful service life, they also suppress the dust at the point of generation itself. A flooded-bed dust-scrubber (Campbell, et al. 1983) is usually integrated onto the continuous miner to arrest dust from close to the active face. These fan-powered scrubbers have an impingement screen flooded with water, which also serves as the filter element. A demister downstream of the screen removes the excess water from the air cleaned. These conventional scrubbers have been found to be very effective in alleviation of respirable dust levels underground (Chao and De-sheng 2000) (Colinet, Reed and Potts 2013). However, the inefficiencies of the flooded-bed dust scrubbers arise out of their internal components. Depending on the mining conditions, the screen may be clogged by the accumulation of the trapped dust particles. The resistance of the scrubber system is increased reducing the airflow. The flooded-bed dust-scrubber system would, therefore, require frequent maintenance of the screen and the demister (Listak 2010). Since any maintenance needs to be carried out under supported roof, this leads to loss of availability of the equipment as well. In addition to this, the continuous miner operators could be exposed to elevated levels of dust when satisfactory airflow at the face is not achieved."