Continuous Miner Ventilation - pem.engr.uky.edu
Transcript of Continuous Miner Ventilation - pem.engr.uky.edu
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College of Engineering
Mining Engineering
Continuous Miner VentilationDust Mitigation Research at UK
KY Professional Engineers in Mining SeminarAugust 26, 2016Dr. Chad Wedding
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College of Engineering
Mining Engineering
• Revised full shift samplingImmediate corrective actions
• Improved record keeping• Increased medical surveillance
August 1st, 2014
• Continuous personal dust monitor (CPDM)• High exposure occupations- more sampling.February 1st, 2016
• Overall dust standard: 2.0 - 1.5 mg/m3
• Miners workplace: 1.0 - 0.5 mg/m3August 1st, 2016
Source: http://www.msha.gov/endblacklung/docs/summaryEffectiveDates.pdf
MSHA New Dust Rule
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College of Engineering
Mining Engineering
UK Dust Mitigation Research
Flooded Bed
Scrubber for
Longwall Shearer
Novel Vortecone Scrubber
Technology Transfer
Passive Wing
Regulator
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College of Engineering
Mining Engineering
Passive Wing Regulator
• Full scale test gallery for testing dust and methane controls
• 1:1 continuous miner– Body sprays– Rotating drum
• Combination of engineering controls– Scrubber– Wing Regulator– Sprays
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College of Engineering
Mining Engineering
Longwall Dust Control Challenges
Air Quantity, 67 kcfm
High ProductionAirflow along the
faceMultiple, scattered
sources of dust
Air Quantity, 7 kcfm
Relatively lower production
Blind headingLocalized source
Long
wal
lR
oom and Pillar
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College of Engineering
Mining Engineering
Flooded Bed Scrubber for Longwall Shearer
• Along with dilution and water sprays, common dust capture technology for continuous miner units
• Cleaning efficiencies between 60% and 90% (NIOSH 1997)( USBM, 1990)
• Potential for longwall shearer
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College of Engineering
Mining Engineering
Conceptual Layout
Duct
Inlet
Fan
Discharge
Flooded bed & Demister
• Scrubber incorporated into Joy 7LS Shearer
• Two new compartments added
• Length increase from 55’ to 62’
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College of Engineering
Mining Engineering
Airflow Arrangement
Dust Laden Air from Leading Drum
Scrubbed Air
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College of Engineering
Mining Engineering
Research Approach
Full Scale
Prototype
Reduced Scale
Modeling
CFD Modeling
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College of Engineering
Mining Engineering
CAD Geometry
Original shearer model provided by JOY
Original
UK Modifications
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College of Engineering
Mining Engineering
Velocity Contours
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College of Engineering
Mining Engineering
Velocity Contours
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College of Engineering
Mining Engineering
Dust Capture wrt Time & Flow through Scrubber
0
10
20
30
40
50
60
70
80
90
100
0 2 4 6 8 10 12 14 16 18 20
Perc
ent C
aptu
re
Time (Second)
635076258900102001140012700
500 fpm Face Velocity
Scrubber Flow
rate (cfm)
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College of Engineering
Mining Engineering
Dust Capture wrt Time & Flow through Scrubber
0
10
20
30
40
50
60
70
80
90
100
0 2 4 6 8 10 12 14 16 18 20
Perc
ent C
aptu
re
Time (Second)
635076258900102001140012700
Scrubber Flow
rate (cfm)
580 fpm Face Velocity
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College of Engineering
Mining Engineering
Dust Capture
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College of Engineering
Mining Engineering
Projected Captures
Scrubber Flow Rates
Aver
age
flow
at t
he
face
6,350cfm
7,625 cfm
8,900 cfm
10,200 cfm
11,400 cfm
12,700 cfm
500 fpm 85.9 87.1 85.5 82.8 84.8 90.0
580 fpm 75.6 86.8 87.6 84.4 88.4 90.8
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College of Engineering
Mining Engineering
Reduced Scale Modeling
• 1:20 scaled model of the setup
• Replicates problem set up in CFD
• Used the same velocities encountered in the mine, all other surfaces stationary.
• CO2 [tracer gas] mimics the dust particles under the suction of shop vacuum [scrubber].
• Flow volumes calculated and concentrations measured using gas monitors.
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College of Engineering
Mining Engineering
Reduced Scale Results
Reduced scale results agree with CFD model results
No Scrubber w/CO2 Scrubber w/CO2Capture
EfficiencyAir Velocity CO2 Content (%)
Air Velocity (fpm) CO2 Content (%)m/s fpm m/s fpm
2.06 405 0.60 2.06 406 0.08 94.55%2.32 456 0.52 2.34 460 0.11 87.23%2.54 500 0.52 2.57 505 0.11 87.23%2.82 555 0.47 2.79 550 0.14 78.57%3.07 605 0.41 3.05 600 0.14 75.00%
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College of Engineering
Mining Engineering
Full Scale Prototype
• Concept verification to be completed at the NIOSH campus in Pittsburgh
• Full-scale testing with functional scrubber prototype
• Mock up miner constructed from 80/20 Al extrusion and PVC plastic
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College of Engineering
Mining Engineering
Full Scale Prototype
• 50HP centrifugal fan with VFD for powering scrubber
• Allen Bradley PLC for control and instrumentation
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College of Engineering
Mining Engineering
Preliminary Experiments
NIOSH Dust Gallery in Pittsburgh
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College of Engineering
Mining Engineering
Preliminary Testing
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College of Engineering
Mining Engineering
Preliminary Results
Dust concentrations
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College of Engineering
Mining Engineering
Vortecone Scrubber for Mining
• UK/Toyota Joint development• Applicable for respirable size
fraction• High cleaning efficiency• Minimal maintenance• Scalable in match air
requirements – From 200 cfm lab models to
60,000 cfm at Toyota
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College of Engineering
Mining Engineering
Four main components:1. Cone shape inlet2. Mixing chamber3. Vortex chamber4. Discharge
Works on the principle of vortex interaction of particle-laden airflow with water
Novel Vortecone Scrubber
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College of Engineering
Mining Engineering
Computational mesh employed in the computational domain
Velocity vectors on three parallel Planes
CFD Modeling (cont.)
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College of Engineering
Mining Engineering
Representative Velocity Contours
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College of Engineering
Mining Engineering
Particle Tracking
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College of Engineering
Mining Engineering
Cleaning Efficiency by Count
92
92.5
93
93.5
94
94.5
95
95.5
96
96.5
97
92
93
94
95
96
97
5 6 7 8 10 12 14 16 18 20
% C
lean
ing
effic
ienc
y
Inlet Velocity
% Cleaning Eff. Vs Inlet Velocity
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College of Engineering
Mining Engineering
Cleaning Efficiency by Mass
0.00000
0.00050
0.00100
0.00150
0.00200
0.00250
0.00300
0.0E+00
5.0E-04
1.0E-03
1.5E-03
2.0E-03
2.5E-03
3.0E-03
5 6 7 8 10 12 14 16 18 20
% M
ass
Inlet Velocity
% Mass Escaped Vs Inlet Velocity
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College of Engineering
Mining Engineering
Results / Conclusions
• Solid concept for flooded bed scrubber incorporated into a longwall shearer
• Capture efficiency of dust generated from the headgate drum exceeds 70-80%– CFD, reduced scale model, full scale
prototype• Vortecone CFD modeling suggests high
cleaning efficiency
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College of Engineering
Mining Engineering
Acknowledgement
On behalf of those who have worked on the material presented, I would like to express our gratitude to those who
have made our research possible.• Alpha Foundation• Alliance Coal• NIOSH• JOY Global