In addition to ventilation practices, the application of water via sprays is the most economical and popular means of combating respirable dust in an underground coal mine. Due to a noticeable increase in black lung among coal miners and new dust regulations, surfactants or wetting agents have been used to aid in dust suppression. The surfactant facilitates the wetting process by lowering the surface tension and allowing the hydrophobic coal dust to come into contact with the water. One of the most straightforward and effective benchtop tests is a simple wetting test. Although there are variations of this type of test, principle and technique remain the same. A known amount of dust was placed on the surface of a solution and the time it takes for all the dust to fall through the interface would be the wetting rate. This investigation examined the specific density of the bulk dust and concentration of a surfactant in solution and their effects on the wetting rate. It was found that both factors were significant in determining the wetting rate. It was seen that the surfactant had a more significant effect on the dust which consisted mostly of coal particle when compared to a dust with a higher non-coal mineral content. Additionally, full-scale tests were conducted to determine the effect of the surfactant at a constant concentration. During the field implementation, the surfactant was pumped through the mines spray water to the cutter heads of the continuous miner. A large number of uncontrollable variables present during the implementation, made determining the effects difficult, and the resulting impact from the surfactant inconclusive. Further long-term testing would be needed while accounting for all of the identified variables. Significantly higher concentration was however found when using the continuous personal dust monitor as opposed to the older personal dust samples when left in the same environment. Additionally, a very significant drop in dust concentrations was observed when the miner operators were allowed to activate the scrubbers. / Master of Science / People who work in mines are exposed to many dangers and illnesses. One of the illnesses, which has in recent history resurged, is black lung. Black lung is a disease caused by coal dust entering the lungs. The body’s reaction to it is to build scar tissue around the piece of dust. If this happens enough times over the miner’s career, then it becomes nearly impossible to breath. Normally, to prevent this from happening, water is sprayed in the coal before it is chipped off by the machine. Since this appears to no longer be effective, soapy chemicals are added to the water, which helps to keep the dust from lifting into the air in the first place. One of the easiest ways to test whether the chemicals are working well or not is to conduct a wetting test. When conducting a wetting test, a known about of dust is placed on top of the water and chemical mixture, and the time it takes for all of the dust to be wet is call the wetting rate. To get better results in an actual mine, faster wetting rates were sought after. The wetting test showed that the two main factors which determine the wetting were how much coal is in the coal and rock dust mixture and how much chemical is used. It was seen that the chemical had a more significant effect on the dust which had mostly of coal particle when compared to dust with more rock dust. Another study was conducted at a mine with only one mixture of water and chemical. During the study, the chemical was pumped through the mine and to the cutter heads of the continuous miner. A continuous miner is the name of the equipment used to mine coal and other soft material. The cutter head is the piece of the equipment which actually makes contact with coal. Since the conditions at the mine were not ideal and not enough data was taken, the resulting effect of the chemical could not be certain. More long-term studies need to be done in the future to help account for the less than ideal conditions. There were, however, larger amounts of dust when using new sampling equipment as opposed to the older equipment given the same conditions. Also, smaller amounts of dust were seen when the miner operators were allowed to activate the air cleaning attachments on the continuous miner. These issues should be revisited in the future.

Dust creates health and safety issues in mining and there are several different ways to reduce the amount of respirable dust created. Dust particles also affect the operation and efficiency of mining equipment. One device currently used to reduce dust in a coal mine is a flooded-bed dust scrubber. These type of scrubbers are found on continuous miners and are designed to capture dust particles close to the cutting head. However, the fibrous screens on the flooded-bed dust scrubber clog easily reducing both production and the quality and quantity of air miners are exposed too. The flooded-bed dust scrubber was designed in the 1980s and has not seen any significant changes since. A Vortecone is a wet scrubber system designed to capture small particles in the air and can easily replace the flooded-bed dust scrubber system on a continuous miner. The Vortecone was initially developed to capture over-sprayed paint particles and due to the capture ability was converted over into the mining industry. The first design of the Vortecone had two outlets and a large pressure drop across the system. The Vortecone was redesigned to have one outlet in order to increase confinement time of particles and thus increase the capture abilities. Using CFD analysis and laboratory testing, the redesigned Vortecone has been proven to have a lower resistance than the original design as well as the currently used convention screens. The Vortecone also proved to have a high capture efficiency at high airflows. This maintenance-free wet scrubber device requires much less maintenance than a conventional screen and thus can be used continually without interrupting production. The Vortecone has been designed so it can easily be mounted onto a continuous miner in place of the currently used scrubbers.

O objetivo deste trabalho foi investigar, sob o enfoque da modelagem matemática, a operação de escrubagem da bauxita proveniente da jazida Miltônia 3, da Mina de Bauxita de Paragominas-PA, com vistas a fornecer parâmetros para previsão de seu desempenho e otimização. Para isso, foi realizada uma campanha de experimentos de escrubagem, em um tambor desagregador de laboratório, baseada em planejamento fatorial. Os parâmetros operacionais avaliados foram os seguintes: grau de enchimento, tempo de residência da polpa e velocidade de rotação. A variável de resposta selecionada foi a quantidade de finos (partículas menores que 0,037 mm) no produto desagregado. O programa de experimentos permitiu a análise da influência de cada variável operacional selecionada na desagregação da bauxita. De acordo com os resultados obtidos, o parâmetro operacional que produziu o efeito mais significativo na variável de resposta foi o grau de enchimento. O modelo desenvolvido foi validado através da comparação entre os valores obtidos em ensaios de escrubagem em uma unidade piloto e aqueles previstos pelo modelo. Os valores da quantidade de finos, no produto desagregado, previstos pelo modelo apresentaram uma excelente aproximação com os dados experimentais da operação em escala piloto. / The aim of this study was to investigate and model the bauxite scrubbing of bauxite samples from Miltonia 3, a Vale operation at Pará state, Brazil. The experimental program included the design of a standard laboratory test, from which parameters were derived for predicting the operation of a scrubber in steady state conditions. Three main variables were selected for the laboratory experimental program using the factorial design technique. These were load fraction, residence time and rotation speed. The amount of fines was determined through screening both feed and product of the scrubbing test. The former was considered as a material characteristic while the second was the dependent variable, i.e. the result of the scrubbing process. An empirical model was developed according to which the load fraction was found the most important variable to the scrubbing process. Residence time was also included in the model due to its importance in designing scrubbers for industrial plants. To validate the model a comprehensive pilot plant program was carried out with the same bauxite sample from Miltonia 3 deposit used in the laboratory investigations. The comparison between experimental data and model calculated values indicated a good agreement, as most values were within ±10% deviation range.

O objetivo deste trabalho foi investigar, sob o enfoque da modelagem matemática, a operação de escrubagem da bauxita proveniente da jazida Miltônia 3, da Mina de Bauxita de Paragominas-PA, com vistas a fornecer parâmetros para previsão de seu desempenho e otimização. Para isso, foi realizada uma campanha de experimentos de escrubagem, em um tambor desagregador de laboratório, baseada em planejamento fatorial. Os parâmetros operacionais avaliados foram os seguintes: grau de enchimento, tempo de residência da polpa e velocidade de rotação. A variável de resposta selecionada foi a quantidade de finos (partículas menores que 0,037 mm) no produto desagregado. O programa de experimentos permitiu a análise da influência de cada variável operacional selecionada na desagregação da bauxita. De acordo com os resultados obtidos, o parâmetro operacional que produziu o efeito mais significativo na variável de resposta foi o grau de enchimento. O modelo desenvolvido foi validado através da comparação entre os valores obtidos em ensaios de escrubagem em uma unidade piloto e aqueles previstos pelo modelo. Os valores da quantidade de finos, no produto desagregado, previstos pelo modelo apresentaram uma excelente aproximação com os dados experimentais da operação em escala piloto. / The aim of this study was to investigate and model the bauxite scrubbing of bauxite samples from Miltonia 3, a Vale operation at Pará state, Brazil. The experimental program included the design of a standard laboratory test, from which parameters were derived for predicting the operation of a scrubber in steady state conditions. Three main variables were selected for the laboratory experimental program using the factorial design technique. These were load fraction, residence time and rotation speed. The amount of fines was determined through screening both feed and product of the scrubbing test. The former was considered as a material characteristic while the second was the dependent variable, i.e. the result of the scrubbing process. An empirical model was developed according to which the load fraction was found the most important variable to the scrubbing process. Residence time was also included in the model due to its importance in designing scrubbers for industrial plants. To validate the model a comprehensive pilot plant program was carried out with the same bauxite sample from Miltonia 3 deposit used in the laboratory investigations. The comparison between experimental data and model calculated values indicated a good agreement, as most values were within ±10% deviation range.