Respirable coal mine dust (RCMD) is one of the biggest occupational health hazards. Dusty mining environments can cause life-threatening respiratory health problems for coal miners known as black lung. Over the last 20 years, the flooded bed dust scrubber (FBS) has been employed as an integral component of dust control strategies for underground continuous mining operations. These units have been shown to be effective and robust in mining environments; however, several technical challenges and knowledge gaps limit their performance and efficiency. Despite the capability of the FBS, there are numerous technical challenges that limit its performance and efficiency. In particular, the static panel filter, instrumental in most scrubber designs, is fundamentally limited in collection efficiency and causes numerous operational challenges including rapid clogging. Furthermore, the current design of the filter panel is not capable of evenly wetting the entire surface area. This allows dust-laden air to pass through the filter media and decreases the cleaning capability of the FBS. In this research, both a lab-scale and a full-scale vibration-enhanced FBS with a liquid-coated filter panel were designed, manufactured, and tested. The results confirmed that a vibration-induced filter panel enhances dust collection performance and reduces mesh clogging. In addition, laboratory-scale mesh clogging tests showed that a hydrophilic mesh provided superior clogging mitigation and better performance. Typical results from bench-scale tests showed notable improvements in dust collection efficiencies by over 6% in wet condition and over 7% in dry condition while reducing mass accumulation in the filter by almost 10% in wet condition and over 40% in dry condition. The prototype testing was less conclusive, with deviations between the static mesh and vibrating mesh depending on the mesh density and operating conditions. Nevertheless, with the highest mesh density tested (30-layer), the vibrating mesh notably outperformed the static mesh with superior collection efficiency and reduced airflow loss. The system was further analyzed to investigate the size-by-size recovery of dust particles to various endpoints in the scrubber, under both vibrating and static conditions. Results show that while a majority of the particles are recovered into the demister sump, nearly a quarter of the dust mass is recovered upstream of the screen. In addition, the data confirm that vibration prompts notable improvements to collection efficiency, particularly in the finest size class (- 2.5 micron). / Doctor of Philosophy / Coal mine dust is an unintended and unavoidable consequence of coal extraction operations that poses significant health and safety risks. The inhalation of small, respirable dust particles can cause incurable lung diseases, including silicosis and coal workers' pneumoconiosis known as black lung. To minimize occupational hazards of underground coal mine dust, the Mine Safety and Health Administration (MSHA) periodically brings legislation to the industry. The recent respirable dust rule mandates reducing the maximum allowable respirable dust concentrations in the mine environment to below 1.5 mg/m3 at the working face and below 0.5 mg/m3 at intake entries. In order to comply with these regulations, modern mining techniques utilize several dust mitigation strategies, and the flooded-bed dust scrubber (FBS) is one such technology used extensively on continuous miners. The conventional static panel filter, instrumental in most scrubber designs, however, is fundamentally limited in collection efficiencies due to a high clogging rate and a tradeoff between mesh density and airflow rate. Moreover, poorly wetted areas allow dust-laden air to pass through the filter media. To overcome these deficiencies, a novel liquid-coated vibrating mesh panel is introduced in this research. A laboratory-scale dust scrubber unit and a full-scale unit with a vibration-enhanced mesh screen panel were manufactured and employed to investigate the efficacy of the concept as compared to that of a static mesh. A series of experimental design studies were employed to determine the effective vibrational parameters, scrubber operational parameters, and the impact of mesh variations on dust collection and clogging mitigation. Optimized results from this research were also evaluated against those of a static mesh to determine performance improvement while investigating the mechanisms controlling dust collection and particle department through the scrubber system. Results from the laboratory study show that vibrating mesh conditions, higher water flow rates, and a hydrophilic mesh screen panel led to an improvement in the cleaning efficiency of the scrubber system. Compared to a static-mesh to FBS, the vibrating-mesh FBS showed a significant reduction in pressure drop across the mesh screen indicating lower air loss through the test duration. Overall, the findings confirm that vibrating mesh conditions have the ability to improve filter clogging issues while maintaining high collection efficiencies which can lead to better and healthier working conditions and prolonged operational time with less frequent maintenance. This research supports further technological advancement in mine dust mitigation technologies.
| Identifer | oai:union.ndltd.org:VTETD/oai:vtechworks.lib.vt.edu:10919/116507 |
| Date | 18 October 2023 |
| Creators | Uluer, Mahmud Esad |
| Contributors | Mining Engineering, Noble, Christopher Aaron, Amini, Seyed Hassan, Karfakis, Mario G., Shahab, Shima, Keles, Serhat |
| Publisher | Virginia Tech |
| Source Sets | Virginia Tech Theses and Dissertation |
| Language | English |
| Detected Language | English |
| Type | Dissertation |
| Format | ETD, application/pdf, application/pdf |
| Rights | In Copyright, http://rightsstatements.org/vocab/InC/1.0/ |
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