Optimized canopy air curtain dust protection using a two-level manifold and computational fluid dynamics

The key takeaway of this study is the significant improvement in dust protection for roof bolter operators in underground coal mines. The optimized canopy air curtain (CAC), with a redesigned two-level manifold system, provides uniform airflow distribution that effectively reduces dust exposure. By enhancing the protection of operators from harmful respirable coal and silica dust, this technology can reduce the risk of diseases such as coal workers’ pneumoconiosis (CWP) and silicosis. The application of this optimized CAC design in real-life coal mining operations can dramatically improve worker health and safety by minimizing dust-related exposure, ensuring compliance with industry regulations and prolonging the lifespan of mining equipment by reducing dust accumulation. Background Prolonged exposure to coal dust in mining operations has long been a significant health hazard, contributing to conditions such as CWP and silicosis. In underground mining environments, roof bolter operators are especially vulnerable due to their close proximity to coal and silica dust sources. Previous designs of CACs have offered some level of protection, but with inconsistent results in terms of airflow distribution and dust control efficiency. This study focuses on optimizing the airflow distribution in CACs using computational fluid dynamics (CFD) simulations and laboratory validation. The goal is to enhance the uniformity of airflow over the operator’s breathing zone, which directly impacts the effectiveness of the air curtain in preventing dust infiltration. Fig. 1 CAD drawing of a typical roof bolter equipment showing the structure of the canopy air curtain mounted on its canopy. Methods The study employed a combination of CFD simulations and the Simplex evolutionary operation (EVOP) optimization algorithm to redesign the airflow distribution in the CAC. The optimized CAC design features a two-level manifold system: (1) the first level is responsible for horizontal airflow distribution and (2) the second level delivers air uniformly downward to the operator’s breathing zone.Six key parameters were optimized: the dimensions of the inlet, outlet width, the tapering of the manifold, and the spacing of the outlets. CFD simulations were carried out for each configuration to model the airflow behavior, and the EVOP algorithm was used to iteratively improve the design. A prototype of the optimized CAC was constructed for laboratory testing to validate the CFD results and ensure the practicality of the design in real-world applications. Results The optimized CAC design achieved significant improvements in airflow distribution, with a nonuniformity coefficient of 0.0036 in the laboratory model compared to 0.0049 in the CFD simulations. The use of the two-level manifold system allowed for controlled airflow distribution, particularly in the trapezoidal regions of the roof bolter canopy. The CFD results showed a marked improvement in airflow uniformity, and the laboratory validation confirmed the reliability of the optimized design. Fig. 2 Contour of internal airflow pattern in the CAC. Discussion The results demonstrate that the optimized CAC design significantly improves both the uniformity of airflow and the overall efficiency of dust control. The introduction of the two-level manifold system addresses the limitations of previous designs by ensuring uniform air distribution across the entire plenum, preventing coal dust infiltration in the operator’s breathing zone. The study’s findings suggest that further field testing is warranted to explore the durability and performance of the optimized CAC design under different mining conditions. Implementing this design in real-world settings could greatly reduce the health risks posed to roof bolter operators and other personnel in underground mining environments. Conclusions This study successfully optimized the CAC system using CFD simulations and experimental validation. The optimized design, featuring a two-level manifold system, provides a more uniform airflow distribution, improving dust control efficiency by 23 percent. These results have significant implications for enhancing occupational health and safety in coal mining environments. The next step involves real-world testing to validate the system’s durability and efficiency under operating conditions. Further research is needed to assess the long-term impact of the optimized CAC on dust control in various mining scenarios. Selected references Blackley DJ, Crum JB, Halldin CN, Storey E, Laney AS (2016) Resurgence of progressive massive fibrosis in coal miners — Eastern Kentucky. Morb Mortal Wkly Rep 65(49):1385–1389 Listak JM, Beck TW (2012) Development of a canopy air curtain to reduce roof bolters’ dust exposure. Min Eng 64(7):72–79 Zaid MM, Xu G, Amoah NA (2023) Accuracy of low-cost particulate matter sensor in measuring coal mine dust – A wind tunnel evaluation. Underground Ventilation. CRC Press, pp 274–284

Optimized canopy air curtain dust protection using a two-level manifold and computational fluid dynamics

Authored by: Nana A. Amoah, Mirza Muhammad Zaid, Ashish R. Kumar, Ping Chang and Guang Xu

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