Design of a double-blade swirl wet dust collector for comprehensive mining faces
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摘要:
针对目前用于煤矿综掘工作面环境的除尘器除尘效率低的问题，设计了一种双叶旋流湿式除尘器。根据功能树法确定了该除尘器主要由环状喷雾装置、双旋流叶片、折流除雾板等组成，设计了双旋流叶片以提供更大的离心力，从而提高除尘效率。采用数值模拟方法分析了喷嘴口径、喷雾压力、叶片安装角、叶片转速对除尘器除尘效率的影响规律，基于响应曲面法建立了除尘效率与4种影响因素之间的多元回归方程，得出了令除尘器除尘效率最高的最佳参数：叶片安装角37°，转速1 550 r/min，喷雾压力1.9 MPa，喷雾口径2 mm。基于该参数建立了双叶旋流湿式除尘器虚拟样机，通过仿真得出除尘器的除尘效率为97.21%，安装除尘器后巷道回风侧行人呼吸带粉尘浓度大幅降低。在除尘实验平台及模拟巷道对除尘器模拟机进行测试，结果表明：除尘器的除尘效率平均值为94.80%；应用除尘器后，巷道回风侧行人呼吸带高度平均粉尘浓度由应用前的441.29 mg/m3降低至为269.14 mg/m3，降幅达39.0%。
Abstract:To address the issue of low dust collection efficiency of dust collectors currently used in the environment of coal mine comprehensive mining faces, a double-blade swirl wet dust collector was designed. The dust collector was mainly composed of an annular spray device, double swirl blades, and baffle mist eliminators, with the double swirl blades designed to provide greater centrifugal force and thus improve dust collection efficiency. A numerical simulation method was used to analyze the effects of nozzle diameter, spray pressure, blade installation angle, and blade rotational speed on dust collection efficiency. Based on the response surface methodology, a multivariable regression equation was established between dust collection efficiency and the four influencing factors. The optimal parameters for maximum dust collection efficiency were determined as follows: blade installation angle of 37°, rotational speed of
1550 r/min, spray pressure of 1.9 MPa, and nozzle diameter of 2 mm. Using these parameters, a virtual prototype of the double-blade swirl wet dust collector was established, and simulation results showed that the dust collection efficiency of the dust collector reached 97.21%. After the installation of the dust collector, the dust concentration in the breathing zone of workers on the return air side of the tunnel significantly decreased. Tests on a dust collection experimental platform and in a simulated tunnel indicated that the average dust collection efficiency of the dust collector was 94.80%. After the application of the dust collector, the average dust concentration at the breathing zone of workers on the return air side of the tunnel decreased from 441.29 mg/m3 to 269.14 mg/m3, a reduction of 39.0%. -
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图 2 双叶旋流湿式除尘器物理模型和网格划分
Figure 2. Physical model and mesh generation of double-blade swirl wet dust collector
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图 3 除尘器物理模型网格独立性检验结果
Figure 3. Grid independence test results of physical model of dust collector
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图 4 喷雾参数对除尘器除尘效率的影响
Figure 4. Influence of spray parameters on dust removal efficiency of dust collector
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图 5 叶片参数对除尘器除尘效率影响
Figure 5. Influence of blade parameters on dust removal efficiency of dust collector
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图 6 双叶旋流湿式除尘器虚拟样机
Figure 6. Virtual prototype of double-blade swirl wet dust collector
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图 7 除尘器内部风速及粉尘场仿真结果
Figure 7. Simulation results of air flow and dust field in the dust collector
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图 9 安装除尘器前后巷道粉尘场对比
Figure 9. Comparison of roadway dust field before and after applying dust collector
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图 11 除尘效率的响应曲面模型预测值与实测值对比
Figure 11. Comparison of dust removal efficiency between predicted values by response surface model and the experimental values
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图 13 除尘器应用前后测点位置粉尘浓度对比
Figure 13. Comparison of dust concentration at measuring points before and after application of dust collector
表 1 双叶旋流湿式除尘器初始参数
Table 1 Initial parameters of double-blade swirl wet dust collector
参数 值 参数 值 处理风量/（m3·min−1） 400～600 供水压力/MPa 1～3 叶片转速/（r·min−1） 1 000～2 000 直径/mm 1 000 叶片安装角/（°） 20～60 长度/mm 2 000 用水量/（L·m−3） ≤0.2 喷嘴口径/mm 1.6～2.4 
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表 2 喷雾参数设置
Table 2 Spray parameters setting
参数 值 参数 值 耦合频率 20 雾化半角/（°） 20 雾滴材料 Waterliquid 破碎模型 TAB 喷射方式 Pressure−swirl−atomizer 喷嘴口径/m 0.002 质量流率/（kg·s−1） 0.02 喷雾压力/MPa 2 喷射时间/s 100
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表 3 粉尘参数设置
Table 3 Dust parameters setting
参数 值 参数 值 耦合频率 20 最小粒径/m 1×10−6 粉尘材料 Coal−mv 中位粒径/m 6.03×10−5 喷射方式 Surface 粒径分布规律 Rosin−Rammler 质量流率/（kg·s−1） 0.008 粒径个数 10 最大粒径/m 1×10−4 湍流扩散模型 DRW模型
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表 4 基于响应曲面法的四因素三水平方案
Table 4 Four-factor three-level scheme based on response surface method
水平 因素 A/（°） B/（r·min−1） C/MPa D/mm 1 30 1 250 1.5 1.8 2 40 1 500 2.0 2.0 3 50 1 750 2.5 2.2
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表 5 不同因素下的除尘器除尘效率模拟实验结果
Table 5 Simulated experiment results of dust removal efficiency of dust collector under different factors
方案 A/（°） B/（r·min−1） C/MPa D/mm R/（mg·m−3） 1 40 1 500 2.0 2.0 93.15 2 40 1 500 2.5 1.8 88.57 3 50 1 500 1.5 2.0 81.57 4 40 1 750 2.0 2.2 91.38 5 40 1 500 2.0 2.0 96.02 6 40 1 500 2.0 2.0 95.39 7 50 1 750 2.0 2.0 75.55 8 30 1 500 2.5 2.0 89.17 9 40 1 250 1.5 2.0 86.26 10 40 1 500 1.5 2.2 91.65 11 30 1 250 2.0 2.0 81.65 12 50 1 500 2.0 2.2 77.54 13 40 1 250 2.5 2.0 85.51 14 40 1 500 2.0 2.0 94.93 15 40 1 250 2.0 1.8 87.35 16 30 1 500 2.0 2.2 86.34 17 50 1 500 2.0 2.2 89.22 18 40 1 500 2.0 1.8 78.76 19 40 1 500 2.0 1.8 94.82 20 40 1 500 1.5 1.8 95.62 21 50 1 250 2.0 2.0 78.65 22 30 1 750 2.0 2.0 91.35 23 40 1 500 2.5 2.2 85.84 24 40 1 500 2.0 2.0 96.19
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表 6 除尘器除尘效率响应曲面模型方差分析
Table 6 Variance analysis of response surface model for dust removal efficiency of dust collector
项目 平方和 自由度 均方 显著性检验值 F P 因素 A 310.800 0 1 310.800 0 93.270 0 <0.000 1 B 12.810 0 1 12.810 0 3.840 0 0.070 1 C 37.070 0 1 37.070 0 11.120 0 0.004 9 D 4.060 0 1 4.060 0 1.220 0 0.288 2 AB 40.960 0 1 40.960 0 12.290 0 0.003 5 AC 29.380 0 1 29.380 0 8.820 0 0.010 2 AD 0.8190 01 0.819 0 0.245 8 0.627 8 BC 0.403 2 1 0.403 2 0.121 0 0.733 1 BD 1.270 0 1 1.270 0 0.381 5 0.546 7 CD 0.384 4 1 0.384 4 0.115 4 0.739 2 A2 543.390 0 1 543.390 0 163.070 0 <0.000 1 B2 145.080 0 1 145.080 0 43.540 0 <0.000 1 C2 87.480 0 1 87.480 0 26.250 0 0.000 2 D2 17.590 0 1 17.590 0 5.280 0 0.037 5 模型 1 108.650 0 14 79.190 0 23.760 0 <0.000 1 残差 46.650 0 14 3.330 0 — — 失拟项 40.710 0 10 4.070 0 2.740 0 0.171 8
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表 7 除尘实验结果
Table 7 Experimental data of dust removal
序号 测点处粉尘浓度/（mg·m−3） 2—4号测点粉尘
浓度平均值/（mg·m−3）除尘
效率/%1号 2号 3号 4号 1 905.72 52.64 56.85 34.38 47.96 94.70 2 832.81 36.24 23.36 28.18 29.26 96.49 3 854.47 30.54 57.13 48.55 45.41 94.69 4 866.95 69.28 47.50 57.63 58.13 93.30
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