A Numerical Study on Dust Control: Evaluating the Impact of Spray Angle and Airflow Speed in the Coalescence of Droplets and Dust

Spray dust reduction is one of the most economical and effective technologies for controlling coal dust in coal mining faces. We aimed to reproduce a spray dust reduction process in a simulation and investigate the mechanism by which the spray angle and airflow speed influence the dust reduction effect. Based on the DPM (discrete phase model) and the mixture model, we constructed a spray dust reduction evaluation model by considering two-way momentum coupling between the discrete phase and the continuous phase. The results showed that installing nozzles near the dust source (coal mining drum) significantly reduced the dust concentration at the coal mining face from 0.0005 kg/m3 to 0.0001 kg/m3. The increase in airflow speed and spray angle enhanced the horizontal transportation of droplets and dust, providing opportunities for the droplets to condense the dust; however, if the droplets have too large an angle, this will result in an insufficient concentration of droplets in the vicinity of the dust source. When the spray angle is 45°, increasing the airflow speed provides a better dust reduction effect. The nozzle position should also be set scientifically according to the airflow speed. Based on simulation results, a mathematical calculation model of spray dust reduction efficiency was constructed. These results can guide the key parameters of spray dust reduction systems, such as the installation position of the nozzle, the spray angle, and the airflow speed. This paper provides ideas for simulating spray dust reduction for other dust types.