弧扇泡沫射流高效除尘技术研究
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摘要
现有泡沫除尘技术的泡沫喷射工艺较为粗放，喷射装备较为粗糙，造成泡沫浪费严重，这不仅从一定程度上推高了应用成本，影响除尘效果，还对作业环境产生一定影响。本文在现有泡沫除尘技术基础上，结合泡沫除尘机理及我国采掘机械客观实际，提出了弧扇泡沫射流构想，并采用理论分析、数值模拟、实验室实验，现场工业性试验等方法，分析了弧扇泡沫射流形成机理及发展过程，研制了包含弧扇泡沫喷嘴和可调式喷嘴安装支架的弧扇泡沫高效喷射装置，探讨了风流场对弧扇泡沫射流的影响及其弱化方法，最终形成了以弧扇泡沫高效喷射装置为核心，以附壁风筒为重要组成的弧扇泡沫高效除尘技术。
基于高速摄像技术研究了粉尘与泡沫的耦合作用过程，根据表面物理化学等有关理论，系统分析了泡沫除尘机理。研究表明，泡沫薄膜是拦截粉尘的物理屏障，泡沫薄膜的变形、破裂、振动是其缓解粉尘撞击的主要方式。泡沫除尘包括尘泡接触（碰撞——破裂——碰撞）、尘泡黏附、尘泡黏附体沉降三个过程，泡沫与粉尘的接触效率、黏附效率和沉降效率是决定泡沫除尘效果的关键，而接触效率是最为重要的。研究认为当前泡沫除尘技术的关键之一是改善泡沫喷射状态，提高尘泡接触效率，以实现泡沫高效利用，提升泡沫除尘效果。
对煤矿采掘设备进行了调研，对采掘机械产尘特征进行了分析，提出了适于高效泡沫除尘的最优喷射流型优选标准。以纵轴式采掘机械为应用背景，对实心锥、平扇、弧扇三种喷射流型进行理论对比，结果表明弧扇泡沫射流可在同样包裹尘源的状态下明显降低泡沫用量。基于非牛顿流体力学等相关理论和喷嘴制造实践，提出了弧扇射流的形成方案，对弧扇喷嘴关键尺寸进行了初步设计。分析了弧扇泡沫射流的形成及发展过程，建立了弧扇泡沫射流轴心速度与压力的无量纲公式，阐述了弧扇泡沫射流特征。
设计并构建了高效泡沫除尘技术开发实验平台，并基于该平台，实验分析了喷嘴结构参数对弧扇泡沫射流包裹性能的影响。根据实验结果，分析了喷嘴结构尺寸的确认方法；对喷嘴结构进行了优化，设计了整流翼结构以消除翼流现象，设计了可调式喷嘴安装支架，以改变喷射角度不可调节的现状，实现了泡沫射流对目标靶点的精确打击。此外，实验分析了工况与产泡性能之间的关系，得出了喷嘴的最优工况范围。
通过数值模拟研究了风流场对弧扇泡沫射流的影响，证明了风流场可明显改变泡沫射流运移轨迹，并通过实验验证了模拟结果。提出了通过“风量不变、改变风速分布”的方法来缓解风流场的影响，并设计了一种附壁风筒。数值模拟和实验研究均表明，附壁风筒可在一定程度上缓解风流场对弧扇泡沫射流的影响。
在付村矿3下412掘进工作面进行了现场试验，结果表明：弧扇泡沫高效除尘技术对全尘和呼尘的除尘效率分别达到92.6%和92.5%，有效地降低了井下采掘工作面的粉尘浓度，取得显著的防尘效果。其全尘除尘效率在平扇喷嘴和实心锥喷嘴基础上分别提高了5.6%和10.4%，呼尘除尘效率在平扇喷嘴和实心锥喷嘴基础上分别提高了5.6%和11.7%。使用附壁风筒后，无论采用弧扇、平扇还是实心锥喷嘴，泡沫除尘效率普遍小幅提高，平均增幅2.7%。试验结果证明了弧扇泡沫射流高效除尘技术可实现泡沫的高效利用，在消耗相同泡沫的情况下有效提高了泡沫除尘效率。
The existing foam spray equipment is rather rough and spray process is moreextensive, resulted in a serious waste of foam, which not only increases the cost anddecrease efficiency of dust removal, but also influences the operating environment.Based on the existing foam dust control technologies and the mechanism of dustcontrol with foam, the paper proposes the idea of arc foam jet with considering thereality of mining machinery in our country. In this paper, through theoretic analysis,numerical simulation, laboratory experiments and field tests, it analyzes the formingand developing mechanism of arc foam jet. It also develops efficient foam sprayequipment consisting of arc foam nozzle and adjustable installation device, discusshow wind field affects the foam spray and weaken its efficiency. As a result, we get anefficient foam dust control technology with efficient foam spray as the core deviceand ventilation duct with Coanda effect (VDCE) as the important part.
The interaction process of dust particle with foam was captured based onhigh-speed photography technology in this research. Depending on superficialphysical chemistry and mechanics and so on, it analyzes the mechanism of dustcontrol with foam. The results revealed that the foam film is the physical barrierblocking dust. The deformation, rupture and vibration of foam films are the majormodes to alleviate the impact of dust particles. Three distinct regimes of the dustremoval with foam were identified, namely, the impact between particle and foam(collision-rupture-collision), the attachment of the particle and foam, and thesedimentation of particle-foam agglomerates. Contact efficiency, adhesion efficiencyand deposition efficiency are three keys to foam dust control, and the contactefficiency is the most important thing. The current study suggests that one of the keyfoam dust control technologies is improving the state of foam spray, which canachieve efficient foam spray and increase the contact efficiency. Finally improve theeffect of foam.
Through the researching on mining machinery and analyzing on thecharacteristics of dust arising from mining equipment, the paper proposes the standardfor optimum spray pattern to get fine foam spray. Take vertical-axis roadheader asapplication background, it analyses three kinds of foam jet shapes: the full cone jet,flat jet and arc jet. Theoretical comparison is made on the minimum volume of foamwhen using the full cone jet, flat jet and arc jet. The results show that the arc jet is the better choice for achieving the efficient foam dedusting. In the same condition ofenwrapped dust source, the arc jet requires the least amount of foam. Based onnon-newtonian fluid mechanics and other related theories and the manufacturingtechnology of nozzle, it proposes the formation scheme of arc spray pattern andpreliminary design for the critical size of jet nozzle. Combined with jet mechanics andother relevant theories, high-speed photography technology and numerical simulationmethod, this dissertation studies the formation and the development process of thefoam arc spray, establishes center velocity and pressure dimensionless equations ofarc jet spray and elaborates the characteristics of arc jet spray.
Experiment platform for design of efficient dust control technology with foam isdevised and constructed. Base on this platform, it analyzes the fabric parameters ofnozzle which can affect the enwrapping performance of the foam spray. Based onexperimental results, it comes to a design method which can confirm the fabricparameter of nozzle and optimize the structure of nozzle; it also designs the rectifierwing to eliminate wing current phenomenon. The adjustable installation support ofnozzle is designed to make sure the foam jet wrap the dust source efficiently. Inaddition, the experiment analyzes the relationship between the operation conditionand performance of arc foam nozzle, and gets the optimal working condition range ofthe nozzle.
In order to reveal the influence of airflow on the dispersion of foam ejected fromroadheader-mounted external nozzle, the paper studies the arc foam jet distributionunder the condition of gentle breeze and normal forced ventilation in heading face.The results show that airflow can significantly affect the trajectory of foam jet. Inorder to mitigate the effect of airflow on foam jet, it brings forward a method as“change the wind speed distribution with the same amount of wind”, which canalleviate the impact of airflow, and design a VDCE. Numerical simulation andexperimental results show that the application of VDCE can effectively mitigate theinfluence of airflow on the foam jet.
The field experiment carried out in3下412heading face of Fucun coal mine. Theresult shows that the efficient dust control technology with arc foam jet can reducetotal dust and respiratory dust to92.6%and92.5%respectively, which consists with aarc foam nozzle as the core device and VDCE as the important part. Its total dustsuppression efficiency is5.6%and10.4%higher than the flat nozzle and full conenozzle. Its respirable dust suppression efficiency is5.6%and11.7%higher than the flat nozzle and full cone nozzle. The dust suppression efficiency when using VDCEaveragely increase2.7%, whatever the nozzle is arc, flat or full cone. It proves that theefficient foam dust control technology with arc foam jet can weaken the influence ofairflow on foam dispersion. The results prove that efficient foam dust controltechnology with arc foam jet makes the foam highly used, and improve the efficiencyof the foam dust control. On the one hand, the technology puts forward a brand newconcept for foam dust control, on the other hand, it gives a reference to design dustremoval device of mining equipment.
基于高速摄像技术研究了粉尘与泡沫的耦合作用过程，根据表面物理化学等有关理论，系统分析了泡沫除尘机理。研究表明，泡沫薄膜是拦截粉尘的物理屏障，泡沫薄膜的变形、破裂、振动是其缓解粉尘撞击的主要方式。泡沫除尘包括尘泡接触（碰撞——破裂——碰撞）、尘泡黏附、尘泡黏附体沉降三个过程，泡沫与粉尘的接触效率、黏附效率和沉降效率是决定泡沫除尘效果的关键，而接触效率是最为重要的。研究认为当前泡沫除尘技术的关键之一是改善泡沫喷射状态，提高尘泡接触效率，以实现泡沫高效利用，提升泡沫除尘效果。
对煤矿采掘设备进行了调研，对采掘机械产尘特征进行了分析，提出了适于高效泡沫除尘的最优喷射流型优选标准。以纵轴式采掘机械为应用背景，对实心锥、平扇、弧扇三种喷射流型进行理论对比，结果表明弧扇泡沫射流可在同样包裹尘源的状态下明显降低泡沫用量。基于非牛顿流体力学等相关理论和喷嘴制造实践，提出了弧扇射流的形成方案，对弧扇喷嘴关键尺寸进行了初步设计。分析了弧扇泡沫射流的形成及发展过程，建立了弧扇泡沫射流轴心速度与压力的无量纲公式，阐述了弧扇泡沫射流特征。
设计并构建了高效泡沫除尘技术开发实验平台，并基于该平台，实验分析了喷嘴结构参数对弧扇泡沫射流包裹性能的影响。根据实验结果，分析了喷嘴结构尺寸的确认方法；对喷嘴结构进行了优化，设计了整流翼结构以消除翼流现象，设计了可调式喷嘴安装支架，以改变喷射角度不可调节的现状，实现了泡沫射流对目标靶点的精确打击。此外，实验分析了工况与产泡性能之间的关系，得出了喷嘴的最优工况范围。
通过数值模拟研究了风流场对弧扇泡沫射流的影响，证明了风流场可明显改变泡沫射流运移轨迹，并通过实验验证了模拟结果。提出了通过“风量不变、改变风速分布”的方法来缓解风流场的影响，并设计了一种附壁风筒。数值模拟和实验研究均表明，附壁风筒可在一定程度上缓解风流场对弧扇泡沫射流的影响。
在付村矿3下412掘进工作面进行了现场试验，结果表明：弧扇泡沫高效除尘技术对全尘和呼尘的除尘效率分别达到92.6%和92.5%，有效地降低了井下采掘工作面的粉尘浓度，取得显著的防尘效果。其全尘除尘效率在平扇喷嘴和实心锥喷嘴基础上分别提高了5.6%和10.4%，呼尘除尘效率在平扇喷嘴和实心锥喷嘴基础上分别提高了5.6%和11.7%。使用附壁风筒后，无论采用弧扇、平扇还是实心锥喷嘴，泡沫除尘效率普遍小幅提高，平均增幅2.7%。试验结果证明了弧扇泡沫射流高效除尘技术可实现泡沫的高效利用，在消耗相同泡沫的情况下有效提高了泡沫除尘效率。
The existing foam spray equipment is rather rough and spray process is moreextensive, resulted in a serious waste of foam, which not only increases the cost anddecrease efficiency of dust removal, but also influences the operating environment.Based on the existing foam dust control technologies and the mechanism of dustcontrol with foam, the paper proposes the idea of arc foam jet with considering thereality of mining machinery in our country. In this paper, through theoretic analysis,numerical simulation, laboratory experiments and field tests, it analyzes the formingand developing mechanism of arc foam jet. It also develops efficient foam sprayequipment consisting of arc foam nozzle and adjustable installation device, discusshow wind field affects the foam spray and weaken its efficiency. As a result, we get anefficient foam dust control technology with efficient foam spray as the core deviceand ventilation duct with Coanda effect (VDCE) as the important part.
The interaction process of dust particle with foam was captured based onhigh-speed photography technology in this research. Depending on superficialphysical chemistry and mechanics and so on, it analyzes the mechanism of dustcontrol with foam. The results revealed that the foam film is the physical barrierblocking dust. The deformation, rupture and vibration of foam films are the majormodes to alleviate the impact of dust particles. Three distinct regimes of the dustremoval with foam were identified, namely, the impact between particle and foam(collision-rupture-collision), the attachment of the particle and foam, and thesedimentation of particle-foam agglomerates. Contact efficiency, adhesion efficiencyand deposition efficiency are three keys to foam dust control, and the contactefficiency is the most important thing. The current study suggests that one of the keyfoam dust control technologies is improving the state of foam spray, which canachieve efficient foam spray and increase the contact efficiency. Finally improve theeffect of foam.
Through the researching on mining machinery and analyzing on thecharacteristics of dust arising from mining equipment, the paper proposes the standardfor optimum spray pattern to get fine foam spray. Take vertical-axis roadheader asapplication background, it analyses three kinds of foam jet shapes: the full cone jet,flat jet and arc jet. Theoretical comparison is made on the minimum volume of foamwhen using the full cone jet, flat jet and arc jet. The results show that the arc jet is the better choice for achieving the efficient foam dedusting. In the same condition ofenwrapped dust source, the arc jet requires the least amount of foam. Based onnon-newtonian fluid mechanics and other related theories and the manufacturingtechnology of nozzle, it proposes the formation scheme of arc spray pattern andpreliminary design for the critical size of jet nozzle. Combined with jet mechanics andother relevant theories, high-speed photography technology and numerical simulationmethod, this dissertation studies the formation and the development process of thefoam arc spray, establishes center velocity and pressure dimensionless equations ofarc jet spray and elaborates the characteristics of arc jet spray.
Experiment platform for design of efficient dust control technology with foam isdevised and constructed. Base on this platform, it analyzes the fabric parameters ofnozzle which can affect the enwrapping performance of the foam spray. Based onexperimental results, it comes to a design method which can confirm the fabricparameter of nozzle and optimize the structure of nozzle; it also designs the rectifierwing to eliminate wing current phenomenon. The adjustable installation support ofnozzle is designed to make sure the foam jet wrap the dust source efficiently. Inaddition, the experiment analyzes the relationship between the operation conditionand performance of arc foam nozzle, and gets the optimal working condition range ofthe nozzle.
In order to reveal the influence of airflow on the dispersion of foam ejected fromroadheader-mounted external nozzle, the paper studies the arc foam jet distributionunder the condition of gentle breeze and normal forced ventilation in heading face.The results show that airflow can significantly affect the trajectory of foam jet. Inorder to mitigate the effect of airflow on foam jet, it brings forward a method as“change the wind speed distribution with the same amount of wind”, which canalleviate the impact of airflow, and design a VDCE. Numerical simulation andexperimental results show that the application of VDCE can effectively mitigate theinfluence of airflow on the foam jet.
The field experiment carried out in3下412heading face of Fucun coal mine. Theresult shows that the efficient dust control technology with arc foam jet can reducetotal dust and respiratory dust to92.6%and92.5%respectively, which consists with aarc foam nozzle as the core device and VDCE as the important part. Its total dustsuppression efficiency is5.6%and10.4%higher than the flat nozzle and full conenozzle. Its respirable dust suppression efficiency is5.6%and11.7%higher than the flat nozzle and full cone nozzle. The dust suppression efficiency when using VDCEaveragely increase2.7%, whatever the nozzle is arc, flat or full cone. It proves that theefficient foam dust control technology with arc foam jet can weaken the influence ofairflow on foam dispersion. The results prove that efficient foam dust controltechnology with arc foam jet makes the foam highly used, and improve the efficiencyof the foam dust control. On the one hand, the technology puts forward a brand newconcept for foam dust control, on the other hand, it gives a reference to design dustremoval device of mining equipment.
引文
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