14th United States/North American Mine Ventilation Symposium, 2012 Calizaya & Nelson 2012, University of Utah, Dept.

t. of Mining Engineering

A CFD analysis of air flow patterns in the face area for continuous miner making a straight initial cut
V. K. Kollipara
Southern Illinois University, Carbondale, Illinois, USA

D. D. Relangi and Y. P. Chugh

Southern Illinois University, Carbondale, Illinois, USA
ABSTRACT: Airflow patterns in a room-and-pillar mine face area are critical for understanding the dust dispersion characteristics and for designing engineering controls. Computational Fluid Dynamics (CFD) technique was used and its use was validated with the published experimental data under controlled conditions. This study analyzed airflow patterns in a room-and-pillar mining face area when Continuous Miner (CM) is making a straight initial cut. Four different scenarios of straight initial cut were simulated. In each scenario, low air velocity (LAV) and re-circulation (RC) zones were identified from mining workers exposures point of view. Scrubber operation effect on airflow patterns was not found to be very significant. In addition, it was also found that scrubber suction efficiency of dust laden air from the face area may be low until the CM advances about 1.52 m (5-ft). 1 Introduction
similar analyses for different CM cuts to develop a complete picture for the design of engineering controls. Typically, several different types of cuts are used in a room-and-pillar mining section (Figure 1). These include: 1) Straightinitial cut: Cut made in an entry with face location less than 3 m (10 ft) past the LOXC, 2) Straight deep cut: Cut made in an entry with face location at start of the cut between 3 m (10 ft) and 12 m (40 ft) past the LOXC, 3) Straightdeepest cut: Cut made in an entry with face location at start of the cut over 12 m (40 ft) past the LOXC, 4) Cross-cut right or lefthole through: Typically the second cut into a cross cut that intersects the adjacent entry, 5) Cross cut right or leftmined straight ahead: The first cut made into a cross cut by mining straight ahead perpendicular to the entry from adjacent cross cut, 6) Turn cross cut right or left: Turning a cross cut from an entry. Thus, this paper presents an analysis of airflow patterns for a straight initial cut.

During coal cutting process, a large fraction of respirable dust particles (< 7m) becomes airborne and is under the influence of carrier fluid (air) properties. The dust particles remain airborne for long duration and are difficult to control and capture. Coal and quartz dust is primarily controlled through use of water sprays and face ventilation. Thus, it is fundamentally important to scientifically understand the airflow patterns in the face area (that correspond to the dust dispersion characteristics) and then design appropriate engineering controls to wet the dust. Since it is very difficult to study the airflow patterns experimentally, CFD modeling approach was chosen for this research. Such data has to be developed for all CM cut types. CFD studies on studying airflow patterns at SIUC began with analyzing airflow patterns (Alam, (2006)) in a room-and-pillar mining face area with line curtain (LC) installed but without any cutting equipment. Kantipudi (2009) expanded Alam studies by incorporating continuous miner (CM), LC and wet-scrubber in modeling and analyzed airflow patterns in the face area of the last open x-cut (LOXC). The study focused on when the CM is making a straight deep cut. Results indicated that LC position, cut type and cut sequence, and scrubber operation affect the airflow patterns in the face area. Similar study was performed by Kollipara and Chugh (2012) when CM is making a right turn cut. During this study, effect of air leakage through LC at the roof and floor level on airflow patterns was studied in addition to the parameters evaluated by Kantipudi (2009). Results showed that air leakage near LC significantly affects the volume of the air at the end of the LC and thus airflow patterns in the face area. It is thus important to perform

Goals and Specific Objectives

The overall goal of this paper is to analyze airflow patterns in a room-and-pillar mining face area when CM is making a straight initial cut. The specific objectives are to: 1) Perform validation of the use of the CFD code ANSYS Fluent and, 2) Identify low air velocity (LAV) and recirculation (RC) zones for four different scenarios of this cut.

Taylors Experiments and CFD Validation Studies

The use of the CFD code was validated with the experimental data on airflow patterns conducted by

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Taylor et al., 2004. The objective of the experiments was to analyze the airflow patterns and possibly methane distributions in the face area for both box-cut and slab-cut operations of a CM. Thus, experimental set-up was modeled and the authors simulated both box-cut and slabcut operations in a commercial CFD code Fluent. The CFD airflow patterns in the face area for both box-cut and slab-cut operations, developed by Kollipara and Chugh (Kollipara and Chugh., 2011) are in a reasonable agreement with the experimental data. The magnitude of those velocity vectors (air flow patterns) are within 10% of the experimental data. Thus, CFD modeling here can be used to study airflow patterns in the face area. Due to page limitation, validation results (Kollipara et al., 2012) are not discussed here.

CFD Modeling

4.1 Description of the Physical Problem Figure 2 shows a 2-D schematic of a room-and-pillar mining layout with scrubber-integrated CM about to make a straight initial cut for four different scenarios. Scenario 1 represents the first cut advancing an entry beyond a Tjunction type LOXC intersection with intake entering on the right side and exhausting through the open crosscut on the left. Some air leakage can occur through the entry behind the CM. Scenario 2 represents the first cut

advancing an entry beyond an L-type LOXC intersection with an open intake crosscut to the right and air exhausting out via the entry behind the CM to the first return LOXC. Intake air leakage can occur through the open crosscut located directly across from the LOXC return. Scenario 3 is similar to scenario 2 with the CM advancing from an L-type intersection but without an open return crosscut behind. The entry advanced by the CM in scenario 3 serves as the return air course. As is scenario 2 air leakage can occur through the crosscut behind the CM. In scenario 4 the CM advances from an L-type LOXC intersection with an open return crosscut on the left side and intake air entering through the entry behind the CM. A line curtain is typically used immediately out-by the LOXC intersection to course the intake air to the mining face. The figure also shows the location of LC for scenario 4 where the end of LC is positioned about 1.52 m (5ft) from the back end of the CM body. Distance between (DCR) coal rib and the end of the LC is about 1.2 m (4 ft.). Air volume at the end of the LC is well above 3.5 m3/sec (~ 7,000 cfm). Air leakage can occur through the both LC and through the crosscut behind the CM. Further details (CM description and assumptions) are included in A CFD analysis of air flow patterns in the face area for continuous miner making a right turn cut, SME Annual Meeting, 2012, Seattle, Washington.

Figure 1. 2-D representation of different cuts.

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O2

I1

O1

O2 O1

O2 O1

I2 I1 O1

I2

Figure 2. 2-D schematic of CM making a straight initial cut 4 Scenarios. (I1 = inlet 1, I2 = Inlet 2, O1 = outlet 1, O2 = Outlet 2). 4.2 Description of Models Simulated Twelve models of CM making a straight cut were simulated as described in Table 1 below. Installation of LC was not necessary for this cut except scenario 4. Since the geometry of scenario 2 and 3 is similar, line curtain (no leakage was provided at the roof and floor levels) effect was studied in scenario 2 and compared with scenario 3 results. 4.3 Boundary Conditions Boundary conditions for all models are shown in Table 2. When scrubber is turned on, pressure boundary conditions were used to study changes in intake air and LC air volumes. This analysis is not possible if mass flow rate is fixed at the inlet. A fan boundary condition was used at the scrubber outlet based on typical scrubber discharge volume of about 3.5 m3/sec (~ 7,000 cfm). Wall roughness effect on the flow was analyzed by assigning roughness values of 0.0762 m (3-inch) and 0.025 m (1inch) for walls and CM. Air density (1.243 kg/m3), atmospheric pressure (103169 Pa), viscosity (1.8e-05 m2/sec) and temperature (289.14 K) of air were calculated (U.S. Standard Atmosphere, 1976) for 152 m (500 ft) mining depth. Table 1. List of models simulated. Model No 1 2 3 4 5 6 7 8 9 10 11 12 Description Scenario -1, No Equipment Scenario -1, With CM, Scrubber OFF Scenario -1, With CM, Scrubber OFF Scenario -2, No Equipment Scenario -2, With CM, Scrubber OFF Scenario -2, With CM, Scrubber OFF Scenario -3, No Equipment Scenario -3, With CM, Scrubber OFF Scenario -3, With CM, Scrubber OFF Scenario -4, No Equipment Scenario -4, With CM, Scrubber OFF Scenario -4, With CM, Scrubber OFF

Table 2. Boundary Conditions.

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Model 1 2 3 4 5 6 7 8 9 10 11 12

Inlet 1 14 kg/sec 14 kg/sec 1.647 Pa 14 kg/sec 14 kg/sec 2.728 Pa 14kg/sec 14kg/sec 2.86 Pa 14 kg/sec 14 kg/sec 6.228 Pa

Inlet 2 2.33 kg/sec 2.33 kg/sec 0.116 pa 2.33 kg/sec 2.33 kg/sec 0.114 Pa 2.33 kg/sec 2.33 kg/sec 0.081 pa

Outflow 1 4 kg/sec 4 kg/sec 0.0134 Pa 4 kg/sec 4 kg/sec 0.0494 pa 16.34 kg/sec 16.34 kg/sec -0.66 pa 12.24 kg/sec 12.24 kg/sec 0.0544 pa

Outflow 2 10 kg/sec 10 kg/sec 0.39 pa 12.24 kg/sec 12.24 kg/sec -0.456 Pa 4 kg/sec 4 kg/sec -0.152 pa

Results and Discussion

For all the models simulated, velocity vectors were plotted at 1.52 m (5 ft.) above the ground and used to identify low air velocity (LAV) and re-circulation (RC) zones.
5.1 Scenario 1

(5-ft) for the following reasons: 1) Entire intake air volume (~ 24, 000 cfm) is used for diluting the dust generated near the face area, 2) CM and HUO are in a safe zone with and without scrubber operation, and 3) Scrubber has low probability of sucking in dust-laden air near the face.

Three models were simulated for each scenario (Table 1). Figures 3, 4, and 5 show the velocity vectors for Models 1, 2 and 3. Letters M and H indicate the location of CM and HUO operators. 1. Zone A (Model 1) is a combination of both LAV and RC regions, whereas the same Zone A in Model 2 is only a LAV zone where HUO is located. 2. Zone B (Model 2) is a higher velocity zone (~1.78 m/sec as compared to ~1 m/sec in Model 1). This is due to reduced crosssectional area due to the presence of CM. However, CM operator is in a safe zone and HUO is in a LAV zone. 3. For the Model 3 (Scrubber on, Figure 5), airflow patterns change significantly. HUO is in a RC zone. However, he may not be exposed to high dust concentration due to dilution from intake air volume. 4. Overall, CM is always in a fresh air zone, whereas HUO could be either in LAV or RC zones but may not be exposed to high dust concentration. However, dust exposure levels to HUO can change once CM advances beyond 1.52m (5 ft). In addition, analysis of air flow distribution suggests that scrubber suction efficiency of dust-laden air is lower until CM advances beyond 1.52 m

Figure 3. Velocity vectors - Model 1

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Figure 4. Velocity vectors - Model 2.

3. In Model 6 (Figure 8), where scrubber is switched on, RC zone B is completely eliminated. However, Zone A is transformed into a combination of LAV and RC zones. HUO may however be exposed to high dust concentration. In addition, Figure 6 shows that air from the leakage section is diverted towards the HUO location due to the high pressure curtain created by scrubber discharged air along the left rib of the mine opening. This additional air can dilute the dust near HUO location. 4. Overall, CM is always in a fresh air zone and HUO could be either in LAV or RC zones. LC installation may not play a major role. Similar to the reasons explained above for scenario 1, scrubber suction efficiency of dust-laden air is small.

Figure 5. Velocity vectors - Model 3. 5.2 Scenario 2

Figure 6. Velocity vectors - Model 4.

Three models were simulated and Figures 6, 7, and 8 shows the velocity vectors for Models 4, 5 and 6. 1. Zone A and Zone B ((Model 4) are a combination of LAV and RC zones. Similar to physical conditions, air leakage of 2.33 kg/sec (~ 4,000 cfm) was provided from the adjacent x-cut. Some re-circulation was observed in the NW corner where there is potential for methane accumulation. However, its effect is neutralized by high intake air volume (~ 14 kg/sec, 24,000 cfm). 2. With CM in position to cut (Model 5), RC Zone B is minimized and Zone A is better ventilated. This is due to increase in air velocity above the CM body and LC position (see Figure 7). This helps to maintain uniform flow across the width of the opening. Both HUO and MO are in a fresh air zone.

Figure 7. Velocity vectors - Model 5.

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Figure 8. Velocity vectors - Model 6. 5.3 Scenario 3

Scenario 3 is very similar to scenario 2 except that air outflow is different and LC is not installed. Figures 9, 10, and 11 show the velocity vectors for Models 7, 8 and 9. 1. In model 7, the air flow throughout the domain is uniform with no LAV and RC zones except partial re-circulation in the NW corner. 2. Even when the CM is in the position to cut (Model 8), air velocity is uniform except that HUO could be in LAV Zone A. 3. In Model 9, when scrubber is switched on, HUO is in a combination of RC and LAV zones. Again, air from the leakage section (Zone B) is being diverted to face area for the reasons above for scenario 2. CM is in a fresh air zone always. 4. Overall, this scenario is similar to scenario 2.

Figure 9. Velocity vectors - Model 8.

Figure 10. Velocity vectors - Model 9. 5.4 Scenario 4

Figures 12, 13, and 14 show the velocity vectors for Models 10, 11 and 12. Air leakage of 2.33 kg/sec was provided as shown in the Figure 12. 1. Zone A (Model 10, Figure 12) is a high velocity zone (~ 3.5 m/sec) due to the LC position and it reduces the cross-sectional area for the air to reach the face area. However, volume of the air at the end of the LC is maintained around 3.5 m3/sec (7,000 cfm). Zone B (Model 11) is a combination of LAV and RC zones. 2. Similar to Model 10, Zone A (Model 11, Figure 13) is a high velocity zone and Zone

Figure 11. Velocity vectors - Model 7.

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3.

4.

5.

6.

B (Model 11) is a combination of LAV and RC zones. However, both MO and HUO are in a fresh air zone. Compared to other scenarios, airflow patterns here change significantly when scrubber is switched on. Intake air volume is decreased by 50% and this could be due to following reasons: 1) Resistance due to LC is modeled as a wall with no leakage at roof and floor levels, and 2) Scrubber discharge (4.4 kg/sec) volume creates a high pressure hydraulic curtain resisting the incoming air. In addition, recirculated air (see Zone E in Figure 14) across the entire x-sectional area blocks the intake air. Thus the HUO is in a RC zone and he could be exposed to dust laden air if scrubber dust control efficiency is low. Due to decrease in air volume in intake and to satisfy the pressure requirements across the between intake and return air domain, air volume was increased by 75 % in Zone D (near air leakage) in Figure 14. Here, the intake air is bypassed to return location (Figure 14) without reaching the face area. This will increase the dust concentration levels in face area and downwind. Air from return side (see Zone C in Figure 14) travels back to the face area to satisfy the scrubber pressure requirements. This could create a volume of air borne dust in the face area re-circulating over a period of time. This air could also travel to MO operator. Zones A and B remain the same Overall, both MO and HUO could be in a dust-laden air zone.

Figure 13. Velocity vectors - Model 11.

Figure 14. Velocity vectors - Model 12.

Concluding Remarks

This paper has analyzed airflow patterns in the face area when CM is making a straight initial cut. Analyses have developed the following scientific data. Low air velocity and air re-circulation zones when CM is about to make box-cut in a straight initial cut. For scenarios 1, 2 and 3, it appears based on the visual observation of airflow patterns that scrubber efficiency for sucking in dust-laden air is small. In addition, dust in face area is mostly diluted by intake air (16 kg/sec, ~ (24,000 cfm)) until CM advances 1.52 m (5-ft) into the cut. LC position and scrubber operation significantly affect the air flow patterns in the face in scenario 4 as compared to other scenarios.

Figure 12. Velocity vectors - Model 10.

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The analyses above should be extended to remaining type of cuts. Data base should then be created to optimize the CM cut-sequence, CM cut-advancement, scrubber operation and LC position for improved dust control.

Acknowledgements

The authors sincerely acknowledge Illinois Clean Coal Institute of the Department of Commerce and Economic Opportunity, Harrold Gurley and coal companies for technical support as needed. The technical support provided by FLUENT technical staff is highly appreciated.

References

Alam, M M, 2012. An Integrated Approach to Dust Control in Coal Mining Face Areas of a Continuous Miner and its Computational Fluid Dynamics Modeling, MS Thesis, Southern Illinois University, Carbondale, IL. Kantipudi, R, 2009. Computational Fluid Dynamics Modeling of Airflow Patterns around a Room and Pillar Mining Face Area, Masters Thesis, Southern Illinois University, Carbondale, IL. Kollipara, V K and Chugh, Y P, 2012. A CFD analysis of air flow patterns in face area for continuous miner making a right turn cut, SME Annual Meeting, Seattle, Washington. Kollipara, V.K and Chugh, Y P, 2011. Validation of use of CFD Technique to Study Airflow Patterns in the Face Area, Internal Study, Southern Illinois University, Carbondale, IL.

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