Simulation analysis and engineering application of distribution characteristics about multi-stage atomization field for cutting dust in fully mechanized mining face

To improve the dust suppression efficiency of the external spray systems of shearers, a dust reduction method consisting of shearer external multi-stage atomization and dust removal fan was proposed. Computational fluid dynamics-based numerical simulation was combined with atomization experiments to analyze the migration and distribution of the cutting dust and multi-stage atomization field under airflow at the 2307 fully mechanized mining face of the Tangkou mine. The results show that with adding dust removal fan and multi-stage atomization points, the peak area of wind speed appeared on both sides of the shearer, and the wind speed was greater than 2.7 m/s, the dust concentration on the downside side of the shearer decreased, the spray coverage area increased significantly, and the droplet concentration at the shearer drum was the largest, exceeding 0.05 kg/m³. According to the research results, the multi-stage atomization arrangement of single-fluid water nozzles of shearer was put forward, and the field application was carried out. Compared with the engineering application results of the single-stage atomization dust suppression system, the total dust reduction rate of the synergistic effect of multi-stage atomization external spray with dust removal fan for the shearer is 87.12%, which is 38.59% higher than that of the conventional single-stage atomization dust suppression system.