Research on integrated dust removal technology and equipment for shearers

To address the severe dust generation caused by rib spalling and caving during coal cutting by shearers in fully mechanized coal mining faces of coal mines, as well as the poor effect of source control, an integrated dust removal technology matched with shearers is proposed, and an integrated dust remover for shearers is designed. Combining numerical simulation and experimental research, studies are carried out on the dust suction characteristics, dust removal characteristics, and key technical parameters of the dust remover. The key technical parameters for integrated dust removal during shearer coal cutting mainly include the dust suction air volume of the dust remover, the position of the dust suction port, the wind speed of dust-laden airflow, the filter mesh size, and the spray flow rate. Factors such as the dust suction air volume and the position of the dust suction port affect the dust migration and distribution in the shearer area and the dust suction effect of the dust remover, while the dust removal efficiency and ventilation resistance of the dust remover are related to factors such as the wind speed of dust-laden airflow, the filter mesh size, and the spray flow rate. The dust suction effect of the dust remover is negatively correlated with the height of the dust suction port and positively correlated with the dust suction air volume; however, when the dust suction air volume increases to a certain extent, the dust suction efficiency tends to stabilize. Considering the on-site adaptability of the dust suction port, the optimal process parameter combinations (dust suction port height, dust suction air volume) for fully mechanized mining faces with mining heights of 3 m, 6 m, and 8 m are 1.15 m and 90 m³/min, 1.15 m and 120 m³/min, and 1.15 m and 150 m³/min, respectively. The filter mesh size and spray flow rate exhibit a positive correlation with dust removal efficiency, whereas the wind speed of dust-laden airflow exerts a negative correlation with it; in contrast, the ventilation resistance is positively correlated with the filter mesh size, spray flow rate, and wind speed of dust-laden airflow. Under experimental conditions, when the filter mesh size is 24 mesh (700 μm), the spray flow rate is 20 L/min, and the wind speed of dust-laden airflow is 10 m/s, the dust removal efficiency of the filter exceeds 95.1%, and the ventilation resistance is 400 Pa. Field application results of the integrated high-efficiency dust remover matched with shearers show that the equipment can effectively reduce the respirable dust concentration in the shearer area of fully mechanized mining faces by more than 75%.