Design and parameter optimization of dual-blade swirling wet dust collector in fully mechanized excavation face

To address the issue of suboptimal dust removal performance in the swirling wet dust collectors used in fully mechanized excavation face, a dual-blade swirling wet dust collector was designed. Using the functional tree method, the dust collector was determined to consist primarily of an annular spray device, dual swirling blades, and baffle demisting plates. The dual swirling blades provide greater centrifugal force to enhance dust removal efficiency. By utilizing the triple dust-capturing effects of the internal atomization zone, swirling zone, and dewatering zone, efficient purification of dust-laden polluted air is achieved. Based on the practical application needs of coal mines, the external dimensions, airflow capacity, and other technical parameters were determined. A numerical simulation method was used to conduct a single-factor analysis of the effects of nozzle diameter, spray pressure, blade installation angle, and blade rotation speed on the dust removal efficiency of the wet dust collector. Through response surface methodology, a multiple regression equation was established between dust removal efficiency and each influencing factor, identifying the optimal parameters that maximize dust removal efficiency. A virtual prototype of the dual-blade swirling wet dust collector was then developed. Finally, an experimental testing platform was designed and constructed to evaluate the dust removal efficiency of the wet dust collector and its dust reduction performance in mine tunnels under optimal parameters. The results indicated that the optimal parameter scheme for maximizing dust removal efficiency was: blade installation angle of 37°, rotation speed of 1550 rpm, spray pressure of 1.9 MPa, and nozzle diameter of 2 mm. The simulated dust removal efficiency under these optimal parameters was 97.21%, with an average measured efficiency of 94.80%, and a maximum relative error of 3.91%. The average dust concentration at the breathing height on the return air side of the tunnel decreased from 441.29 mg/m3 to 269.14 mg/m3, a reduction of 39.0%, validating the effectiveness of this wet dust collector in reducing dust in mine tunnels.