NIOSH Ventilation Meeting
Face Ventilation System Analysis and Design
with help of CFD simulations
NIOSH Grant 2000 - 2009
Todor Petrov, Graduate Student,
Mining Department, University of Kentucky
Outline
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About myself
Objectives
Classes completed
Research performed
Results of the conducted research study
– Validation of SC/Tetra CFD code using PIV measurements of 1:15
scaled physical model
– Validation of SC/Tetra CFD code using airflow and methane
measurements collected during experiments conducted in NIOSH
Ventilation Gallery with equipment free face area
– Validation of SC/Tetra CFD code using airflow and methane
measurements collected during benchmark experiments conducted in
NIOSH Ventilation Gallery with a continuous miner equipped with a
scrubber
– CFD simulations of face ventilation applying original geometry of
JOY14CM15 continuous miner
• Future work
About myself
EDUCATION
• University of Kentucky
– PHD Student
• University of Mining and Geology, Sofia, Bulgaria
– MSc in Mining Engineering, specialization Underground Mining
– Postgraduate: Computer Technologies, Information and Control
Systems
EXPERIENCE
• University of Mining and Geology, Sofia, Bulgaria
– Assistant Professor in Mine Ventilation and Safety
– R&D Engineer at UMG Research Institute
Classes completed
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Advanced Mine Ventilation (MNG 641)
Topics in Mining Engineering - Blasting (MNG 699)
Seminar in Mining Engineering (MNG 771)
Advanced Control System Analysis (ME 645)
Scale Modeling (ME 565)
Combustion Phenomena (ME 536)
Numerical Analysis (CS 537)
Preparing Future Faculty (GS 650)
Total credit hours: 21
Objectives
To provide the mining industry an effective
CFD simulation package for analysis and
design of face ventilation systems during
deep cut mining.
Research Performed
• CFD code validation using data obtained from
previously conducted experiments on small scale and
full size physical models.
• CFD code optimization for best performance
• Preliminary CFD simulations of face ventilation
scenarios for blowing and exhausting line-brattice.
Results of the conducted
research study
Validation of SC/Tetra CFD code using PIV measurements
of 1:15 scaled physical model
A. PIV Data (Wala et. al. 2000-2004)
3,6 m
4,3 m
4,9 m
6.1 m
(12 ft)
(14 ft)
(16 ft)
(20 ft)
B. Simulated results
3,6 m
4,3 m
4,9 m
6.1 m
(12 ft)
(14 ft)
(16 ft)
(20 ft)
Experimental Setup
Equipment free face area; Tide-rib distance 2 ft; Setback 35 ft; Height 7 ft; Flow rate 2700 cfm
Results of SC/Tetra CFD simulations
for free of equipment face area
3,6
4,3 m
4,9 m
6.1 m
(12‘
(14')
(16')
(20’)
A
A
A
A
(a) Curtain distance from the rib of 0.3 m (1 ft)
3,6
4,3 m
4,9 m
6.1 m
(12‘
(14')
(16')
(20’)
B
B
A
A
Results of the simulation study for flow rate
• 1.3 m3/s (2700 cfm)
The results for
• 1.7 m3/s (3500 cfm),
• and 2.6 m3/s (5500 cfm)
are similar
Stages of the flow behavior
Line
brattice
distance
d', (ft)
(b) Curtain distance from the rib of 0.6 m (2 ft)
Entry width, w (ft)
12
13
14
15
16
20
3,6
4,3 m
4,9 m
6.1 m
1
A*
A
A*
A
A
A
(12‘
(14')
(16')
(20’)
2
B*
B
B*
C*
A*
A*
3
B
B
B
B
B
B
4
B*
B*
B*
B
B
B*
B
B
B
B
(c) Curtain distance from the rib of 1.2 m (4 ft)
The asterisks mark the validated scenarios
Validation of Cradle SC/Tetra CFD code
using airflow and methane measurements collected during experiments
conducted in NIOSH Research Gallery for equipment free face area
• Experimental results
• Simulation results
Ch4
0 .6
0 .5
0 .4
0 .3
0 .2
0 .1
0
Experimental setup
•30 feet deep Box cut
(35 ft setback distance)
• 6000 cfm air flow rate
• 5.27 cfm methane flow rate
20
30
The results
of this experimental
studies were presented during 2005 SME Annual Meeting
X
at Salt Lake City (Taylor et. al., 2005).
Measured and simulated methane distribution
0.70
0.60
3.5’
0.50
CH4
0.40
0.30
0.20
0.10
0.00
0
5
10
15
20
25
30
35
40
Measurement point number
•
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Experimental data v/s simulation results for the mid-plane
Correlation coefficient = 0.72
Validation of SC\Tetra CFD code using airflow and methane measurements collected during
benchmark experiments conducted in NIOSH Research Gallery
with a continuous miner equipped with a scrubber
The results of the experimental study were
presented during 12th U.S./North American
Mine ventilation Symposium (Wala et. al.
2008)
X-Y Plan view above the miner
Section in X-Y middle plane
X-Y Plan view below the miner
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Simulated scenario:
Box cut
Box cut width 13 ft
Total entry width 16.5 ft
Tide rib distance 2 ft
Air flow 4000 cfm
Scrubber flow 4000 cfm
Methane flow 13.4 cfm
Section in X-Z plane
Measured and simulated methane distribution
0.60
0.50
0.40
CH4
0.30
0.20
0.10
0.00
0
5
10
15
20
25
30
Measurement point number
• Correlation coefficient = 0.65
35
40
Simulated methane concentration for different
position of the miner
Miner turned
left on 1.5 deg
Parallel position
Miner turned
Right on 1.5 deg
• Same scenario as previews for 3 different positions of the miner
Simulated methane Concentration
Miner turned
left on 1.5 deg
Parallel position
Miner turned
Right on 1.5 deg
• 3D view with isosurface of methane concentration = 1%
CFD simulation of face ventilation applying original
geometry of JOY14CM15 continuous miner
Geometry provided by Joy Mining Machinery Inc
Blowing line brattice
Simulated scenario:
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Blowing line brattice
Box cut
Box cut width 13 ft
Total entry width 16.5 ft
Tide rib distance 2 ft
Air flow 6000 cfm
Scrubber 4000 cfm
Methane flow 13.4 cfm
Scrubber effect on methane concentration.
Blowing line brattice
Methane concentrations above the miner
(plane z=5.6 ft)
Scrubber off
Scrubber 4000 cfm
Scrubber 5000 cfm
Blowing line brattice
• Methane concentration profiles
Exhausting line brattice
Scrubber OFF
Isosurface of methane concentration of 5%
Exhausting line brattice
Scrubber ON
4000 cfm
Isosurface of methane concentration 1%
Exhausting line brattice
Methane concentrations above the miner
(plane z=5.6 ft)
Simulated scenario:
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Scrubber off
Scrubber 4000 cfm
Exhausting line brattice
Box cut
Box cut width 13 ft
Total entry width 16.5 ft
Tide rib distance 2 ft
Air flow 6000 cfm
Scrubber 4000 cfm
Methane flow 13.4 cfm
Future work
• Design and development of CFD models database
for different face ventilation systems.
• Design and development of specialized software
engine for automation of Face Ventilation
Simulation process based on Microsoft VB
interface supported by Cradle to handle SC/Tetra
built-in functions as methods and variables.
• Testing and validation study of the developed
design package
Concept for automation of Face Ventilation Simulation process
Todor Petrov, University of Kentucky
Face Vent. Sym.
SCT prime
CAD
files
Model
files
Specify model
FVS
database
SCT pre
Condition
files
SCT post
SCT solver
Specify conditions
START
SCT pre
Conditions
file
Model
file