applied

sciences
Article
Experimental Studies on the Spraying Pattern of a
Swirl Nozzle for Coal Dust Control
Guijun Gao 1,2, * , Changjiang Wang 3 and Ziming Kou 1,2
1 College of Mechanical Engineering, Taiyuan University of Technology, Taiyuan 030024, China;
zmkou@163.com
2 Shanxi Provincial Engineering Laboratory (Research Center) for Mine Fluid Control, Taiyuan 030024, China
3 Department of Engineering and Design, University of Sussex, Brighton BN1 9RH, UK;
c.j.wang@sussex.ac.uk
* Correspondence: gaogj161@163.com; Tel.: +86-138-0343-2565




Received: 23 July 2018; Accepted: 21 September 2018; Published: 30 September 2018


Abstract: The experimental and numerical studies were performed to understand the atomization
mechanism of pressure spray of a swirl nozzle. The design and performance parameters such as spray
cone angle, velocity of particles, spray pressure, and Sauter Mean Diameter (SMD) of the droplets
were studied using a laser particle size analyzer and high-speed camera. The results show that the
SMD increases at first, then decreases as the spray distance increases, and finally tends to be stable
after 1 m. The SMD is largest in the center of the spray field and decreases gradually along the radial
direction. The SMD distribution is more concentrated near the nozzle. Increasing spray pressure
and deceasing nozzle diameter both can make the SMD distribution more concentrated and uniform.
The swirl nozzle has been used in a coal mine and was shown to be very effective in suppressing coal
dust compared to other traditional nozzles.

Keywords: swirl nozzle; coal dust collector; particle SMD; atomization

1. Introduction
Coal dust of the mining industry causes the number one health problem in coal miners:
pneumoconiosis (black lung). Excessive coal dust in underground coal mines can also cause disastrous
explosions [1,2]. Water spraying is one of the most efficient and cost-effective measures to reduce dust
concentration in coal mines [3]. This method uses small water particles sprayed by a nozzle to capture
the coal dust in the air. Consequently, the method to produce tiny water particles and the diameter of
the water particles are important for reducing coal dust. If the diameter of water is near the diameter
of coal dust, according to Wang Peng-fei [4], better dust removal can be achieved. Pang Jiewen et al. [5]
had measured the coal dust particle size. The results showed that the distribution scope of the major
coal dust particle size is about 10–100 µm. There are three main kinds of methods to produce tiny water
droplets to capture coal dust: rotary spray [6], ultrasonic atomization [7–9], and spray nozzle [10,11].
The rotary spray uses a rotating disk to produce tiny water particles. This method has been widely
used in industry, such as in the fields of dust suppression [6] and for cutting tool cooling [12]. In recent
years, many studies on the rotary atomized dust collector have been launched from the shear fracture
of liquid membrane, but ideal particle sizes are hard to obtain [13]. Bizjan et al. [14] experimentally
investigated the mechanism of ligament formation on a spinning wheel using photographs taken by
a high-speed camera. Three different liquids with Newtonian properties were used at various flow
rates, and the wheel rotational speed was varied in a wide range. Kamiya et al. [15] investigated liquid
disintegration in ligament and sheet formation mode and developed a mathematical model of unstable
wave growth for the spinning disk. Nelson K. Akafuah et al. [16] used an infrared thermography-based

Appl. Sci. 2018, 8, 1770; doi:10.3390/app8101770 www.mdpi.com/journal/applsci

Appl. Sci. 2018, 8, 1770 2 of 14

technique for the characterization and visualization of liquid sprays. The Sauter Mean Diameter
(SMD) is about 20–55 µm, but the speed rotary bell atomizer is very high, above 20,000 rpm. Jacob E.
Wilson [17] used high-speed shadow graph imaging to visualize the edge of a serrated rotary bell at
speeds varying between 5000 and 12,000 rpm. The droplet (ranging from 40 to 300 µm) diameters
formed a normal distribution.
Ultrasonic atomization can also be used to produce water particles to reduce coal dust [18].
Ultrasonic atomization has also been widely used in many fields of science, such as household
humidifiers and medical science [19], so many peoples have studied it. Takahisa et al. [7] investigated
the effect of the frequency on the size distribution of ultrasonic mist. A bimodal distribution was
obtained for the mist generated by ultrasonic atomization with a wide-range particle spectrometer.
The peak diameter decreased with increasing frequency, and the concentration of the mist particles
increased in the smaller range. Balasubrahmanyam et al. [20] tried by experimentation to understand
the mechanism of ultrasonic vibration at the gas liquid interface causing the atomization of liquid.
It has been found that the average droplet size produced by the pseudo-plastic liquid is less than
that produced by the viscous Newtonian liquid having viscosity equal to zero-shear rate viscosity
of the shear thinning liquid. Barreras et al. [21] performed an experimental study to improve the
understanding of the characteristics of ultrasonic water atomization when excited with waves in the
MHz range. It was confirmed that the droplet size distributions are relatively independent of the
forcing voltage. For the oscillation frequency in the present measurements, 1.65 MHz, the droplet size
distribution function presents a main peak between 3 and 5 µm. The supersonic swirling separation is a
new technology for gas processing. Yan Y and Chuang W [22,23] used the Discrete Particle Method
to study the particle motion in supersonic flows with a strong swirl. The results showed that the
separation efficiency reached over 80% when the droplet diameter was more than 1.5 µm. For the
large delta wing, the collection efficiency reaches 70% with 2 µm particles, indicating a good separation
performance of the proposed supersonic separator. Chuang Wen, et al. [24] carried out the numerical
simulation with experimental separator by using numerical methods; the results show that the viscous
heating and strong swirling flow cause adverse pressure in the annular channel, which may negatively
affect the separation performance. Chuang Wen, et al. [25] set up an experimental system for testing the
separation efficiency of three new designed separators with wet air. Under a strong swirling flow field,
the separation efficiency reached over 95%. Yan Yang, et al. [26] developed the computational fluid
dynamics modeling to optimize the vane structures; results indicate that 45–60◦ swirl angle, 0.125–0.3
dimensionless height, and 8–16 vanes are reasonable for gas purification using the supersonic separator.
Spray nozzles are used more than the rotary spray and ultrasonic atomization in coal dust control.
Many scientific researchers have focused their work on spray nozzles. Benajes et al. [27] conducted
an experimental study to analyze the influence of conical and cylindrical nozzle orifices on injection
rate behavior of a common-rail fuel injection system at maximum needle lift in a cavitation test rig.
Payri et al. [28] studied the spray penetration and liquid length under evaporating conditions for
various nozzle geometries. Hadef et al. [29] measured a kerosene air blast atomized spray flame
between two co-swirling air streams by a phase-doppler particle sizing system, and found a small
liquid exists in the center of the combustor due to larger droplets with the swirl effect. Both particle
image velocimetry (PIV) and phase-doppler anemometry (PDA) have been used for measurements on
the droplet velocity and droplet size. Measurement were made by Husted and Petersson [30] using
PIV and PDA; they indicate that higher throw length can be achieved with a full cone nozzle compared
to a hollow cone nozzle, when both nozzles have the same cone angle and flow rate.
Swirl nozzle is one kind of spray nozzle that has been widely used in many industrial fields [31].
Soltani, M.R. [32] performed an experimental investigation to explore the characteristics of sprays
produced by a liquid-liquid coaxial swirl atomizer. The results indicate that the maximum Sauter
Mean Diameter of droplets along the injection axis moves to the outer periphery of the spray and
increases downstream. In this paper, a swirl nozzle is developed for generating water spray for dust
control in coal mines, as shown in Figure 1. The nozzle can not only convert the liquid pressure into
Appl. Sci. 2018, 8, 1770 3 of 14
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the kinetic
the kinetic energy
energy ofof the
the liquid,
liquid, but
but also
also produce
produce the
the liquid
liquid eddy
eddy to to form
form a conical
conical cavity
cavity in the center
the swirl
of the swirl chamber
chamber so so that
that the
the eddied
eddied liquid
liquid in the
the form
form of
of aa liquid
liquid film
film sprays
sprays out
out at
at high-speed
high‐speed
from the
the nozzle.
nozzle. The liquid, after leaving the nozzle, is no longer restricted by the inner wall of the the
nozzle and spreads into the air. air. The
The slight
slightdisturbance
disturbanceof ofthe
theair
airacts
actson
onthe
thehigh‐speed
high-speedjetjettotoform
forma
aturbulent
turbulentwave.
wave.TheTheamplitude
amplitudeofofthe thedisturbance
disturbanceincreases
increaseswhen
whenthe the kinetic
kinetic energy
energy of the small
small
volume liquid
volume liquid is
is greater
greater than
than the
the surface
surface tension
tension of
of the
the liquid,
liquid, and
and thethe liquid
liquid film
film breaks
breaks and
and forms
forms
small fog
small fog particles
particles under
under strong
strong vibrations.
vibrations.

Figure
Figure 1. Tangential injection
1. Tangential injection swirl
swirl nozzle
nozzle (A
(A is
is cross
cross section
section symbols
symbols for
for location).
location).

The mechanism for using spray to control dust is that the produced tiny droplets capture smaller
The mechanism for using spray to control dust is that the produced tiny droplets capture smaller
dust particles in the air. According to the theory, for the tiny water droplets to capture dust particles,
dust particles in the air. According to the theory, for the tiny water droplets to capture dust particles,
the relationship between the smallest dust particle size to be captured and conical cavity droplet size is
the relationship between the smallest dust particle size to be captured and conical cavity droplet size
expressed by the following formula [33].
is expressed by the following formula [33].
s
d pmin = 9𝜇𝐷w S𝑆tk
9µD
(1)
𝑑 = ρ p v0 (1)
𝜌 𝑣
where d pmin represents is the dust particle diameter (m), µ is dynamic viscosity, Dw is a droplet diameter,
where 𝑑 represents is the dust particle diameter (m), μ is dynamic viscosity, 𝐷 is a droplet
Stk is the stokes number, ρ p is the dust density, and v0 is the air flow rate. Equation (1) shows that the
diameter, 𝑆 is the stokes number, 𝜌 is the dust density, and 𝑣 is the air flow rate. Equation (1)
square of the particle diameter d pmin is proportional to the droplet size Dw . When the other parameters
shows that the square of the particle diameter 𝑑 is proportional to the droplet size 𝐷 . When
in Equation (1) are fixed, d pmin depends only on the droplet diameter Dw . In other words, to capture
the other parameters in Equation (1) are fixed, 𝑑 depends only on the droplet diameter 𝐷 . In
the smaller particle size, the size of the fog particles Dw should be reduced accordingly. Since the
other words, to capture the smaller particle size, the size of the fog particles 𝐷 should be reduced
respirable dust that causes pneumoconiosis is very small (less than 10 microns) [1], it is expected that
accordingly. Since the respirable dust that causes pneumoconiosis is very small (less than 10 microns)
the nozzle can spray out more tiny droplets to reduce the respirable dust more effectively. Therefore, it
[1], it is expected that the nozzle can spray out more tiny droplets to reduce the respirable dust more
is necessary to study the atomization characteristics of the droplet particles for spraying dust.
effectively. Therefore, it is necessary to study the atomization characteristics of the droplet particles
According to the tests performed with swirl nozzles [34], the relationship between the water
for spraying dust.
consumption rate of the nozzle and the pressure of water is determined to be
According to the tests performed with swirl nozzles [34], the relationship between the water
consumption rate of the nozzle and theQpressure √ water
= kD Pof × 10−6is
w
determined to be
/60 (2)
𝑄 = 𝑘𝐷 𝑃 × 10 ∕ 60 (2)
where Q is the conical nozzle flow rate (m3 /s), D is the nozzle diameter (m), Pw is the water pressure
where Q
(MPa), is the
and k isconical
the testnozzle flow (k
coefficient rate (m3/s),At
= 1.34). D the
is the nozzle
same diameter
time, flow 𝑃
nozzle (m), rateisQthe
canwater pressure
be described
(MPa),
as and 𝑘 is the test coefficient (k = 1.34). At the same time, nozzle flow rate Q can be described
follows.
as follows. D 2
Q = v·π ·( ) (3)
2
𝐷
where v represents water jet velocity (m/s) and 𝑄 =D𝑣is∙nozzle
𝜋 ∙ ( )orifice diameter (m). Substituting Equation(3)
(3)
2
into Equation (2) the following expression is obtained.
where 𝑣 represents water jet velocity (m/s) and D is nozzle orifice diameter (m). Substituting
Equation (3) into Equation (2) the following expression200·k √ is obtained.
v= Pw (4)
3· π
200 ∙ 𝑘
𝑣= 𝑃 (4)
It can be seen from Equation (4) that the water 3 ∙ 𝜋jet velocity v is proportional to the square root of
the water pressure Pw . As the spray pressure Pw increases, the axial velocity v of the fog increases
It can be seen from Equation (4) that the water jet velocity 𝑣 is proportional to the square root
accordingly. Thus, the relative velocity of the fog particles with the ambient air increases (weber
of the water pressure 𝑃 . As the spray pressure 𝑃 increases, the axial velocity 𝑣 of the fog
numbers increase), which in turn promotes further atomization of the droplets.
increases accordingly. Thus, the relative velocity of the fog particles with the ambient air increases
(weber numbers increase), which in turn promotes further atomization of the droplets.
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2. Research Method
2. Research Method
2.1. Numerical Study of Both Spray Nozzles
2.1. Numerical Study of Both Spray Nozzles
In recent years, the application of computational fluid dynamics (CFD) in spray atomizer design
and Inanalysis has received
recent years, more and
the application more attentionfluid
of computational fromdynamics
researchers (CFD)andinengineers
spray atomizer[35], asdesign
it can
provide
and detailed
analysis and useful
has received moreinformation
and more about the fluid
attention from flows and particles
researchers that are usually
and engineers [35], asdifficult
it can
to produce
provide by experimental
detailed methods. CFD
and useful information abouthas the been
fluid used
flowsto andsimulate
particlesthe two‐phase
that are usually flows in both
difficult to
swirl nozzles
produce and traditional
by experimental methods. nozzles
CFD in hasorder to gain
been used understanding
to simulate of the differences
the two-phase flows in bothinswirl flow
characteristics
nozzles between
and traditional the two
nozzles nozzles.
in order to gainThe major difference
understanding between the
of the differences swirl
in flow nozzle and
characteristics
traditional
between thenozzle structurally
two nozzles. The is that difference
major swirl nozzles force the
between the swirl
mass nozzle
flow intoandeddy chambers
traditional in a
nozzle
tangential direction
structurally is that swirlwhile the traditional
nozzles force the mass nozzle
flowdoes
intothis
eddy in chambers
an axial direction.
in a tangential direction while
In this research,
the traditional the standard
nozzle does this in ank‐ɛ turbulence
axial direction. model by Launder and Sharma [36] was used. The
computational domainthe
In this research, was an eddyk-ε
standard chamber
turbulenceof 6 mmmodel in radius and theand
by Launder spray nozzle[36]
Sharma waswas 1.5 mm
used. in
diameter.
The A full 3‐D
computational simulation
domain was an waseddy
carried out inof
chamber order
6 mm to in
generate
radius the
andoverall flownozzle
the spray path linewaswhen
1.5 mm the
conditions
in diameter.of Athe
fulltwo‐nozzle
3-D simulation model waswere identical
carried out inincluding
order to boundary
generate the conditions.
overall flow path line when
The computational
the conditions fluid dynamics
of the two-nozzle model were (CFD) software
identical Fluent boundary
including 18.2 was used to simulate the water
conditions.
jet generation in both spray
The computational fluidnozzles.
dynamics The meshsoftware
(CFD) for the computational
Fluent 18.2 wasdomain used towas generated
simulate using
the water
software ANSYS Workbench 18.2. There are 12,257 hexahedral cells
jet generation in both spray nozzles. The mesh for the computational domain was generated using and 65,194 nodes. In this model,
several boundary
software conditions 18.2.
ANSYS Workbench for both
Therenozzles are defined.
are 12,257 hexahedral The inlet
cellsboundary
and 65,194 condition
nodes. Inwas thisspecified
model,
by velocity‐inlet
several boundary at the speedfor
conditions of both
21 m/s and outlet
nozzles was specified
are defined. The inlet by boundary
pressure‐outlet
condition at thewasatmospheric
specified
pressure.
by Both inlet
velocity-inlet at theand
speedoutlet
of 21turbulent
m/s andintensity
outlet was are specified
specified byby a standard value
pressure-outlet at theofatmospheric
5%. All the
wall boundary
pressure. conditions
Both inlet and outlet were derivedintensity
turbulent for no sliparestationary
specified by walls.
a standard value of 5%. All the wall
boundary conditions were derived for no slip stationary walls.
2.2. Experimental Setup
2.2. Experimental Setup
Experiments were conducted to study the performance of the swirl nozzle. A dedicated test
Experiments
system for spraywere conductedanalysis
characteristic to studywas the established
performance atofthe
theMine
swirlFluid
nozzle. A dedicated
Control test
Laboratory,
system for spray characteristic analysis was established at the Mine
Taiyuan University of Technology. Tap water was used as the working medium, the tap water from Fluid Control Laboratory, Taiyuan
University
the tank was of Technology.
pressurizedTap water
to the was pressure
preset used as the byworking medium,pump
a high‐pressure the tapand
water thenfrom the tank
forced was
out from
pressurized to the preset pressure by a high-pressure pump and then forced out from the swirl nozzle.
the swirl nozzle.
At
Atpresent,
present,optical
opticalmeasurement
measurementtechniques
techniquesare arethe
themost
mostsuitable
suitableto tomeasure
measurethe thecharacteristics
characteristics
of
ofwater
watermist,
mist,andandaanumber
numberof ofdifferent
differenttechniques
techniquesare areavailable.
available.In Inthis
thisstudy,
study,OMEC OMECDP-2 DP‐2particle
particle
size analyzer was used to measure the particle size of the fog field.
size analyzer was used to measure the particle size of the fog field. Measurements were carriedMeasurements were carried outoutat
1.0, 1.2,1.2,
at 1.0, andand1.51.5
mm mmnozzle
nozzle orifices and
orifices andpressures
pressures from
from 2 to 6 MPa.
2 to 6 MPa.AAHX-6 HX‐6high-speed
high‐speedcamera camerawas was
used
usedto torecord
recordandandinvestigate
investigatethe theangle
angleof of water
water sprays.
sprays. The experiment system is shown in Figure 2.

Figure2.2.Measurement
Figure Measurementsetupsetupwith
withswirl
swirlnozzle
nozzleand
andLaser
LaserDoppler
DopplerAnemometry.
Anemometry.(1: (1:receiver,
receiver,2:2:swirl
swirl
nozzle, 3: transmitter, 4: pressure gauge, 5: high pressure pump unit, 6: flow meter, 7: valve, 8: tank,
nozzle, 3: transmitter, 4: pressure gauge, 5: high pressure pump unit, 6: flow meter, 7: valve, 8: tank,
9:9:high-speed
high‐speedcamera,
camera,10:
10:computer).
computer).
Appl. Sci. 2018, 9, x FOR PEER REVIEW 5 of 15
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9, 1770
x FOR PEER REVIEW 55 of 15
of 14
The experimental measurement system was tested in the Mine Fluid Control Laboratory. The
The experimental
setup was surrounded withinmeasurement
a plastic curtainsystem was tested
to maintain in the Mine
an enclosure spaceFluid
andControl
avoid airLaboratory.
flow that The
The experimental measurement system was tested in the Mine Fluid Control Laboratory. The
flowsetup
could setup
causewas surrounded
errors. within apressure
The hydraulic plastic curtain
gauge to maintain
was used to anmonitor
enclosureand space and avoid
maintain the air
spray that
was
couldsurrounded
cause within
errors. The a plastic
hydraulic curtain to
pressuremaintain
gauge an
wasenclosure
used tospace and
monitor avoid
and air flow
maintain that
the could
spray
pressure at its preset value. A flow meter was used to record the nozzle flow rate and a high‐speed
cause
pressureerrors. The
at itsto hydraulic
preset value. pressure gauge was used to monitor and maintain the spray pressure
camera was used capture theAvelocity
flow meter was
of movementused toand
record the nozzle
atomization flow of
angle ratefog
and a high‐speed
particles.
at its preset
camerathe was value. A flow
used to capture meter was used
the velocity to record
of movement the nozzle
and flow rate and a high-speed camera
Meanwhile, distribution of fog particles size was measured by theatomization
DP‐2 particleangle of fog particles.
size analyzer at
was used
Meanwhile, to capture the velocity of movement and atomization angle of fog particles. Meanwhile, the
different locationsthe distribution
by changing theofrelative
fog particles
positionsize
of was measured
the nozzle. Theby the DP‐2 particle
experimental site is size
shownanalyzer
in at
distribution of fog particles size was measured by the DP-2 particle size analyzer at different locations
Figuredifferent
3. locations by changing the relative position of the nozzle. The experimental site is shown in
by changing
Figure 3. the relative position of the nozzle. The experimental site is shown in Figure 3.

Figure 3. Setup and testing of the swirl nozzle.

Figure 3. Setup and testing of the swirl nozzle.
For analysis and recording, a coordinate system (Figure 4) was established in the spray area. The
horizontal For analysis
axisanalysis andrecording,
and
H and verticalrecording, a acoordinate
axis L are coordinate
in the radial system
system (Figure
(Figure
and axial 4) was
4) was
directions established
established
of the nozzle, in spray
in the the spray
area.area.
respectively, The
The
and the horizontal
horizontal
unit axis
is cm. axis
For H and
H example,
and vertical
vertical axisaxis
point LFigure
ALinare are
in in
thethe radial
4 radial and
and
indicates axial
axial
that directions
directions
laser positionofofisthe
the nozzle,
nozzle,
250 respectively,
respectively,
cm from the
and the unit is cm. For example, point A in Figure 4 indicates
axial direction of the nozzle and 20 cm from the radial direction of the nozzle. that laser position is 250 cm from the
axial direction of the nozzle and 20 cm from the radial direction of the nozzle.
from the radial direction of the nozzle.

Nozzle
Nozzle 100
100 H(cm)
H(cm)

100
100

200
200

300
300
L(cm)
L(cm)
Figure 4. Coordinate system was established in the spray area. H = horizontal axis and L = vertical axis.
Figure 4. Coordinate system was established in the spray area. H = horizontal axis and L = vertical
Figure 4. Coordinate system was established in the spray area. H = horizontal axis and L = vertical
axis. The particle size measured by the DP-02 laser particle size analyzer is the distribution of particle
axis.
size passing through the laser line. However, accurate measuring the size distribution and velocity
The particle
of the size measured
droplets, assize
well as by the DP‐02and
coalescence laserbreak-up
particle size analyzer
events is difficult
the distribution
areanalyzer
still of particle
The
size passing particlethe
through measured
laser by the DP‐02
line. However, lasermeasuring
accurate particle size is thetodistribution
the size distribution
achieve. The sizes of
of particle
and velocity
size passing through the laser line. However, accurate measuring the size distribution and velocity
Appl. Sci. 2018, 9, x FOR PEER REVIEW 6 of 15
Appl. Sci. 2018, 8, 1770 6 of 14

of the droplets, as well as coalescence and break‐up events are still difficult to achieve. The sizes of
droplets are
droplets are usually
usually characterized
characterizedbybyDD10, ,DD50,, DD90,, DD[3,2],, and
and DD[4,3],, etc. The volumetric median
10 50 90 [3,2] [4,3] etc. The volumetric median
diameter D 50 is used as the average particle size of droplets, and it is the diameter at which 50% of
diameter D50 is used as the average particle size of droplets, and it is the diameter at which 50% of
the total
the total of
of the
the droplets
droplets in
in volume
volume exhibit
exhibit smaller
smaller diameter
diameter than than this
this characteristic
characteristic diameter
diameter [37–39].
[37–39].
Here the Sauter mean diameter
Here the Sauter mean diameter d dSMD is adopted [4].
is adopted [4].
SMD

m m
𝑑d ==
SMD ∑𝑛ni𝑑d3i / ∑ ni𝑛d2i𝑑 (5)
(5)
i =1 i =1

where 𝑚 isisthe
where m thenumber
numberofof droplet
droplet diameter
diameter segments and d𝑑i and
segments and andn𝑛. are
arethe
thedroplet
droplet diameter
diameter and
and
i
number of
number of the 𝑖 thsegments,
the ith segments,respectively.
respectively.

3. Results
3. Results and
and Discussion
Discussion

3.1. Numerical Simulation Results

Figure 5 shows the resulting flow fields inside the nozzle structures before the water droplets
were ejected in air for for the
the two
twoswirl
swirland
andtraditional
traditionalnozzles.
nozzles.TheTheswirl
swirlnozzle
nozzlemass
massflow
flowpath
pathlines in
lines
Figure
in Figure5a 5a
arearesignificantly
significantly different from
different thatthat
from of the traditional
of the nozzle
traditional (no swirl)
nozzle in Figure
(no swirl) 5b. The
in Figure 5b.
results
The indicate
results thatthat
indicate swirl
swirlnozzle
nozzlecancan
cause inner
cause innerfluid
fluidwhirling
whirlingwhile
whilethe
thetraditional
traditional nozzle
nozzle only
allows the inner fluid to to flow
flow directly.
directly.
Figure 5c,d
5c,dshow
showthe thevelocity
velocity distribution
distributionon the nozzle
on the outlet
nozzle face along
outlet the L‐direction.
face along Figure 5c
the L-direction. shows
Figure 5c
that when
shows thatthe
when swirl
thenozzle is usedisatused
swirl nozzle a given
at aposition, the velocity
given position, varies varies
the velocity more evenly in a large
more evenly in arange
large
with the
range maximum
with the maximum velocity beingbeing
velocity aboutabout
8 m/s.8However,
m/s. However,the traditional nozzlenozzle
the traditional produces a flowa field
produces flow
(Figure
field 5d) in5d)
(Figure which the velocity
in which distribution
the velocity formsforms
distribution a narrow band with
a narrow bandthe
withmaximum
the maximumvelocity being
velocity
only 3only
being m/s. 3They
m/s.haveThey same
have axial
samevelocity but different
axial velocity tangential
but different velocity. velocity.
tangential As indicated by Equation
As indicated by
(1), the faster
Equation tangential
(1), the velocity velocity
faster tangential can produce tinier water
can produce tinierdroplets for capturing
water droplets dust particles.
for capturing dust particles.

(a)
Figure 5. Cont.
Appl. Sci. 2018, 8, 1770 7 of 14
Appl. Sci. 2018, 9, x FOR PEER REVIEW 7 of 15

(b)
outlet
8

X 0
Velocity
(Mixture) -2
(m/s)
-4

-6

-8
-0.8 -0.6 -0.4 -0.2 0.0 0.2 0.4 0.6 0.8
Position(mm)

(c)
outlet
3

0
X
Velocity
-1
(Mixture)
(m/s)
-2

-3

-4
-0.8 -0.6 -0.4 -0.2 0.0 0.2 0.4 0.6 0.8
Position(mm)

(d)
Figure 5. Results of numerical simulations of two types of nozzles: (a) the swirl nozzle mass flow path
line, (b) the traditional nozzle mass flow path line, (c) the X-velocity
X‐velocity on the swirl nozzle outlet face,
and (d) the X-velocity
X‐velocity on the traditional
traditional nozzle
nozzle outlet
outlet face.
face.
Appl.
Appl. Sci.
Sci.2018,
2018, 9,
8, x1770
FOR PEER REVIEW 8 8ofof 15
14

3.2. The Relationship between Droplet SMD and Spray Pressure and Nozzle Diameter
3.2. The Relationship between Droplet SMD and Spray Pressure and Nozzle Diameter
Figure 6a shows that the SMD curve is varied with spray pressure and nozzle diameter. When
Figure
the spray 6a shows
pressure thatthan
is less the SMD
4 MPa,curve
the is varied with
droplets’ SMDspray pressure
decreases and nozzle
rapidly diameter.
with the increaseWhen the
of spray
spray pressure is less than 4 MPa, the droplets’ SMD decreases rapidly
pressure. When the spray pressure is above 5 MPa, the droplets’ SMD decrease slowly with the with the increase of spray
pressure. This
pressure. When the spray
indicates thatpressure
the sprayispressure
above 5has MPa, the droplets’
a significant SMD
effect decrease
on liquid slowly with
atomization. the
As the
pressure. This indicates that the spray pressure has a significant effect on liquid
kinetic energy of the droplets increases with the spray pressure, the higher kinetic energy is most atomization. As the
kinetic energy of the droplets increases with the spray pressure, the higher kinetic
likely to cause breakage of larger droplets into smaller ones. Figure 6 also shows that when the spray energy is most likely
to cause breakage
pressure reaches 5ofMPa, largereven
droplets
if theinto smaller
spray ones.continues
pressure Figure 6 also shows that
to increase, fogwhen the spray
particle SMD pressure
will not
be reduced greatly. In other words, Figure 6a shows that at the same spray pressure, smallerreduced
reaches 5 MPa, even if the spray pressure continues to increase, fog particle SMD will not be nozzle
greatly. In
aperture canother words,
produce Figureparticle.
smaller 6a shows that at6bthe
Figure samethe
shows spray pressure,between
comparison smaller nozzle aperture
the nozzle and thecan
produce smaller
traditional nozzles particle.
[40] in Figure
the SMD. 6b shows
The SMD the comparison
of this swirlbetween
nozzle isthe nozzlethan
smaller and the
the traditional
traditional
nozzles for 1.5 mm and this swirl nozzle is smaller than the traditional nozzles for 1 mmfor
nozzles [40] in the SMD. The SMD of this swirl nozzle is smaller than the traditional nozzles when1.5 mm
the
and this
spray swirl nozzle
pressure is above is smaller
3 MPa.than the traditional
According nozzles
[4,5], better forremoval
dust 1 mm when theachieved
can be spray pressure
using is above
smaller
3 MPa. According
diameter particles. [4,5], better dust removal can be achieved using smaller diameter particles.

145

125
SMD（μm）

1mm
105 1.2mm

85 1.5mm

65
2 3 4 5 6
P(MPa)
(a)
220

180
SMD（μm)

140 1mm
Traditiona for 1mm
100 1.5mm
Traditiona for 1.5mm
60
2 3 4 5 6
P(MPa)

(b)
Figure
Figure 6.
6. Size
Size of
of droplets
droplets (Sauter
(Sauter Mean
Mean Diameter,
Diameter, SMD)
SMD) in
in different
different spray
spray pressures
pressures (P)
(P) and
and nozzle
nozzle
diameters.
diameters. (a)
(a)SMD
SMD andand spray
spray pressures
pressures for
for three
three nozzle
nozzle apertures.
apertures. (b)
(b) The
The comparison
comparison between
between the
the
nozzle
nozzle and
and the
the traditional
traditional nozzles
nozzles in
in the
the SMD.
SMD.

3.3. The
3.3. The Relationship
Relationship between
between Atomization
Atomization Angle
Angle and
and Spray
Spray Pressure
Pressure and
and Nozzle
Nozzle Aperture
Aperture
Figure 7a
Figure 7a shows
shows thethe relationship
relationship between
between thethe atomization
atomization angles
angles and
and spray
spray pressures
pressures for for three
three
nozzle apertures. It can be seen that the atomization angle reduces when the spray
nozzle apertures. It can be seen that the atomization angle reduces when the spray pressure increasespressure increases
from 22 to
from to 44 MPa,
MPa, andand the
the atomization
atomizationangle
anglereduces
reducesslowly
slowlywhen
whenthe thespray
spraypressure
pressureisisabove
above44MPa, MPa,
and even more slowly above 5 MPa. Although Figures 6 and 7 share the similar trends, Figure 66 is
and even more slowly above 5 MPa. Although Figures 6 and 7 share the similar trends, Figure is
caused by
caused by high‐speed
high-speed secondary
secondary breakup
breakup [41],
[41], and
and high
high speed
speed aerodynamic
aerodynamic forceforce can
can lead
lead toto the
the
droplets’ SMD decreasing rapidly when the pressure is less than 4 MPa and decreasing
droplets’ SMD decreasing rapidly when the pressure is less than 4 MPa and decreasing slowly above slowly above
55 MPa.
MPa. Figure
Figure 7b7b shows
shows thethe comparison
comparison between
between the
the nozzle
nozzle and
and the
the traditional
traditional nozzles
nozzles in in the
the spray
spray
angle. For
angle. For1.2
1.2mmmmdiameter,
diameter,asas anan example,
example, thethe
SMDSMD of this
of this swirl
swirl nozzle
nozzle is smaller
is smaller thanthan
thatthat
of theof
traditional nozzles from 2 MPa to 6 MPa. The decrease of atomization cone angle leads to the
Appl. Sci. 2018, 8, 1770 9 of 14

Appl. Sci. 2018, 9, x FOR PEER REVIEW 9 of 15

the traditional nozzles from 2 MPa to 6 MPa. The decrease of atomization cone angle leads to the
continuous
continuous reduction of the
reduction of the effective
effective dust
dustfall
fallarea
areaof
offog
fogflow,
flow,which
whichisisnot
notconducive
conducivetoto the
the capture
capture of
of coal dust [4].
coal dust [4].

83

78
angle θ（º）

73 1mm
1.2mm
68
1.5mm
63
2 3 4 5 6
P (MPa)

(a)
90
Angle θ（deg）

80
70
60 1.2mm
50
40 Traditionan for
30 1.2
2 3 4 5 6
P(MPa)

(b)
Figure
Figure 7.7. Atomization
Atomization angle
angle inin different
different spray
spray pressures. (a) Atomization
pressures. (a) Atomizationangles
anglesand
andspray
spraypressures
pressures
for three
for three nozzle
nozzle apertures.
apertures. (b)
(b) The
The comparison
comparison between
between the
the nozzle
nozzle and
and the
the traditional
traditional nozzles
nozzles in
in the
the
spray angle.
spray angle.

3.4. Axial
3.4. Axial andand Radial
Radial Distributions
Distributions of of Particle
Particle SMD
SMD
Figure 88shows
Figure showsthe theparticle
particleSMDSMDininthe thecentral
centralaxis
axis along
along thethe axial
axial direction
direction of of
fogfog
flowflow
spraysprayin
in the
the fogfog field.
field. It canIt be
can be seen
seen that the
that with with the increase
increase of thedistance
of the axial axial distance
from the from the the
nozzle, nozzle, the fog
fog particle
particle
SMD SMD increases
increases rapidlyrapidly
and the and the maximum
maximum diameterdiameter is about
is about 10 cm10 cmfromfromthethe nozzle,and
nozzle, andthenthen itit
decreases dramatically
decreases dramatically withinwithin the
the distance
distance ofof 50
50 cm.
cm.After
After100 100cm,
cm,thethecurve
curvegradually
graduallybecomes
becomeslevel. level.
This is because the density of fog particles is large at the near field of the
This is because the density of fog particles is large at the near field of the nozzle, but the coupling nozzle, but the coupling
process between
process between the the high
high velocities
velocities of of particles
particles and
and perturbation
perturbation of of aerodynamic
aerodynamic force force makes
makes larger
larger
particles start
particles start aa second
second atomization
atomization [42].[42]. At
At the
the same
same time,
time, the
the large
large distance
distance and and space
space is is good
good for for
reducing particle collisions with each other to some degree. Both the particle
reducing particle collisions with each other to some degree. Both the particle collision and particle collision and particle
second atomization
second atomization gradually
graduallyreachreachequilibrium
equilibriumat atabout
about50 50 cm
cm away
away fromfrom the
the nozzle,
nozzle, so so the
the curve
curve
beyond 100
beyond 100 cmcm isis nearly
nearly horizontal.
horizontal.
Figure 9 shows the distribution
Figure 9 shows the distribution of particle
of particleSMD in the
SMD inradial direction
the radial in the spray
direction in thefield
sprayat different
field at
different axial positions. It can be seen that the particle SMD is larger in the center of the fog the
axial positions. It can be seen that the particle SMD is larger in the center of the fog than in thanrim,in
and droplets diameter gradually decreases along the radial direction. Because
the rim, and droplets diameter gradually decreases along the radial direction. Because a large number a large number of fog
particles
of exist near
fog particles existthe nozzle,
near at this point,
the nozzle, at thisthe outside
point, air cannot
the outside air be sucked
cannot be into
suckedthe into
internal
the fog field
internal
to mix
fog fieldfully
to with fog particles,
mix fully with fog which depresses
particles, which thedepresses
degree of the fog degree
particlesofbreaking. Therefore,
fog particles near
breaking.
Therefore, near of the nozzle, there are more concentrated fog particles and greater fog particle SMD.a
of the nozzle, there are more concentrated fog particles and greater fog particle SMD. In contrast,
large
In amount
contrast, of airamount
a large is sucked into
of air the fog into
is sucked fieldtheat further
fog fielddistances
at furtheraway fromaway
distances the axial
fromlinetheof the
axial
fog field, and many tiny particles produced by first and second breakup
line of the fog field, and many tiny particles produced by first and second breakup [30] are [30] are transported to the
transported to the spray boundaries by the drag forces from the surrounding air and, therefore, the
fog particles’ SMD are smaller than that of particles in the center field.
Appl. Sci. 2018, 8, 1770 10 of 14

spray
Appl. Sci.boundaries
2018, 9, x FORby theREVIEW
PEER drag forces from the surrounding air and, therefore, the fog particles’
10 SMD
of 15
areAppl.
smaller than
Sci. 2018, 9, x that of particles
FOR PEER REVIEW in the center field. 10 of 15

200
200
150
SMD(μm) 150
SMD(μm) 2MPa
100 2MPa
100
3MPa
50 3MPa
50 4MPa
4MPa
0
00 50 100 150 200 250 300
0 50 100 150 200 250 300
L(cm)
L(cm)

(a)
(a)
200
200

150
150
SMD(μm)
SMD(μm)

100
100 2MPa
2MPa
3MPa
3MPa
5050
4MPa
4MPa
00
00 55 10
10 15
15 20
20 25
25 30
30
L(cm)
L(cm)

(b)
(b)
Figure
Figure 8.The
Theaxial
axialdistribution
distribution of
of droplet
droplet diameter. (a)
(a)The
diameter.(a) Theaxial
axialdistribution
distributionof of
droplet diameter
droplet over
diameter over
Figure 8.8.The axial distribution of droplet diameter. The axial distribution of droplet diameter over
300
300 cm.
cm. (b)
(b) The
The axial
axial distribution
distribution within
within 30
30 cm.
cm.
300 cm. (b) The axial distribution within 30 cm.

100
10095
9590 100cm
SMD (μm)

9085 100cm
SMD (μm)

150cm
8580
150cm
8075 200cm
7570 200cm
250cm
7065 250cm
300cm
65 0 5 10 15 20 25 30
0 5 10 15
H（cm） 20 25 30 300cm
H（cm）
Figure 9.
Figure 9. The radial
radial distribution
distributionofofdroplets’
droplets’diameter.
diameter.
Figure 9. The radial distribution of droplets’ diameter.
3.5. Speed
3.5. SpeedDistribution
DistributionofofFog
FogParticles
Particles
3.5. Speed
TheDistribution
The velocities ofdroplets
velocitiesofof Fog Particles
droplets were
were investigated atdifferent
investigated at differentspray
spraypressures
pressures and
and at at different
different axial
axial
distances
distances and
andare
The velocities areshown
shown
of ininFigures
droplets were10
Figures 10 and 11,
11, respectively.
investigated respectively.
at different Figure
Figure
spray1010pressures
showsthat
shows thatat at
and a point
a point
at in the
in the
different fog fog
axial
field,
field,
distances the
the andspeed
speed areofof fogparticles
fog
shown particles
in Figures increases
increases
10 andwith the
the increase
increaseofof
11, respectively. spray
spray10
Figure pressure.
shows For
pressure. example,
For
that atexample,
a point when
when
in thethefog
the
nozzle
nozzle aperture
aperture is is
1.21.2
mm,mm,whenwhensprayspraypressure
pressureisisincreased
increasedfromfrom22toto3,3,4,4,and
and55MPa,MPa,the thespeed
speedof offog
field, the speed of fog particles increases with the increase of spray pressure. For example, when the
fog particles
particles is increased
is increased from 28 m/sto to 43 m/s.However,
However, aboveabove 5 MPa, the growth rate of of
fogfog
particle
nozzle aperture is 1.2 frommm, when28 m/s spray 43pressure
m/s. is increased from MPa,2 to the
3, 4,growth
and 5 MPa,rate particle
the speed of
speed
speed tends
tends totobebe small.
small. AtAt the
the same
same time,
time, Figure
Figure 10
10 also
alsoshows
shows that
thatthe
thesmall
small nozzle
nozzle aperture
aperturehashas
fog particles is increased from 28 m/s to 43 m/s. However, above 5 MPa, the growth rate of fog particle
smaller
smaller fogfogparticle
particlespeedspeedthanthan that of of the
the large
large nozzle aperture at the
thesame spray pressure.
speed tends to be small. At the that
same time, Figurenozzle aperture
10 also showsatthat same
the spray
small pressure.
nozzle aperture has
Figure1111shows
Figure showsthe therelationship
relationship between
between the the velocity
velocity of
offog
fogparticles
particles and
and the
theaxial distance
axial distancefrom from
smaller fog particle speed than that of the large nozzle aperture at the same spray pressure.
center
center of the
of the11fogfog field.
field.the It indicates that the
It indicates thatbetween velocity
the velocity of fog particles
of fog particles decreases gradually
decreases gradually when the axial
when thefrom axial
Figure
distance shows
increases in therelationship
fog field at different spray the velocity of fog
pressure. For particles
example,and at 5 the
MPa, axial
thedistance
axial speed
distance
center increases in the fog field at different spray pressure. For example, at 5 MPa, the axial speed
axialis
is 50ofm/s
theatfog
100field.
cm and It indicates that theto
then is reduced velocity
20 m/s ofat fog
300 particles
cm. This decreases
is because gradually when the
when the nozzle’s high
distance increasessprays
inner pressure in theout fogthe
field
fogatparticles
differentwithspray
high pressure. For example,
speed relative to the air at speed,
5 MPa,athe largeaxial
partspeed
of
is 50 m/s at 100 cm and then is reduced to 20 m/s at 300 cm. This is because
the kinetic energy of the fog particles is used to overcome air shearing and resistance. In this process, when the nozzle’s high
inner pressure sprays out the fog particles with high speed relative to the air speed, a large part of
the kinetic energy of the fog particles is used to overcome air shearing and resistance. In this process,
 Appl. Sci. 2018, 8, 1770 11 of 14
Appl. Sci. 2018, 9, x FOR PEER REVIEW 11 of 15

Appl. Sci. 2018, 9, x FOR PEER REVIEW 11 of 15

the
50larger
m/s atdiameter
100 cm and of fogthenparticles is sheared
is reduced and at
to 20 m/s broken,
300 cm. theThis
kinetic energy when
is because of thethe
fognozzle’s
particleshigh
is
Appl. Sci. 2018, 9, x FOR PEER REVIEW 11 of 15
further lost,
pressure so that
spraystheoutspeed
the of
fog fog particles
particles with reduces
high speed sharply.
relative With
to the the
the larger diameter of fog particles is sheared and broken, the kinetic energy of the fog particlesthe
inner air speed
speed, of
a fog
large particles
part of is
decreasing,
kinetic
the larger
further the
energy shear
of
diameter
lost, the effect
fog
so thatofthe of
fogspeed air
particles on
particles fog
is usedparticles
to
is sheared
of fog particles gradually
overcome
and air reduces,
shearing
broken,sharply.
reduces the
and
the kinetic possibility
resistance.
Withenergy of
In shear
this
of theoffog
the speed crushing
process,
particles
fog the
particles is
and the loss
larger
further
decreasing, ofthe
diameter
lost, energy
so of fog
that
shear of
the fogspeed
effect particles
particles
of airisof
on are
fogreduced
sheared
fog particles
particles and,
and broken, therefore,
reducesthe kinetic
gradually theenergy
sharply.
reduces, fog
theparticle
With of speed
thespeed
the rate
fog particles
possibility ofof decreases
fog
shear is further
particles
crushing
gradually
lost,the
decreasing,
and with
so loss
that the
of the
the increase
speed
shear
energy offog
fog
effect
of in
of axial
air on
particlesdistance.
particles fogreduces
are sharply.
particles
reduced Withreduces,
gradually
and, therefore,the speed theofparticle
the fog fog particles
possibility decreasing,
of shear
speed crushing
rate decreasesthe
shear
and theeffect
gradually loss of energy
of
with air
theon fog particles
of fog
increase axialgradually
particles
in reduces,
are reduced
distance. and,the possibility
therefore, of shear
the fog crushing
particle speed and the loss of
rate decreases
energy of fog particles
gradually with the increase are
45 reduced and,
in axial distance.therefore, the fog particle speed rate decreases gradually with
the increase in axial distance.40 45
v（m/s）

3540
45 1mm
v（m/s）

3040
35 1.2mm
1mm
v（m/s）

2530
35 1mm
1.5mm
1.2mm
2025
30
2 3 4 5 6 1.2mm
1.5mm
25
20
1.5mm
20 2 3 4
P（MPa）
5 6
2 3 4 5 6
P（MPa）
Figure 10. Droplet velocity in different spray pressures.
P（MPa）
Figure 10. Droplet velocity in different spray pressures.
60 Figure
Figure10. Dropletvelocity
10.Droplet velocityin
indifferent
differentspray
spraypressures.
pressures.
5060
2MPa
4060
V(m/s)

50
3MPa
2MPa
3050
V(m/s)

40 2MPa
4MPa
3MPa
V(m/s)

2040
30 3MPa
5MPa
4MPa
1030
20 4MPa
6MPa
100 150 200 250 300 5MPa
20
10
L（cm） 5MPa
6MPa
10 100 150 200 250 300
100 150 200
L（cm） 250 300 6MPa
Figure 11. The axialL（cm）
distribution of droplet velocity.
Figure 11. The axial distribution of droplet velocity.
Figure 11. The axial distribution of droplet velocity.
4. 4.
Comparison ofof
Comparison the Effects
the ofof
Effects the
theNozzle
Nozzle ininPractice
Practice
Figure 11. The axial distribution of droplet velocity.
4. Comparison
TheThe swirl
swirl of thewas
nozzle
nozzle Effects
was used
used ofinthe
in aNozzle
a coalcoalmine infor
mine Practice
for spraying
spraying andand dust
dust settling
settling asas shown
shown in in Figure
Figure 12.12.
It4. Comparison
Itcan
canThe
bebeseen
seen thatof the
that the
the Effects
swirl of thesprays
nozzle
nozzle Nozzle
sprays outintiny
out Practice
tiny water
water droplets
dropletsregularly.
regularly.
swirl nozzle was used in a coal mine for spraying and dust settling as shown in Figure 12. Inspectors
Inspectors in the
in coal
the mine
coal
had
mine monitored
had
It canThe monitored
be swirl coalthe
nozzle
seen that dust
coalwasconcentration
dust
swirl concentration
used regularly,
in a sprays
nozzle coal mine
outfor and
regularly,
tiny they
andcompared
spraying
water they dust
droplets that
andcompared with
thatthe
settling
regularly. with
as results
shown
Inspectors after
the results
inin the swirl
theafter
Figure 12.
coal
Itnozzle
the
mineswirl
can had was
be seenused;
nozzle that
monitored the
was thedata
used; are
swirl
coal dust listed
thenozzle
data insprays
are Table
listed1.
concentration outThe
in data
Table
tiny
regularly, 1.in
waterandTable
The 1 are
data
droplets
they in the
Table
compared average
1that
regularly. of
thefive
areInspectors
with measurements.
average
the of five
in the
results coal
after
Table
measurements.
mine
the had
swirl1 shows that
monitored
nozzle wasthe
Table swirl
1coal
shows
used; dust
thenozzle
that had
theareswirl
concentration
data very
listed good
nozzle had
regularly,
in Table application
very
and
1. good
Thethey effects
compared
data in dust
application
in Table that settling,
1effects
are theinthe
with such
dust settling,
results
average asofat the
after
five
such aseast
at the 1035 east 3
1035 tunnel of the1tunnel
coalthe of
mine thewhere
coal mine where
thenozzle
dust the dust
concentration concentration
was 1was
8.5 mg/m 8.5 mg/m
using using
a traditional a
3
the swirl
measurements. nozzle was
Table used;
shows data
that theareswirl
listed in Table
had 1. Thegood
very data in Table
application are the
effects average
in dust of five
settling,
traditional
nozzle, nozzle,
while afterwhile
using after
the using
swirl the
nozzle,swirl
coalnozzle,
dust coal dust
concentration concentration
was reduced was to reduced
6.51 mg/m to 3 ; the
6.51
measurements.
such as at the 1035 Tableeast1 shows
tunnelthat thecoal
of the swirl nozzle
mine wherehadthe very good
dust application was
concentration effects
8.5inmg/m
dust3settling,
using a
mg/m
coal
such ;
as the
3dust
at coal
the dust
concentration
1035 concentration
east was
tunneldecreased
of was
the decreased
by
coal 23%.
mine by
where 23%.
the dust concentration
traditional nozzle, while after using the swirl nozzle, coal dust concentration was reduced to 6.51 was 8.5 mg/m 3 using a

traditional
mg/m 3; the nozzle,
coal dust while after using
concentration was thedecreased
swirl nozzle,by 23%. coal dust concentration was reduced to 6.51
mg/m3; the coal dust concentration was decreased by 23%.

Figure 12.12.
Figure Swirl nozzle
Swirl being
nozzle used
being inin
used a coal mine.
a coal mine.

Figure 12. Swirl nozzle being used in a coal mine.

Figure 12. Swirl nozzle being used in a coal mine.
Appl. Sci. 2018, 8, 1770 12 of 14

Table 1. Swirl nozzle spray dust effect in coal mine.

Location Traditional Nozzle Swirl Nozzle Reduction

1035 East tunnel 8.5mg/m3 6.51 mg/m3 23%
Belt tunnel 13 mg/m3 11 mg/m3 15%

5. Conclusions
The experimental and numerical studies about the mechanism and effectiveness of a swirl nozzle
have been described for dust control and the nozzle was successfully used in underground coal mines.
Further investigations may be performed on the interactions between traditional nozzle structure and
this swirl nozzle structure in the chamber, and eddy simulations could be conducted. However, the
current study can provide the following conclusions:
(1) For this swirl nozzle, when the spray pressure is low, the particles’ SMD decreases rapidly
with the increase of the spray pressure. When the pressure reaches 5 MPa, the particles’ SMD
decreases slowly; even if the spray pressure continues to increase, the particles’ SMD reduces
very slowly. According to this character, a normal pressure pump can be used in practice instead
of an expensive high-pressure pump for cost reduction.
(2) Along the axial distance from the nozzle, the fog particles’ SMD increase rapidly and then decrease
rapidly; after 100 cm, it gradually becomes stable. The processes of increase and decrease are
relatively short. The particles’ SMD was the largest in the center of the fog field and decreases
gradually along the radial direction.
(3) The axial speed of particles increases with the increase of spray pressure, however, the increase
rate tends to be slow when the pressure is above 5 MPa. The speed of particles decreases with
the increase of aperture under the same spray pressure. The speed of the fog particles decreases
gradually with the increase of axial distance in the fog field, and the rate of decrease gradually
slows down.
(4) Increasing of spray pressure and decreasing of nozzle aperture will make the fog particles’ size
distribution more concentrated and uniform. The fog particles’ size distribution is also more
uniform where it is further away from the nozzle axially and radially.

Author Contributions: G.G., C.W. and Z.K. conceived the whole procedure of this study; G.G. performed,
analyzed the mechanical tests and wrote writing-original draft preparation; G.G. and C.W. made revisions of the
manuscript; Z.K. carried out project management and investigation.
Funding: This research was funded by the Joint Funds of the National Natural Science Foundation of China (No.
U1261107) and the Fundamental Research Funds of the Natural Science of Shanxi Province (No. 2012011018-1).
Conflicts of Interest: The authors declare no conflict of interest.

Nomenclature
dpmin dust particle diameter (m)
∆s distribution of fog particle size
U dynamic viscosity
Stk stokes number
ρp dust density
v0 air flow rate
D nozzle diameter (m)
Dw droplet diameter
Q nozzle flowrate (m3 /s)
Pw pressure of water (MPa)
k test coefficient (k = 1.34)
v water jet speed (m/s)
dSMD Sauter mean diameter
Appl. Sci. 2018, 8, 1770 13 of 14

di the droplet diameter

ni number of ith segment
m the number of droplet diameter segments

Abbreviations
SMD Sauter mean diameter
PIV Particle image velocimetry
PDA Phase-doppler anemometry
CFD Computational fluid dynamics
LDA Laser doppler anemometry

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