Research on the Cumulative Dust Suppression Effect of Foam and Dust Extraction Fan at Continuous Miner Driving Face

The heading face is one of the zones most severely affected by dust pollution in underground coal mines, and dust control becomes even more challenging during roadway excavation with continuous miners. To improve dust mitigation in environments characterized by intense dust generation, high ventilation demand, and large cross-sectional areas, this study integrates numerical simulations, laboratory experiments, and field tests to investigate the physicochemical properties of dust, airflow distribution, dust migration behavior, and a comprehensive dust control strategy combining airflow regulation, foam suppression, and dust extraction fan systems. The results show that dust dispersion patterns differ markedly between the left-side advancement and right-side advancement of the roadway; however, the wind return side of the continuous miner consistently exhibits the highest dust concentrations. The most effective purification of dust-laden airflow is achieved when the dust extraction fan delivers an airflow rate of 500 m3/min and is positioned behind the continuous miner on the return side. After optimization of foam flow rate and coverage based on the cutting head structure of the continuous miner, the dust suppression efficiency reached 78%. With coordinated optimization and on-site implementation of wall-mounted ducted airflow control, foam suppression, and dust extraction fan systems, the total dust reduction rate at the heading face reached 95.2%. These measures substantially enhance dust control effectiveness, improving mine safety and protecting worker health. The resulting reduction in dust concentration also improves visibility for underground intelligent equipment and provides practical guidance for industrial application.