Corncob-Derived Binder with Synergistic Dust Control: Fabrication, Multi-Scale Characterization, and Field-Relevant Performance

Aiming at addressing two critical challenges in railway tunnel coal transportationdust pollution threatening driving safety and the insufficient performance of existing dust suppressantsthis study developed an environmentally friendly biobased adhesive dust suppressant. This material was prepared using corncob as the main matrix, combined with an acrylic acid (AA) monomer, cross-linking agent ethylene glycol dimethacrylate (EGDMA), and surfactant sodium dodecyl sulfate (SDS). With evaporation resistance, dust-binding crust solidification performance, and wind erosion resistance as the evaluation indicators, the optimal formulation of the material was determined through orthogonal experiments. Scanning electron microscopy (SEM) and Fourier transform infrared spectroscopy (FTIR) were employed to characterize the microscopic morphology and structure of the material. The results showed that the optimal mass ratio of AA:EGDMA:SDS was 2:2:1. The obtained dust suppressant exhibited an adhesive structure, which could form a dense scale-like solidified layer on the coal dust surface and effectively fill the gaps between coal dust particles. Molecular dynamics simulations revealed the dynamic wetting process of the material molecules at the coal-water interface: rapid molecular diffusion in the initial stage, directional molecular aggregation to form a cross-linked network in the middle stage, and the system reaching a dynamic equilibrium state at 300 ps. The unique amphiphilic molecular structure of this material significantly enhanced the microscopic interaction between coal and water molecules. By constructing a simulation experimental system, the optimal application concentration of the dust suppressant was determined to be 1.5%. At this concentration, the peak dust concentration was 3.5 mg·m^-3, the average concentration was stabilized at 1.3 mg·m^-3, and the duration of dust emission caused by airflow disturbance was shortened to 46 s, achieving the best comprehensive dust suppression effect.