CFD Modeling of Ventilation and Dust Flow Behavior in Polishing and the Design of an Innovative Wet Dust Removal System

Fine aluminum dust pollution in the polishing process was detected during a field survey. To obtain a fundamental understanding of the airflow patterns and the fine dust dispersion characteristics during a polishing process, computational fluid dynamics simulations were first performed to analyze the data collected in field measurements. The inappropriate ventilation arrangement and lack of effective dust control measures were identified as the main reasons for the high dust exposure levels (in excess of 1000 μg/m³). Simulation results showed that inhalable dust particles (PM10) could be significantly diluted at the operator's breathing level by adding a supply air inlet above the operating area. Moreover, dry dust collection systems create a risk of aluminum dust explosion accidents. An innovative design of wet dust removal system which could mitigate the occurrence of dust explosions was proposed and then implemented on site. An independent field dust assessment showed that a reduction of fine dust particles up to 95% in the worker's breathing area and the fine dust in the vents was reduced to 80%. Therefore, the proposed strategies are implemented immediately to address the combustible dust in the polishing working environment and can provide guidance for operators.