Improved foam application at the tunnel face with large ventilation volume and low pressure supplied water.

• The cavitating jet pump is simultaneously used as a mixing device and flow meter. • 3D printed foam nozzle and vertical foam generator are designed and tested. • The proposed system reduced the required water inlet pressure to 0.87 MPa. • Dust is successfully suppressed in tunneling face with high ventilation volume. Due to large energy loss, current foam technology for dust suppression requires high inlet water pressure, but performance is poor where ventilation volume is high. This paper proposes modifying key foam device components, including the agent mixing device, foam generator, and nozzle, to address these problems. A cavitating jet pump was simultaneously employed for accurate agent mixing and flow meter, guaranteeing accurate agent flow and low energy loss. A vertical foam generator was designed to increase foam volume and ensure even foam distribution among the foam nozzles. The two-layered foam nozzles were designed and fabricated using 3D printing to ensure even and thick foam impact area on the dust source, effectively blocking dust escape passages. Experiments were performed in the laboratory and on a real heading face. Ventilation volume was 560–570 m3/min for the field experiment with initial total dust concentration 589–679 mg/m3. The proposed system reduced required inlet water pressure to 0.87 MPa, while achieving 86.8% average total dust suppression efficiency and reducing long-term time average respirable dust concentration to 3.9–5.7 mg/m3. This study will help improve performance and expand application fields for foam dust suppression technology. [ABSTRACT FROM AUTHOR]