Optimization and field application of an eco-friendly molasses-based dust suppressant for open-pit coal mine haul roads
Abstract To overcome the limitations of conventional water-based dust suppression in arid, high-temperature open-pit coal mine haul roads, this study developed an innovative molasses-based dust suppressant with enhanced water retention and consolidation capabilities. The formulation leverages molass...
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Nature Portfolio
2025-07-01
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| Series: | Scientific Reports |
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| Online Access: | https://doi.org/10.1038/s41598-025-11965-0 |
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| author | Yu Zhang Junlong Yan Wei Zhou Weiqing Zhang Xiang Lu Peiyuan Li Fanghui Yang Zhifan Wang |
| author_facet | Yu Zhang Junlong Yan Wei Zhou Weiqing Zhang Xiang Lu Peiyuan Li Fanghui Yang Zhifan Wang |
| author_sort | Yu Zhang |
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| description | Abstract To overcome the limitations of conventional water-based dust suppression in arid, high-temperature open-pit coal mine haul roads, this study developed an innovative molasses-based dust suppressant with enhanced water retention and consolidation capabilities. The formulation leverages molasses-a sugar industry byproduct with inherent anti-evaporation properties-as its core component, supplemented with surfactant (sodium dodecyl benzene sulfonate, SDBS), humectant (glycerol), and hygroscopic (calcium chloride, CaCl₂) additives. Employing response surface methodology (RSM), the optimal composition was determined to be: 31.06% molasses, 0.73 g/L SDBS, 1.68% glycerol, and 1.50% CaCl2. Experimental validation confirmed the model’s reliability, showing < 3% deviation between predicted and actual performance metrics. Field evaluation produced significant results: small-scale testing with 2.5-ton and 4.4-ton mine vehicles maintained dust-free conditions for three consecutive days, while medium-scale trials with loaded (550-ton) and unloaded (225-ton) haul trucks achieved effective dust control for over 6 h. The suppressant creates a durable, homogeneous consolidation layer with substantial mechanical strength when applied. The suppression mechanism combines immediate dust wetting with prolonged suppression via dust particle solidification post water evaporates. |
| format | Article |
| id | doaj-art-e151092882214bb6a85a05dbddbcff42 |
| institution | Kabale University |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-07-01 |
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| spelling | doaj-art-e151092882214bb6a85a05dbddbcff422025-08-20T03:42:53ZengNature PortfolioScientific Reports2045-23222025-07-0115111610.1038/s41598-025-11965-0Optimization and field application of an eco-friendly molasses-based dust suppressant for open-pit coal mine haul roadsYu Zhang0Junlong Yan1Wei Zhou2Weiqing Zhang3Xiang Lu4Peiyuan Li5Fanghui Yang6Zhifan Wang7Haerwusu Open Pit Coal Mine, Shenhua Zhungeer Energy and Resource Comprehensive Development Co Ltd, CHN Energy Investment Group Co LtdState Key Laboratory for Fine Exploration and Intelligent Development of Coal Resources, China University of Mining and TechnologyState Key Laboratory for Fine Exploration and Intelligent Development of Coal Resources, China University of Mining and TechnologyState Key Laboratory for Fine Exploration and Intelligent Development of Coal Resources, China University of Mining and TechnologySchool of Mines, China University of Mining and TechnologyState Key Laboratory for Fine Exploration and Intelligent Development of Coal Resources, China University of Mining and TechnologyState Key Laboratory for Fine Exploration and Intelligent Development of Coal Resources, China University of Mining and TechnologySchool of Safety Engineering, China University of Mining and TechnologyAbstract To overcome the limitations of conventional water-based dust suppression in arid, high-temperature open-pit coal mine haul roads, this study developed an innovative molasses-based dust suppressant with enhanced water retention and consolidation capabilities. The formulation leverages molasses-a sugar industry byproduct with inherent anti-evaporation properties-as its core component, supplemented with surfactant (sodium dodecyl benzene sulfonate, SDBS), humectant (glycerol), and hygroscopic (calcium chloride, CaCl₂) additives. Employing response surface methodology (RSM), the optimal composition was determined to be: 31.06% molasses, 0.73 g/L SDBS, 1.68% glycerol, and 1.50% CaCl2. Experimental validation confirmed the model’s reliability, showing < 3% deviation between predicted and actual performance metrics. Field evaluation produced significant results: small-scale testing with 2.5-ton and 4.4-ton mine vehicles maintained dust-free conditions for three consecutive days, while medium-scale trials with loaded (550-ton) and unloaded (225-ton) haul trucks achieved effective dust control for over 6 h. The suppressant creates a durable, homogeneous consolidation layer with substantial mechanical strength when applied. The suppression mechanism combines immediate dust wetting with prolonged suppression via dust particle solidification post water evaporates.https://doi.org/10.1038/s41598-025-11965-0Open-pit coal miningHaul roadRoad dustMolasses-based dust suppressantWater retentionDust consolidation |
| spellingShingle | Yu Zhang Junlong Yan Wei Zhou Weiqing Zhang Xiang Lu Peiyuan Li Fanghui Yang Zhifan Wang Optimization and field application of an eco-friendly molasses-based dust suppressant for open-pit coal mine haul roads Scientific Reports Open-pit coal mining Haul road Road dust Molasses-based dust suppressant Water retention Dust consolidation |
| title | Optimization and field application of an eco-friendly molasses-based dust suppressant for open-pit coal mine haul roads |
| title_full | Optimization and field application of an eco-friendly molasses-based dust suppressant for open-pit coal mine haul roads |
| title_fullStr | Optimization and field application of an eco-friendly molasses-based dust suppressant for open-pit coal mine haul roads |
| title_full_unstemmed | Optimization and field application of an eco-friendly molasses-based dust suppressant for open-pit coal mine haul roads |
| title_short | Optimization and field application of an eco-friendly molasses-based dust suppressant for open-pit coal mine haul roads |
| title_sort | optimization and field application of an eco friendly molasses based dust suppressant for open pit coal mine haul roads |
| topic | Open-pit coal mining Haul road Road dust Molasses-based dust suppressant Water retention Dust consolidation |
| url | https://doi.org/10.1038/s41598-025-11965-0 |
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