Numerical Simulation of Erosion Wear in Slurry Pipeline Based on DDPM-RSM

doi:10.11902/1005.4537.2024.177

Journal of Chinese Society for Corrosion and protection

2025, Vol. 45

Issue (3): 709-719 DOI: 10.11902/1005.4537.2024.177

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Numerical Simulation of Erosion Wear in Slurry Pipeline Based on DDPM-RSM

XIAO Qikun¹^,², MA Jun¹^,²(

), GUO Kai¹^,², XIONG Xin¹^,², YUAN Haoran¹^,²

^1.Faculty of Information Engineering and Automation, Kunming University of Science and Technology, Kunming 650500, China
^2.Yunnan Key Laboratory of Intelligent Control and Application, Kunming University of Science and Technology, Kunming 650500, China

Cite this article:

XIAO Qikun, MA Jun, GUO Kai, XIONG Xin, YUAN Haoran. Numerical Simulation of Erosion Wear in Slurry Pipeline Based on DDPM-RSM. Journal of Chinese Society for Corrosion and protection, 2025, 45(3): 709-719.

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Abstract

In order to reveal the erosion wear mechanism of pipeline during conveying iron ore concentrate containing slurry, a method based on the so called “dense discrete phase model” (DDPM) and “response surface methodology” (RSM) is proposed to analyze the erosion wear characteristics of slurry pipeline, and simulate the erosion wear behavior of pipeline caused by iron ore concentrate during the slurry conveying process. Meanwhile, the influence of single factor and multi-factor coupling on the erosion wear of pipeline is also analyzed. Firstly, a computational fluid dynamics (CFD) model is established by combining the actual working conditions of iron ore concentrate transportation; secondly, the accuracy of the E/CRC (Erosion/Corrosion Research Center) erosion model is verified by using the open dataset, which shows that the model can be used to calculate the erosion wear of the slurry pipeline; finally, the effect of inlet velocity, particle size, particle mass flow rate and slurry flow direction on the erosion wear of the pipeline is investigated, and RSM tests are designed to analyze the importance of different factors. The results show that: the erosion rate increases with the increase of inlet velocity, namely, in the range of 1.5-2.0 m/s the pipeline erosion wear is the smallest; with the increase of particle size, the erosion rate shows the trend of decreasing and then increasing, for particle size of 100 μm, hence, the pipeline erosion wear can be effectively reduced; with the increase of the particle mass flow rate, the maximum erosion rate increases first, then decreases, and finally tends to be stabilized; By taking the critical mass flow rate and the economics of pipeline transportation into account, the propriate particle mass flow rate should be selected above 2.5 kg/s. The influence of three flow field factors on pipeline erosion wear is inlet velocity > particle mass flow rate > particle size; under multi-factor coupling, the combined effect of inlet velocity and particle size has the greatest influence on pipeline erosion wear. The method proposed in this study can provide a theoretical basis for pipe erosion protection.

Key words: slurry transportation computational fluid dynamics erosion wear dense discrete phase model response surface methodology numerical simulation

Received: 04 June 2024 32134.14.1005.4537.2024.177

ZTFLH:

TG174

Fund: National Natural Science Foundation of China(62173168);Yunnan Province Basic Research Program(202101BE070001-055)

Corresponding Authors: MA Jun, E-mail: mjun@kust.edu.cn

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	XIAO Qikun
	MA Jun
	GUO Kai
	XIONG Xin
	YUAN Haoran

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https://www.jcscp.org/EN/10.11902/1005.4537.2024.177 OR https://www.jcscp.org/EN/Y2025/V45/I3/709

Fig.1 Geometry model of pipeline

Fig.2 Different flow directions of the fluid in the pipeline: (a) flow 1, from top to lower left; (b) flow 2, from lower left to top; (c) flow 3, from upper left to down; (d) flow 4, from down to upper left

Fig.3 Pipeline meshing for computational simulation

Fig.4 Grid independence test

Fig.5 Pipeline model proposed in the reference^[28]

Fig.6 Comparison of calculated and experimental values of elbow erosion rate

Fig.7 Maximum erosion rate as a function of inlet velocity

Fig.8 Contours of pipeline erosion rates at the inlet velocities of 1.5 (a), 2.0 (b), 2.5 (c), 3.0 (d), 4.0 (e) and 5.0 (f) m/s

Fig.9 Relationship between maximum erosion rate and particle size

Fig.10 Contours of pipeline erosion rates at the particle sizes of 50 (a), 100 (b), 200 (c), 300 (d), 400 (e) and 500 (f) μm

Fig.11 Relationship between maximum erosion rate and particle mass flow rate

Fig.12 Contours of pipeline erosion rates at the particle mass flow rates of 0.5 (a), 1.0 (b), 1.5 (c), 2.0 (d), 3.0 (e) and 4.0 (f) kg/s

Fig.13 Relationships between maximum erosion rate and inlet velocity under the conditions of different flow directions of the fluid in pipeline

Table 1 RSM-BBD experimental design and results

Table 2 ANOVA table

Fig.14 Contour diagrams of interactions of different response factors: (a) inlet velocity and particle size, (b) inlet velocity and particle mass flow rate, (c) particle size and particle mass flow rate

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