Slurry Flow Erosion In Centrifugal Pump CFD Simulation

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  • The problem numerically simulates Slurry Flow in Centrifugal Pump using ANSYS Fluent software.
  • We design the 3-D model with the Design Modeler software.
  • We Mesh the model with ANSYS Meshing software, and the polyhedra element number equals 1,498,132.
  • We use the Frame Motion to define the rotational movement in the rotating zone.
  • The DPM multiphase is activated to model the effect of solid particles on erosion.
  • The activated erosion models are Generic, Finnie, McLaury, Oka, and DNV.
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Description

Slurry Flow Erosion In Centrifugal Pump CFD Simulation, ANSYS Fluent Tutorial

Description

Centrifugal pumps are a kind of rotating machinery used in hydropower, dredging, petroleum, mining, etc. Many centrifugal pumps are used for slurry pipeline transportation systems. One of the common problems for these pumps is erosion, which reduces hydraulic performance, increases the noise and vibration level, and sometimes causes the failure of the pumps.

The failure leads to the replacement of the defective and the shutting down of the whole transportation system. So, investigating erosion characteristics has always been a significant research topic in
pumping systems. The erosion predictions for centrifugal pumps still need to be improved in experimental and numerical approaches. Therefore, prediction methods that consider the flow mechanism inside the pump need to be improved to assist in reducing pump erosion.

We use ANSYS Fluent software to stimulate the slurry flow in the centrifugal pump. We perform this CFD project and investigate it by CFD analysis.

We designed a centrifugal pump in which the computational domain consists of rotating and stationary zones. The flow enters the pump through the stationary part entrance and then turns into the rotational zone. The rotating region of the pump rotates with a rotational speed equal to 1000 rpm. The fluid rotates as the blades rotate and then reaches the pump outlet.

First, we simulated water flow using the SST k-w turbulence model to see the flow behavior through a centrifugal pump, the range of pressure drop, the velocity contour, and the other results, such as streamlines, shown in the results.

Second, we simulated the slurry flow, including water as the base fluid and calcium carbonate as particles with 8% concentration, using a multiphase DPM model, which is applied to investigate two-phase flows with particle concentrations less than 10% numerically. In slurry flow, particles hit the blades and cause erosion, which is essential to investigate in this simulation.

We solved the slurry in steady and unsteady particle treatment. The unsteady simulation aims to show the particle path lines. Also, we obtained an animation of the fluid flow in the pump to understand better particle injection, flowing, and rotating in the domain.

Finally, we considered the steady solution to see the erosion on the blades. We used pure water simulation results as initial predictions for solving the model with DPM since accuracy takes more time in multiphase models.

We modeled the geometry of the project using Design Modeler software. Then we meshed the model with ANSYS Meshing software. The mesh model is polyhedral, and the number of cells equals 1,498,132.

Slurry Flow Erosion In Centrifugal Pump Methodology

In this problem, the DPM model solves the slurry flow via two-way interaction between the discrete phase and water. The particles are injected from the inlet surface as inert and in the rosin-rammler model.

Multiple Reference Frames (MRF) model has been applied for the rotation simulation. The diameter of particles is considered equal to 100 µm. The SST k-w turbulent modal is used for both water and slurry flow.

The different erosion models on blade walls in boundary setup are activated. These models are Generic, Finnie, McLaury, Oka, and DNV.

The High Order Time Relaxation and Wraped-Face Gradient Correction are activated to achieve better convergence.

Conclusion

This simulation mainly aims to see the erosion created by particles on the blades so you can see the erosion rate contours in the attached files. The results show that the blade edges’ erosion rate is higher than in other parts.

The pressure and velocity contours, velocity vectors, particle tracks, and path lines are also presented for the pure water, steady and unsteady DPM solution for the problem. Additionally, particle movement in the domain is shown via animation.

The contours show that the pressure increases radially; By increasing the pressure from the pump’s central part to the periphery. Also, due to the rotational motion of the blades in the central part, you can see the maximum speed in this part and the maximum value of the pressure difference or pressure gradient.

Erosion

Reviews

  1. Avatar Of Mrs. Verna Olson Ii

    Mrs. Verna Olson II

    The tutorial is quite comprehensive and covers crucial aspects of erosion in centrifugal pumps. I’m curious as to how the erosion rate varies with different particles sizes in addition to the modeled 100 5m calcium carbonate particles.

    • Avatar Of Mr Cfd Support

      MR CFD Support

      In our current simulation setup, we focused on a specific particle size of 100 5m for calcium carbonate particles. Erosion rate indeed varies with particle size; larger particles might cause more significant erosion due to their higher mass and possibly higher impact forces. To determine how erosion rate changes with different particle sizes, further simulations with varying diameters would need to be configured and run, incorporating the same boundary conditions and flow characteristics while adjusting for the targeted particle size. This would give insight into the relationship between particle size and erosion rate in centrifugal pumps.

  2. Avatar Of Sydney Gerhold

    Sydney Gerhold

    The depth and detail in this report on slurry flow erosion in centrifugal pumps are impressive! I’m particularly pleased with how clearly the impact of erosion on the efficiency and durability of the pump is conveyed. Moreover, the combination of multiphase DPM model for the particle tracking and various erosion models presents a comprehensive analysis, providing valuable insights for the maintenance and design improvement of centrifugal pumps.

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Thank you for the positive feedback! We’re glad to hear that the simulation met your expectations and provided useful insights. If you have any further questions or need more information on our products and services, please don’t hesitate to ask.

  3. Avatar Of Judah Mueller

    Judah Mueller

    Was comprehensive turbulence modeling introduced to account for the complex phenomena in the pump and slurry interaction?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Yes, comprehensive turbulence modeling was leveraged in this case using the SST k-w model, giving a detailed description of the interaction between the slurry particles and the turbulent flow within the centrifugal pump.

  4. Avatar Of Adella Hegmann

    Adella Hegmann

    I found the erosion rate contour results particularly insightful. Can you detail how the different erosion models (like Finnie, McLaury, etc.) influenced the final prediction of erosion rates? Was one model more predictive of the observed outcomes than others?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Thank you for your comprehensive review and thoughtful question. The selection of an erosion model can indeed influence the prediction of erosion rates on the blades. Each model operates on a different set of assumptions and suit different conditions or materials. With respect to this particular simulation and the models available, it is postulated that factors such as particle velocity, impact angle, and material of the blade were taken into account by the models. Depending on the real-world correlation, one model might predict the erosion with better accuracy over others based on empirical data fostering that specific case. For this simulation, skirmishing through various models allowed simulation to convergence towards a more realistic outcome. Erosion prediction would highly center around matching the most pertinent physical theory to the actual process environment within the centrifugal pump.

  5. Avatar Of Ericka Senger

    Ericka Senger

    I really appreciated the detailed explanation of the centrifugal pump erosion simulation using ANSYS Fluent. The findings on the distribution of erosion rates on the blade edges compared to other parts added valuable insights into pump design considerations.

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Thank you for your positive feedback! We’re glad that you found the simulation details and results insightful and helpful for understanding pump erosion. Your appreciation means a lot to us, and we strive to consistently provide comprehensive analyses that can aid in better pump design and operation.

  6. Avatar Of Lura Gusikowski

    Lura Gusikowski

    The tutorial looks very detailed, which erosion detection model turned out to be more accurate for predicting blade damage in this type of pump?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      In this CFD simulation, several erosion models are employed, including Generic, Finnie, McLaury, Oka, and DNV. The accuracy of these models can depend on the specific conditions of the simulation. Generally, the Oka model tends to provide a more accurate prediction for impeller blade erosion due to its comprehensive approach in considering the impingement angle, impact velocity, and size of the slurry particles. However, the best model can vary based on the empirical data and the specific characteristics of the pump and slurry being used in the simulation.

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