Study of erosion prediction of turbulent gas-solid flow in plugged tees via CFD-DEM

In many industrial applications, sand erosion wear is the main cause of equipment failure, particularly in the transferring pipeline fittings. In order to reduce the adverse consequences of erosion in bends, in this study the potential usage of plugged tees instead of standard elbows under a wide range of flow conditions is examined. A computational fluid dynamics (CFD) model coupled with discrete element method (DEM) was used and the particle-laden flows with different fluid velocities in the corresponding geometries carrying various entrained particle mass loadings were simulated. The reliability of selected turbulence models as well as rebound and erosion models were verified by comparing the model predictions with the available experimental data. The final simulation model included the E/CRC erosion model, and the Grant and Tabakoff rebound model. The DEM used in the computational model includes the effects of particles rotation and collisions between the particles. The study also considered the effect of modifications of the plugged length of the tee geometries. The simulation results indicated that, as the particle mass loading increases, the effectiveness of plugged tee compared to the standard elbow increases. Moreover, although increasing the plugged length will generally reduce the erosion rate due to the cushioning effect, the rate of reduction depends on mass loading. [Display omitted] •Investigation regarding the optimum use of plugged tees rather than standard elbows.•Discussing erosion rate over a wide range of mass loadings using different interaction regimes.•Examination of modifications on plugged geometry.•Investigation of carrier fluid velocity on erosion rate over a set of conditions.