Jie Wu and Lachlan Graham
Mar 2014
MINERALS DOWN UNDER FLAGSHIP
Reduced Erosion in Multiphase Flow -AMIRA P931B
• Solid particles in flow- erosive wear damage
Background
AMIRA P931B| Dr Jie Wu | Page 1.2
• Develop fluid dynamics design solutions to erosion problems
• Sponsor driven case studies
• Erosion fundamentals
Since 2006 have been building a “Erosion Knowledge Base” contains a growing collection of flow design examples
and reports for mineral processing applications.
Only P931 sponsors can access the “Erosion Knowledge Base” .
AMIRA P931 Research Strategy
AMIRA P931B| Dr Jie Wu | Page 1.3
How we do it? Methodology: modeling and testing
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Slurry erosion test rig Erosion measurements
CFD modelling
Measured erosion distribution - pipe elbow Validate improved erosion performance
CSIRO pipe elbow
~40% less erosion
Standard 1.5D bend
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Examples of Design Solutions - tee
Inlet Flow
Blanked end
Outlet Flow
Vortex
Erosion here
Vortex erosion on blanked tee
Erosion here
Sharp edged tee
Tee with large fillets
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Erosion Diagnostic Tool
• To identify wear causes
• To develop solution “road maps” for wear items:
pump inlet pipe spools,
mill screens
non-return valves in Wirth pump
orifice plate in the back pressure stage
Lunkenheimer valves
etc
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• Vortex erosion: R 3-5
• Flashing erosion: R 600 for Ti-2 piping in Vale’s Sudbury EW plant case
• Non-uniform flow erosion: R 100 for an orifice case , for example
Severe Erosion Attack
1max_
max cylinderE
ER
AMIRA P931B| Dr Jie Wu | Page 1.8
)(fVE nwhere
V
• Vortex due to surface disturbance – severe erosion
Vortex Erosion – higher than for direct impact
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Flashing Erosion
T1, P1
T2, P2
Pressurised hot
water inlet
Outlet
Much higher velocity due to flashing
1%w/w boiling, ~x10 velocity
Where: pipe components after digesters non-return valve in PD pumps
Movie
AMIRA P931B| Dr Jie Wu | Page 1.10
Erosion Diagnostic Tool
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Plant Input Data Fill in yellow boxes
Part Wear information Measured maximum erosion 1 mm
Service life 10 days
Erosion rate 0.100 mm/day
Material type Carbon steel
Particle information Particle concentration 40 % w/w
Particle size: d50 0.5 mm
Flow information Slurry flow rate 200 m^3/hr
Flow area 0.02 m^2 e.g. area of pipe or duct
Flow velocity 2.78 m/s This calculated based on the flow rate and area
Diagnostic OutputErosion ratio, R 0.23
Likely erosion type Impact
Suggested mechanism Impact at an angle where erosion is larger, some redesign opportunity to change impact angles to reduce erosion.
For solution examples see Sheet No. 2
Calculation results for CSIRO Peak cylinder erosion 0.55 mm/day This varies depending on material
Do not alter this section Particle concentration 26.6 % w/w
Particle size : d50 0.2 mm
Test velocity 6.00 m/s
Estimated cylinder erosion 0.44 mm/day This is the estimated erosion of a test cylinder under plant conditions
Budget
AMIRA P931B| Dr Jie Wu | Page 1.12
Proposed sponsorship levels for the P931B project are: AUD$ pa#
Continuing P931A Sponsor Major Operating Sponsor $54,000
Minor Operating Sponsor $27,000
New Sponsor Major Operating Sponsor $67,500
Minor Operating Sponsor $33,700
Supplier Sponsor $33,700
Likely timing: 1st July 2014 – 30th June 2017
Thank you CSIRO Process Science and Engineering Dr Jie Wu Project Leader
t +61 3 9252 6173 e [email protected] w www.csiro.au/CPSE
MINERALS DOWN UNDER FLAGSHIP
