Multiphase Computational Fluid Dynamics Analysis of Hydro-Abrasive Wear in Slurry Pipelines Using the Oka Erosion Model with Ultrasonic Validation

Beltrán Quispe D.; Otazú Ayque P.; Lazo Alarcon L.; Beltran Quispe V. · International Journal of Heat and Technology (2026) · DOI: 10.18280/ijht.440218

Resumen

This study investigates hydro-abrasive wear mechanisms in cyclone feed slurry pipelines used in copper processing plants, focusing on localized failure at Y junction interfaces where empirical criteria are insufficient. A high-fidelity Eulerian-Lagrangian Computational Fluid Dynamics coupled with the Discrete Phase Model (CFD-DPM) framework was implemented, incorporating the Herschel Bulkley model to represent non-Newtonian slurry behavior and Oka's erosion formulation to describe particle wall interactions. Model predictions were assessed against Ultrasonic Testing (UT) data obtained from Spool 32 using a SIUI SMARTOR device, yielding a Normalized Root Mean Square Error (NRMSE) of 6.8%. Due to the limitations of UT for composite linings, this comparison represents an indirect validation of the predicted wear patterns. Results indicate that asymmetric momentum redistribution and high velocity impingement generate localized degradation, with a minimum residual thickness of 10.7 mm identified in critical zones. Erosion scaling analysis shows that material response is governed by hardness dependent regimes, placing elastomeric and ceramic linings in distinct erosion domains under equivalent operating conditions. These findings support the use of alumina based linings in high impact regions and provide a physically grounded framework for material selection and maintenance planning in slurry transport systems.

Instituciones: Universidad Nacional de San Agustín de Arequipa