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

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)(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

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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

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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 jie.wu@csiro.au w www.csiro.au/CPSE

MINERALS DOWN UNDER FLAGSHIP