Optimizing pressure drop in 90° bend horizontal pipelines for dense slurry flow: A response surface methodology approach

Efficient transportation of minerals and solid materials through pipelines requires very complex parameters and conditions. This research investigates the correlations between different flow parameters and pipe design elements to predict bend pressure drop—a factor that indicates the possibility of erosion both in the straight pipeline sections and in the bends. Adopting a response surface methodology approach, this study identifies material conveyance conditions with best results while maintaining minimal bend pressure drop. The research shows the significant influence of slurry concentration, velocity, particle diameter, particle concentration, and pipe diameter on bend pressure drop. The speed of conveyance turns out to be the main variable that affects the bend section, whereas in the horizontal pipe portions, the pipe diameter becomes more important. This research paper gives critical consideration of the factors controlling material conveyance with the aim of reducing bend pressure drop by up to 15% for dense slurry flow inside horizontal pipelines. This study reports the outcomes, including the results of the right design values for the parameters as 1.787 m/s, 8.82, 450 μm, 466.442 mm, and 1.2 for inlet velocity of the mixture, solid volume concentration, particle size, pipe diameter, and bend ratio. The response parameter bend pressure drop was 49.7 Pa at such conditions. This study provides valuable insights into optimizing material conveyance by understanding and manipulating these key parameters to reduce bend pressure drop by up to 15% in dense slurry flow within horizontal pipelines.