Effect of suspended particles on erosion characteristics of impeller steels utilizing combined CFD and DOE approach

Purpose The process of conveyance of solid–liquid mixtures poses a significant challenge due to the considerable wear and tear experienced by critical components. This issue not only affects the lifespan of the system but also jeopardizes its safe operation. The purpose of this study is to numerically and experimentally investigate the erosion wear behavior of impeller steels (SS-410 and S-317) using Computational Fluid Dynamics (CFD) and Design of Experiments (DOE) techniques, aiming to address the significant challenges posed by wear in slurry transportation systems. Design/methodology/approach In this study, a robust two-phase solid-liquid model combining CFD with Discrete Phase Modeling (DPM) was applied to simulate the effects of coal-ash slurries on impeller steel. Additionally, an experimental evaluation was conducted using the DOE approach to analyze the impact of various parameters on impeller steel. This integrated methodology enabled a comprehensive analysis of erosion wear behavior and the influence of multiple factors on impeller durability by leveraging CFD for fluid flow dynamics and DPM to model particle interactions with the steel surface. Findings Simulation results highlight a strong link between particle size and the wear life of impeller steel. Through simulations and experiments on SS-410 and SS-317 under varied conditions, it’s evident that SS-410 outperforms SS-317 due to its higher hardness and density. This is supported by Taguchi’s method, with SS-410 showing a higher Signal-to-Noise ratio. Notably, particle size emerges as the most influential parameter compared to others. Originality/value Current research primarily focuses on either CFD or experimentation to predict pump impeller steel erosion wear, lacking relevant erosion mechanism insights and experimental data. This study bridges this gap by employing both CFD and DPM methods to comprehensively investigate particle effects on pump impeller steel and elucidate erosion mechanisms.