Numerical Investigations of the Influence of the Spool Structure on the Flow and Damage Characteristics of Control Valves

This study investigates the flow dynamics and damage characteristics of liquid level control valves in direct coal liquefaction processes. The primary failure mechanisms are identified as eccentric jet-induced unilateral wall damage, cavitation erosion, and solid particle erosive wear. A numerical simulation framework was developed to analyze the effects of varying spool angles (72°, 90°, 98°, 105°, and 120°) on flow stability, cavitation dynamics, and erosion patterns. The key findings include the following: A spool angle of 90° achieves the most uniform pressure distribution and minimizes eccentric jet phenomena. Spool geometry modifications exhibit a negligible influence on cavitation characteristics. Reduced wear rates are observed at smaller spool angles (72° and 90°), with the lowest particle-induced erosion occurring at 90°. There is a certain correlation between the particle residence time and the wear of the valve core wall, which is illustrated in the shorter residence times that are correlated with accelerated material degradation. The optimal spool angle of 90° simultaneously mitigates eccentric jet effects, cavitation, and erosive wear. This research provides novel insights for predictive failure analysis and the structural optimization of control valves in high-pressure multi-phase flow systems.