Impact of solid particle geometry, size, and intensity, coupled with fluid velocity, on erosion dynamics in elbow conduits

Sand production poses a significant challenge because of erosion caused by solid particles in turbulent flows, particularly in elbows and fittings. This research explores the influence of solid particle geometry, size, intensity, elbow radius of curvature, and fluid velocity on erosion dynamics in elbows under vertical flow conditions via the CFD-DPM (discrete phase model) coupling method. The novelty of this study lies in its integrative approach, which involves simultaneously analyzing multiple interrelated parameters and validating predictions with detailed experimental data. This provides more realistic insights into erosion behavior and more practical guidelines for minimizing wear in industrial pipelines. The numerical results were verified through experimental investigation. The findings revealed that increasing the number of particles increased the erosion rate up to a certain point, after which erosion did not change. This can be attributed to surface saturation, particle shielding, and energy dissipation mechanisms. Larger particles cause more erosion, whereas smaller, rounded particles cause less erosion. Furthermore, high flow rates and lower elbow radii of curvature induce higher impact pressures, especially on outer elbow surfaces, intensifying erosion for larger particles. Therefore, this study identifies the combined effects of particle and flow parameters that critically influence elbow erosion, highlighting effective control strategies to prolong equipment life. Future work should focus on developing mitigation strategies and exploring alternative materials to reduce erosion under turbulent flow conditions.