SDP Presentation.pptx

Senior Design Project Presentation on
Computation of slurry flow through horizontal bend
and effects of its characteristics on rate of erosion in
pipelines
Supervisors:
Dr. A. Mahapatro
Dr. S. P. Jena
Presented by:
Kalpanta Mahapatra
(1841018054)
Abhisekh Lugun
(1841018014)
Gourab Jena
(1841018082)
Mechanical Engineering
Institute of Technical Education & Research
Siksha ‘O’Anusandhan Deemed to be University, Bhubaneswar
July, 2022

Contents
• Introduction
• Literature Survey
• Design Scheme
• Testing, Analysis, And Evaluation
• Socio-economic Issues Associated With The Project
• Engineering Tools And Standards
• Conclusion
Friday, 08
July 2022
Computation of slurry flow through horizontal bend and effects of its characteristics on
rate of erosion in pipelines
2

Introduction
• The evidence of flows involving a suspension of fine solid materials in a fluid can
be traced back to 1860s in Egypt’s Suez Canal and other Roman & Greek empires
as well.
• The earliest experimentation published related to solid-water mixture flow dates
back to 1906
• Understanding the characteristics of liquid & solid particles transport in industrial
contexts requires instrumentation - that can make fast, accurate, and autonomous
measurements in addition to those which are also expected to be reliable, fast, and
unobtrusive.
• Slurry transportation via pipelines has proven to be cost-effective, safe-to-handle,
and highly reliable for long-distance transportation during the previous few
decades
• New slurry transportation methods have enabled us to move minerals and
materials across large distances in a safe and efficient manner.
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Introduction – Slurry Transportation in India
• The first modern-age industrial slurry transportation in India was successfully
experimented & installed successfully in coal mines after the Second World War
• Because the Indian subcontinent is rich in minerals, mining occurs on a daily
basis throughout the terrain. The generated ores are delivered by numerous routes,
including highways, trains, canals, and underground pipelines.
• According to extensive statistical analysis and research, the cost of transporting
ore slurry via road is similar to Rs 6/ton/km. The cost of rail is equivalent to Rs
2.83/ton/km. In comparison to these figures, the slurry pipeline is much cheaper,
at Rs 0.60/ton/km, lowering transportation costs by almost 80%.
• On a yearly basis, India emits 0.75 metric tons of greenhouse gases (carbon
dioxide) per citizen, resulting in 41 kg of CO2 per ton for every 200 kilometers
travelled.
• If pipelines are utilized instead of roads and railroads, pollution levels can be
greatly reduced because slurry pipelines produce only 3.9 kg of CO2 per ton
every 200 km distance.
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July 2022
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Introduction – Operational Procedure
• In a hydraulic transportation system, the crushed solid particles are kept in
suspension in water stream as a lifting force is created due to the difference in
static pressures between flow velocities.
• Adequate flow velocity ensures that the solid materials travel with the effect of
the lifting force.
• The solids are kept in suspension mode by creating turbulence in pipeline.
• The flow & mixture characteristics such as flow velocity, solid concentration,
particle size, etc. play an important role in the preservation of the pipeline as they
can be responsible for pressure loss, leaks, backflow, spills, etc.
• Bends in pipelines are prone to aggravated wear and are at a greater risk of
rupture.
• However, bends in pipelines also ensure flexibility in routing through difficult
terrains.
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July 2022
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Literature Survey
• The first and foremost matter of concern when it comes to study of flow
properties in pipe bends is sudden pressure drop. Along with the flow
characteristic, pipeline geometry also plays an important role in pressure drops.
Kalyanraman et al. (1972) were the first to conclude that a bend ratio of 5 is most
optimum for pressure loss.
• Bozzini et al. (2003) proposed a numerical simulation in four-phase flows and
investigated the effect of key operating parameters including flow velocity,
particulate content and gas volume fraction. Results showed that velocity was the
most influential paremeter to affect erosion wear
• Njobuenwu et al. (2012) developed an erosion model to analyze and predict
erosion on concave and convex region of the pipe bend.
• Though there are numerous models available to predict corrosion and erosion
wear, the affecting dangling parameters are always subject to change based on
pipe, flow and fluid characteristics. Owing to the complexity of the process,
empirical formula are most suited for calculations.
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July 2022
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Customer Needs
• Customer needs are the most important
pain points that the consumer wishes to
be resolved or restricted. Customer
needs can act as a base for any project
objective, addressing any problem that
is being faced by them, when used.
• Based on the conducted survey, it was
evident that an effective solid
transportation system must include:
Easy operation
Cost efficiency
Reliability for timely transport
Easy maintenance
Pipeline coating, if applicable, for
erosion
Design emphasized on landscapes
Cheap leak detection systems
Heavy initial investment
Environmentally friendly
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Product Function
• The intended performance is the
output. So the product functions to
create outputs after accepting inputs
which can be any component,
assembly, subassembly, or finished
good. For instance, the pipeline
transportation functions to transport
slurries a certain distance away after
the input in form of slurry and initial
boundary conditions is provided
• The need-function-form concept of
engineering design, where our
emphasis is on converting client
demands for a product to the product
functionalities, is the essence of such a
paradigm.
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• Based on the customer needs deduced, a model of how a product should operate is to be
created after we understand the theories associated with it.
• Everything a product does is functional, so clarifying the concepts and designing the product
architecture is necessary.
Fig – FAST diagram for pipeline transportation experimentation

Product Teardown and Experimentation
• Product teardown is the process of disassembling a product in order to better
understand each of its components work and how the manufacturers, it succeeds.
• A product breakdown provides three key functions:
 Analysis and dissection during
reverse engineering.
 Knowledge and experience for a
person's personal database.
 Benchmarking for competitiveness.
• It also aids in a better knowledge of
each component of the product by
focusing on the minute nuances.
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Benchmarking and Engineering Specification
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Product Architecture
• The aim was always to outline a fundamental method for creating modular
product architecture and so was the main objective is to transform consumer
demands into conceptual product designs.
• Small modules within the product must be found in order to achieve this goal.
And therefore the procedure starts with a product function structure and continues
with clustering, producing preliminary geometry, and defining interactions.
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Concept Generation
• The primary purpose of idea creation is to generate as many ideas as possible. It
also describes the moment when technology is chosen or created to meet the
demands of the client.
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July 2022
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Concept Selection
• Each already generated concept variant needs to be assessed, compared, and one
workable concept must be picked. The order of magnitude estimation should be
used to assess a product concept's technological viability.
• And so the granular version of the Eulerian model was deemed adequate for this
experiment. This is because the non-granular model does not include models for
particle friction and collisions, which are thought to be important in slurry flow.
• Since in this experiment we are focused on generic erosion rate in the pipe elbow,
so standard wall roughness model is used
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Concept Embodiment
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Analytical Design
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Numerical Modeling and Analysis
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Testing
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Results, Analysis and Evaluation
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Socio-economic Issues Associated With The Project
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Engineering Standards
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Conclusion
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References
• Baha Abulnaga, P.E., 2021. Slurry systems handbook. McGraw-Hill Education.
• Hsu, T.J., Jenkins, J.T. and Liu, P.L.F., 2003. On two‐phase sediment transport: Dilute flow. Journal of Geophysical Research: Oceans, 108(C3).
• Schramm, L.L., 2006. Emulsions, foams, and suspensions: fundamentals and applications. John Wiley & Sons.
• Peker, S.M. and Helvaci, S.S., 2011. Solid-liquid two phase flow. Elsevier.
• Albion, K.J., Briens, L., Briens, C. and Berruti, F., 2011. Multiphase flow measurement techniques for slurry transport. International Journal of
Chemical Reactor Engineering, 9(1).
• Bahadur, S. and Badruddin, R., 1990. Erodent particle characterization and the effect of particle size and shape on erosion. Wear, 138(1-2), pp.189-
208.
• Desale, G.R., Gandhi, B.K. and Jain, S.C., 2006. Effect of erodent properties on erosion wear of ductile type materials. Wear, 261(7-8), pp.914-921.
• Singh, G., Kumar, S. and Sehgal, S.S., 2018. Taguchi approach to erosion wear optimization of WC-10Co-4Cr sprayed austenitic steel subjected to
equisized slurry. Industrial Lubrication and Tribology.
• Deng, T., Bingley, M.S. and Bradley, M.S., 2004. The influence of particle rotation on the solid particle erosion rate of metals. Wear, 256(11-12),
pp.1037-1049.
• Heilbronner, R. and Keulen, N., 2006. Grain size and grain shape analysis of fault rocks. Tectonophysics, 427(1-4), pp.199-216.
• Gupta, R., Singh, S.N. and Sehadri, V., 1996. Prediction of uneven wear in a slurry pipeline on the basis of measurements in a pot
tester. International Journal of Multiphase Flow, 22(S1), pp.152-152.
• Desale, G.R., Gandhi, B.K. and Jain, S.C., 2006. Effect of erodent properties on erosion wear of ductile type materials. Wear, 261(7-8), pp.914-921.
• Gupta, R., Singh, S.N. and Sehadri, V., 1995. Prediction of uneven wear in a slurry pipeline on the basis of measurements in a pot
tester. Wear, 184(2), pp.169-178.
• Kumar, R., Bhandari, S. and Goyal, A., 2017. Slurry erosion performance of high-velocity flame-sprayed Ni-20Al2O3 and Ni-10Al2O3-10TiO2
coatings under accelerated conditions. Journal of Thermal Spray Technology, 26(6), pp.1279-1291.
• Round, G.F. and Hessari, A.R., 1987. Rheology of coal slurries, pH and size distribution effects. Particulate and Multiphase Processes, 3, pp.329-
340.
• Kaushal, D.R. and Tomita, Y., 2002. Solids concentration profiles and pressure drop in pipeline flow of multisized particulate slurries. International
journal of multiphase flow, 28(10), pp.1697-1717.
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References
• Singh, M.K., Kumar, S. and Ratha, D., 2020. Computational analysis on disposal of coal slurry at high solid concentrations through
slurry pipeline. International Journal of Coal Preparation and Utilization, 40(2), pp.116-130.
• Singh, K.P., Kumar, A. and Kaushal, D.R., 2022. Experimental investigation on effects of solid concentration, chemical additives, and
shear rate on the rheological properties of bottom ash (BA) slurry. International Journal of Coal Preparation and Utilization, 42(3), pp.609-
622.
• KALYANARAMAN, K. and AJ, R., 1973. CHARACTERISTICS OF SAND-WATER SLURRY IN 90OHORIZONTAL PIPE BENDS.
• Turian, R.M., Ma, T.W., Hsu, F.L., Sung, M.J. and Plackmann, G.W., 1998. Flow of concentrated non-Newtonian slurries: 2. Friction
losses in bends, fittings, valves and venturi meters. International journal of multiphase flow, 24(2), pp.243-269.
• Bozzini, B., Ricotti, M.E., Boniardi, M. and Mele, C., 2003. Evaluation of erosion–corrosion in multiphase flow via CFD and
experimental analysis. Wear, 255(1-6), pp.237-245.
• Mansouri, A., Arabnejad, H., Shirazi, S.A. and McLaury, B.S., 2015. A combined CFD/experimental methodology for erosion prediction. Wear, 332,
pp.1090-1097.
• Njobuenwu, D.O. and Fairweather, M., 2012. Modelling of pipe bend erosion by dilute particle suspensions. Computers & Chemical
Engineering, 42, pp.235-247.
• Ito, H., 1960. Pressure losses in smooth pipe bends.
• Kaushal, D.R., Kumar, A., Tomita, Y., Kuchii, S. and Tsukamoto, H., 2013. Flow of mono-dispersed particles through horizontal bend. International
Journal of Multiphase Flow, 52, pp.71-91.
• Drew, D.A., Lahey, R.T., 1993. Particulate Two – Phase Flow. Butterworth-Heinemann Publications, Boston, pp. 509–566.
• Drew, D.A., 1982. Mathematical modeling of two-phase flow. WISCONSIN UNIV-MADISON MATHEMATICS RESEARCH CENTER.
• Lun, C.K.K., Savage, S.B., Jeffrey, D.J. and Chepurniy, N., 1984. Kinetic theories for granular flow: inelastic particles in Couette flow and slightly
inelastic particles in a general flowfield. Journal of fluid mechanics, 140, pp.223-256.
• Gidaspow, D., Bezburuah, R. and Ding, J., 1991. Hydrodynamics of circulating fluidized beds: kinetic theory approach (No. CONF-920502-1).
Illinois Inst. of Tech., Chicago, IL (United States). Dept. of Chemical Engineering.
• Schaeffer, D.G., 1987. Instability in the evolution equations describing incompressible granular flow. Journal of differential equations, 66(1), pp.19-
50.
• Syamlal, M., O'Brien, T.J., Benyahia, S., Gel, A. and Pannala, S., 2008. Open-source software in computational research: a case study. Modelling and
simulation in engineering, 2008.
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References
• Richardson, J.R., Zaki, W.N., 1954. Sedimentation and fluidization: Part I. Trans. Inst.Chem. Eng. 32, pp 35–53.
• Garside, J. and Al-Dibouni, M.R., 1977. Velocity-voidage relationships for fluidization and sedimentation in solid-liquid systems. Industrial &
engineering chemistry process design and development, 16(2), pp.206-214.
• Launder, B.E. and Spalding, D.B., 1972. Lectures in mathematical models of turbulence.
• Yakhot, V. and Orszag, S.A., 1986. Renormalization group analysis of turbulence. I. Basic theory. Journal of scientific computing, 1(1), pp.3-51.
• Choudhury, D., 1973. Introduction to the renormalization group method and turbulence modeling. Fluent incorporated.
• Schaan, J., Sumner, R.J., Gillies, R.G. and Shook, C.A., 2000. The effect of particle shape on pipeline friction for Newtonian slurries of fine
particles. The Canadian Journal of Chemical Engineering, 78(4), pp.717-725.
• Kaushal, D.R. and Tomita, Y., 2002. Solids concentration profiles and pressure drop in pipeline flow of multisized particulate slurries. International
journal of multiphase flow, 28(10), pp.1697-1717.
• Launder, B.E. and Spalding, D.B., 1972. Lectures in mathematical models of turbulence.
• Yakhot, V. and Orszag, S.A., 1986. Renormalization group analysis of turbulence. I. Basic theory. Journal of scientific computing, 1(1), pp.3-51.
• Choudhury, D., 1973. Introduction to the renormalization group method and turbulence modeling. Fluent incorporated.
• Schaan, J., Sumner, R.J., Gillies, R.G. and Shook, C.A., 2000. The effect of particle shape on pipeline friction for Newtonian slurries of fine
particles. The Canadian Journal of Chemical Engineering, 78(4), pp.717-725.
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July 2022
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