CFD–DEM analysis of erosion in 90° elbow pipe induced by different particle shapes

Abstract

This study presents a comprehensive investigation into the impact of particle shape on erosion behavior in 90° elbow pipes using a coupled Discrete Element Method (DEM) and Computational Fluid Dynamics (CFD) approach. The study focuses on three distinct particle shapes—polyhedron, sphero-cylinder, and sphere—representing a range of angularities and curvatures typical in industrial environments. A validation of the model against experimental data demonstrated that polyhedral particles provided the highest predictive accuracy for erosion patterns, reflecting the complex nature of particle interactions in realistic scenarios. Polyhedral particles, with their irregular surfaces and sharp edges, exhibited enhanced impact aggressiveness and dynamic motion, leading to greater erosion severity. In contrast, spherical particles resulted in underestimated erosion rates due to their smoother shape and less disruptive interactions with the flow, underscoring the limitations of using idealized particle geometries in erosion simulations. Trajectory and force analyses further emphasized the unique behavior of polyhedrons, which exhibited more erratic motion and higher drag forces, while sphero-cylindrical particles displayed intermediate characteristics. These results highlight the importance of incorporating non-spherical particle geometries into erosion models for improved predictive accuracy. The findings offer valuable insights for future erosion studies and industrial applications, particularly in enhancing the design of systems to minimize wear and prolong equipment lifespan.