Dynamic fluid flow model for phosphate slurry pipeline: OCP main pipeline as case study

The transportation of phosphate slurry through large-scale pipelines presents significant challenges due to the complex behavior of multiphase flows, particularly with varying solid content, density, and dynamic viscosity. Efficient and accurate prediction of flow behavior is critical for optimizing the operation of such pipelines. This work aims to develop a dynamic computational model to simulate phosphate slurry flow in pipelines. The case study focuses on the OCP Group’s main slurry pipeline, which links the mining sites at Khouribga to the industrial plants at Jorf Lasfar, Morocco. This pipeline system spans a total length of 187.124 km, consisting of 5237 pipes with an inner diameter ranging from 0.8546 m to 0.8578 m, and features several elevation changes along its ground level. Using a section-averaged, dynamic approach and the Finite Volume scheme, the model computes essential flow parameters, including density, dynamic viscosity, and pressure, for the incompressible and non-Newtonian slurry and process water flows. The model’s accuracy is validated against on-site measured data, showing an average deviation of $\pm 0.32\text{\%}$ for outlet density, and below 10% for pressure along the pipeline, underscoring the model’s reliability. Additionally, a sensitivity analysis was conducted to illustrate the impact of key parameters on the predicted head losses and pressures along the pipeline. This analysis shows that the slurry viscosity is the most critical parameter, significantly influencing these predictions. This model provides high accuracy and reasonable CPU time for real-time simulation and monitoring, while also offering significant potential for optimizing pipeline operations and ensuring the reliability of phosphate transport.