Effect of particle properties on erosion in slurry transport pipeline: Velocity, size, mass flow rate and shape

In the process of backfill mining, transporting slurry with large particles through pipelines at high flow rates poses risks of erosion-induced failures. Therefore, it is crucial to study the influence of particle properties on pipeline erosion rates. This study investigates the effects of coal-gangue particle characteristics, including velocity, diameter, mass flow rate, and shape factor, on erosion rates in filling pipelines. Through numerical simulation, it is found that particle velocity and shape factor are primary contributors to erosion, while diameter and mass flow rate also contribute, albeit to a lesser degree. Analysis shows that velocity and diameter influence erosion by affecting particle kinetic energy and impact force, while mass flow rate alters particle–wall collision frequency. The shape factor impacts erosion mechanisms by modifying particle resistance, particle–wall interactions, and erosion patterns. Pipeline geometry and orientation further influence erosion behavior; vertical bends and T-junctions show the highest sensitivity to velocity, whereas horizontal bends are more affected by shape factor. Optimal operating parameters to minimize erosion include a velocity of 1–2 m/s, diameter below 10 mm, mass flow rate under 6 kg/s, and shape factor under 0.2. Deviating from these recommendations, particularly when two or more parameters exceed the suggested range, significantly increases erosion-related downtime, adversely affecting operational efficiency. This study offers practical insights for enhancing the durability and efficiency of filling pipeline systems in coal mining applications.