https://orcid.org/0000-0002-5438-0833
Abstract
Cage-typed sleeve control valve (CSCV) is the key basic equipment in direct coal liquefaction projects. The working condition of CSCV has the characteristics of high-pressure difference, high velocity, and high solid content. There is a general issue of liquid–solid two-phase erosion wear in CSCV, which can easily lead to the failure of the internal structure in the valve cage. Therefore, it is necessary to study erosion wear characteristics of internal structures in the valve cage. Considering the real conditions of erosion wear in the valve cage, a simplified T-shaped flow path is designed, and the precision of both the liquid–solid two-phase flow model and the erosion prediction model is validated. The flow characteristics and erosion wear characteristics in the T-shaped flow path under different working conditions are studied. Based on the simulation results of different structural parameters and boundary conditions, the erosion wear of the T-shaped flow path is predicted and calculated by the response surface method. Subsequently, the prediction formula for the maximum erosion rate is derived. The formula enables the swift determination of optimal structural parameters for the flow path, aiming to mitigate damage to the valve caused by erosion wear. This work can quickly predict the erosion wear rate of the key areas in the valve cage, which can provide a certain reference value for the life prediction and structural optimization of CSCV, and it can also benefit the safety and maintenance of the coal liquefaction system.
References
1.
Dou
,
Z.
,
Jiang
,
J. C.
,
Wang
,
Z. R.
,
Pan
,
X. H.
,
Shu
,
C. M.
, and
Liu
,
L. F.
, 2017
, “
Applications of RBI on Leakage Risk Assessment of Direct Coal Liquefaction Process
,” J. Loss Prev. Process. Ind.
,
45
, pp. 194
–202
.10.1016/j.jlp.2016.12.0062.
Ou
,
G.
,
Cao
,
X.
,
Wang
,
C.
,
Duan
,
A.
, and
Jin
,
H.
, 2022
, “
CFD-DEM-Based Numerical Simulation of Erosion Characteristic of Multistage Pressure Relief String Regulating Valve
,” J. Appl. Fluid Mech.
,
15
(4
), pp. 999
–1015
.10.47176/jafm.15.04.10223.
Zheng
,
Z. J.
,
Ou
,
G. F.
,
Ye
,
H. J.
,
Zhang
,
L. T.
,
Wang
,
C.
,
Jin
,
H. Z.
, and
Shu
,
G. P.
, 2016
, “
Investigation on Failure Process and Structural Optimization of a High Pressure Letdown Valve
,” Eng. Fail. Anal.
,
66
, pp. 223
–239
.10.1016/j.engfailanal.2016.04.0234.
He
,
J.
,
Liu
,
Q. H.
,
Long
,
Z.
,
Zhang
,
Y. J.
,
Liu
,
X. M.
,
Xiang
,
S. B.
,
Li
,
B. B.
, and
Qiao
,
S. Y.
, 2022
, “
Characteristics of Cavitation Flow for a Regulating Valve Based on Entropy Production Theory
,” Energies
,
15
(17
), p. 6480
.10.3390/en151764805.
Yi
,
J. Z.
,
Hu
,
H. X.
,
Zheng
,
Y. G.
, and
Zhang
,
Y.
, 2016
, “
Experimental and Computational Failure Analysis of a High Pressure Regulating Valve in a Chemical Plant
,” Eng. Fail. Anal.
,
70
, pp. 188
–199
.10.1016/j.engfailanal.2016.07.0156.
Hamed
,
M. H.
,
Ibrahim
,
K. A.
, and
El-Kadi
,
M. A.
, 2010
, “
CFD Evaluation of Solid Particles Erosion in Curved Ducts
,” ASME J. Fluids Eng.
,
132
(7
), p. 071303
.10.1115/1.40019687.
Zolfagharnasab
,
M. H.
,
Salimi
,
M.
,
Zolfagharnasab
,
H.
,
Alimoradi
,
H.
,
Shams
,
M.
, and
Aghanajafi
,
C.
, 2021
, “
A Novel Numerical Investigation of Erosion Wear Over Various 90-Degree Elbow Duct Sections
,” Powder Technol.
,
380
, pp. 1
–17
.10.1016/j.powtec.2020.11.0598.
Peng
,
W. S.
,
Cao
,
X. W.
,
Hou
,
J.
,
Ma
,
L.
,
Wang
,
P.
, and
Miao
,
Y. C.
, 2021
, “
Numerical Prediction of Solid Particle Erosion Under Upward Multiphase Annular Flow in Vertical Pipe Bends
,” Int. J. Pressure Vessels Piping
,
192
, p. 104427
.10.1016/j.ijpvp.2021.1044279.
Cui
,
B. C.
,
Chen
,
P.
, and
Zhao
,
Y. Q.
, 2022
, “
Numerical Simulation of Particle Erosion in the Vertical-Upward-Horizontal Elbow Under Multiphase Bubble Flow
,” Powder Technol.
,
404
, p. 117437
.10.1016/j.powtec.2022.11743710.
Zhang
,
Y. L.
,
McLaury
,
B. S.
, and
Shirazi
,
S. A.
, 2009
, “
Improvements of Particle Near-Wall Velocity and Erosion Predictions Using a Commercial CFD Code
,” ASME J. Fluids Eng.
,
131
(3
), p. 031303
.10.1115/1.307713911.
Ou
,
G. F.
,
Ouyang
,
P. W.
,
Zheng
,
Z. J.
,
Jin
,
H. Z.
,
Bie
,
K. B.
, and
Wang
,
C.
, 2019
, “
Investigation on Failure Process and Structural Improvement of a High-Pressure Coal Water Slurry Valve
,” Eng. Fail. Anal.
,
96
, pp. 1
–17
.10.1016/j.engfailanal.2018.09.00312.
Bilal
,
F. S.
,
Sedrez
,
T. A.
, and
Shirazi
,
S. A.
, 2021
, “
Experimental and CFD Investigations of 45 and 90 Degrees Bends and Various Elbow Curvature Radii Effects on Solid Particle Erosion
,” Wear
,
476
, p. 203646
.10.1016/j.wear.2021.20364613.
Guzmán
,
J. E. V.
, and
Zenit
,
R.
, 2011
, “
Application of the Euler–Lagrange Method to Model Developed Hydrodynamic Slugs in Conduits
,” ASME J. Fluids Eng.
,
133
(4
), p. 041301
.10.1115/1.400376314.
Peters
,
A.
, and
el Moctar
,
O.
, 2020
, “
Numerical Assessment of Cavitation-Induced Erosion Using a Multi-Scale Euler–Lagrange Method
,” J. Fluid Mech.
,
894
, p. A19
.10.1017/jfm.2020.27315.
Yin
,
Y. B.
,
Yuan
,
J. Y.
, and
Guo
,
S. R.
, 2017
, “
Numerical Study of Solid Particle Erosion in Hydraulic Spool Valves
,” Wear
,
392–
393, pp. 174
–189
.10.1016/j.wear.2017.09.02116.
Liu
,
X. Q.
,
Ji
,
H.
,
Liu
,
F.
,
Li
,
N. A.
,
Zhang
,
J. N.
, and
Ren
,
W.
, 2022
, “
Particle Motion and Erosion Morphology of the Spool Orifice in an Electro-Hydraulic Servo Valve Under a Small Opening
,” Proc. Inst. Mech. Eng., Part C
,
236
(6
), pp. 3160
–3173
.10.1177/0954406221103491217.
Hu
,
G.
,
Zhang
,
P.
,
Wang
,
G. R.
,
Zhu
,
H.
,
Li
,
Q. C.
,
Zhao
,
S. P.
,
Qiao
,
K.
, and
Wang
,
T.
, 2017
, “
Performance Study of Erosion Resistance on Throttle Valve of Managed Pressure Drilling
,” J. Pet. Sci. Eng.
,
156
, pp. 29
–40
.10.1016/j.petrol.2017.05.01118.
Ma
,
G. F.
,
Lin
,
Z.
, and
Zhu
,
Z. C.
, 2020
, “
Investigation of Transient Gas-Solid Flow Characteristics and Particle Erosion in a Square Gate Valve
,” Eng. Fail. Anal.
,
118
, p. 104827
.10.1016/j.engfailanal.2020.10482719.
Liu
,
J. G.
,
Wang
,
G. S.
,
Peng
,
T. H.
, and
Jiang
,
S. Q.
, 2019
, “
Numerical Simulation of Solid Particle Erosion in Aluminum Alloy Spool Valve
,” Math. Probl. Eng.
,
2019
, pp. 1
–16
.10.1155/2019/946540620.
Yu
,
W. C.
,
Fede
,
P.
,
Climent
,
E.
, and
Sanders
,
S.
, 2019
, “
Multi-Fluid Approach for the Numerical Prediction of Wall Erosion in an Elbow
,” Powder Technol.
,
354
, pp. 561
–583
.10.1016/j.powtec.2019.06.00721.
Ghafori
,
H.
, 2020
, “
Computational Fluid Dynamics (CFD) Analysis of Pipeline in the Food Pellets Cooling System
,” J. Stored Prod. Res.
,
87
, p. 101581
.10.1016/j.jspr.2020.10158122.
Peng
,
D. H.
,
Dong
,
S. H.
,
Wang
,
Z. Q.
,
Wang
,
D. Y.
,
Chen
,
Y. N.
, and
Zhang
,
L. B.
, 2021
, “
Characterization of the Solid Particle Erosion of the Sealing Surface Materials of a Ball Valve
,” Metals
,
11
(2
), p. 263
.10.3390/met1102026323.
Wheeler
,
D. W.
, and
Wood
,
R. J. K.
, 2005
, “
Erosion of Hard Surface Coatings for Use in Offshore Gate Valves
,” Wear
,
258
(1–4
), pp. 526
–536
.10.1016/j.wear.2004.03.03524.
Du
,
R.
,
Zhou
,
Y.
,
Zhang
,
A.
,
Du
,
Z. H.
,
Zhang
,
X. Y.
, and
Yuan
,
X. L.
, 2021
, “
An Optimized E/CRC Erosion Model of Round Particles for Hydraulic Spool Valves With Euler–Lagrange Two-Phase Simulation
,” Tribol. Trans.
,
64
(5
), pp. 795
–812
.10.1080/10402004.2021.191244525.
Zhang
,
J.
,
Lian
,
Z. H.
,
Zhou
,
Z. M.
,
Xiong
,
M.
, and
Yang
,
X. L.
, 2022
, “
Erosion Wear of KQ52 Alloy Steel Multi-Function Four-Way Valve Emergent Discharge Behaviors
,” Trans. Indian Inst. Met.
,
75
(1
), pp. 217
–228
.10.1007/s12666-021-02416-126.
Lin
,
Z.
,
Ruan
,
X. D.
,
Zhu
,
Z. C.
, and
Fu
,
X.
, 2014
, “
Three-Dimensional Numerical Investigation of Solid Particle Erosion in Gate Valves
,” Proc. Inst. Mech. Eng., Part C
,
228
(10
), pp. 1670
–1679
.10.1177/095440621349854327.
Marinaro
,
G.
,
Frosina
,
E.
,
Senatore
,
A.
, and
Stelson
,
K. A.
, 2021
, “
A Fast and Effective Method for the Optimization of the Valve Plate of Swashplate Axial Piston Pumps
,” ASME J. Fluids Eng.
,
143
(9
), p. 091203
.10.1115/1.405070628.
Lin
,
Z.
,
Wang
,
D. R.
,
Tao
,
J. Y.
,
Zhu
,
Z. C.
, and
Guo
,
X. M.
, 2022
, “
Transient Regulating Characteristics of V-Port Ball Valve in Opening and Closing Process
,” ASME J. Fluids Eng.
,
144
(10
), p. 101201
.10.1115/1.405419129.
Sato
,
Y.
,
Yaji
,
K.
,
Izui
,
K.
,
Yamada
,
T.
, and
Nishiwaki
,
S.
, 2017
, “
Topology Optimization of a No-Moving-Part Valve Incorporating Pareto Frontier Exploration
,” Struct. Multidiscip. Optim.
,
56
(4
), pp. 839
–851
.10.1007/s00158-017-1690-830.
Corbera Caraballo
,
S.
,
Olazagoitia Rodríguez
,
J. L.
,
Lozano Ruiz
,
J. A.
, and
Álvarez Fernández
,
R.
, 2017
, “
Optimization of a Butterfly Valve Disc Using 3D Topology and Genetic Algorithms
,” Struct. Multidiscip. Optim.
,
56
(4
), pp. 941
–957
.10.1007/s00158-017-1694-431.
Wang
,
L.
,
Zheng
,
S.
,
Liu
,
X.
,
Xie
,
H.
, and
Dou
,
J.
, 2021
, “
Flow Resistance Optimization of Link Lever Butterfly Valve Based on Combined Surrogate Model
,” Struct. Multidiscip. Optim.
,
64
(6
), pp. 4255
–4270
.10.1007/s00158-021-03060-532.
Ou
,
G.
,
Luo
,
M.
,
Gu
,
Y.
, and
Jin
,
H.
, 2022
, “
Study on Erosion-Wear Characteristics of Bidirectional Metal Seal Floating Ball Valve in Liquid-Solid Two-Phase Flow Environment
,” Proc. Inst. Mech. Eng., Part C
epub.10.1177/0954406222112533333.
Mazur
,
Z.
,
Campos-Amezcua
,
R.
,
Urquiza-Beltrán
,
G.
, and
Garcı́a-Gutiérrez
,
A.
, 2004
, “
Numerical 3D Simulation of the Erosion Due to Solid Particle Impact in the Main Stop Valve of a Steam Turbine
,” Appl. Therm. Eng.
,
24
(13
), pp. 1877
–1891
.10.1016/j.applthermaleng.2004.01.00134.
Wang
,
G. R.
,
Chu
,
F.
,
Tao
,
S. Y.
,
Jiang
,
L.
, and
Zhu
,
H.
, 2015
, “
Optimization Design for Throttle Valve of Managed Pressure Drilling Based on CFD Erosion Simulation and Response Surface Methodology
,” Wear
,
338–339
, pp. 114
–121
.10.1016/j.wear.2015.06.00135.
Sedrez
,
T. A.
,
Shirazi
,
S. A.
,
Rajkumar
,
Y. R.
,
Sambath
,
K.
, and
Subramani
,
H. J.
, 2019
, “
Experiments and CFD Simulations of Erosion of a 90 Elbow in Liquid-Dominated Liquid-Solid and Dispersed-Bubble-Solid Flows
,” Wear
,
426–427
, pp. 570
–580
.10.1016/j.wear.2019.01.01536.
Haider
,
A.
, and
Levenspiel
,
O.
, 1989
, “
Drag Coefficient and Terminal Velocity of Spherical and Nonspherical Particles
,” Powder Technol.
,
58
(1
), pp. 63
–70
.10.1016/0032-5910(89)80008-737.
Alobaid
,
F.
,
Almohammed
,
N.
,
Farid
,
M. M.
,
May
,
J.
,
Rößger
,
P.
,
Richter
,
A.
, and
Epple
,
B.
, 2022
, “
Progress in CFD Simulations of Fluidized Beds for Chemical and Energy Process Engineering
,” Prog. Energy Combust. Sci.
,
91
, p. 100930
.10.1016/j.pecs.2021.10093038.
Gosman
,
A. D.
, and
Loannides
,
E.
, 1983
, “
Aspects of Computer Simulation of Liquid-Fueled Combustors
,” J. Energy
,
7
(6
), pp. 482
–490
.10.2514/3.6268739.
Grant
,
G.
, and
Tabakoff
,
W.
, 1975
, “
Erosion Prediction in Turbomachinery Resulting From Environmental Solid Particles
,” J. Aircr.
,
12
(5
), pp. 471
–478
.10.2514/3.5982640.
Vieira
,
R. E.
,
Mansouri
,
A.
,
McLaury
,
B. S.
, and
Shirazi
,
S. A.
, 2016
, “
Experimental and Computational Study of Erosion in Elbows Due to Sand Particles in Air Flow
,” Powder Technol.
,
288
, pp. 339
–353
.10.1016/j.powtec.2015.11.02841.
Zhang
,
Y.
,
Reuterfors
,
E. P.
,
McLaury
,
B. S.
,
Shirazi
,
S. A.
, and
Rybicki
,
E. F.
, 2007
, “
Comparison of Computed and Measured Particle Velocities and Erosion in Water and Air Flows
,” Wear
,
263
(1–6
), pp. 330
–338
.10.1016/j.wear.2006.12.04842.
Zeng
,
L.
,
Zhang
,
G. A.
, and
Guo
,
X. P.
, 2014
, “
Erosion–Corrosion at Different Locations of X65 Carbon Steel Elbow
,” Corros. Sci.
,
85
, pp. 318
–330
.10.1016/j.corsci.2014.04.045
