Experimental Study and Analysis on Wear Characteristics of Mining Pumps Transporting Solid-Liquid Two-Phase Flows
Abstract
:1. Introduction
2. Methods: Three-Dimensional Wear Model and Numerical Method
2.1. Three-Dimensional Modelling
2.2. Numerical Calculation Method
2.2.1. Meshing
2.2.2. Numerical Calculation Method
2.2.3. Hydraulic Performance Test
2.3. Boundary Conditions
3. Results: Prediction of Wear Characteristics in a Mining Pump
3.1. Wear Model
3.2. Computational Scheme
3.3. Wear Predictions for the Low-Flow Condition
3.3.1. Analysis of Particle Motion Trajectories and Concentrations
3.3.2. Wear Rates of the Flow-Passing Components
3.4. Wear Predictions for the Rated-Flow Condition
3.4.1. Analysis of Particle Motion Trajectories and Concentrations
3.4.2. Wear Rates of the Flow-Passing Components
3.5. Wear Predictions for the High-Flow Condition
3.5.1. Analysis of Particle Motion Trajectories and Concentrations
3.5.2. Wear Rates of the Flow-Passing Components
4. Experiment: Wear Experiment Verification
4.1. Experimental Methodology
4.2. Comparison between Experimental and Numerical Results
5. Conclusions
- (1)
- Numerical simulations were performed to compare the wear on the impeller and guide-vane surfaces under several conditions. During the transportation of small particles, the first-stage guide vane always exhibited the greatest surface wear, at all flow rates. However, during the transportation of large particles, the second-stage guide vane exhibited the least surface wear in the low-flow and rated-flow conditions, whereas in the high-flow condition, the first-stage guide vane exhibited the least surface wear. Therefore, the surface strength of the first-stage guide vane should be prioritized in the design and construction of small, two-stage mining pumps.
- (2)
- In the pump wear experiment, which was performed at the pump’s rated flow, severe wear was observed at the radial inlet of the pump, as well as the LE and TE of the first-stage impeller and second-stage impeller. Moreover, the surface wear on the second-stage impeller was more severe than that on the first-stage impeller. Hence, the flow-passing components must be strengthened at these locations.
- (3)
- A comparison was performed between numerically simulated and experimentally observed wear characteristics, which showed that the numerical and experimental results are consistent with each other. Therefore, the numerical method used in this work can accurately predict the surface wear of flow-passing components in mining pumps.
- (4)
- As mining pumps work in complex operating environments and comprise several flow-passing components, their particle motions are highly complex. When a mining pump is used to transport solid-liquid two-phase flows, the solid particles cause varying degrees of wear in the flow-passing components. However, by predicting the wear characteristics of mining pumps using an appropriate numerical method and erosive wear model, pump designers and manufacturers may use the insights gained from these predictions to selectively strengthen the parts of the flow-passing components that are expected to experience significant wear. Thus, the methods proposed in this study are expected to function as a suitable numerical method and wear model that is well-suited for this purpose.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Impeller | Guide Vane | ||
---|---|---|---|
Parameter | Value | Parameter | Value |
Inlet diameter/mm | 60 | Number of blades/piece | 8 |
Outer diameter/mm | 116 | Wrap angle/° | 90 |
Number of blades/piece | 6 | Inlet inner diameter/mm | 120 |
Blade wrap angle/° | 130 | Inlet outer diameter/mm | 145 |
Exit placement angle/° | 28 | Outlet inner diameter/mm | 25 |
Outlet width/mm | 12 | Outlet outer diameter/mm | 60 |
Mesh Scheme Number | Impeller (Ten Thousand) | Guide Vane (Ten Thousand) | Inlet/Outlet Section (Ten Thousand) | Total (Ten Thousand) | Head (m) |
---|---|---|---|---|---|
1 | 9.1 | 24.9 | 13.2 | 94 | 31.71 |
2 | 15.2 | 42.0 | 22.8 | 160 | 30.84 |
3 | 20.0 | 55.1 | 29.9 | 210 | 31.22 |
4 | 29.1 | 80.2 | 42.9 | 300 | 30.35 |
5 | 51.5 | 142 | 76.0 | 530 | 30.36 |
6 | 66.0 | 184 | 101 | 700 | 30.31 |
b | c | x | y | w | z |
---|---|---|---|---|---|
−13.3 | 7.85 | 1.09 | 0.125 | 1 | 1 |
Flow Conditions | Particle Volume Concentration | Particle Density | Particle Size (mm) |
---|---|---|---|
0.65Qd | 7.5% | 1900 kg/m3 | 1, 3, 5 |
1.0Qd | 7.5% | 1900 kg/m3 | 1, 3, 5 |
1.3Qd | 7.5% | 1900 kg/m3 | 1, 3, 5 |
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Hong, S.; Hu, X. Experimental Study and Analysis on Wear Characteristics of Mining Pumps Transporting Solid-Liquid Two-Phase Flows. Appl. Sci. 2024, 14, 5634. https://doi.org/10.3390/app14135634
Hong S, Hu X. Experimental Study and Analysis on Wear Characteristics of Mining Pumps Transporting Solid-Liquid Two-Phase Flows. Applied Sciences. 2024; 14(13):5634. https://doi.org/10.3390/app14135634
Chicago/Turabian StyleHong, Shunjun, and Xiaozhou Hu. 2024. "Experimental Study and Analysis on Wear Characteristics of Mining Pumps Transporting Solid-Liquid Two-Phase Flows" Applied Sciences 14, no. 13: 5634. https://doi.org/10.3390/app14135634
APA StyleHong, S., & Hu, X. (2024). Experimental Study and Analysis on Wear Characteristics of Mining Pumps Transporting Solid-Liquid Two-Phase Flows. Applied Sciences, 14(13), 5634. https://doi.org/10.3390/app14135634