Improved Prediction of Sand Erosion by Accurate Particle Shape Representation in CFD-DEM Modelling

Predicting accurate erosion rate due to sand particles in oil and gas production is important for maintaining safe and reliable operations while maximizing output efficiency. Computational Fluid Dynamic (CFD) is a powerful tool for erosion prediction as it provides detailed erosion pattern in complex geometry. In an effort to improve accuracy of erosion prediction, this paper proposes an algorithm to accurately represent particle shape in CFD erosion simulation through coupling with Discrete Element Method (DEM) for non-spherical shape particles. The fluid motions are predicted by CFD and the particle movements (including particle-particle and particle-wall collisions) and fluid-particle interaction are calculated using DEM. It is widely known that sand particles are of finite volume with a non-spherical shape, accurate representation of sand particles is important in CFD modelling for accurate prediction of erosion rate. Traditional CFD approach usages lagrangian tracking of sand particles through Discrete Phase Model (DPM), where a particle is assumed as a point mass for the calculation of trajectory and particle-wall interaction. Particle impact velocity and impact angle are important parameter in determining erosion. Assumption of point mass in DPM approach, will not capture particle-wall interaction accurately especially when particles are of non-spherical in shape. In additional, DPM approach ignores particle-particle interactions. This can adversary affect the accuracy of erosion predictions. Integrating non-spherical DEM collision algorithm with CFD erosion simulation, will overcome these limitations and improve erosion predictions. Benefits of this CFD-DEM erosion modelling was demonstrated for gas-solid flow in a 2" pipework which consists of out-of-plane elbows in series and blind-tees. Experimental dataset [1] for erosion pattern on each elbow was used to validate CFD predictions. Three different erosion CFD simulations were performed, traditional DPM based CFD simulation, CFD-DEM simulation for spherical shape particles and CFD-DEM simulation for non-spherical shape particles. CFD-DEM coupled simulations clearly show an improvement on erosion predictions compared to DPM based CFD simulation. Effect of non-spherical shape on rebound angle during particle-wall collision is captured accurately in CFD-DEM simulation. CFD-DEM simulation using non-spherical particle, was able to predict erosion pattern closer to experimental observations. This paper will demonstrate an increase in accuracy of sand erosion prediction by integrating DEM collision algorithm in CFD modelling. The prediction results of elbow erosion subject to a condition of dilute gas-particle flow are validated against experimental data. Improved prediction of erosion risk will increase the safety and reliability of oil & gas operations, while maximizing output efficiency.