Comparison of Erosion Characteristics in Complex Pipeline Configurations Using CFD–DEM: A Study on Bends, Reducers, and Tee-Reducers

Abstract

Pipeline erosion poses critical challenges to safety and efficiency in many industries, with bends being the most commonly studied components due to their frequent application in pipeline layouts. However, other key geometries such as reducers and tees are also widely employed and prone to erosion, yet their erosion behavior remains less understood. This study investigates and compares erosion patterns in these components using a computational fluid dynamics–discrete element method (CFD–DEM) approach. Flow characteristics, particle dynamics, and erosion ratios are analyzed under various gas velocities and particle sizes. Findings reveal that while higher gas velocities increase erosion in all geometries, bends are particularly vulnerable due to centrifugal forces concentrating impacts on the outer wall. In contrast, reducers experience significantly lower erosion ratios, as their narrowing design reduces particle-wall collisions. These insights are valuable for optimizing pipeline design and enhancing durability in industrial applications.