cfd modelling of solid-liquid two-phase flow in a centrifugal pump and investigation of the effects of fluid flow rate and particle concentration on erosion rate

Centrifugal pumps are extensively employed in mining, petrochemical, and wastewater treatment industries, where handling solid–liquid two-phase flows often results in the erosive wear of internal components. this study investigates slurry-induced erosion in a single-stage centrifugal pump through a three-dimensional cfd model developed in comsol multiphysics. the model integrates lagrangian particle tracking with an empirical erosion correlation and is validated with experimental data reported in the literature, showing good agreement with an average relative error of below 5%. parametric simulations were conducted to examine the effects of two key operating parameters: flow rate and particle concentration. the results indicate that at sub-design flow rates, the prolonged particle residence time increases impact frequency, leading to severe localized erosion near the blade leading edges. conversely, operating at rates close to the design flow rate and up to 1.4 qd reduces erosion intensity and promotes a more uniform wear distribution. increasing particle concentration produces a nearly linear rise in the maximum erosion rate—from approximately 3 mm/year at 0.5% to over 22 mm/year at 3%—while also expanding the affected blade area. moreover, larger particles intensify erosion severity and shift erosion zones toward the downstream blade regions, altering the wear mechanism. overall, the validated cfd framework provides a robust and predictive tool for evaluating both erosion intensity and spatial distribution in slurry-handling centrifugal pumps. the findings emphasize the importance of optimizing operational parameters and applying wear-resistant materials to enhance pump durability and reduce maintenance costs.