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Particle erosion is a commonly occurring phenomenon, and it plays a significantly important role in service life. However, few simulations have replicated erosion, especially the detailed evolution process. To address this complex issue, a new method for establishing the solution of the erosion evolution process was developed. The approach is introduced with the erosion model and the dynamic mesh. The erosion model was applied to estimate the material removal of erosion, and the dynamic mesh technology was used to demonstrate the surface profile of erosion. Then, this method was applied to solve a typical case—the erosion surface deformation and the expiry period of an economizer bank in coal-fired power plants. The mathematical models were set up, including gas motion, particle motion, particle-wall collision, and erosion. Such models were solved by computational fluid dynamics (CFD) software (ANSYS FLUENT), which describes the evolution process of erosion based on the dynamic mesh. The results indicate that: (1) the prediction of the erosion profile calculated by the dynamic mesh is in good agreement with that on-site; (2) the global/local erosion loss and the maximum erosion depth is linearly related to the working time at the earlier stage, but the growth of the maximum erosion depth slows down gradually in the later stage; (3) the reason for slowing down is that the collision point trajectory moves along the increasing direction of the absolute value of θ as time increases; and (4) the expiry period is shortened as the ash diameter increases.

A Novel Method for the Prediction of Erosion Evolution Process Based on Dynamic Mesh and Its Applications