Erosive wear due to the fact of sand severely affects hydrocarbon production industries and, consequently, various sectors of the mineral processing industry. In this study, the effect of the elbow geometrical configuration on the erosive wear of carbon steel for silt–water–air flow conditions were investigated using material loss analysis, surface roughness analysis, and microscopic imaging technique. Experiments were performed under the plug flow conditions in a closed flow loop at standard atmospheric pressure. Water and air plug flow and the disperse phase was silt (silica sand) with a 2.5 wt % concentration, and a silt grain size of 70 µm was used for performing the tests. The experimental analysis showed that silt impact increases material disintegration up to 1.8 times with a change in the elbow configuration from 60° to 90° in plug flow conditions. The primary erosive wear mechanisms of the internal elbow surface were sliding, cutting, and pit propagation. The maximum silt particle impaction was located at the outer curvature in the 50° position in 60° elbows and the 80° position in 90° elbows in plug flow. The erosion rate decreased from 10.23 to 5.67 mm/year with a change in the elbow angle from 90° to 60°. Moreover, the microhardness on the Vickers scale increased from 168 to 199 in the 90° elbow and from 168 to 184 in the 60° elbow.

Erosion-corrosion of elbow configurations has recently been a momentous concern in hydrocarbon processing and transportation industries. The carbon steel 90° elbows are susceptible to the erosion-corrosion during the multiphase flow, peculiarly for erosive slug flows. This paper studies the erosion-corrosion performance of 90° elbows at slug flow conditions for impact with 2, 5, and 10 wt.% sand fines concentrations on AISI 1018 carbon steel exploiting quantitative and qualitative analyses. The worn surface analyses were effectuated by using laser confocal and scanning electron microscopy. The experiment was conducted under air and water slug flow containing sand fines of 50 µm average size circulated in the closed flow loop. The results manifest that with the increase of concentration level, the erosion-corrosion magnitude increases remarkably. Sand fines instigate the development of perforation sites in the form of circular, elongated, and coalescence pits at the elbow downstream and the corrosion attack is much more obvious with the increase of sand fines concentration. Another congruent finding is that cutting and pitting corrosion as the primitive causes of material degradation, the 10 wt.% sand fines concentration in carrier phase increases the erosion-corrosion rate of carbon steel up to 93% relative to the 2 wt.% sand fines concentration in slug flow.

Polymeric materials such as High density polyethylene(HDPE) are ductile in nature, having very low strength. In order to improve strength by non-treated rigid fillers, polymeric materials become extremely brittle. Therefore, this work focuses on achieving pseudo-ductility (high strength and ductility) by using a combination of rigid filler particles (CaCO₃ and bentonite) instead of a single non-treated rigid filler particle. The results of all tensile-tested (D638 type i) samples signify that the microstructural features and surface properties of rigid nano fillers can render the required pseudo-ductility. The maximum value of tensile strength achieved is 120% of the virgin HDPE, and the value of elongation is retained by 100%. Furthermore, the morphological and fractographic analysis revealed that surfactants are not always going to obtain polymer–filler bonding, but the synergistic effect of filler particles can carry out sufficient bonding for stress transfer. Moreover, pseudo-ductility was achieved by a combination of rigid fillers (bentonite and CaCO₃) when the content of bentonite dominated as compared to CaCO₃. Thus, the achievement of pseudo-ductility by the synergistic effect of rigid particles is the significance of this study. Secondly, this combination of filler particles acted as an alternative for the application of surfactant and compatibilizer so that adverse effect on mechanical properties can be avoided.