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Volume 114
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Breakage characteristics of columnar catalyst in a vertical-to-horizontal bend during dilute-phase pneumatic conveying
Tao Jiang a, Xiao Jiang a e, Xuedong Liu a *, Siduo Song b, Bing Pan a, Chengze Li c, Sheng Yao d
a School of Mechanical Engineering and Railway Transit, Changzhou University, Changzhou, 213164, China
b School of Mechanical and Power Engineering, East China University of Science and Technology, Shanghai, 200237, China
c Department of Mathematics, University of Toronto, Toronto, ON, M5S 1A1, Canada
d Jiangsu Tianpeng Petrochemical Technology Co., Ltd, Nanjing, 211100, China
e Jiangsu Meilan Chemical Co., Ltd., Taizhou, 225300, China
10.1016/j.partic.2026.04.018
Volume 114, July 2026, Pages 365-383
Received 9 February 2026, Revised 15 April 2026, Accepted 27 April 2026, Available online 3 May 2026, Version of Record 15 May 2026.
E-mail: xdliu_65@126.com
Highlights

• CFD-DEM coupled with Ab-t10 breakage model is used to simulate catalyst breakage.

• Effect of operating conditions and bend curvature ratio on particle breakage.

• Investigation on impact energy distribution and fragment formation.

• Response surface models for prediction of breakage and pressure drop.


Abstract

Particle breakage during pneumatic conveying remains a critical issue in catalyst handling, particularly in pipelines where intensive particle-particle and particle-wall collisions occur. In this study, the breakage and flow characteristics of brittle columnar catalyst in a single bend were systematically investigated using a coupled CFD-DEM approach. The breakage model was experimentally calibrated based on single-particle impact tests and was implemented to account for impact-induced fragmentation under conveying conditions. Effects of airflow velocity (15–25 m/s), feeding rate (0.4–0.8 kg/s), and bend curvature ratio (R/D = 1–5) on particle motion, impact energy distributions, and breakage extent were analyzed. The results show that increasing airflow velocity significantly intensifies particle breakage as it shifts the impact energy distributions toward higher-energy collisions and enhances the high-energy fragmentation. In contrast, feeding rate exhibits a comparatively weaker influence on collision intensity and breakage extent. A smaller bend curvature ratio (R/D) leads to increased particle impact severity, leading to enhanced breakage. A response surface analysis based on the Box-Behnken design was employed to evaluate the combined influence of these parameters and to establish predictive models for median particle size and bend pressure drop, providing a reference for the system optimization.

Graphical abstract
Keywords
Catalyst; Non-spherical particle; Particle breakage; CFD-DEM; Pneumatic conveying
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