Study on Erosion Patterns of Cyclone Desanders at Shale Gas Wellheads

In shale gas extraction, solid particles such as fracturing proppants cause erosion in production and transmission pipelines. Cyclone desanders are widely used for gas-solid separation, but high-velocity sand-laden fluids frequently induce equipment failure, leakage and safety risks. Therefore, research on erosion and protective measures is essential. This study focuses on the desander at the M shale gas wellhead, where wall thickness was measured at three monitoring points to determine erosion rates. A CFD-based numerical erosion model for the cyclone desander was developed using ANSYS Fluent within the ANSYS Workbench 19.2 environment (ANSYS, Inc., Canonsburg, PA, USA). The model was validated by comparing simulation results with field data, revealing the distribution patterns of the velocity field, pressure field, and erosion rate. The study analyzed the impact of nine factors on desander erosion: inlet aspect ratio, cylinder radius, cone length, dust discharge port diameter, exhaust port diameter, particle size, particle concentration, inlet velocity, and operating pressure, clarifying the erosion variation patterns for each factor. SPSSAU V25.0 (Beijing Qingsi Technology Co., Ltd., Beijing, China) was employed to analyze the significance of these nine factors, identifying six significant influencing factors: inlet aspect ratio, cylinder diameter, dust discharge port diameter, particle size, particle concentration, and inlet velocity. Subsequently, response surface analysis was performed using Design-Expert 13 (Stat-Ease, Inc., Minneapolis, MN, USA) to obtain the relationship between the factors and their impact on maximum erosion, leading to the establishment of a predictive model for the maximum erosion rate. In addition, geometry optimization, local wall thickening, coating protection, material selection, and bionic rib structures were discussed as erosion-mitigation strategies. The optimized geometry reduced the erosion rate at the inlet and dust discharge outlet by 20.4% and 21.8%, respectively, while the bionic rib structure reduced the maximum erosion rate by 58%.