Numerical Simulation of Drilling Fluid Flow in Centrifugal Pumps

Centrifugal pumps are widely used in the oil and mining industries. In contrast to water pumps, the centrifugal pumps in the oil and mining industries are used for the transportation of drilling fluid, which is typically non-Newtonian fluid. Drilling fluids are usually modeled as power-law fluids with varying shear viscosity and imposed shear rates. In this paper, a numerical simulation of power-law fluid flow in a centrifugal pump was simulated, varying only in the flow-rate magnitude, using water flow as a comparison. The simulation results show that the pump used for drilling fluid presents a lower head and efficiency but a higher shaft power than that used for water. The flow patterns of both the water pump and the drilling fluid pump were investigated in terms of pressure fluctuation, turbulent kinetic energy, and radial force on the impeller. In contrast to the literature, this paper also analyzes the pressure pulsations in the individual blades of the impeller, as well as those in the volute path. In the case of drilling fluid, it was found that the viscous effect made the flow at the end of the blades highly irregular, and this could be attributed to the pressure generated by them. At the same time, the fluid flow at the small cross-section of the volute was more sensitive to the rotation of the impeller. In addition, the effects of the shear collision exerted on the outlet fluid of the impeller and the fluid in the volute, as well as the dynamic and static interferences, made the non-Newtonian power-law fluid consume more mechanical energy than the water. The results of this paper can be used as a reference for improving the design of centrifugal pumps using non-Newtonian fluids as media.