Slurry Velocity Research Articles

CFD analysis of the erosion wear through 90° bend of different area ratio at high slurry concentration

Using the commercial computational fluid dynamics package ANSYS FLUENT, the behaviour of slurry erosion wear at 90° pipe bends was studied with varied area ratios (AR = 1–2). In this investigation, two influencing parameters have also been selected, such as slurry flow velocity (4−10 m/s) and the low to high slurry concentration of the fly ash (2.5%–40% by volume). To make a slurry, fly ash particles (150 µm) were mixed with water. Euler–Lagrange was used to forecast slurry erosion wear accurately. Simulations of the slurry flow within the bend pipeline were conducted with the help of a standard k-ɛ turbulence model and a two-way coupling approach. The findings of the simulation were validated against the existing research to ensure their accuracy. The study observed that the average erosion rate was directly proportional to the flow velocity and solid concentration of the slurry, while the average erosion rate was inversely proportional to the AR at all flow parameters. The findings indicate that the minimum and maximum erosion wear are found in AR = 2 and AR = 1, respectively. In the case of AR = 2, the average erosion rate is reduced by an average of 5.47 and 2.5 times at given flow parameters (slurry velocity and solid concentration) as compared to the AR = 1 and 1.5, respectively.

The Effect of Fracture Wall Surface Roughness on Proppant Transport

Summary Proppant transport into created fractures is crucial in maximizing hydrocarbon recovery in unconventional reservoirs. Injected proppants keep the created fractures open, enhancing final fracture conductivity and propped and effective fracture length. The roughness and width of the created fracture are also important in proppant transport and distribution within induced fractures, affecting fracture conductivity. This study investigates the effect of fracture width on proppant transport into a complex slot system with 3D-printed rough wall surfaces. This study builds upon previous experimental work (Tatman et al. 2022), exploring different fracture roughness profiles and varying fracture widths. The effects of proppant densities, sizes, and concentrations on proppant transport within rough fracture surfaces were also investigated. A laboratory-scaled slot apparatus was used to examine the effects of various parameters. The slot consisted of a 4-ft-long primary fracture intersecting with a secondary fracture at a 90o angle. The wall surface roughness was printed using 3D printing technology and average fracture widths were set at 0.1 in. and 0.2 in. Fresh water (1 cp) with proppant concentrations of 1 ppg and 2 ppg and proppant sizes of 100-mesh sand [2.65 specific gravity (SG)], 40/70-mesh sand (2.65 SG), and 35/45-mesh ultralightweight (ULW) proppant (1.07 SG) were tested. The results show that fracture wall roughness impacts proppant transport behavior. The rough wall surface formed irregular proppant dune shapes and trapped some of the injected proppant at different locations within the slot, which is distinct from smooth wall surfaces. Decreasing the fracture width of a rough wall surface had a significant impact on proppant transport. The majority of the injected proppant was transported away from the injection point due to the increased slurry velocity. This led to improved proppant transport due to redirected flow direction and associated decreased proppant settling velocities, and a decrease in the proppant-dune-building rate near the inlet point, which carried more proppant deep into the secondary slot. Increasing the proppant concentration had a positive impact on proppant transport within both tested fracture widths by increasing the proppant-dune-buildup rate along the fracture slot and increasing the proppant-covered area inside fractures. The slurry injection rate had a great impact on low-density proppant transport. Decreasing the injection rate for lighter proppant (1.07 SG) helped to build a proppant dune near the injection point, increasing the proppant-covered area. Conversely, the higher injection rate carried the majority of the lighter proppant farther and out of the slots. Larger proppant sizes, (i.e., 40/70-mesh sand) resulted in a large proppant-covered area for both tested fracture widths, due to more particle-to-wall interaction, particle-to-particle interaction, and high density, which increased the settling velocity. However, injecting lighter and larger proppant sizes, such as 35/45-mesh ULW proppant, resulted in less settling and more particles suspended during injection due to lower density.

Investigating Slurry Flow Patterns in Chemical Mechanical Polishing (CMP) Using Computational Fluid Dynamic (CFD) Simulations

Chemical Mechanical Polishing has emerged as a leading area approach for planarizing wafer surfaces during semiconductor manufacturing due to its ability to provide defect-free and uniform surfaces. Achieving nanoscale planarity on a wafer and die is one of the most significant steps in the process [1]. As part of the CMP process, it is essential to understand the interactions between consumables to facilitate the production of smooth and mirror-like surfaces [2], [3]. Simulation and numerical modeling have become critical means for elucidating intricate flow patterns to probe the underlying fundamentals of CMP processes. The computational fluid dynamics (CFD) simulations provide a detailed understanding of fluid flow behavior for various conditions [4], [5]. This study uses a three-dimensional CFD simulation to provide an understanding of the slurry flow pattern and its effects on CMP performance. Several CFD simulations were performed to study the effect of different parameters on slurry flow patterns. The simulations provided information on the interaction between the slurry, the wafer surface, and the polishing pad, in addition to the abrasive distribution, slurry velocity, and pressure variations within the CMP tool. It was observed that changing the pad and wafer rotation speeds, the wafer-pad gap size and the center-to-center distance affect the slurry flow conditions. For the same rotational speeds, as the center-to-center distance decreases, the flow velocity increases toward the wafer edge. Moreover, with the same rotation speed, the pad rotation dominates the wafer rotation speed.[1] B. Suryadevara, Advances in Chemical Mechanical Planarization (CMP). Woodhead Publishing, 2021.[2] J. Seo, Journal of Materials Research, 36, 235–257, 2021.[3] A. R. Mazaheri and G. Ahmadi, J Electrochem Soc, 150, G233, 2003.[4] J. Tu, K. Inthavong, and G. Ahmadi, Springer Science & Business Media, 2012.[5] G. Ahmadi, “Chapter 2 -, R. Kohli and K. L. Mittal, Eds., Oxford: William Andrew Publishing, 2012, pp. 81–105.

Study on the Flow Velocity of Safe and Energy-Saving Transportation of Light-Particle Slurry

In order to determine the recommended flow velocity for the safe and energy-saving transport of ice-slurry-type light particle slurries, it is necessary to study the flow characteristics of light particle slurries, especially the critical flow velocity. Therefore, in this paper, a numerical simulation method based on the mixed turbulence model with the RANS (Reynolds averaged Navier Stokes) equation is used, and a new concentration distribution method is proposed for the first time to derive the critical flow velocity, as follows: the flow velocity of the light particle slurry when the ratio of the solid volume fraction vf at the position of 0.08D above the bottom of the pipeline to that at the center of the pipeline, vf/vf(y) = 0.75, is taken as the critical flow velocity. The flow changes in the slurry (polyethylene particles with a density of 922 kg/m3 and water) under 0.1–1.0 m/s (at intervals of 0.1 m/s) were investigated experimentally, and the pressure drop data obtained from the experiments were used to determine the recommended flow rate for safe and energy-saving transportation of the light particle slurry. The pipe diameter used for the experiments and simulations was 28 mm, and the solid-phase particle sizes were 0.3 mm, 0.4 mm, and 0.5 mm, with solid-phase contents of 5 vol%, 10 vol%, 15 vol%, and 20 vol%. In addition, the experimental and numerical simulation results show that an increase in solid-phase content and particle size leads to an increase in critical flow velocity.

Experimental study of pipeline pressure loss laws with large-size gangue slurry during the process of industrial-grade annular pipe transportation

Gangue grouting and backfilling mining technology is one of the key techniques to achieve solid waste disposal and rock movement control in coal mines. The pipeline conveying performance of gangue slurry determines the success or failure of backfilling engineering directly. Due to the high cost of crushing small-sized gangue, research on pipeline transportation of large-sized gangue slurry has been gradually highlighted. In this study, the gangue slurry ratio optimization test and industrial-grade pipeline transportation experiments were conducted, and the optimal ratio of gangue slurry with different large particle size grading was obtained. Additionally, the rheological parameter changes of gangue slurry in pipeline transportation were analyzed, and the changes in slurry mass concentration, slurry flow velocity, and particle size matching of pressure loss in the straight and bent pipe sections of the transportation pipeline were studied. The results show that the optimal ratio for the 0–5 mm particle size gangue slurry is the mass concentration of 65 % and a mass proportion of 0.3: 2: 1 for 2–5 mm, 0.15–2 mm, and 0–0.15 mm particle size gangue; the optimal ratio for the 0–2 mm particle size gangue slurry gangue is the mass concentration of 60 % and a mass proportion of 2:1 for 0.15–2 mm and 0–0.15 mm particle size gangue. Both the mass concentration, flow velocity, and particle size grading of the gangue slurry have a significant impact on the pressure loss during pipeline transportation. The mass concentration of the gangue slurry has the most significant impact on the pressure loss in the straight pipe section, while the flow velocity has the highest impact on the pressure loss in the bent pipe section. The research results provide a theoretical basis for the design of pipeline transportation parameters for gangue grouting and backfilling projects.

Dynamic characterization of water hammer in gangue fly ash slurry pipelines during valve closure

In the process of coal-filling mining, the gangue fly-ash slurry (GFS) needs to be transported over a long distance to reach the gobs. The abrupt closure of the valve during the transportation of GFS can result in a water hammer that significantly endangers the stability and safety of the pipeline transport system. To study the fluctuations in pressure induced by abrupt closure of the valve, experiments on the rheological parameters of gangue-coal ash slurry were conducted. Transient numerical simulations were carried out using the computational fluid dynamics method for various valve closing times. The results indicate that, with the increase of slurry concentration, the yield stress of the slurry significantly increases. When the concentration exceeds 76%, the increase in yield stress reaches 38.4% and 35.1%, respectively. Upon valve closure, the internal pressure of the slurry in the pipeline exhibits periodic dynamic oscillations. As the duration of valve closure increases, the frequency of periodic water hammer events decreases. The maximum water hammer pressure caused by valve closure decreases with the increasing distance between the valve and the closure point. At the same time, the intensity of maximum water hammer pressure fluctuations increases with the increase in slurry concentration and flow velocity in the pipeline. The results can provide references for water hammer protection and pipeline selection during the transportation of backfill slurry in mining.

Investigating the Critical Velocity of Cement Slurry with Contamination and Applying the Results to Improve Primary Cementing Job Design

Investigating the Critical Velocity of Cement Slurry with Contamination and Applying the Results to Improve Primary Cementing Job Design

Research on the cuttings discharge in air cushion chamber of slurry shield based on CFD-DEM coupling method

The rapid discharge of cuttings from the air cushion chamber is crucial for the construction safety and excavation efficiency of the slurry shield. Previous studies have mainly focused on the transport characteristics of cuttings in the slurry discharge pipe, while the complete process of cuttings entering the slurry discharge pipe from the air cushion chamber until they are discharged was often overlooked. Based on the CFD-DEM coupling method and combined with actual engineering, this paper established a numerical model that can more completely reflect the cuttings discharge process during slurry shield tunneling, and the effects of the slurry velocity at slurry gate and scouring pipes, inclination angle of slurry discharge pipe, cuttings diameter and shape coefficient were investigated by analyzing the variation in the mass flow rate, mass of discharged cuttings, and discharged ratio. The results revealed that increasing the slurry velocity can promote the discharge of cuttings. To keep the discharged rate at a high level, it is recommended that the slurry velocity at the slurry gate should be greater than 0.15 m/s. Reducing the inclination angle of the discharge pipe is conducive to the rapid discharge of cuttings. Cuttings with large diameter or small shape coefficient are more prone to accumulate in the air cushion chamber and cause clogging risk. The research results not only help to improve engineers' understanding of cuttings discharge in slurry shield, but also provide practical guidance for formulating relevant construction measures.

Study on the diffusion and deposition law of pore slurry in gangue filling zone based on CFD-DEM coupling.

In this study, the slurry diffusion in a cavity filled with coal gangue was studied by combining experimental and numerical simulation methods. By calibrating slurry and particle materials, the grouting process in coal gangue filling area is simulated successfully, and the change of slurry diffusion flow field and particle movement and settling process in different dimensions are deeply analyzed. Both experimental and numerical simulation results show that the particle settlement presents a bell-shaped curve, which is of great significance for understanding the particle movement and settlement behavior in the filling cavity. In addition, it is found that the grouting speed has a significant effect on the particle settlement during the slurry diffusion process. When the grouting speed increases from 0.1m /s to 0.2m /s, the particle settlement and diffusion range increases about twice. In the plane flow field, it is observed that the outward diffusion trend and speed of grouting are more obvious. It is worth noting that in the whole process of grouting, it is observed that with the increase of grouting distance and depth, both the velocity of slurry and particles show a trend of rapid initial decline and gradually slow down, and the flow velocity of slurry near the grouting outlet at a flow rate of 0.2m/s is 2-4 times that of 0.1m/s. This provides important enlightenment for the porous seepage effect at different grouting speeds.

Coupling effect between magnetic wires and its influence on high gradient magnetic separation performance

High gradient magnetic separation (HGMS) is effective for the separation of weakly magnetic minerals, and this method is achieved through the use of matrix, which is made of huge numbers of rod wires. So that the coupling effect of magnetic field and flow field between wires has a marked effect on the HGMS performance. In the investigation, the coupling effect between magnetic wires and its influence on high gradient magnetic separation performance were theoretically described and simulated using COMSOL Multiphysics. It is found that the magnetic field round a wire would be affected by the neighboring wires, and then a coupling effect of magnetic field between wires was produced, increasing the magnetic induction intensity on the upstream and downstream of wire surface. And the coupling effect of flow field could increase the slurry velocity at the regions of the wire surface with azimuth angles of 0° and 90°, which is beneficial for the selective capture of wire. These simulated results were basically validated with the experimental separation, using an innovative Magnetic Capture Analysis Method. It is found that the wire spacing has significant effect on the coupling effect of magnetic wires, and a critical spacing for wires could achieve an excellent coupling effect, which is beneficial for the improvement of HGMS performance. This investigation contributes to improve HGMS performance in concentrating fine weakly magnetic ores.

Quality of Mixedness Using Information Entropy in a Counter-Current Three-Phase Bubble Column

Knowledge of mixing phenomena is of great value in the mineral and other chemical and biochemical industries. This work aims to analyze the quality of mixedness (QM), the intrinsic mass transfer (MT) number, and the MT efficiency based on information entropy theory in the counter-current microstructured slurry bubble column. A thorough analysis is conducted to assess the effects of particle loading, gas and slurry velocity, and axial variation on the QM. The range of gas velocity, slurry velocity, particle size, and particle loading was 0.011–0.075 m/s, 0.018–0.058 m/s, 242.72–408.31 μm, and 15.54–88.94 kg/m3, respectively. QM is a time-dependent parameter, and the concept of contact time has been used for scale-up purposes. The maximum QM was achieved at dimensionless times of 0.40 × 10−3, 0.15 × 10−3, and 0.85 × 10−3 for the maximum superficial gas velocity, particle loading, and axial height, respectively. The gas velocity positively influenced both the intrinsic MT number and its efficiency. In contrast, the slurry velocity and particle loading had a negative effect. The present theoretical analysis will pave the path for industrial process intensification in counter-current flow systems.

Heat transfer enhancement of power-law fluid in a solar-driven pretreatment system for microalgae hydrothermal liquefaction

In this article, the flow and heat transfer performance of microalgae slurry in a solar-driven rectangular absorption tube with embedded vortex generators were studied by data optimization analysis and numerical simulation. The orthogonal test design method was used to establish an orthogonal test table by changing the shape, height, spacing, and fluid flow rate of the vortex generator to determine the optimal combination of various factors. Then the response surface analysis method was used for further optimization analysis. Eventually, the flow and heat transfer performance of microalgae slurry were studied numerically, and the optimal data were verified. The results show that the optimal comprehensive heat transfer performance (PEC) is delivered by the cylindrical vortex generator with height of 9 mm and spacing of 28 mm when the inlet velocity of microalgae slurry is 0.02 m/s. It can be seen that the data analysis method combined with numerical simulation can optimize the experimental process parameters and save the cost of the engineering design process, effectively and practically.

Performance of HVAF sprayed WC-10Co-4Cr coating onto cast 21-4N steel for slurry erosion: Characterization and erosion rate studies

In this study, 86WC-10Co-4Cr powder was thermally sprayed onto cast 21-4N steel using High Velocity Air-Fuel (HVAF) technology. The deposited coating exhibited a dense structure with minimal porosity (1.0 ± 0.3%) and excellent fracture toughness (5.1 ± 0.3 MPa m1/2). Slurry erosion tests had shown that the HVAF-coated steel had significantly improved erosion resistance compared to uncoated steel, attributed to its high hardness, fracture toughness, and dense microstructure. Statistical analysis revealed that slurry velocity and impact angle were the most influential parameters. Further, Field emission scanning electron microscope (FE-SEM) image analysis showed that the coated steel exhibited a brittle mode of material removal, while the bare steel displayed a ductile mode. Overall, the study highlights the effectiveness of HVAF-sprayed 86WC-10Co-4Cr coatings in enhancing erosion resistance, providing valuable insights into the coating’s microstructure and performance under different erosion conditions.

Anti-scour performance of fluidized solidified slurry in dynamic water for scour repair

A novel method using fluidized solidified slurry for scour repair and protection around offshore foundation has been proposed recently. After being pumped to seabed area around foundation for scour protection or into the developed scour holes for scour repair, the fluidized solidified slurry is kept around the foundation for solidification which is still at a vulnerable state experiencing erosion and scour in the dynamic ocean water environment. Moreover, a reliable evaluation of loss of fluidized solidified slurry in scour repair or protection design using the new method requires to consider both the loss in pumping operation and solidification. Therefore, anti-scour performance of fluidized solidified slurry during solidification process is key for the novel technology. The current work conducted a series of experimental tests using a self-designed specially-targeted flume testing device to study the effects of flow property of fluidized solidified slurry and flow velocity of dynamic water on the anti-scour performance of solidified slurry in solidification under current. The retention rate of solidified slurry and scouring state were evaluated and discussed. Results indicates that the flow value that describing the pumpability of fluidized solidified slurry, is a key factor which affecting the critical starting velocity that characterizing the critical state of incipient motion. The critical starting velocity decreases with the flow value of fluidized solidified slurry. When the water flow velocity of current is larger than the critical starting velocity, the loss of fluidized solidified slurry is great, which can be evaluated by the retention rate. Empirical formulas for calculating the critical starting velocity and retention rate of fluidized solidified slurry in solidification was then proposed for the performance evaluation of fluidized solidified slurry application under current.

Pulsation curves strengthen the high gradient magnetic separation process Ⅱ: Consideration of separation performance

The use of pulsating slurry has been found to be effective in overcoming matrix blockage and improving separation selectivity in high gradient magnetic separators (HGMS). The velocity of the pulsating slurry is regulated by a sinusoidal cycle function, which causes the downward velocity to be much greater than the upward velocity due to the superposition of the sinusoidal pulsation velocity and the feeding velocity. However, the unbalanced velocity configuration in the up-downward stroke limits separation efficiency. This paper investigates the use of asymmetrical pulsation curves in a lab-scale HGMS to balance the velocity configuration and consequently improve separation performance. Magnetic field strength, feed velocity, and pulsating frequency were varied in separate experiments to determine the effect of pulsation curves on separation performance. The asymmetrical pulsation curve with a faster upward stroke and slower downward stroke was found to achieve a TiO2 concentrate grade of 23.94 %, a recovery of 66.78 %, and a separation efficiency of 50.46 % for the separation of ilmenite. When the concentrate grade is slightly higher, this new curve shows an increase of 5.68 % in recovery and 5.05 % in separation efficiency compared to the conventional sinusoidal pulsation curve. This improvement is attributed to a simultaneous strengthening of the material loose-adsorption process by separately regulating the pulsating upward and downward strokes.

Numerical analysis of slurry flow in pile‐end grouting of the drilling with prestressed concrete pipes

AbstractUnderstanding the diffusion law of cement slurry is the key to analyzing and evaluating the reinforcement effect of grouting. This study aimed to reveal the flow grouting mechanism of slurry in the reserved space between piles and soil and the penetration diffusion rule of slurry in the soil around the piles. For this purpose, the grouting slurry was regarded as a Newtonian fluid. The Navier–Stokes equations of fluid mechanics and renormalization group k–ε model were used to study the flow diffusion of slurry in the reserved space around a pile for grouting the drilling with prestressed concrete pipes. The permeability of soil slurry was determined using Darcy's law, and the flow field of slurry during grouting was numerically simulated. The results showed that the flow velocity of slurry and the reinforcement effect of grouting decrease gradually as the flow path extends. The radial flow of slurry in the grouting pipe shows a clear trend of circumferential diffusion. The slurry thickness in the reserved space for grouting decreases with an increase in the distance from the grouting outlet. Its attenuation trend becomes more obvious with increasing grouting height. The grouting thickness directly reflects the filling effect of slurry and is an important index to evaluate the grouting effect of drilling with prestressed concrete pipes.

Development and Performance of High Chromium White Cast Irons (HCWCIs) for Wear–Corrosive Environments: A Critical Review

There is a huge demand for high-performance materials in extreme environments involving wear and corrosion. High chromium white cast irons (HCWCIs) display better performance than many materials since they are of sufficient hardness for wear protection and can be tailored in chemical compositions to improve corrosion resistance; however, their performance is often still inadequate. This article reviews the chemical composition and microstructure design aspects employed to tailor and develop HCWCIs with combined corrosion and wear resistance. The performance of these alloys under wear and corrosion is reviewed to highlight the influence of these parameters in the industry. Existing challenges and future opportunities, mainly focusing on metallurgical alloy development aspects like chemical composition, casting, and heat treatment design, are highlighted. This is followed by suggestions for potential developments in HCWCIs to improve the performance of materials in these aggressive environments. Many variables are involved in the design to obtain suitable microstructures and matrix composition for wear–corrosion resistance. Computational modeling is a promising approach for optimizing multi-design variables; however, reliable field performance data of HCWCIs in wear–corrosion environments are still inadequate. Quantitative evaluation of the wear–corrosion performance of HCWCIs requires the development of laboratory and field tests using standard conditions like abrasive type and sizes, severity of loading, slurry velocity, pH, and temperature to develop wear–corrosion maps to guide alloy development.

Numerical simulation study on multiphase flow pattern of hydrate slurry

The research on the multiphase flow characteristics of hydrate slurry is the key to implementing the risk prevention and control technology of hydrate slurry in deep-water oil and gas mixed transportation system. This paper established a geometric model based on the high-pressure hydrate slurry experimental loop. The model was used to carry out simulation research on the flow characteristics of gas-liquid-solid three-phase flow. The specific research is as follows: Firstly, the effects of factors such as slurry flow velocity, hydrate particle density, hydrate particle size, and hydrate volume fraction on the stratified smooth flow were specifically studied. Orthogonal test obtained particle size has the most influence on the particle concentration distribution. The slurry flow velocity is gradually increased based on stratified smooth flow. Various flow patterns were observed and their characteristics were analyzed. Secondly, increasing the slurry velocity to 2 m/s could achieve the slurry flow pattern of partial hydrate in the pipeline transition from stratified smooth flow to wavy flow. When the flow rate increases to 3 m/s, a violent wave forms throughout the entire loop. Based on wave flow, as the velocity increased to 4 m/s, and the flow pattern changed to slug flow. When the particle concentration was below 10%, the increase of the concentration would aggravate the slug flow trend; if the particle concentration was above 10%, the increase of the concentration would weaken the slug flow trend, the increase of particle density and liquid viscosity would weaken the tendency of slug flow. The relationship between the pressure drop gradients of several different flow patterns is: slug flow > wave flow > stratified smooth flow.

Analysis of multi-particulate flow through the horizontal eccentric annulus considering the borehole cleaning

Multi-particulate flow CFD modelling is carried out while taking eccentricity into account considering drilling horizontal oil wells. The present work focuses on the effect of different cuttings sizes and their concentration on borehole cleaning. The carrier phase is a CMC-Bentonite solution which is a non-Newtonian fluid and the secondary phase is sand cuttings with different sizes. The RNG-k-ε turbulence mixture model is implemented along with the Eulerian-Eulerian multiphase model. The present CFD work has been validated with different experimental work and analytical results. The cutting size distribution in terms of volume fraction has been plotted along the various planes. Contours for volume fraction for different cutting size and inlet cuttings concentrations are also obtained. The increase in turbulence kinetic energy through increase inlet axial slurry velocity and drillpipe rotation (from v = 1 m/s, N = 50 rpm to v = 3.5 m/s, N = 100 rpm) is very effective in reducing cuttings accumulation for slurry A. The migration of cuttings from stationary zone to suspension zone is high for larger cuttings as compared to smaller cuttings from plane P2. The equivalent two-phase simulation for considered five-phase flow of slurry A has the similar cuttings distribution.

Global sensitivity analysis for phosphate slurry flow in pipelines using generalized polynomial chaos

Slurry transportation via pipelines has garnered growing attention across various industries worldwide, thanks to its efficiency and environmental friendliness. It has emerged as a vital tool for conveying significant volumes of raw phosphate material from extraction points to industrial plants, where it is processed into fertilizers. Yet, optimal and secure pipeline operations necessitate the careful calibration of several physical parameters and their interplay to minimize energy losses. A thorough exploration of the flow pressure drop and the various factors that influence it constitutes a crucial step in attaining this goal. The computational fluid dynamics techniques required to simulate three-dimensional slurry pipe flows pose formidable challenges, primarily due to their high computational costs. Furthermore, numerical solutions for slurry flows are frequently subject to uncertainties arising from the initial and boundary conditions in the mathematical models employed. In this study, we propose the use of polynomial chaos expansions to estimate the uncertainty inherent in the desired slurry flow and perform a sensitivity analysis of flow energy efficiency. In this framework, five parameters are considered as random variables with a given probability distribution over a prescribed range of investigation. The uncertainty is then propagated through the two-phase flow model to statistically quantify their effect on the results. Our findings reveal that variations in slurry velocity and particle size play a pivotal role in determining energy efficiency. Therefore, controlling these factors represents a critical step in ensuring the efficient and safe transportation of slurry through pipelines.