Analysis of Abrasive Wear of Cowles-Type Impeller Discs in a Batch Process

Abstract

Industrial batch dispersion processes are widely used in various production sectors due to their ability to promote the homogenization of systems containing suspended solid particles. In these processes, Cowles-type impeller discs play a fundamental role in generating shear and dispersing materials and are subjected to severe operating conditions that favor abrasive wear. This study aimed to analyze the abrasive wear of a Cowles-type impeller disc used in industrial batch processes by evaluating mass loss and inspecting geometric changes resulting from operation. The methodology consisted of periodic mass measurements and visual analysis of the component over approximately 90 hours of operation. The results showed a cumulative mass loss of 0.890 kg, corresponding to 15.10% of the disc’s initial mass, as well as significant degradation of the peripheral teeth. It was concluded that the combination of high peripheral velocities, the presence of abrasive particles, and high solid concentrations directly contributes to the progressive removal of material, reinforcing the importance of wear monitoring to increase equipment service life and operational reliability.