Bimodal model of slurry viscosity with application to coal-slurries. Part 2. High shear limit behavior

It is shown that in a truly bimodal coal-water slurry the hydrodynamic interactions between the coarse particles impose on the fine fraction a shear rate higher than that applied externally by the viscometer walls. A semi-empirical function of the coarse volume fraction is obtained for this correction factor to the applied shear rate. The derivation of this shear correction factor is based on lubrication concepts and introduces the maximum packing fraction,ø _m, at which flow can take place.ø _m is obtainable from a simple dry packing experiment. It is shown that the contribution of the coarse particles to the viscosity rise can be successfully described by a viscosity model employing the same concepts used to derive the shear correction factor. The bimodal model is applied in the high shear limit to polymodal coal slurries with a continuous particle size distribution. In the model, the contribution of the coarse particles to the viscosity rise is taken from separate viscosity measurements for the coarse coal particles, while the contribution to the viscosity of the fine coal particles is taken to be that given by the measured viscosity of colloidal suspensions of monomodal rigid spheres. It is shown that there is a ratio of coarse to fine fraction volumes in the continuous size distribution, corresponding to a specific separating particle size, for which the measured viscosities of the polymodal slurries match almost perfectly over the whole solids volume fraction range with the viscosity values obtained using the bimodal approach. The match is found to be relatively insensitive to the precise value of the separating particle size.     

A simple semiempirical model for the effective viscosity of multicomponent suspensions

We propose a methodology to approximate the viscosity of multicomponent suspensions. The procedure consists of successive applications of expressions for the viscosity of binary mixtures, originally written as the product of monomodal stiffening functions. First, the viscosity of a binary mixture made of the two smallest components is calculated. This allows to extract a volume fraction that will be used, together with the volume fraction of the third component, to feed the next iteration of the procedure to calculate the viscosity of a trimodal mixture and so on. The application of this approach to arbitrary mixtures requires the detailed knowledge of the geometry of the system in the form of size ratios and compositions. When this information is unknown, an approximation of the model can still be used as a fitting tool. With that purpose, the final expression for the viscosity is written in terms of an effective volume fraction that is further approximated by the use of a (1,2) Padé approximant. This approximation allows to incorporate the crowding effects due to different species in a volume fraction-dependent crowding factor that can be used as a fitting parameter to match experimental or simulation data. We have applied the model to mixtures of particles with different sizes and tested its accuracy comparing with experimental results obtaining very good agreement.     

Viscosity of concentrated noncolloidal bidisperse suspensions

At the same solid volume fraction (Φ) the relative viscosity (η _r ) of a concentrated noncolloidal bidisperse suspension of hard spherical particles is lower than that of a monodisperse suspension. In this paper a semi-analytical viscosity model of noncolloidal bidisperse suspensions is derived using an integration method. In this model the random loose packing density obtained by computer simulation is taken as the limit of solid volume fraction Φ _m which depends upon both the diameter ratio (λ) of large to small particles and the volume fraction of large particles (ξ=Φ _l /Φ). This model shows that at high solid volume fraction, Φ > 0.40, both λ and ξ significantly influence η _r . For example, at Φ=0.5, it predicts that for monodisperse suspensions η _r =70, while for bidisperse suspensions (λ=2 and ξ=0.7) η _r =40. Comparison shows that, at high solid volume fraction (0.4–0.5), the relative viscosity predicted by this model is in good agreement with that predicted by the work of Shapiro and Probstein (1992) and of Patlazhan (1993), but is higher than that predicted by the work of others. Received: 27 February 2001 Accepted: 25 April 2001     

An experimental study of multimodal glass suspension rheology to test and validate a polydisperse suspension viscosity model

Experimental measurements of non-colloidal multimodal suspension viscosities are performed over a wide range of mixing ratios and used to test the robustness and predictive capability of a recent viscosity model (Mwasame et al. in Phys Fluids 28:061701, 2016b), subsequently referred to as the MWB model. Three unimodally distributed particle suspensions with narrow size distributions are blended to make the bimodal and trimodal suspensions used in the rheological experiments. We demonstrate how predictions for mixture viscosities can be made using the MWB model only requiring the volume-weighted average particle sizes and viscosity correlations of the individual unimodal suspensions comprising the blend. The resultant model predictions are found to be in good agreement with measured bimodal and trimodal viscosity data to within expected experimental uncertainty. The datasets provided here can be used to validate future modeling efforts, and the MWB model can be used to optimize the viscosity of multimodal suspension mixtures for specific performance criteria.     

An empirical model predicting the viscosity of highly concentrated, bimodal dispersions with colloidal interactions

The relationship between particle size distribution and viscosity of concentrated dispersions is of great industrial importance, since it is the key to get high solids dispersions or suspensions. The problem is treated here experimentally as well as theoretically for the special case of strongly interacting colloidal particles. An empirical model based on a generalized Quemada equation is used to describe η as a function of volume fraction for mono- as well as multimodal dispersions. The pre-factor η˜ accounts for the shear rate dependence of η and does not affect the shape of the η vs φ curves. It is shown here for the first time that colloidal interactions do not show up in the maximum packing parameter and φ_max can be calculated from the particle size distribution without further knowledge of the interactions among the suspended particles. On the other hand, the exponent ɛ is controlled by the interactions among the particles. Starting from a limiting value of 2 for non-interacting either colloidal or non-colloidal particles, ɛ generally increases strongly with decreasing particle size. For a given particle system it then can be expressed as a function of the number average particle diameter. As a consequence, the viscosity of bimodal dispersions varies not only with the size ratio of large to small particles, but also depends on the absolute particle size going through a minimum as the size ratio increases. Furthermore, the well-known viscosity minimum for bimodal dispersions with volumetric mixing ratios of around 30/70 of small to large particles is shown to vanish if colloidal interactions contribute significantly. Received: 7 June 2000/Accepted: 12 February 2001     

The rheology of suspensions of porous zeolite particles in polymer solutions

We present data and predictive models for the shear rheology of suspended zeolite particles in polymer solutions. It was found experimentally that suspensions of zeolite particles in polymer solutions have relative viscosities that dramatically exceed the Krieger–Dougherty predictions for hard sphere suspensions. Our investigations show that the major origin of this discrepancy is due to the selective absorption of solvent molecules from the suspending polymer solution into zeolite pores. The effect raises both the polymer concentration in the suspending medium and the particle volume fraction in the suspension. Consequently, both the viscosity of the polymer solution and the particle contribution to the suspension viscosity are increased. We propose a predictive model for the viscosity of porous zeolite suspensions by incorporating a solvent absorption parameter, α, into the Krieger–Dougherty model. We experimentally determined the solvent absorption parameter by comparing viscosity data for suspensions of porous and nonporous MFI zeolite particles. Our results are in good agreement with the theoretical pore volume of MFI particles.     

A self-similar behavior for the relative viscosity of concentrated suspensions of rigid spheroids

A viscosity model for suspensions of rigid particles with predictive capability over a wide range of particle volume fraction and shear conditions is of interest to quantify the transport of suspensions in fluid flow models. We study the shear viscosity of suspensions and focus on the effect of particle aspect ratio and shear conditions on the rheological behavior of suspensions of rigid bi-axially symmetric ellipsoids (spheroids). We propose a framework that forms the basis to microscopically parameterize the evolution of the suspension microstructures and its effect on the shear viscosity of suspensions. We find that two state variables, the intrinsic viscosity in concentrated limit and the self-crowding factor, control the state of dispersion of the suspension. A combination of these two variables is shown to be invariant with the imposed shear stress (or shear rate) and depends only on the particle aspect ratio. This self-similar behavior, tested against available experimental and numerical data, allows us to derive a predictive model for the relative viscosity of concentrated suspensions of spheroids subjected to low (near zero) strain rates. At higher imposed strain rates, one needs to constrain one of the state variables independently to constrain the state of dispersion of the suspension and its shear dynamic viscosity. Alternatively, the obtained self-similar behavior provides the means to estimate the state variables from the viscosity measurements made in the laboratory, and to relate them to microstructure rearrangements and evolution occurring during deformation.     

A generalized equation for rheology of emulsions and suspensions of deformable particles subjected to simple shear at low Reynolds number

We present analyses to provide a generalized rheological equation for suspensions and emulsions of non-Brownian particles. These multiparticle systems are subjected to a steady straining flow at low Reynolds number. We first consider the effect of a single deformable fluid particle on the ambient velocity and stress fields to constrain the rheological behavior of dilute mixtures. In the homogenization process, we introduce a first volume correction by considering a finite domain for the incompressible matrix. We then extend the solution for the rheology of concentrated system using an incremental differential method operating in a fixed and finite volume, where we account for the effective volume of particles through a crowding factor. This approach provides a self-consistent method to approximate hydrodynamic interactions between bubbles, droplets, or solid particles in concentrated systems. The resultant non-linear model predicts the relative viscosity over particle volume fractions ranging from dilute to the the random close packing in the limit of small deformation (capillary or Weissenberg numbers) for any viscosity ratio between the dispersed and continuous phases. The predictions from our model are tested against published datasets and other constitutive equations over different ranges of viscosity ratio, volume fraction, and shear rate. These comparisons show that our model, is in excellent agreement with published datasets. Moreover, comparisons with experimental data show that the model performs very well when extrapolated to high capillary numbers (C a?1). We also predict the existence of two dimensionless numbers; a critical viscosity ratio and critical capillary numbers that characterize transitions in the macroscopic rheological behavior of emulsions. Finally, we present a regime diagram in terms of the viscosity ratio and capillary number that constrains conditions where emulsions behave like Newtonian or Non-Newtonian fluids.     

A model for the shear viscosity of non-colloidal suspensions with Newtonian matrix fluids

We present a model for the shear viscosity of non-colloidal suspensions with Newtonian matrix fluids. The model is based on the original idea first presented by Brinkman (Applied Sci Research A1:27-34. 1947) for the viscous force exerted by a flowing fluid on a dense swarm of spherical particles. In particular, we consider an inertialess suspension in which the mean flow is driven by a pressure difference, and simultaneously, the suspension is subject to simple shear. Assuming steady state, incompressibility and taking into account a resistance force which is generated due to the presence of the particles in the flow, the three-dimensional governing equations for the mean flow around a single spherical particle are solved analytically. Self-consistency of the model provides a relationship between the resistance parameter and the volume fraction of the solid phase. A volume, or an ensemble, averaging of the total stress gives the bulk properties and an expression for the relative (bulk) viscosity of the suspension. The viscosity expression reduces to the Einstein limit for dilute suspensions and agrees well with empirical formulas from the literature in the semi-dilute and concentrated regimes. Since the model is based on a single particle and its average interaction with the other particles is isotropic, no normal stress differences can be predicted. A possible method of addressing this problem is provided in the paper.     

Shear behaviour of biopolymer suspensions with spheroidal and cylindrical particles

The rheological behaviour of suspensions is influenced by many parameters, one of which is the particle shape. For rigid particle suspensions a number of studies demonstrate the effects of the particle aspect ratio. Indeed, fibres are widely used as rheology modifiers in different materials such as synthetic polymers. This work is concerned with testing the hypothesis that regularly shaped particles with aspect ratios larger than one that are made of gelled biopolymers could be used as rheology modifiers for biopolymer solutions. Biopolymers, and mixtures thereof are a widely used ingredient in foods and other products with structure functionality. Tailoring rheology modifiers by morphology offers an alternative to using different biopolymers. It is demonstrated how biopolymer suspensions with regular spheroidal, or cylindrical particle shapes can be produced by gelling the droplet phase of a liquid two phase biopolymer mixture in a shear field. Biopolymers were chosen such that gelation is initiated by cooling. Shear-cooling at constant stresses leads to the formation of ellipsoidal particles. Cylindrical particles can be generated by stepping up the shear stress prior to gelation, i.e., stretching the droplet phase into fibrils, and trapping the shape prior to break-up through gelation. Morphologies and steady shear rheological data for suspensions of the two biopolymers gellan and κ-carrageenan with an internal phase volume of 0.2 are reported. The influence of particle shape on relative viscosity is pronounced. At high shear stresses particle orientation leads to decreased viscosity with increasing particle aspect ratio. In the low shear region, higher aspect ratio suspensions show higher viscosities. Additionally, the material properties, including the interfacial tension, which influence the suspension morphology are reported. Received: 3 March 2000 Accepted: 22 August 2000     

Dispersion state and rheology of hectorite particles in water over a broad range of salt and particle concentrations

The relationship between the rheological properties of deionized aqueous suspensions of hectorite particles and the dispersion states of the particles has been studied with a broad range of salt and particle concentrations. The shear viscosity of the hectorite suspensions decreases drastically after exhaustively deionizing the suspensions with ion-exchange resins. By means of DLS measurements, it is clarified that the average size of the flocs of hectorite particles decreases and reaches the Stokes diameter of the individual particle as the degree of deionization advances. This fact strongly supports the idea that the electrical double layer around the hectorite particles expands significantly in the exhaustively deionized state and the particles are well-dispersed individually and do not form a three-dimensional network structure composed of particles, whereas such a network structure forms in the presence of a large amount of salt. In the case of exhaustively deionized state, the suspension forms a glassy state, at high particle fractions. The results show the importance of the electrical double layer that causes a strong repulsive force among the particles on the particle dispersion state, especially in the exhaustive deionization area below 10^− 4 M, and on the rheological properties; the hectorite suspension can be considered a Newtonian liquid in the deionized state, but it becomes elastic-solid in the presence of salt above a certain concentration confirmed by normal stress measurements.     

Rheological behavior of concentrated suspensions as affected by the dynamics of the mixing process

The rheological characterizations of concentrated suspensions are generally carried out assuming “well-mixed” suspensions. However, the variation of the concentration distributions of the ingredients of the formulation, i.e., the “goodness of mixing”, the size and shape distributions of the particle clusters and the rheological behavior of the suspension all depend on the thermo-mechanical history that the suspension is exposed to during the mixing process. Here, various experimental tools are used for the characterization of the degree of mixedness (concentration distributions) of various ingredients along with the characterization of rheological material functions, wall slip behavior and the maximum packing fraction of a graphite/elastomer suspension. The degree of mixedness values of the ingredients of the suspensions processed using batch and continuous processes and under differing operating conditions were characterized quantitatively using wide-angle X-ray diffraction and thermo gravimetric analysis and were elucidated under the light of the electrical properties of the suspension as affected by the mixing process. Upon achieving better homogeneity of the graphite particles and the binder and decreases in the size and breadth of the size distributions of particle clusters (as inferred from electrical measurements and maximum packing fraction values), the elasticity (storage modulus) and the shear viscosity (magnitude of the complex viscosity from small-amplitude oscillatory shear and shear viscosity from steady torsional and capillary rheometry) of the suspension decreased significantly and the wall slip velocity values increased. These findings demonstrate the intimate relationships that exist between the rheological behavior of concentrated suspensions and the thermo-mechanical history that they are exposed to during the processing stage and suggest that the preparation conditions for suspensions should be carefully selected and well documented to achieve reproducible characterization of rheological material functions.     

Preparation of well-dispersed magnetorheological fluids and effect of dispersion on their magnetorheological properties

In this work, we describe methods for the preparation of suspensions of micron-sized iron particles grafted with different surfactants. The aim is to obtain well-dispersed magnetorheological (MR) fluids. The effectiveness of the surfactants as dispersants was analyzed quantitatively by means of rheological measurements. With this objective, the viscosity of the suspensions was measured, and the results were compared with the prediction of the Batchelor’s formula (Batchelor, J Fluid Mech 83:97–117, 1977). The effect of dispersion on the MR properties of the suspensions was also studied. It was found that the quality of the dispersion of a suspension does not have an important effect on the magnitude of the field-induced yield stress but does on the change of viscosity induced by the field. It was also found that the transition from the solid-like state to the liquid-like one happens very smoothly for well-dispersed suspensions, contrarily to the abrupt transition for poorly dispersed suspensions.     

Shear rheometry and visualization of glass fiber suspensions

The nonlinear rheological behavior of short glass fiber suspensions has been investigated in this work by rotational rheometry and flow visualization. A Newtonian and a Boger fluid (BF) were used as suspending media. The suspensions exhibited shear thinning in the semidilute regime and weaker shear thinning in the transition to the concentrated one. Normal stresses and relative viscosity were higher for the BF suspensions than for the Newtonian ones presumably due to enhanced hydrodynamic interactions resulting from BF elasticity. In addition, relative viscosity of the suspensions increased rapidly with fiber content, suggesting that the rheological behavior in the concentrated regime is dominated by mechanical contacts between fibers. Visualization of individual fibers and their interactions under flow allowed the detection of aggregates, which arise from adhesive contacts. The orientation states of the fibers were quantified by a second order tensor and fast Fourier transforms of the flow field images. Fully oriented states occurred for shear rates around 20 s^− 1. Finally, the energy required to orient the fibers was higher in step forward than in reversal flow experiments due to a change in the spatial distribution of fibers, from isotropic to planar oriented, during the forward experiments.     

Rheological properties of concentrated latex suspensions of poly(styrene-butadiene)

Concentrated suspensions of charged latex particles of poly(styrene-butadiene) have been used as model systems to investigate the influence of surface charges on the rheology of colloidal suspensions. The suspensions were found to behave as elastic solids at small strains and to require a finite stress to flow. This was related to an ordered structure of the suspensions at rest, resulting from electrostatic and van der Waals forces. Important shear-thinning effects were observed as a consequence of structure rearrangements under shear. At a fixed shear rate, the steady-shear viscosity as a function of the ionic strength exhibits a minimum. Under oscillatory shear flow, the behavior of the concentrated suspensions was found to be non-linear above a very small strain amplitude. The non-linear output signal from dynamic experiments was analyzed using a fast Fourier transform algorithm. A maximum in the third harmonic intensity as a function of the strain amplitude was observed and the intensity of higher harmonics decreased with increasing ionic strength. The behavior of the suspensions could be adequately described using the structural model of Yziquel et al. (Yziquel F, Carreau PJ, Moan M, Tanguy PA (1999) Rheological modeling of concentrated colloidal suspensions. J Non-Newtonian Fluid Mech 86:133–155).     

Influence of suspension viscosity on Brownian relaxation of filler particles

Brownian relaxation caused by Brownian movement of particles in suspensions can macroscopically be probed by small-amplitude oscillatory shear experiments. Phenomenological considerations suggest a direct proportionality between suspension viscosity and Brownian relaxation times. To verify this relation experimentally, a set of nanocomposite suspensions with viscosities varying over five decades is presented. The suspensions are chosen in a way to ensure that particle-particle interactions and average particle-particle distances are identical so that they can be used as a model system to study the mere influence of suspension viscosity on Brownian relaxation. The suggested linear relationship between suspension viscosity and Brownian relaxation time can be confirmed. Moreover, a verification of a recently introduced characteristic timescale for Brownian relaxation is presented.     

The rheology of suspensions of vinylon fibers in polymer liquids. I. Suspensions in silicone oil

Summary The steady shear flow properties of suspensions of vinylon fibers in silicone oil were measured by means of a cone-plate type rheometer. Three kinds of vinylon fibers used had no distributions of length and were more flexible than glass fibers and the like. The content of the fibers ranged from 0 to 7 wt.%. Shear viscosity, the first normal-stress difference, yield stress, and relative viscosity were discussed. Shear viscosity and relative viscosity increased with the fiber concentration and the aspect ratio, and depended upon the shear rate. The applicability of Ziegel's equation of viscosity for fiber suspensions was investigated. The first normal-stress difference increased with the fiber concentration, aspect ratio, and shear rate and its relative increase was much larger than for shear stress and viscosity depending on the properties of the characteristic time, The yield stress could be determined by Casson plots for large aspect ratio fiber suspensions even in low concentration comparing with the suspensions of spherical particles or powder. The influence of the flexibility of the fibers for the rheological properties of the fiber suspensions can not be ignored.With 12 figures and 2 tables     

Self-organized domain microstructures in a plate-like particle suspension subjected to rapid simple shear

The evolution of the microstructure and rheological properties of plate-like particle suspensions subjected to rapid simple shear is studied numerically. In response to the shear-induced strain, particles in the suspensions rearrange to form a steady-state microstructure, and the suspension viscosity reaches a steady value. Under this condition, the microstructure is composed of two domains having different particle fractions and particle orientations. In the matrix (particle-poor) and cluster (particle-rich) domains, the particles’ long axes are oriented subparallel to the shear plane and normal to the maximum compressive principal direction, respectively. A higher particle concentration and friction coefficient enhance the development of cluster domains relative to matrix domains leading the intensity of the preferred particle orientation to decrease and the number of contacting particles, the aspect ratio of clusters, the inter-particle force, and the suspension viscosity to increase. The domain microstructure is governed by two factors: (1) geometric relations between the particle orientation and the maximum compressive axes and (2) the magnitude of particle–fluid and particle–particle interactions. The first factor results in the coupling of the particle orientation and the local fraction of particles, which is an important character of the domain microstructure. The second factor controls the relative development of the cluster and matrix domains through the change in the particles’ rotational behavior. Our results suggest that the microstructure of plate-like suspensions subjected to rapid shear is predictable in terms of the cluster stability, which has important implications for the kinematics of flow-related microstructures in nature and manufacturing.     

Bimodal model of slurry viscosity with application to coal-slurries. Part 1. Theory and experiment

The rheological behavior of stable slurries is shown to be characterized by a bimodal model that represents a slurry as made up of a coarse fraction and a colloidal size fine fraction. According to the model, the two fractions behave independently of each other, and the non-Newtonian behavior of the viscosity is solely caused by the colloidal fraction, while the coarse fraction increases the viscosity level through hydrodynamic interactions. Data from experiments run with colloidal coal particles of about 2–3 µm average size dispersed in water show the viscosity of these colloidal suspensions to exhibit a highly shearrate-dependent behavior and, in the high shear limit, to match very closely the viscosity of suspensions of uniform size rigid spheres although the coal volume fraction must be determined semi-empirically. Different amounts of coarse coal particles are added to the colloidal suspension and the viscosity of the truly bimodal slurries measured as a function of shear rate. In agreement with the bimodal model, the measured shear viscosities show the coarse fraction to behave independently of the colloidal fraction and its contribution to the viscosity rise to be independent of the shear rate. It is shown that the shear rate exerted on the colloidal fraction is higher than that applied by the viscometer as a result of hydrodynamic interactions between the coarse particles, and that it is this effective higher shear rate which is necessary to apply in the correlations. For determining the coal volume fraction a relatively simple and quite accurate measurement technique is developed for determining the density and void fraction of coarse porous particles; the technique directly relates volume fraction to mass fraction.     

Steady shear rheology of dilute polystyrene particle gels

This paper describes an experimental study on dispersions of monodisperse polystyrene (PS) spheres with a typical radius of 1 μm, dispersed in an electrolyte at high ionic strength, screening the electrostatic repulsion. These suspensions gelate at rest even at low volume fractions of PS particles. The density of the particles is matched with the solvent by using deuterium oxide for volume fractions φ≤0.117. Steady-state flow curves, viscosity as a function of shear rate, are measured and reported for 0.014<φ<0.322. The measured flow curves are analyzed on the basis of two models: 1. In the giant floc model (van Diemen and Stein 1983, 1984; Schreuder et al. 1986, 1987; Laven et al. 1988), at low shear rates, the shear is not distributed homogeneously but is limited to certain shear planes; the energy dissipation during steady flow is due primarily to overcoming the viscous drag on the suspended particles during motion caused by encounters of particles in the shear planes. Though this model was developed for higher solid volume fractions (0.35–0.425), we found that it also describes the rheology of dilute particle gels for 0.15≤φ≤0.3, using the same values for the parameters in the model as in the high solid volume fraction region. For φ<0.15, the model also describes the data if the fraction of distance by which a moving particle entrains its neighbors, is assumed to increase in this φ region. 2. The model of de Rooij (de Rooij et al. 1993, 1994) considers aggregates in shear flow to be monodisperse impermeable spheres with a fractal structure. The permeability is taken into account by considering a hydrodynamic radius smaller than the gyration radius in the Krieger-Dougherty expression for the hydrodynamic contribution to the viscosity. Through the use of a yield criterion the aggregate radius is modeled as a function of shear rate. We found that the model describes our experimental results, with a combination of parameter values used already by de Rooij, but only for φ<0.15. Received: 7 May 1998 Accepted: 22 December 1998