Numerical simulation of circulation in gas-liquid column reactors: isothermal, bubbly, laminar flow

The gas-liquid flow inside a circular, isothermal column reactor with a vertical axis has been studied using numerical simulations. The flow is assumed to be in the laminar, bubbly flow regime which is characterized by a suspension of discrete air bubbles in a continuous liquid phase such as glycerol water. The mathematical formulation is based on the conservation of mass and momentum principle for the liquid phase. The gas velocity distribution is calculated via an empirically prescribed relative velocity as a function of void fraction. The interface viscous drag forces are prescribed empirically. For some cases a profile shape is assumed for the void ratio distribution. The influence of various profile shapes is investigated. The results are compared with those where the void ratio distribution is calculated from the conservation of mass equation. The mathematical model has been implemented by modifying a readily available computer code for single-phase newtonian fluid flows. The numerical discretization is based on a finite volume approach. The predictions show a good agreement with measurements. The circulation pattern seems not to be so sensitive to the actual shape of the void fraction profiles, but the inlet distribution of it is important. A significantly different flow pattern results when the void fraction distribution is calculated from the transport equation, as compared to those with a priori prescribed profiles. When the void fraction is uniformly distributed over the whole distributor plate, no circulation is observed. Calculations also show that even the two-phase systems with a few discrete bubbles can be simulated successfully by a continuum model.     

Modeling transient churn-annular flows in a long vertical tube

This work investigates the transient behavior of high gas fraction gas-liquid flows in vertical pipes (annular and churn flows). Hyperbolic balance equations for mass, momentum and entropy are written for the gas and liquid, which is split between a continuous film and droplets entrained in the gas core. Closure relationships to calculate the wall and interfacial friction and the rates of droplet entrainment and deposition were obtained from the literature. A finite-difference solution algorithm based on a coefficient matrix splitting method was implemented to deal with sharp variations in the spatial and temporal domains, such as pressure and phase holdup waves. The model results were compared with steady-state experimental data from eight different sources, totaling more than 1500 data points for pressure gradient, liquid film flow rate and void/core fraction. The absolute average deviation between the model and the data was 17% for the pressure gradient and 5.8% for the void fraction. A comparison of the model results with fully transient air-water data generated in a 49-mm ID, 42-m long vertical pipe is also presented. The experimental results consist of two outlet pressure-induced and two inlet mass flow rate-induced transient tests. Two main transient parameters are compared, namely the local void fraction and the pressure difference between selected points along the test section and the outlet (taken as a reference). The comparisons between the experiments and the numerical model indicate that the model was capable of describing the transient annular to churn flow transition with absolute average deviations of 14.5% and 7.9% for the pressure difference and void fraction, respectively.     

Compressible gas-liquid mixture flow at abrupt pipe enlargements

A detailed investigation was made of the flow of compressible gas-liquid mixtures through sudden enlargements in diameter of circular pipes. One-dimensional analysis shows that the dimensionless pressure rise varies with mixture void fraction and mixture momentum, while the establishment of choking conditions at the enlargement is controlled by the length of pipe downstream in which frictional pipe flow occurs. The flows were found to exhibit two characteristic modes, jet flow and submerged flow, with intermediate flows displaying unsteady oscillation between these modes. The distance to the downstream position of maximum pressure increased steadily with mixture void fraction when the upstream pipe outlet was choked, varying from 5 to 50 times the downstream pipe diameter. If the flow was not choked, this distance was much smaller and showed discrete fixed values associated with the mode of flow.

One-dimensional analysis accurately predicted maximum pressure, but when flow was choked at the enlargement the calculation was sensitive to the pressure in the region of separated flow surrounding the central jet in the enlargement. Although analysis of maximum pressure in terms of flow expansion and normal shock gave a general indication of the maximum pressure (which was thus concluded to depend on the general flow processes expected in the enlargement), accurate prediction of maximum pressures will depend on empirical knowledge of the separated flow region pressures. The maximum pressure rise was found to be in the range extending down to 0.3 of the upstream pipe outlet pressure and reduced with void fraction; it was also influenced by the enlargement area ratio. Flows in the approach and outlet pipes were found to be compressible, frictional pipe flows of the Fanno type, with somewhat reduced friction factors occurring in the outlet pipe.     

Analytical solutions for transverse distributions of stream-wise velocity in turbulent flow in rectangular channel with partial vegetation

The theory of poroelasticity is introduced to study the hydraulic properties of the steady uniform turbulent flow in a partially vegetated rectangular channel. Plants are assumed as immovable media. The resistance caused by vegetation is expressed by the theory of poroelasticity. Considering the influence of a secondary flow, the momentum equation can be simplified. The momentum equation is nondimensionalized to obtain a smooth solution for the lateral distribution of the longitudinal velocity. To verify the model, an acoustic Doppler velocimeter (ADV) is used to measure the velocity field in a rectangular open channel partially with emergent artificial rigid vegetation. Comparisons between the measured data and the computed results show that the method can predict the transverse distributions of stream-wise velocities in turbulent flows in a rectangular channel with partial vegetation.     

Modeling study of three-phase low liquid loading flow in horizontal pipes

A theoretical study is conducted to model the flow characteristics of three-phase stratified wavy flow in horizontal pipelines with a focus on the low liquid loading condition, which is commonly observed in wet gas pipelines. The model predictions are compared to the experimental data of Karami et al. (2016a, b). These experiments were conducted with water or 51 wt% of MEG in the aqueous phase, and inlet aqueous phase fraction values from 0 to100%.Modeling of three-phase flow can be described as a combination of two-phase gas-liquid flow modeling, and a liquid phase oil-water mixing modeling. A mechanistic model is proposed to predict flow characteristics of three-phase stratified wavy flow in pipeline. For the gas-liquid interactions, Watson's (1989) combined momentum balance equation derivation was applied. However, the calculation procedure was reversed, and the wave celerity was assumed as an input, while interfacial friction factor was one of the model's outputs. The liquid-liquid interactions were modeled using a simple energy balance equation and shift in liquid phase center of gravity calculations. The liquid phases can be separated, partially mixed, or fully mixed. The bottom aqueous film velocity was calculated using the law of the wall formulation, and was used to calculate the flowing aqueous phase fraction.The model predictions of different flow characteristics for two and/or three-phase flows were compared with available experimental data. The pressure gradient, wave amplitude, and aqueous phase fraction predictions were in good agreement with the experimental data. However, the liquid holdup predictions were slightly under-predicted by the model. Overall, an acceptable agreement was observed for all cases.Most of the common multiphase stratified flow models are developed with the assumption of steady-state conditions and with constant interfacial friction factor value. This study proposes a novel method to model stratified flow. The predictions are in acceptable agreement with experimental data conducted under stratified wavy flow pattern conditions.     

Studies on two-phase co-current air/non-Newtonian shear-thinning fluid flows in inclined smooth pipes

In this work, co-current flow characteristics of air/non-Newtonian liquid systems in inclined smooth pipes are studied experimentally and theoretically using transparent tubes of 20, 40 and 60 mm in diameter. Each tube includes two 10 m long pipe branches connected by a U-bend that is capable of being inclined to any angle, from a completely horizontal to a fully vertical position. The flow rate of each phase is varied over a wide range. The studied flow phenomena are bubbly flow, stratified flow, plug flow, slug flow, churn flow and annular flow. These are observed and recorded by a high-speed camera over a wide range of operating conditions. The effects of the liquid phase properties, the inclination angle and the pipe diameter on two-phase flow characteristics are systematically studied. The Heywood–Charles model for horizontal flow was modified to accommodate stratified flow in inclined pipes, taking into account the average void fraction and pressure drop of the mixture flow of a gas/non-Newtonian liquid. The pressure drop gradient model of Taitel and Barnea for a gas/Newtonian liquid slug flow was extended to include liquids possessing shear-thinning flow behaviour in inclined pipes. The comparison of the predicted values with the experimental data shows that the models presented here provide a reasonable estimate of the average void fraction and the corresponding pressure drop for the mixture flow of a gas/non-Newtonian liquid.     

Interfacial area concentration in gas–liquid bubbly to churn flow regimes in large diameter pipes

This study performed a survey on existing correlations for interfacial area concentration (IAC) prediction and collected an IAC experimental database of two-phase flows taken under various flow conditions in large diameter pipes. Although some of these existing correlations were developed by partly using the IAC databases taken in the low-void-fraction two-phase flows in large diameter pipes, no correlation can satisfactorily predict the IAC in the two-phase flows changing from bubbly, cap bubbly to churn flow in the collected database of large diameter pipes. So this study presented a systematic way to predict the IAC for the bubbly-to-churn flows in large diameter pipes by categorizing bubbles into two groups (group 1: spherical or distorted bubble, group 2: cap bubble). A correlation was developed to predict the group 1 void fraction by using the void fraction for all bubble. The group 1 bubble IAC and bubble diameter were modeled by using the key parameters such as group 1 void fraction and bubble Reynolds number based on the analysis of Hibiki and Ishii (2001, 2002) using one-dimensional bubble number density and interfacial area transport equations. The correlations of IAC and bubble diameter for group 2 cap bubbles were developed by taking into account the characteristics of the representative bubbles among the group 2 bubbles and the comparison between a newly-derived drift velocity correlation for large diameter pipes and the existing drift velocity correlation of Kataoka and Ishii (1987) for large diameter pipes. The predictions from the newly-developed two-group IAC correlation were compared with the collected experimental data in gas–liquid bubbly to churn flow regimes in large diameter pipes and their mean absolute relative deviations were obtained to be 28.1%, 54.4% and 29.6% for group 1, group 2 and all bubbles respectively.     

Wall shear stress and void fraction in Poiseuille bubbly flows: Part I: simple analytic predictions

Upward, co-current bubbly flows in a vertical rectangular duct are investigated at low liquid Reynolds numbers. The conditions considered are such that the pseudo-turbulent stresses remain negligible compared to the viscous stresses. The void fraction transverse distribution is idealised as step-functions and is then inserted in the conservation equations supplemented by appropriate closure laws. Analytical expressions are then obtained for the axial velocity profiles, for the lineic gas fraction and for the wall friction. The sensitivity of these quantities to the void distribution, characterised by the void fraction and the width of the three layers introduced, is discussed. It is shown that differential buoyancy effects govern the modification of the liquid velocity profiles. Notably, void peaking near walls is able to induce a wall shear stress many times higher than its single-phase flow counterpart at the same liquid flow rate. Also, the presence of a near wall region free of gas favours the onset of downward directed secondary flows. All these features correspond to experimental observations, and a few quantitative comparisons are also presented which support the validity of the model even in case of void coring. A companion paper (part II) will be devoted to systematic comparisons between predictions and experiments in the case of axisymmetric Poiseuille bubbly flows.     

One-group interfacial area transport equation and its sink and source terms in narrow rectangular channel

The characteristics of two-phase flow in a narrow rectangular channel are expected to be different from those in other channel geometries, because of the significant restriction of the bubble shape which, consequently, may affect the heat removal by boiling under various operating conditions. The objective of this study is to develop an interfacial area transport equation with the sink and source terms being properly modeled for the gas–liquid two-phase flow in a narrow rectangular channel. By taking into account the crushed characteristics of the bubbles a new one-group interfacial area transport equation was derived for the two-phase flow in a narrow rectangular channel. The random collisions between bubbles and the impacts of turbulent eddies with bubbles were modeled for the bubble coalescence and breakup respectively in the two-phase flow in a narrow rectangular channel. The newly-developed one-group interfacial area transport equation with the derived sink and source terms was evaluated by using the area-averaged flow parameters of vertical upwardly-moving adiabatic air–water two-phase flows measured in a narrow rectangular channel with the gap of 0.993 mm and the width of 40.0 mm. The flow conditions of the data set covered spherical bubbly, crushed pancake bubbly, crushed cap-bubbly and crushed slug flow regimes and their superficial liquid velocity and the void fraction ranged from 0.214 m/s to 2.08 m/s and from 3.92% to 42.6%, respectively. Good agreement with the average relative deviation of 9.98% was obtained between the predicted and measured interfacial area concentrations in this study.     

A compressible two-layer model for transient gas–liquid flows in pipes

This work is dedicated to the modeling of gas–liquid flows in pipes. As a first step, a new two-layer model is proposed to deal with the stratified regime. The starting point is the isentropic Euler set of equations for each phase where the classical hydrostatic assumption is made for the liquid. The main difference with the models issued from the classical literature is that the liquid as well as the gas is assumed compressible. In that framework, an averaging process results in a five-equation system where the hydrostatic constraint has been used to define the interfacial pressure. Closure laws for the interfacial velocity and source terms such as mass and momentum transfer are provided following an entropy inequality. The resulting model is hyperbolic with non-conservative terms. Therefore, regarding the homogeneous part of the system, the definition and uniqueness of jump conditions is studied carefully and acquired. The nature of characteristic fields and the corresponding Riemann invariants are also detailed. Thus, one may build analytical solutions for the Riemann problem. In addition, positivity is obtained for heights and densities. The overall derivation deals with gas–liquid flows through rectangular channels, circular pipes with variable cross section and includes vapor–liquid flows.     

The interrelation between void fraction fluctuations and flow patterns in two-phase flow

A fast response, linearized X-ray void measurement system has been used to obtain statistical measurements in normally fluctuating air-water flow in a rectangular channel. It is demonstrated that the probability density function (PDF) of the fluctuations in void fraction may be used as an objective and quantitative flow pattern discriminator for the three dominant patterns of bubbly, slug, and annular flow. This concept is applied to data over the range of 0.0 to 37 m/sec mixture velocities to show that slug flow is simply a transitional, periodic time combination of bubbly and annular flows. Film thicknesses calculated from the PDF data are similar in magnitude in both slug and annular flows. Calculation of slug length and residence time ratios along with bubble lengths in slug flow are also readily obtainable from the statistical measurements. Spectral density measurements showed bubbly flow to be stochastic while slug and annular flows showed periodicities correlatable in terms of the liquid volume flux.     

Bubble and liquid turbulence characteristics of bubbly flow in a large diameter vertical pipe

The bubble and liquid turbulence characteristics of air–water bubbly flow in a 200 mm diameter vertical pipe was experimentally investigated. The bubble characteristics were measured using a dual optical probe, while the liquid-phase turbulence was measured using hot-film anemometry. Measurements were performed at six liquid superficial velocities in the range of 0.2–0.68 m/s and gas superficial velocity from 0.005 to 0.18 m/s, corresponding to an area average void fraction from 1.2% to 15.4%. At low void fraction flow, the radial void fraction distribution showed a wall peak which changed to a core peak profile as the void fraction was increased. The liquid average velocity and the turbulence intensities were less uniform in the core region of the pipe as the void fraction profile changed from a wall to a core peak. In general, there is an increase in the turbulence intensities when the bubbles are introduced into the flow. However, a turbulence suppression was observed close to the wall at high liquid superficial velocities for low void fractions up to about 1.6%. The net radial interfacial force on the bubbles was estimated from the momentum equations using the measured profiles. The radial migration of the bubbles in the core region of the pipe, which determines the shape of the void profile, was related to the balance between the turbulent dispersion and the lift forces. The ratio between these forces was characterized by a dimensionless group that includes the area averaged Eötvös number, slip ratio, and the ratio between the apparent added kinetic energy to the actual kinetic energy of the liquid. A non-dimensional map based on this dimensionless group and the force ratio is proposed to distinguish the conditions under which a wall or core peak void profile occurs in bubbly flows.     

The development of the structure of water – air bubble grid turbulence

The development of the turbulent flow field generated due to the interaction of grid turbulence with a swarm of bubbles is investigated experimentally, in a vertical channel of rectangular cross section. Void fraction and streamwise mean and rms velocity distributions have been measured at several distances from the grid, with an optical probe and Laser Doppler Velocimetry, in relation to the air flow rate ratio. The obtained results indicate that close to the grid the void fraction and velocity distributions are dictated by the bubble injectors’ location on the grid. Downstream the void fraction distribution changes to a double peak pattern. The velocity distribution is characterized by a shear layer between the wall area and the central area of the channel. The extend of this shear layer is increasing as the distance from the grid and the gas flow rate ratio are increasing, and is associated with a corresponding increase of the turbulence fluctuations. Autocorrelation and spectra measurements at the centre of the channel show a reduction of the flow scales for low void fraction. Consistently, power spectra distributions indicate that bubbles cause a redistribution of energy manifested by the relative enhancement of the intermediate scales’ energy content and a consequent reduction in the larger scales. These trends are gradually alleviated and reversed at large distances from the grid, as the air flow rate is increased.     

Flow characteristics in hydraulically equilibrium two-phase flows in a vertical 2 × 3 rod bundle channel

In order to increase data on two-phase flow distribution in a multi-subchannel system, being similar to a rod bundle, experiments have been carried out using water and air at ambient pressure and temperature as the working fluids and a newly constructed 2 × 3 rod bundle channel as the test channel. The channel contained six rods in rectangular array and two-kinds of six subchannels, simulating a BWR fuel rod bundle. Experimental data on flow distribution and pressure drop along each subchannel axis were obtained in various single- and two-phase flows under a hydraulic equilibrium flow condition. From the measured pressure drop in the single-phase flow, friction factor data in each subchannel were obtained. The two-phase pressure drop data were compared with calculations by a simple, one-dimensional, one-pressure two-fluid model. In addition, Taylor bubble velocity in each subchannel in slug-churn flows was measured with a double needle contact probe. Using the bubble velocity data, we obtained a subchannel void fraction in each subchannel, and discussed a relationship of the subchannel void fractions between two different subchannels. Results of such experiments and discussions are presented in this paper.     

Interfacial measurements in stratified types of flow. Part I: New optical measurement technique and dry angle measurements

The development of a new non-intrusive computerized image analysis and optical observation method for accurately detecting the vapor–liquid interface in stratified two-phase flows is presented. This technique is applied to a round horizontal sight glass tube using a monochromatic laser sheet for observing two-phase flow patterns and for measuring cross-sectional dry angles and void fractions in these types of flow. The cross-sectional image observed externally is distorted by refraction and is thus reconstructed by computer. From this image, the shape of the vapor–liquid interface is detected and the dry angle and void fraction are accurately determinable over a wide range of conditions for a glass tube of 13.6 mm diameter. Results for dry angle are reported here while the test facility and void fraction measurements are presented in Part II. R-22 and R-410A are the test fluids. Dry angles were quite close to values predicted for stratified flow and much larger than comparable values for air–water flows.     

The prediction of two-phase mixture level and hydrodynamically-controlled dryout under low flow conditions

A theory is given for the thermal-hydraulic phenomena during uncovery of a flow channel. This is relevant to a reactor core under typical small break or operational transient conditions. A distinct equivalent collapsed liquid level and a two-phase-mixture level are defined in the model. The former represents the liquid inventory in the channel, while the latter characterizes the heat transfer regimes. The definition of these levels are coupled through the mass and energy conservation equations, and the constitutive relations for void fraction and net vapor generation location.Analytical solutions are obtained for the transient variation of both the collapsed liquid and the two-phase mixture levels.The analyses have been compared with existing single-tube data with uniform heat flux, and rod bundle experiments with an axial power profile and inlet feedwater flow. The results demonstrate the potential of the present model for application to reactor conditions.     

An investigation of void fraction in liquid slugs for horizontal and inclined gas—liquid pipe flow

The void fraction in liquid slugs has been determined for air—water fiow in horizontal and near-horizontal pipes by a newly-developed conductance probe technique. A semi-empirical correlation has been developed and compared with the present measurements and available data. This correlation predicts reasonably well the observed effects of diameter, inclination and physical properties.     

Quantitative limits of thermal and fluid phenomena measurements using the neutron attenuation characteristics of materials

Temporal and spatial resolution of the neutron radiographic technique were investigated in order to apply this technique to the visualization and measurement of thermal and fluid phenomena. The temporal resolution of three imaging methods of temporally resolved neutron radiography-static neutron radiography with a pulsed neutron beam and high frame rate neutron radiography with either a pulsed or steady neutron beam-was studied. It was determined that the temporal resolution was determined by the sensitivity and light decay time of the image detector and statistical variation of neutrons, and the resolution limits of static and dynamic imaging methods were estimated to be a few microseconds and a few hundred microseconds, respectively. An image processing method was proposed to measure flow characteristics such as void fraction. By performing an error analysis to calculate the limit value of liquid film thickness that can be measured by neutron radiography, it was determined that the limit value of a rectangular channel gap or round tube diameter should be smaller than 3.25 or 4.00 mm, respectively, for measuring the void fraction of air-water flow within an error of 10%. The void fraction measuring method was experimentally confirmed by comparing the void fraction values in a rectangular duct with a 2.4-mm gap obtained by neutron radiography with those obtained by optical and conductance probe methods. It was shown quantitatively that the measurement error decreased when consecutive frames were temporally integrated.     

A pressure–velocity coupling approach for high void fraction free surface bubbly flows in overset curvilinear grids

A methodology for improved robustness in the simulation of high void fraction free surface polydisperse bubbly flows in curvilinear overset grids is presented. The method is fully two‐way coupled in the sense that the bubbly field affects the continuous fluid and vice versa. A hybrid projection approach is used in which staggered contravariant velocities at cell faces are computed for transport and pressure–velocity coupling while the momentum equation is solved on a collocated grid arrangement. Conservation of mass is formulated such that a strong coupling between void fraction, pressure, and velocity is achieved within a partitioned approach, solving each field separately. A pressure–velocity projection solver is iterated together with a predictor stage for the void fraction to achieve a robust coupling. The implementation is described for general curvilinear grids detailing particulars in the neighborhood to overset interfaces or a free surface. A balanced forced method to avoid the generation of spurious currents is extended for curvilinear grids. The overall methodology allows simulation of high void fraction flows and is stable even when strong packing forces accounting for bubble collisions are included. Convergence and stability in one‐dimensional (1D) and two‐dimensional (2D) configurations is evaluated. Finally, a full‐scale simulation of the bubbly flow around a flat‐bottom boat is performed demonstrating the applicability of the methodology to complex problems of engineering interest. Copyright © 2015 John Wiley & Sons, Ltd.     

The effect of magnetic field on two-phase liquid metal flow

In this paper, the basic equations of two-phase liquid metal flow in a magnetic field are derived, and specifically, two-phase liquid metal MHD flow in a rectangular channel is studied, and the expressions of velocity distribution of liquid and gas phases and the ratioK ₀ of the pressure drop in two-phase MHD flow to that in single-phase are derived. Results of calculation show that the ratioK ₀ is smaller than unity and decreases with increasing void fraction and Hartmann number because the effective electrical conductivity in the two-phase case decreases. The Project is supported by the National Natural Science Foundation of China.