Gas–liquid two-phase flows in rectangular polymer micro-channels

This study addresses gas–liquid two-phase flows in polymer (PMMA) micro-channels with non-molecularly smooth and poorly wetting walls (typical contact angle of 65°) unlike previous studies conducted on highly wetting molecularly smooth materials (e.g., glass/silicon). Four fundamentally different topological flow regimes (Capillary Bubbly, Segmented, Annular, Dry) were identified along with two transitory ones (Segmented/Annular, Annular/Dry) and regime boundaries were identified from the two different test chips. The regime transition boundaries were influenced by the geometry of the two-phase injection, the aspect ratio of the test micro-channels, and potentially the chip material as evidenced from comparisons with the results of previous studies. Three principal Segmented flow sub-regimes (1, 2, and 3) were identified on the basis of quantified topological characteristics, each closely correlated with two-phase flow pressure drop trends. Irregularity of the Segmented regimes and related influencing factors were addressed and discussed. The average bubble length associated with the Segmented flows scaled approximately with a power law of the liquid volumetric flow ratio, which depends on aspect ratio, liquid superficial velocity, and the injection system. A simplified semi-empirical geometric model of gas bubble and liquid plug volumes provided good estimates of liquid plug length for most of the segmented regime cases and for all test-channel aspect ratios. The two-phase flow pressure drop was measured for the square test channels. Each Segmented flow sub-regime was associated with different trends in the pressure drop scaled by the viscous scale. These trends were explained in terms of the quantified flow topology (measured gas bubble and liquid plug lengths) and the number of bubble/plug pairs. Significant quantitative differences were found between the two-phase pressure drop in the polymer micro-channels of this study and those obtained from previous glass/silicon micro-channel studies, indicating that the effect of wall surface properties is important. Pressure drop trends on the capillary scale along gas bubbles extracted from the measurements in square micro-channels indicated a linear dependence on the Capillary number and did not agree with those predicted by highly idealized theory primarily because explicit and implicit assumptions in the theory were not relevant to practical conditions in this study.     

Theoretical analysis of pressure-drop type instabilities in an upflow boiling system with an exit restriction

 In this work, two-phase flow pressure-drop type instabilities in an upflow boiling system are studied theoretically. Dynamic simulations of the pressure-drop type instabilities require the knowledge of the steady state characteristics of the system in terms of the pressure drop versus the mass flow rate. In a boiling system with an exit restriction at the outlet of the boiling channel, the pressure drop through the system concentrates at the exit restriction. Therefore, the correlation of the pressure drop of the two-phase mixture flowing through the exit restriction (i.e. a sharp-edged orifice) is essential in the calculation of the total pressure drop of the system. A model for the exit restriction is developed and compared with the experimental results covering a wide range of vapor quality with different heat inputs and inlet subcoolings. The drift-flux model is adopted to predict the steady state characteristics of the boiling system. The dynamic oscillations of the quasi-static pressure-drop type instabilities in the boiling system are simulated and good predictions of the system stability boundary and oscillatory characteristics are obtained when compared with the experimental results. Received on 4 May 2000     

Modeling Non-Darcian Single- and Two-Phase Flow in Transparent Replicas of Rough-Walled Rock Fractures

While it is generally assumed that in the viscous flow regime, the two-phase flow relative permeabilities in fractured and porous media depend uniquely on the phase saturations, several studies have shown that for non-Darcian flows (i.e., where the inertial forces are not negligible compared with the viscous forces), the relative permeabilities not only depend on phase saturations but also on the flow regime. Experimental results on inertial single- and two-phase flows in two transparent replicas of real rough fractures are presented and modeled combining a generalization of the single-phase flow Darcy’s law with the apparent permeability concept. The experimental setup was designed to measure injected fluid flow rates, pressure drop within the fracture, and fluid saturation by image processing. For both fractures, single-phase flow experiments were modeled by means of the full cubic inertial law which allowed the determination of the intrinsic hydrodynamic parameters. Using these parameters, the apparent permeability of each fracture was calculated as a function of the Reynolds number, leading to an elegant means to compare the two fractures in terms of hydraulic behavior versus flow regime. Also, a method for determining the experimental transition flow rate between the weak inertia and the strong inertia flow regimes is proposed. Two-phase flow experiments consisted in measuring the pressure drop and the fluid saturation within the fractures, for various constant values of the liquid flow rate and for increasing values of the gas flow rate. Regardless of the explored flow regime, two-phase flow relative permeabilities were calculated as the ratio of the single phase flow pressure drop per unit length divided by the two-phase flow pressure drop per unit length, and were plotted versus the measured fluid saturation. Results confirm the dependence of the relative permeabilities on the flow regime. Also the proposed generalization of Darcy’s law shows that the relative permeabilities versus fluid saturation follow physical meaningful trends for different liquid and gas flow rates. The presented model fits correctly the liquid and gas experimental relative permeabilities as well as the fluid saturation.     

Effect of diameter on two-phase pressure drop in narrow tubes

The effect of tube diameter on two-phase frictional pressure drop was investigated in circular tubes with inner diameters of 0.6, 1.2, 1.7, 2.6 and 3.4 mm using air and water. The gas and liquid superficial velocity ranges were 0.01-50 m/s and 0.01-3 m/s, respectively. The gas and liquid flow rates were measured and the two-phase flow pattern images were recorded using high-speed CMOS camera. Unique flow patterns were observed for smaller tube diameters. Pressure drop was measured and compared with various existing models such as homogeneous model and Lockhart-Martinelli model. It appears that the dominant effect of surface tension shrinking the flow stratification in the annular regime is important. It was found that existing models are inadequate in predicting the pressure drop for all the flow regimes visualized. Based on the analysis of present experimental frictional pressure drop data a correlation is proposed for predicting Chisholm parameter “C” in slug annular flow pattern. For all other flow regimes Chisholm’s original correlation appears to be adequate except the bubbly flow regime where homogeneous model works well. The modification results in overall mean deviation of pressure drop within 25% for all tube diameters considered. This approach of flow regime based modification of liquid gas interaction parameter appears to be the key to pressure drop prediction in narrow tubes.     

Numerical analysis of two-phase flow from a stratified region through a small circular side branch

A numerical analysis using a commercial CFD code, ANSYS CFX, was used to model two-phase flow discharging from a stratified region through a small branch of circular cross-section. The purpose of this study is to assess the capability of the code in predicting the pertinent flow parameters and to generate detailed results that can provide insights into some of the flow phenomena. The inhomogeneous, free surface model was used and the code predictions were evaluated by comparing results with previous correlation equations and experimental data. Results were obtained for the critical heights of the interface at the onsets of gas and liquid entrainment, as well as the mass flow rate and quality during two-phase discharge. Additional results including force balances and pressure contours were also analysed to provide insight into the flow characteristics just before the onsets of liquid and gas entrainment. All results are in good agreement with existing correlation equations and experimental data. CFD modelling is therefore a possible tool for predicting the correct results for discharging two-phase flow for the geometry under consideration; the computation time required to obtain converged results, however, was found to be excessive.     

Experimental investigation of the flow pattern,pressure drop and void fraction of two-phase flow in the corrugated gap of a plate heat exchanger

The two-phase flow in the corrugated gap created by two adjacent plates of a plate heat exchanger was investigated experimentally. One setup consisting of a transparent corrugated gap was used to visualize the two-phase flow pattern and study the local phenomena of phase distribution, pressure drop and void fraction. Saturated two-phase R365mfc and an air-water mixture were used as working fluids.In a second experimental setup, the heat transfer coefficients and the pressure drop inside an industrial plate heat exchanger during the condensation process of R134a are determined. Both experimental setups use the same type of plates, so the experimental results can be connected and a flow pattern model for the condensation in plate heat exchangers can be derived. In this work the results of the flow pattern visualization, the two-phase pressure drop in the corrugated gap and the void fraction analysis by measurement of the electrical capacity are presented. A new pressure drop correlation is derived, which takes into account different flow patterns, that appear during condensation. The mean deviation of the presented pressure drop model compared to the experimental data and data from other experimental works is 18.9%. 81.7% of the calculated pressure drop lies within ±30% compared to the experimental data.     

Relative Permeability Analysis of Tube Bundle Models,Including Capillary Pressure

The analytical equations for calculating two-phase flow, including local capillary pressures, are developed for the bundle of parallel capillary tubes model. The flow equations that are derived were used to calculate dynamic immiscible displacements of oil by water under the constraint of a constant overall pressure drop across the tube bundle. Expressions for averaged fluid pressure gradients and total flow rates are developed, and relative permeabilities are calculated directly from the two-phase form of Darcy's law. The effects of pressure drop and viscosity ratio on the relative permeabilities are discussed. Capillary pressure as a function of water saturation was delineated for several cases and compared to a steady-state mercury-injection drainage type of capillary pressure profile. The bundle of serial tubes model (a model containing tubes whose diameters change randomly at periodic intervals along the direction of flow), including local Young-Laplace capillary pressures, was analyzed with respect to obtaining relative permeabilities and macroscopic capillary pressures. Relative permeabilities for the bundle of parallel tubes model were seen to be significantly affected by altering the overall pressure drop and the viscosity ratio; relative permeabilities for the bundle of serial tubes were seen to be relatively insensitive to viscosity ratio and pressure, and were consistently X-like in profile. This work also considers the standard Leverett (1941) type of capillary pressure versus saturation profile, where drainage of a wetting phase is completed in a step-wise steady fashion; it was delineated for both tube bundle models. Although the expected increase in capillary pressure at low wetting-phase saturation was produced, comparison of the primary-drainage capillary pressure curves with the pseudo-capillary pressure profiles, that are computed directly using the averaged pressures during the displacements, revealed inconsistencies between the two definitions of capillary pressure.     

Choking and shock phenomena in a single component two-phase flow including vibrational effects

An analytical and experimental investigation including vibratory effects of flashing flow in a tube with a sharp edged entrance is presented. A free streamline flow model is applied to predict choking in single-component two-phase flow. By identifying three separate regimes (i.e. jet flow, two-phase homogeneous flow, and single-phase liquid flow) in the flashing flow system, an expression is obtained for the prediction of the minimum stagnation pressure loss under choked flow conditions. A normal shock located between the flashing two-phase mixture and the single-phase liquid was experimentally observed. The location of the shock is predicted as a function of the stagnation pressure drop across the tube. The analytical predictions are verified by experimental data.     

Magnetohydrodynamic pressure drop in ducted two-phase flows

Two models are presented for predicting magnetohydrodynamic pressure drop in two phase gas—liquid flows of conducting fluids for large values of Hartmann number. The first of these models treats the gas—liquid mixture as a single homogeneous pseudofluid with averaged mixture properties. The second model assumes that the flow pattern is one where the liquid is displaced to the duct walls as a liquid film and the gas flows in the central core. It is shown that the two models do not differ significantly in their predictions of overall pressure drop for vaporising two-phase flow of potassium. There is little experimental data available for testing the models but very satisfactory agreement is found between measurements of magnetic pressure drop of NaK—nitrogen mixtures at low quality and the predictions of both models.     

A separated flow model for predicting two-phase pressure drop and evaporative heat transfer for vertical annular flow

A separated flow model has been developed that is applicable to vertical annular two-phase flow in the purely convective heat transfer regime. Conservation of mass, momentum, and energy are used to solve for the liquid film thickness, pressure drop, and heat transfer coefficient. Closure relationships are specified for the interfacial friction factor, liquid film eddy-viscosity, turbulent Prandtl number, and entrainment rate. Although separated flow models have been reported previously, their use has been limited, because they were tested over a limited range of flow and thermal conditions. The unique feature of this model is that it has been tested and calibrated against a vast array of two-phase pressure drop and heat transfer data, which include upflow, downflow, and microgravity flow conditions. The agreements between the measured and predicted pressure drops and heat transfer coefficients are, on average, better or comparable to the most reliable empirical correlations. This separated flow model is demonstrated to be a reliable and practical predictive tool for computing two-phase pressure drop and heat transfer rates. All of the datasets have been obtained from the open literature.     

Void fraction and pressure drop during external upward two-phase cross flow in tube bundles – part II: Predictive methods

The present paper is the Part II of a broad study concerning void fraction and pressure drop for air-water upward external flow across tube bundles. In the Part I, the experimental facility and the data regression procedures were described and the experimental results are presented and discussed. Initially, Part II presents a literature review concerning void fraction and pressure drop predictive methods available in the open literature for two-phase upward flow across tube bundles. Next, the methods from literature are compared among them and with the database presented in paper Part I. Significant discrepancies are observed among the predictive methods, and deviations as high as two orders of magnitude are verified among the predicted values of pressure drop. Then, a new void fraction predictive method is proposed based on the experimental results and on the minimum kinetic energy principle. This method provides satisfactory predictions of the results described in paper Part I and also of independent data from the literature. A new predictive method for frictional pressure drop during two-phase flow based on two-phase multiplier is also proposed. This method predicted 94% of the experimental data obtained in the present study within an error margin of ± 30%, and also provides accurate predictions of independent results for triangular tube bundles gathered in the open literature.     

Analysis and application of solid-gas flow inside a venturi with particle interaction

A two-phase one-dimensional solid—gas flow model which describes the flow inside a variable area duct has been developed. The model includes multiparticle equations and considers particle—particle interaction. Predictions have been compared with experimental data for the pressure drop and pressure recovery through two venturis at different solid to gas loading ratios. Accurate knowledge of the particle-size distribution is extremely important for good comparison. No meaningful single particle-size diameter is found that yields predictions to agree with the measurements. The venturi may be used as a measuring device for solid—gas flow rates for systems if the particle-size distribution is accurately known. However, the venturi-diffuser section loses its effectiveness in recovering the pressure as the solid loading increases.     

Friction factor improved correlations for laminar and turbulent gas–liquid flow in horizontal pipelines

We develop improved correlations for two-phase flow friction factor that consider the effect of the relative velocity of the phases, based on a database that includes 2560 gas–liquid flow experiments in horizontal pipes. The database includes a wide range of operational conditions and fluid properties for two-phase friction factor correlations. We classify the experiments by liquid holdup ranges to obtain composite analytical expressions for two-phase friction factor vs. the Reynolds number by fitting logistic dose curves to the experimental data with. We compute the liquid holdup values used to classify the experimental data using correlations proposed previously. The Reynolds number is based on the mixture velocity and the liquid kinematic viscosity. The Fanning friction factor for gas–liquid is defined in term of the mixture velocity and density. Additionally, we sort the experimental data by flow regime and obtain the two-phase friction factor improved correlations for dispersed bubble, slug, stratified and annular flow for different holdup ranges. We report error estimates for the predicted vs. measured friction factor together with standard deviation for each correlation. The accuracy of the correlations developed in this study is compared with that of other 21 correlations and models widely available in the specialized literature. Since different authors use different definitions for friction factors and Reynolds numbers, we present comparisons of the predicted pressure drop for each and every data point in the database. In most cases our correlations predict the pressure drop with much greater accuracy than those presented by previous authors.     

Pressure drop in two phase slug/bubble flows in mini scale capillaries

A segmented two phase slug/bubble flow occurs where a liquid and a gas are pumped into the same tube over a range of Reynolds numbers. This segmented two phase flow regime is accompanied by an increase in pressure drop relative to the single phase flow where only one fluid is flowing in a capillary. This work experimentally and theoretically examines the pressure drop encountered by the slug/bubble flow with varying slug lengths in mini channels. In the experimental work the dimensionless parameters of Reynolds number and Capillary number span over three orders of magnitude, and dimensionless slug length ranges over two orders of magnitude to represent flows typical of mini- and micro-scale systems. It is found, in agreement with previous work, that these dimensionless groups provide the correct scaling to represent the pressure drop in two phase slug/bubble flow, although the additional pressure drop caused by the interface regions was found to be ∼40% less than previously reported.     

A Steady-State Upscaling Approach for Immiscible Two-Phase Flow

The paper presents a model for computing rate-dependent effective capillary pressure and relative permeabilities for two-phase flow, in 2 and 3 space-dimensions. The model is based on solving the equations for immiscible two-phase flow at steady-state, accounting for viscous and capillary forces, at a given external pressure drop. The computational performance of the steady-state model and its accuracy is evaluated through comparison with a commercial simulator ECLIPSE. The properties of the rate-dependent effective relative permeabilities are studied by way of computations using the developed steady-state model. Examples presented show the dependence of the effective relative permeabilities and capillary pressures, which incorporate the effects of fine scale wettability heterogeneity, on the external pressure drop, and thereby on the dimensionless macro-scale capillary number. The effective relative permeabilities converge towards the viscous limit functions as the capillary number tends to infinity. Special cases, when the effective relative permeabilities are rate-invariant, are also studied. The applicability of the steady-state upscaling algorithm in dynamic displacement situations is validated by comparing fine-gridded simulations in heterogeneous reservoirs against their homogenized counterparts. It is concluded that the steady-state upscaling method is able to accurately predict the dynamic behavior of a heterogeneous reservoir, including small scale heterogeneities in both the absolute permeability and the wettability.     

Gas/shear-thinning liquid flows through pipes: Modeling and experiments

In chemical and oil industry gas/shear-thinning liquid two-phase flows are frequently encountered. In this work, we investigate experimentally the flow characteristics of air/shear-thinning liquid systems in horizontal and slightly inclined smooth pipes. The experiments are performed in a 9-m-long glass pipe using air and three different carboxymethyl cellulose (CMC) solutions as test fluids. Flow pattern maps are built by visual observation using a high-speed camera. The observed flow patterns are stratified, plug, and slug flow. The effects of the pipe inclination and the rheology of the shear-thinning fluid in terms of flow pattern maps are presented. The predicted existence region of the stratified flow regime is compared with the experimental observation showing a good agreement. A mechanistic model valid for air/power-law slug flow is proposed and model predictions are compared to the experimental data showing a good agreement. Slug flow characteristics are investigated by the analysis of the signals of a capacitance probe: slug velocity, slug frequency, and slug lengths are measured. A new correlation for the slug frequency is proposed and the results are promising.     

微型管中液滴流动的三维数值模拟

对于微型设备中的低雷诺数流动，毛细力和黏性力起主导作用. 应用相场方法，引 入自由能泛函，研究了二相流体在微型管中流动问题及表面浸润现象，并给出了微型管中二 相流体的无量纲输运方程. 针对方形微管道，利用差分法给出了输运方程的数值求解方法. 最后，模拟了方形直管中的液滴流动和变形的过程，并给出了液滴前后压力差与其它主要物 理参数之间的变化关系. 结果表明，压力差随液滴半径增大而增加，而随毛细管系数的增大 而减小.     

Effective Rheology of Two-Phase Flow in Three-Dimensional Porous Media: Experiment and Simulation

We present an experimental and numerical study of immiscible two-phase flow of Newtonian fluids in three-dimensional (3D) porous media to find the relationship between the volumetric flow rate (Q) and the total pressure difference (\(\Delta P\)) in the steady state. We show that in the regime where capillary forces compete with the viscous forces, the distribution of capillary barriers at the interfaces effectively creates a yield threshold (\(P_t\)), making the fluids reminiscent of a Bingham viscoplastic fluid in the porous medium. In this regime, Q depends quadratically on an excess pressure drop (\(\Delta P-P_t\)). While increasing the flow rate, there is a transition, beyond which the overall flow is Newtonian and the relationship is linear. In our experiments, we build a model porous medium using a column of glass beads transporting two fluids, deionized water and air. For the numerical study, reconstructed 3D pore networks from real core samples are considered and the transport of wetting and non-wetting fluids through the network is modeled by tracking the fluid interfaces with time. We find agreement between our numerical and experimental results. Our results match with the mean-field results reported earlier.     

A Semi-empirical Correlation for Pressure Drop in Packed Beds of Spherical Particles

The effect of a confining wall on the pressure drop of fluid flow through packed beds of spherical particles with small bed-to-particle diameter ratios was investigated to develop an improved pressure drop correlation. The dependency of pressure loss on both wall friction and increased porosity near the wall was accounted for by using a theoretical approach. A semi-empirical model was created based upon the capillary-orifice model, which included a wall correction factor for the inertial pressure loss. In this model, packed beds were treated as a bundle of capillary tubes whose orifice diameter in the core region was different from that of the wall region. Using this model, a new pressure drop correlation was obtained, based on the Ergun equation and applicable for a wide range of Reynolds numbers (10⁻²–10³). The proposed correlation was compared with previous correlations, as well as with experimental data. This correlation showed close agreement with the experimental data for both low- and high-Reynolds number regimes and for a wide range of bed-to-particle diameter ratios. The ratio of the pressure drop in finite packing to that in homogeneous packing was then calculated. This ratio clearly shows how the wall effect depends on the Reynolds number and the bed-to-particle diameter ratio.     

Impact of aspect ratio on flow boiling of water in rectangular microchannels

In this paper we focus on the impact of varying the aspect ratio of rectangular microchannels, on the overall pressure drop involving water boiling. An integrated system comprising micro-heaters, sensors and microchannels has been realized on (1 1 0) silicon wafers, following CMOS compatible process steps. Rectangular microchannels were fabricated with varying aspect ratios (width [W] to depth [H]) but constant hydraulic diameter of 142 ± 2 μm and length of 20 mm. The invariant nature of the hydraulic diameter is confirmed through two independent means: physical measurements using profilometer and by measuring the pressure drop in single-phase fluid flow. The experimental results show that the pressure drop for two-phase flow in rectangular microchannels experiences minima at an aspect ratio of about 1.6. The minimum is possibly due to opposing trends of frictional and acceleration pressure drops, with respect to aspect ratio. In a certain heat flux and mass flux range, it is observed that the two-phase pressure drop is lower than the corresponding single-phase value. This is the first study to investigate the effect of aspect ratio in two-phase flow in microchannels, to the best of our knowledge. The results are in qualitative agreement with annular flow model predictions. These results improve the possibility of designing effective heat-sinks based on two-phase fluid flow in microchannels.