Heat transfer measurements and correlations for air–water flow of different flow patterns in a horizontal pipe

Heat transfer coefficients were measured and new correlations were developed for two-phase, two-component (air and water) heat transfer in a horizontal pipe for different flow patterns. Flow patterns were observed in a transparent circular pipe using an air–water mixture. Visual identification of the flow patterns was supplemented with photographic data, and the results were plotted on the flow regime map proposed by Taitel and Dukler and agreed quite well with each other. A two-phase heat transfer experimental setup was built for this study and a total of 150 two-phase heat transfer data with different flow patterns were obtained under a uniform wall heat flux boundary condition. For these data, the superficial Reynolds number ranged from 640 to 35,500 for the liquid and from 540 to 21,200 for the gas. Our previously developed robust two-phase heat transfer correlation for a vertical pipe with modified constants predicted the horizontal pipe air–water heat transfer experimental data with very good accuracy. Overall the proposed correlations predicted the data with a mean deviation of 1.0% and an rms deviation of 12%.     

On the Electric Potential Induced by a Homogeneous Magnetic Field in a Turbulent Pipe Flow

In this paper we study a turbulent pipe flow of a weakly electrical conducting fluid subjected to a homogeneous magnetic field which is applied perpendicular to the flow. This configuration forms the basis of a so-called electromagnetic induction flow meter. When the Hartmann number is small so that modification of flow by the Lorenz force can be neglected, the influence of the magnetic field results only in a spatially and temporally varying electric potential. The magnitude of the potential difference across the pipe is then proportional to the flow rate and this constitutes the principle of the flow meter. In this study the flow and electric potential are computed with help of a numerical flow simulation called Large-Eddy Simulation (LES) to which we have added an equation for the electrical potential. The results of the LES have been compared with experiments in which the electric potential is measured as a function of time at several positions on the circumference of the pipe. Both the experimental and numerical results for the mean potential at the pipe wall agree very well with an exact solution that can be obtained in this particular case of a homogeneous magnetic field. Furthermore, it is found that fluctuations in the electric potential due to the turbulence, are small compared to the velocity fluctuations. Based on the results we conclude that electrical-magnetic effects in pipe flow can be accurately computed with LES.     

Improvement of a pressure gradient method and its application to an unsteady flow problem

The pressure gradient method using velocity components and components of a pressure gradient as dependent variables has been modified to solve incompressible Newtonian fluid flow problems numerically. Applying this modified method to unsteady-state development of flow in a circular cavity shows that, at least for the case of a low Reynolds number flow, relative errors produced by the proposed method are smaller for most time intervals than those produced by the primitive velocity-pressure variable method and by the standard pressure gradient method. Also it is found that the modified and standard pressure gradient methods can be applied to the unsteady circular cavity flow at a moderate Reynolds number of at least up to 200.     

Experimental study of air–water flow in downward sloping pipes

This paper presents results from seven experimental facilities on the co-current flow of air and water in downward sloping pipes. As a function of the air flow rate, pipe diameter and pipe slope, the required water discharge to prevent air accumulation was determined. In case the water discharge was less than the required water discharge, the air accumulation and additional gas pocket head loss were measured. Results show that volumetric air discharge as small as 0.1% of the water discharge accumulate in a downward sloping section. The experimental data cover all four flow regimes of water-driven air transport: stratified, blow-back, plug and dispersed bubble flow. The analysis of the experimental results shows that different dimensionless numbers characterise certain flow regimes. The pipe Froude number determines the transition from blow-back to plug flow. The gas pocket head loss in the blow-back flow regime follows a pipe Weber number scaling. A numerical model for the prediction of the air discharge as a function of the relevant system parameters is proposed. The novelty of this paper is the presentation of experimental data and a numerical model that cover all flow regimes on air transport by flowing water in downward inclined pipes.     

Numerical simulation of swirling flow in diffusers

A reduced form of Navier–Stokes equations is developed which does not have the usual minimum axial step size restriction. The equations are able to predict accurately turbulent swirling flow in diffusers. An efficient single sweep implicit scheme is developed in conjunction with a variable grid size domain-conforming co-ordinate system. The present scheme indicates good agreement with experimental results for (1) turbulent pipe flow, (2) turbulent diffuser flow, (3) turbulent swirling diffuser flow. The strong coupling between the swirl and the axial velocity profiles outside of the boundary layer region is demonstrated.     

Experimental study of pre-swirl flow effect on the heat transfer process in the entry region of a convergent pipe

Experiments have been performed to study the heat transfer process of swirling flow issued into a heated convergent pipe with a convergent angle of 5° with respect to the pipe axis. A flat vane swirler situated at the entrance of the pipe is used to generate the swirling flow. During the experiments, the Reynolds number ranges from 7970 to 47,820, and the swirl number from 0 to 1.2. It is found that the convergence of the pipe can accelerate the flow which has an effect to suppress the turbulence generated in the flow and reduce the heat transfer. However, in the region of weak swirl (S = 0-0.65), the Nusselt numbers increase with increasing swirl numbers until S = 0.65, where turbulence intensity is expected to be large enough and not suppressible. In the region of strong swirl (S > 0.65), where recirculation flow is expected to be generated in the core of the swirling flow, the heat transfer characteristic can be altered significantly. At very high swirl (S ? 1.0), the accelerated flow in the circumferential direction is expected to be dominant, which leads to suppress the turbulence and reduce the heat transfer. The Nusselt number is found proportional to the swirl number. Correlations of the Nusselt numbers in terms of the swirl number, the Reynolds number and the dimensionless distance are attempted and are very successful in both the weak and the strong swirl regions.     

Finite element,stream function–vorticity solution of steady laminar natural convection

Stream function–vorticity finite element solution of two-dimensional incompressible viscous flow and natural convection is considered. Steady state solutions of the natural convection problem have been obtained for a wide range of the two independent parameters. Use of boundary vorticity formulae or iterative satisfaction of the no-slip boundary condition is avoided by application of the finite element discretization and a displacement of the appropriate discrete equations. Solution is obtained by Newton–Raphson iteration of all equations simultaneously. The method then appears to give a steady solution whenever the flow is physically steady, but it does not give a steady solution when the flow is physically unsteady. In particular, no form of asymmetric differencing is required. The method offers a degree of economy over primitive variable formulations. Physical results are given for the square cavity convection problem. The paper also reports on earlier work in which the most commonly used boundary vorticity formula was found not to satisfy the no-slip condition, and in which segregated solution procedures were attempted with very minimal success.     

Numerical calculations of erosion in an abrupt pipe contraction of different contraction ratios

Erosion predictions in a pipe with abrupt contraction of different contraction ratios for the special case of two‐phase (liquid and solid) turbulent flow with low particle concentration are presented. A mathematical model based on the time‐averaged governing equations of 2‐D axi‐symmetric turbulent flow is used for the calculations of the fluid velocity field (continuous phase). The particle‐tracking model of the solid particles is based on the solution of the governing equation of each particle motion taking into consideration the effect of particle rebound behaviour. Models of erosion were used to predict the erosion rate in mg/g. The effect of Reynolds number and flow direction with respect to the gravity was investigated for three contraction geometries considering water flow in a carbon steel pipe. The results show that the influence of the contraction ratio on local erosion is very significant. However, this influence becomes insignificant when the average erosion rates over the sudden contraction area are considered. The results also indicate the significant influence of inlet velocity variations. The influence of buoyancy is significant for the cases of low velocity of the continuous flow. A threshold velocity below which erosion may be neglected was indicated. Copyright © 2004 John Wiley & Sons, Ltd.     

Self-lubricated transport of aqueous foams in horizontal conduits

The flow characteristics of aqueous foams were studied in a thin flow channel and a round pipe instrumented for pressure gradient and flow rate measurements. The quality of the foam was varied by controlling the volumetric flow rate of liquid and gas, and different flow types were identified and charted. Uniform foams move as a rigid body lubricated by water generated by breaking foam at the wall. A lubrication model leading to a formula for the thickness of the lubricating layer is presented. The formula predicts a layer thickness of 6–8 μm in the channel and 10–12 μm in the pipe. The thickness depends weakly on foam quality. An overall correlation for the friction factor as a function of Reynolds number which applies to both channel and pipe is derived. This correlation is consistent with a model in which a rigid core of foam is lubricated by laminar flow of a water layer in the range of measured thickness.     

Pipe flow of suspensions in turbulent fluid

The general case of a fully developed pipe flow of a suspension in a turbulent fluid with electrically charged particles or with significant gravity effect, or both, and for any inclination of the pipe with the direction of gravity, is formulated. Parameters defining the state of motion are: pipe flow Reynolds number, Froude number, electro diffusion number, diffusion response number, momentum transfer number and particle Knudsen number. Comparison with experimental results is made for both gas-solid and liquid-solid suspensions. It is shown that the gravity effect becomes significant in the case of large pipe diameters and large particle concentrations.     

Drag reduction using surfactants in a rotating cylinder geometry

Turbulent Couette flow between two circular cylinders has been used for drag reduction experiments using surfactants. In the experiments presented here, only the outer cylinder rotates, the inner cylinder remains at rest and accurate measurements of the torque at the inner cylinder are measured. Water is used as a reference fluid. A drag reducing surfactant called Arquad S-50 (Akzo Nobel Surface Chemistry LLC, Chicago, Ill., USA) (5 mM)+NaSal (12.5 mM) was used as the drag reduction agent. This surfactant can reduce the drag up to 70% (a Reynolds number of about 70,000–150,000) as measured by pressure drop in a pipe flow. Experiments in Couette flow also show drag reduction in the turbulent range. Two arrangements were used, (1) one small trip-wire on the inner cylinder, and (2) four larger trip-wires on the outer cylinder. These trips reduce the critical Reynolds number for transition from laminar to turbulent flow. In case (1), we obtained 18% drag reduction at 5,000<Re<15,000 and in case (2), we obtained an average reduction of about 20% at 2,000<Re<10,000, increasing up to 30% at Re=15,000. The paper also discusses two important problems. First, the shear rate is not constant in the radial gap in circular Couette flow. For non-Newtonian fluids, where the molecular viscosity is a function of the shear rate, this effect must be considered. Second, which viscosity should be used in the Reynolds number? For pipe flow measurements, most authors use the viscosity of the solvent (generally water and Newtonian). For measurements in the Couette flow, we use a different approach, which is described in this paper. We conclude that Couette flow is a useful method for drag reduction investigations. Its advantage is the much smaller geometry in comparison to those of conventional test facilities such as wind tunnels, water, or oil channels or in tubes.     

Effect of the pattern of initial perturbations on the steady pipe flow regime

The influence of the inlet flow formation mode on the steady flow regime in a circular pipe has been investigated experimentally. For a given inlet flow formation mode the Reynolds number Re* at which the transition from laminar to turbulent steady flow occurred was determined. With decrease in the Reynolds number the difference between the resistance coefficients for laminar and turbulent flows decreases. At a Reynolds number approximately equal to 1000 the resistance coefficients calculated from the Hagen-Poiseuille formula for laminar steady flow and from the Prandtl formula for turbulent steady flow are equal. Therefore, we may assume that at Re > 1000 steady pipe flow can only be laminar and in this case it is meaningless to speak of a transition from one steady pipe flow regime to the other. The previously published results [1–9] show that the Reynolds number at which laminar goes over into turbulent steady flow decreases with increase in the intensity of the inlet pulsations. However, at the highest inlet pulsation intensities realized experimentally, turbulent flow was observed only at Reynolds numbers higher than a certain value, which in different experiments varied over the range 1900–2320 [10]. In spite of this scatter, it has been assumed that in the experiments a so-called lower critical Reynolds number was determined, such that at higher Reynolds numbers turbulent flow can be observed and at lower Reynolds numbers for any inlet perturbations only steady laminar flow can be realized. In contrast to the lower critical Reynolds number, the Re* values obtained in the present study, were determined for given (not arbitrary) inlet flow formation modes. In this study, it is experimentally shown that the Re* values depend not only on the pipe inlet pulsation intensity but also on the pulsation flow pattern. This result suggests that in the previous experiments the Re* values were determined and that their scatter is related with the different pulsation flow patterns at the pipe inlet. The experimental data so far obtained are insufficient either to determine the lower critical Reynolds number or even to assert that this number exists for a pipe at all.     

Unsteady compressible flow in long pipelines following a rupture

The unsteady frictional flow of a compressible fluid generated in a long pipeline after an accidental rupture is of considerable interest to the offshore gas industry. It answers several important questions concerning safety and pollution, e.g. the flow rate at the broken pipe end. Laboratory tests cannot simulate the rather complex phenomenon satisfactorily. The problem is highly non-linear and no general analytical solution is yet known. In this study, based on computational fluid dynamics, the simplifying assumptions of isothermal and low Mach number flow often applied in the case of unsteady compressible flows in pipelines, have not been used. Owing to the choking condition (Ma=1) which prevails for some time at the broken end. and the cumulative effect of friction over the 145 km long pipeline, we obtain (?p/?x)^t→?∞. This analytically established singularity leads to numerical difficulties which seriously affect the accuracy. For short tubes (such as shock tubes) this negative feature is much less severe. Special procedures were necessary to keep the accuracy within the chosen limit of 1 per cent.     

An improved EMMS model for turbulent flow in pipe and its solution

Based on the existing energy-minimization multi-scale (EMMS) model for turbulent flow in pipe, an improved version is proposed, in which not only a new radial velocity distribution is introduced but also the quantification of total dissipation over the cross-section of pipe is improved for the dominant mechanism of fully turbulent flow in pipe. Then four dynamic equality constraints and some other constraints are constructed but there are five parameters involved, leading to one free variable left. Through the compromise in competition between dominant mechanisms for laminar and fully turbulent flow in pipe respectively, the above four constructed dynamic equality constraints can be closed. Finally, the cases for turbulent flow in pipe with low, moderate and high Reynolds number are simulated by the improved EMMS model. The numerical results show that the model can obtain reasonable results which agree well with the data computed by the direct numerical simulation and those obtained by experiment. This illustrates that the improved EMMS model for turbulent flow in pipe is reasonable and the compromise in competition between dominant mechanisms is indeed a universal governing principle hidden in complex systems. Especially, one more EMMS model for a complex system is offered, promoting the further development of mesoscience.     

The effect of pipe diameter on the structure of gas/liquid flow in vertical pipes

Experimental work on two-phase vertical upward flow was carried out using a 19 mm internal diameter, 7 m long pipe and studying the time series of cross-sectional average void fractions and pressure gradient which were obtained simultaneously. With the aid of a bank of published data in which the pipe diameter is the range from 0.5 to 70 mm, the effect of pipe diameter on flow characteristics of two-phase flow is investigated from various aspects. Particularly, the work focuses on the periodic structures of two-phase flow. Average film thicknesses and the gas flow rate where slug/churn and churn/annular flow transitions occur all increase as the diameter of the pipe becomes larger. On the other hand, the pressure gradients, the frequencies of the periodic structures and the velocities of disturbance waves decrease. The velocity of disturbance waves has been used to test the model of Pearce (1979). It is found that the suggested value of Pearce coefficient 0.8 is reasonable for lower liquid flow rates but becomes insufficient for higher liquid flow rates.     

Space conservation law in finite volume calculations of fluid flow

In the numerical solutions of fluid flow problems in moving co-ordinates, an additional conservation equation, namely the space conservation law, has to be solved simultaneously with the mass, momentum and energy conservation equations. In this paper a method of incorporating the space conservation law into a finite volume procedure is proposed and applied to a number of test cases. The results show that the method is efficient and produces accurate results for all grid velocities and time steps for which temporal accuracy suffices. It is also demonstrated, by analysis and test calculations, that not satisfying the space conservation law in a numerical solution procedure introduces errors in the form of artificial mass sources. These errors can be made negligible only by choosing a sufficiently small time step, which sometimes may be smaller than required by the temporal discretization accuracy.     

Cooling of a viscoelastic film during unsteady extrusion from an annular die

The unsteady extrusion of a viscoelastic film from an annular and axisymmetric die is examined. External, elastic, viscous and inertia forces deform the film, which is simultaneously cooled via forced convection to the ambient air. This moving boundary problem is solved by mapping the liquid/air interfaces onto fixed ones and by employing a regular perturbation expansion for all the dependent variables. The ratio of the film thickness to its inner radius at the exit of the die is used as the small parameter in the perturbation expansion. The fluid mechanical aspects of the process depend on the Stokes, Deborah, Reynolds, and Capillary numbers. The heat transfer in the film and to the environment gives rise to four additional dimensionless groups: the Peclet, Biot and Brinkman numbers and the activation energy, which determines the temperature dependence of fluid viscosity and elasticity. A variable heat transfer coefficient is also considered. For typical fluid properties and process conditions, the Peclet number is very large. In this case it is the ratio of the Biot to the Peclet number, the Stanton number, which arises in the energy conservation equation. It is shown that film cooling becomes important when the Stanton number and/or the activation energy are in the high-end of their typical values. In such cases, the cooling of the parison leads to a more uniform flow and shape for the film. The influence on the process of a variable heat transfer coefficient and the Brinkman number is small. Received: 7 April 1999/Accepted: 10 August 1999     

Damped artificial compressibility iteration scheme for implicit calculations of unsteady incompressible flow

Peyret (J. Fluid Mech., 78, 49–63 (1976)) and others have described artificial compressibility iteration schemes for solving implicit time discretizations of the unsteady incompressible Navier-Stokes equations. Such schemes solve the implicit equations by introduing derivatives with respect to a pseudo-time variable τ and marching out to a steady state in τ. The pseudo-time evolution equation for the pressure p takes the form ?p/? = ?a²??.u, where a is an artificial compressibility parameter and u is the fluid velocity vector. We present a new scheme of this type in which convergence is accelerated by a new procedure for setting a and by introducing an artificial bulk viscosity b into the momentum equation. This scheme is used to solve the non-linear equations resulting from a fully implicit time differencing scheme for unsteady incompressible flow. We find that the best values of a and b are generally quite different from those in the analogous scheme for steady flow (J. D. Ramshaw and V. A. Mousseau, Comput. Fluids, 18, 361–367 (1990)), owing to the previously unrecognized fact that the character of the system is profoundly altered by the pressence of the physical time derivative terms. In particular, a Fourier dispersion analysis shows that a no longer has the significance of a wave speed for finite values of the physical time step δt,. Inded, if on sets a ? |u| as usual, the artificial sound waves cease to exist when δt is small and this adversely affects the iteration convergence rate. Approximate analytical expressions for a and b are proposed and the benefits of their use relative to the conventional values a ～ |u| and b = 0 are illustrated in simple test calculations.