Investigation on heavy crude-water two phase flow and related flow characteristics

In this paper, heavy crude oil–water flows are studied in a horizontal stainless steel test section with 25.4 mm ID and overall length of 50 m. Crude oil (viscosity = 628.1 mPa s, interfacial tension with water = 10.33 mN/m at 60 °C) and water, collected from an oilfield, were used as test fluids. Visual observations, local sampling and pressure drop measurements were used to identify the flow patterns and their transitions. It was found that in all conditions studied there was a water-in-oil emulsion present. At low mixture velocities and water fractions this occupied the whole pipe cross section. As the velocity or the volume fraction increased water appeared to segregate. At high water fractions and mixture velocities annular flow appeared with the water-in-oil emulsion in the core surrounded by a water layer. The results were compared with those from a model oil with the same viscosity. At low water fractions there was a similarity between the patterns observed with the two oil systems characterized by water segregation from an oil continuous dispersion with increasing water fraction or mixture velocity. However, at high water fractions an oil-in-water dispersion formed with the model oil that was not seen with the crude oil. Pressure drop was generally higher for the crude oil system compared to the model one, while in both cases it decreased when water started to segregate and form layers in contact with the pipe wall. The differences between the two oil systems are attributed to the natural surfactants present in the heavy crude oil (such as asphaltenes and resins), which tend to accumulate on the water/oil interface, retard film drainage and maintain the stability of water drops in oil.     

Experimental study on the transition between stratified and non-stratified horizontal oil-water flow

The effect of oil and water velocities, pipe diameter and oil viscosity on the transition from stratified to non-stratified patterns was studied experimentally in horizontal oil-water flow. The investigations were carried out in a horizontal acrylic test section with 25.4 and 19 mm ID with water and two oil viscosities (6.4 and 12 cP) as test fluids. A high-speed video camera was used to study the flow structures and the transition. At certain oil velocity, stratified flow was found to transform into bubbly and dual continuous flows as superficial water velocity increased for both pipe diameters using the 12 cP oil viscosity. The transition to bubbly flow was found to disappear when the 6.4 cP oil viscosity was used in the 25.4 mm pipe. This was due to the low E?tv?s number. Transition to dual continuous flow occurred at lower water velocity for oil velocity up 0.21 m/s when 6.4 cP oil was used in the 25.4 mm ID pipe, while for U_so > 0.21 m/s, the transition appeared at lower water velocity with the 12 cP oil.The effect of pipe diameter was also found to influence the transition between stratified and non-stratified flows. At certain superficial oil velocity, the water velocity required to form bubbly flow increased as the pipe diameter increased while the water velocity required for drop formation decreased as the pipe diameter increased. The maximum wave amplitude was found to grow exponentially with respect to the mixture velocity. The experimental maximum amplitudes at the transition to non-stratified flow agreed reasonably well with the critical amplitude model. Finally, it was found that none of the available models were able to predict the present experimental data at the transition from stratified to non-stratified flow.     

Slip ratio in dispersed viscous oil-water pipe flow

In this article, dispersed flow of viscous oil and water is investigated. The experimental work was performed in a 26.2-mm-i.d. 12-m-long horizontal glass pipe using water and oil (viscosity of 100 mPa s and density of 860 kg/m³) as test fluids. High-speed video recording and a new wire-mesh sensor based on capacitance (permittivity) measurements were used to characterize the flow. Furthermore, holdup data were obtained using quick-closing-valves technique (QCV). An interesting finding was the oil-water slip ratio greater than one for dispersed flow at high Reynolds number. Chordal phase fraction distribution diagrams and images of the holdup distribution over the pipe cross-section obtained via wire-mesh sensor indicated a significant amount of water near to the pipe wall for the three different dispersed flow patterns identified in this study: oil-in-water homogeneous dispersion (o/w H), oil-in-water non-homogeneous dispersion (o/w NH) and Dual continuous (Do/w & Dw/o). The phase slip might be explained by the existence of a water film surrounding the homogeneous mixture of oil-in-water in a hidrofilic-oilfobic pipe.     

Effect of drag reducing polymers on oil–water flow in a horizontal pipe

Measurements of drag-reduction are presented for oil–water flowing in a horizontal 0.0254 m pipe. Different oil–water configurations were observed. The injection of water soluble polymer solution (PDRA) in some cases produced drag reduction of about 65% with concentration of only 10–15 ppm. The results showed a significant reduction in pressure gradient due to PDRA especially at high mixture velocity which was accompanied by a clear change in the flow pattern. Phase inversion point in dispersed flow regime occurred at a water fraction range of (0.33–0.35) indicated by its pressure drop peak which was disappeared by injecting only 5 ppm (weight basis) of PDRA. Effect of PDRA concentration and molecular weight on flow patterns and pressure drops are presented in this study. Influence of salt content in the water phase on the performance of PDRA is also examined in this paper.     

Single-beam gamma densitometry measurements of oil–water flow in horizontal and slightly inclined pipes

Gamma densitometry is a frequently used non-intrusive method for measuring component volume fractions in multiphase flow systems. The application of a single-beam gamma densitometer to investigate oil–water flow in horizontal and slightly inclined pipes is presented. The experiments are performed in a 15 m long, 56 mm diameter, inclinable stainless steel pipe using Exxsol D60 oil (viscosity 1.64 mPa s, density 790 kg/m³) and water (viscosity 1.0 mPa s, density 996 kg/m³) as test fluids. The test pipe inclination is changed in the range from 5° upward to 5° downward. Experimental measurements are reported at three different mixture velocities, 0.25, 0.50 and 1.00 m/s, and the inlet water cut is varied from 0 to 1. The gamma densitometer is composed of radioactive isotope of Am-241 with the emission energy of 59.5 keV, scintillation detector [NaI(Tl)] and signal processing system. The time averaged cross-sectional distributions of oil and water phases are measured by traversing the gamma densitometer along the vertical pipe diameter. Based on water volume fraction measurements, water hold-up and slip ratio are estimated. The total pressure drop over the test section is measured and frictional pressure drop is estimated based on water hold-up measurements. The measurement uncertainties associated with gamma densitometry are also discussed. The measured water hold-up and slip ratio profiles are strongly dependent on pipe inclination. In general, higher water hold-up values are observed in upwardly inclined pipes compared to the horizontal and downwardly inclined pipes. At low mixture velocities, the slip ratio decreases as the water cut increases. The decrease is more significant as the degree of inclination increases. The frictional pressure drop for upward flow is slightly higher than the horizontal flow. In general, there is a marginal difference in frictional pressure drop values for horizontal and downwardly inclined flows.     

Influence of gas injection on phase inversion in an oil–water flow through a vertical tube

An experimental study has been made of the influence of gas injection on the phase inversion between oil and water flowing through a vertical tube. Particular attention was paid to the influence on the critical concentration of oil and water where phase inversion occurs and on the pressure drop increase over the tube during phase inversion. By using different types of gas injectors also the influence of the bubble size of the injected gas on the phase inversion was studied. It was found that gas injection does not significantly change the critical concentration, but the influence on the pressure drop is considerable. For mixture velocities larger than 1 m/s, the pressure drop over the tube increases with decreasing bubble size and at inversion can become even larger than the pressure drop during the flow of oil and water without gas injection.     

Upward and downward inclination oil–water flows

The effect of upward (+5°, +10°) and downward (−5°) pipe inclinations on the flow patterns, hold up and pressure gradient during two-liquid phase flows was investigated experimentally for mixture velocities between 0.7 and 2.5 m/s and phase fractions between 10% and 90%. The investigations were performed in a 38 mm ID stainless steel test pipe with water and oil as test fluids. High-speed video recording and local impedance and conductivity probes were used to precisely identify the different flow patterns. In both positive and negative inclinations the dispersed oil-in-water regime extended to lower mixture velocities and higher oil fractions compared to horizontal flow. A new flow pattern, oil plug flow, appeared at both +5° and +10° inclination while the stratified wavy pattern disappeared at −5° inclination. The oil to water velocity ratio was higher for the upward than for the downward flows but in the majority of cases and all inclinations oil was flowing faster than water. At low mixture velocities the velocity ratio increased with oil fraction while it decreased at high velocities. The increase became more significant as the degree of inclination increased. The frictional pressure gradient in both upward and downward flows was in general lower than in horizontal flows while a minimum occurred at all inclinations at high mixture velocities during the transition from dispersed water-in-oil to dual continuous flow.     

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.     

Experimental investigation of phase inversion in an oil–water flow through a horizontal pipe loop

An experimental study was made of phase inversion in an oil–water flow through a horizontal pipe loop. The experiments started with the flow of a single liquid through the pipe loop; thereafter the second liquid was gradually added (using different injectors and different injection flow rates) until inversion took place. It was found that in this way the point of inversion could be postponed to high values of the dispersed phase volume fraction (>0.8). Samples were taken from the flowing mixture and inspected with the aid of a microscope. Multiple drops consisting of oil droplets in water drops were observed, but multiple drops consisting of water droplets in oil drops were never found. The significance of these observations for the phase inversion mechanism is discussed.     

On the phase inversion process in an oil–water pipe flow

An experimental study of the phase inversion process in an oil–water flow through a pipe was carried out. Special attention was paid to the critical concentration of the dispersed phase at which phase inversion occurs and to the change in morphological structures during inversion. To that purpose two different types of experiments were performed: (1) continuous experiments during which the dispersed phase fraction was gradually increased and (2) direct experiments whereby oil and water were injected simultaneously into the pipe at a certain concentration. During the experiments detailed pictures were taken of the phase inversion process and simultaneously the electrical conductivity of the mixture was measured to determine which liquid formed the continuous phase and which the dispersed phase. Also the pressure gradient over several parts of the pipe was measured.     

Three phase liquid–liquid–gas flows in 5.6 mm and 7 mm inner diameter pipes

Three phase liquid–liquid–gas flow maps in pipes of medium inner diameters (5.6 mm and 7 mm), are presented. A low viscosity paraffin oil (4.5 × 10⁻³ Pa s viscosity and 818.5 kg m⁻³ density at 20 °C), deionised water and air are flowing concurrently in Schott Duran^® glass pipes. A decreasing pipe diameter changes the flow pattern maps and also the behavior of the transition boundaries. Flow patterns are determined by high speed photography. To illuminate the pipe, laser induced fluorescence (LIF) is applied. The laser sheet is cutting through the axial vertical plane of the pipe. The laser light excites a fluorescent dye (uranine) in the water phase to separate the phases optically. The resulting flow maps are compared with literature data and a theoretical model.     

Simultaneous entrainment of oil and water droplets in high Reynolds number gas turbulence in horizontal pipe flow

We develop a 1D cross sectional concentration profile model for oil and water droplets that coexist in the turbulent gas phase (of Re ∼ 10⁶) in near horizontal stratified pipe flows. Entrainment of the oil and water mixture from a liquid film near the bottom of the pipe into the gas is modeled based on earlier single-fluid entrainment correlations. A Gamma distribution for the droplet sizes based on the breakup of liquid filaments, is adopted. An explicit algebraic–exponential formula for the total concentration profile for either phase can then be derived.     

Investigations of phase inversion and frictional pressure gradients in upward and downward oil–water flow in vertical pipes

The present study has attempted to investigate phase inversion and frictional pressure gradients during simultaneous vertical flow of oil and water two-phase through upward and downward pipes. The liquids selected were white oil (44 mPa s viscosity and 860 kg/m³ density) and water. The measurements were made for phase velocities varying from 0 to 1.24 m/s for water and from 0 to 1.87 m/s for oil, respectively. Experiments were carried either by keeping the mixture velocity constant and increasing the dispersed phase fraction or by keeping the continuous phase superficial velocity constant and increasing the dispersed phase superficial velocity. From the experimental results, it is shown that the frictional pressure gradient reaches to its lower value at the phase inversion point in this work. The points of phase inversion are always close to an input oil fraction of 0.8 for upward flow and of 0.75 for downward flow, respectively. A few models published in the literature are used to predict the phase inversion point and to compare the results with available experimental data. Suitable methods are suggested to predict the critical oil holdup at phase inversion based on the different viscosity ratio ranges. Furthermore, the frictional pressure gradient is analyzed with several suitable theoretical models according to the existing flow patterns. The analysis reveals that both the theoretical curves and the experimental data exhibit the same trend and the overall agreement of predicted values with experimental data is good, especially for a high oil fraction.     

Direct contact heat transfer between two immiscible liquids flowing in a horizontal concentric annulus

Direct contact heat transfer between water and a heat transfer oil was investigated under non-boiling conditions in co-current turbulent flow through a horizontal concentric annulus. The ratio of the inner pipe diameter to the outer pipe diameter (aspect ratio) κ = 0.730−0.816; total liquid velocity (mixture velocity) V_T = 0.42−1.1 m/s; inlet oil temperature T_oi = 38−94°C; oil volume fraction in the flowing mixture φ_o = 0.25−0.75 were varied and their effects on the overall volumetric heat transfer coefficient U_v were determined at constant interfacial tension of 48 dynes/cm.

It was found that, in each concentric pipe set, the overall volumetric heat transfer coefficient increased with increasing dispersed phase volume fraction at each constant mixture velocity and reached a maximum at around φ_o = φ_w ≈ 0.5. The maximum U_v values increased with increasing total liquid velocity and decreasing aspect ratio of the annulus. The volumetric heat transfer coefficient was also found to increase with increasing inlet oil temperature and increasing total liquid velocity but to decrease with length along the test section keeping all other parameters constant. Empirical expressions for the volumetric heat transfer coefficient were obtained within the ranges of the experimental parameters.     

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.     

Segmented gas–liquid flow characterization in rectangular microchannels

We used optical methods such as Laser Induced Fluorescence (LIF) and confocal Laser Scanning Microscopy (LSM) to characterize gas–liquid phase distribution in rectangular microchannels. Using a 2 m long microchannel with a hydraulic diameter of 200 μm enables the precise measurement of important parameters such as liquid slug length, bubble length, pressure drop and film thickness at the wall as well as in the corner of the microchannel for low Capillary numbers (Ca) ranging from 2 × 10⁻⁴ to 1 × 10⁻². This range of Ca was obtained by using different fluid pairs such as ethanol, water and different concentrated aqueous solutions of glycerol in combination with nitrogen.     

Experimental studies of adiabatic flow boiling in fractal-like branching microchannels

Experimental results of adiabatic boiling of water flowing through a fractal-like branching microchannel network are presented and compared to numerical model simulations. The goal is to assess the ability of current pressure loss models applied to a bifurcating flow geometry. The fractal-like branching channel network is based on channel length and width ratios between adjacent branching levels of 2^−1/2. There are four branching sections for a total flow length of 18 mm, a channel height of 150 μm and a terminal channel width of 100 μm. The channels were Deep Reactive Ion Etched (DRIE) into a silicon disk. A Pyrex disk was anodically bonded to the silicon to form the channel top to allow visualization of the flow within the channels. The flow rates ranged from 100 to 225 g/min and the inlet subcooling levels varied from 0.5 to 6 °C. Pressure drop along the flow network and time averaged void fraction in each branching level were measured for each of the test conditions. The measured pressure drop ranged from 20 to 90 kPa, and the measured void fraction ranged from 0.3 to 0.9. The measured pressure drop results agree well with separated flow model predictions accounting for the varying flow geometry. The measured void fraction results followed the same trends as the model; however, the scatter in the experimental results is rather large.     

Multiphase drag reduction: Effect of eliminating slugs

Two-phase pressure drop measurements were taken for air/water mixtures in a 0.052-m diameter horizontal pipe with special focus on the superficial liquid velocity range of 0.03–1.2 m/s at superficial gas velocities of 3.8, 5.2, and 6.6 m/s. It was found that the addition of 400 ppm of sodium dodecyl sulfate (SDS) to the water reduced the pressure drop by 25–40% when compared to equal flow rates without SDS. The pressure drop reduction occurred where the SDS eliminated the occurrence of the intermittent flow present with water. It was also found that the same concentration of SDS had virtually no effect on single phase liquid pressure drop. The pressure drop reduction appears to be due solely to the suppression of intermittent flow patterns.     

Characteristics of developing vertical bubbly flow under normal and microgravity conditions

The axial development of the void fraction profile, interfacial area concentration and Sauter mean bubble diameter of adiabatic nitrogen-water bubbly flows in a 9 mm-diameter pipe were measured using stereo image processing under normal and microgravity conditions. The flow measurements were performed at four axial locations (axial distance from the inlet, z normalized by the pipe diameter, D, z/D = 5, 20, 40 and 60) and with various flows: superficial gas velocity of 0.00840-0.0298 m/s, and superficial liquid velocity of 0.138-0.914 m/s. The effect of gravity on radial distribution of bubbles and the axial development of two-phase flow parameters is discussed in detail based on the obtained database and visual observation. Following Serizawa-Kataoka’s phase distribution pattern criteria under normal gravity conditions, the phase distribution pattern map was developed. Similar to normal gravity two-phase flows, wall, core and intermediate void peak patterns are observed under microgravity conditions but a transition void distribution pattern is not observed in the current experimental conditions. The data obtained in the current experiment are expected to contribute to the benchmarking of CFD simulation of phase distribution pattern and interfacial area concentration in forced convective pipe flow under microgravity conditions.