Experimental investigation of a developing two-phase bubbly flow in horizontal pipe

Experimental results for various water and air superficial velocities in developing adiabatic horizontal two-phase pipe flow are presented. Flow pattern maps derived from videos exhibit a new boundary line in intermittent regime. This transition from water dominant to water–gas coordinated regimes corresponds to a new transition criterion C_T = 2, derived from a generalized representation with the dimensionless coordinates of Taitel and Dukler.Velocity, turbulent kinetic energy and dissipation rate, void fraction and bubble size radial profiles measured at 40 pipe diameters for J_L = 4.42 m/s by hot film velocimetry and optical probes confirm this transition: the gas influence is not continuous but strongly increases beyond J_G = 0.06 m/s. The maximum dissipation rate, derived from spectra, is increased in two-phase flow by a factor 5 with respect to the single phase case.The axial evolution of the bubble intercept length histograms also reveal the flow organization in horizontal layers, driven by buoyancy effects. Bubble coalescence is attested by a maximum bubble intercept evolving from 2.5 to 4.5 mm along the pipe. Turbulence generated by the bubbles is also manifest by the 4-fold increase of the maximum turbulent dissipation rate along the pipe.     

Atomization of glycerin with a twin-fluid swirl nozzle

Atomization of liquids with high viscosity is always a challenge, especially when small diameter droplets and high liquid flow rates are simultaneously required. In the present research, the performance of a Venturi–vortex twin-fluid swirl nozzle is examined, attending to its capabilities to generate droplets with diameters below 20 µm when atomizing pure glycerin at room temperature. In this nozzle, air is injected tangentially in a central convergent section, and discharges suctioning the liquid fed to a coaxial chamber, here using a gear pump. The resulting spray is visualized and analyzed. Droplet size distributions are measured with a laser diffractometer. As expected, droplet diameter increases with liquid flow rate, and quickly diminishes when air flow rate is increased. Sauter mean diameters (SMD) below 15 µm can be obtained even when atomizing pure glycerin. However, these values are obtained for relatively low glycerin flow rates (∼5 l/h), and with rather wide distributions. For 10 l/h and an air-to-liquid mass flow rate ratio (ALR) of 13.7 more than 26% of the glycerin volume is atomized in droplets smaller than 20 µm. Liquid ligaments are observed near the nozzle exit, but they tend to break up while moving downstream.     

Bubbly-to-cap bubbly flow transition in a long-26 m vertical large diameter pipe at low liquid flow rate

The concurrent upward two-phase flow of air and water in a long vertical large diameter pipe with an inner diameter (D) of 200 mm and a height (z) of 26 m (z/D = 130) was investigated experimentally at low superficial liquid velocities from 0.05009 to 0.3121 m/s and the superficial gas velocities from 0.01779 to 0.5069 m/s. The resultant void fractions range from 0.03579 to 0.4059. According to the observations using a high speed video camera, the flow regimes of bubbly, developing cap bubbly and fully-developed cap bubbly flows prevailed in the flows. The developing cap bubbly flow appeared as a flow regime transition from bubbly to fully-developed cap bubble flow in the vertical large diameter pipe. The developing cap bubbly flow changes gradually and lasts for a long time period and a wide axial region in the flow direction, in contrast to a sudden transition from bubbly to slug flows in a small diameter pipe. The analysis in this study showed that the flow regime transition depends not only on the void fraction but also on the axial distance in the flow and the pipe diameter. The axial flow development brings about the transition to happen in a lower void fraction flow and the increase of pipe diameter causes the transition to happen in a higher void fraction flow. The measured void fraction showed an N-shaped axial changing manner that the void fraction increases monotonously with axial position in the bubbly flow, decreases non-monotonously with axial position in the developing cap bubbly flow, and increases monotonously again with axial position in the fully-developed cap bubbly flow. The temporary void fraction decrease phenomenon in the transition region from bubbly to cap bubbly flow can be attributed to the formation of medium to large cap bubbles and their gradual growth into the maximum size of cap bubble and/or cluster of large cap bubbles in the developing cap bubbly flow. In order to predict the N-shaped axial void fraction changing behaviors in the flow regime transition from bubbly to cap bubbly flow, the existing 12 drift flux correlation sets for large diameter pipes are reviewed and their predictabilities are studied against the present experimental data. Although some drift flux correlation sets, such as those of Clark and Flemmer (1986) and Hibiki and Ishii (2003), can predict the present experimental data with reasonable average relative deviations, no drift flux correlation set for distribution parameter and drift velocity can give a reliable prediction for the observed N-shaped axial void fraction changing behaviors in the region from bubbly to cap bubbly flow in a vertical large diameter pipe.     

Evolution of turbulence characteristics from straight to curved pipes

Fully developed, statistically steady turbulent flow in straight and curved pipes at moderate Reynolds numbers is studied in detail using direct numerical simulations (DNS) based on a spectral element discretisation. After the validation of data and setup against existing DNS results, a comparative study of turbulent characteristics at different bulk Reynolds numbers Re_b = 5300 and 11,700, and various curvature parameters κ = 0, 0.01, 0.1 is presented. In particular, complete Reynolds-stress budgets are reported for the first time. Instantaneous visualisations reveal partial relaminarisation along the inner surface of the curved pipe at the highest curvature, whereas developed turbulence is always maintained at the outer side. The mean flow shows asymmetry in the axial velocity profile and distinct Dean vortices as secondary motions. For strong curvature a distinct bulge appears close to the pipe centre, which has previously been observed in laminar and transitional curved pipes at lower Re_b only. On the other hand, mild curvature allows the interesting observation of a friction factor which is lower than in a straight pipe for the same flow rate.All statistical data, including mean profile, fluctuations and the Reynolds-stress budgets, is available for development and validation of turbulence models in curved geometries.     

Influence of sudden contractions on in situ volume fractions for oil–water flows in horizontal pipes

Oil–water two-phase flow experiments were conducted in horizontal ducts made of Plexiglas® to determine the in situ oil fraction (holdup) by means of the closing valves technique, using mineral oil (viscosity: 0.838 Pa s at 20 °C; density: 890 kg m⁻³) and tap water. The ducts present sudden contractions from 50 mm to 40 mm i.d. and from 50 mm to 30 mm i.d., with contraction ratios of 0.64 and 0.36, respectively. About 200–320 tests were performed by varying the flow rates of the phases. Flow patterns were investigated for both the up- and downstream pipe in order to assess whether relevant variations of the flow patterns across the sudden contraction take place. Data were then compared with predictions of a specific correlation for oil–water flow and some correlations for gas–water flow. A drift-flux model was also applied to determine the distribution parameter.     

Multi-scale particle dynamics of low air velocity in a horizontal self-excited gas–solid two-phase pipe flow

The particle fluctuation velocities of a horizontal self-excited gas–solid two-phase pipe flow with soft fins near MPD (minimum pressure drop) air velocity are first measured by high-speed PIV in the acceleration and fully-developed regimes. Then orthogonal wavelet multi-resolution analysis and power spectrum are used to reveal multi-scale characteristics of particle fluctuation velocity. It is observed that the pronounced peaks of the spectra of axial and vertical fluctuation velocities appear in the range of low frequency near the bottom of pipe. These peaks of spectra become larger and their frequencies decrease by using fins. In the range of low frequencies (3–25 Hz), the wavelet components of the fluctuating energy of axial particle velocity make the main contribution accounting for 87% and 93% respectively for non-fin and using fins near the bottom of pipe. In the range of relatively high frequency (50–400 Hz), however, the wavelet components of using fins, accounting for about 49%, become smaller than that of non-fin, accounting for about 72%, in the suspension flow regime near the top of pipe. The skewness factor of axial particle fluctuation velocity indicates that the wavelet components follow the Gaussian probability distribution as the central frequency decreases.     

Thermohydraulics of turbulent flow through rectangular and square ducts with axial corrugation roughness and twisted-tapes with and without oblique teeth

The heat transfer and the pressure drop characteristics of turbulent flow of air (10,000 < Re < 100,000) through rectangular and square ducts with combined internal axial corrugations on all the surfaces of the ducts and with twisted-tape inserts with and without oblique teeth have been studied experimentally. The axial corrugations in combination with twisted-tapes of all types with oblique teeth have been found to perform better than those without oblique teeth in combination with axial corrugations. The heat transfer and the pressure drop measurements have been taken in separate test sections. Heat transfer tests were carried out in electrically heated stainless steel ducts incorporating uniform wall heat flux boundary conditions. Pressure drop tests were carried out in acrylic ducts. The flow friction and thermal characteristics are governed by duct aspect ratio, corrugation angle, corrugation pitch, twist ratio, space ratio, length, tooth horizontal length and tooth angle of the twisted-tape, Reynolds number and Prandtl number. Correlations developed for friction factor and Nusselt number have predicted the experimental data satisfactorily. The performance of the geometry under investigation has been evaluated. It has been found that on the basis of constant pumping power, up to 55% heat duty increase occurs for the combined axial corrugation and regularly spaced twisted-tape elements inserts with oblique teeth case compared to without oblique teeth twisted-tape inserts cases in the measured experimental parameters space. On the constant heat duty basis, the pumping power has been reduced up to 47% for the combined enhancement geometry than the individual enhancement geometries. However, full-length and short-length twisted-tapes with oblique teeth in combination with axial corrugations show only marginal improvements over the twisted-tapes without oblique teeth.     

Experimental study on the effect of drag reducing polymer on flow patterns and drag reduction in a horizontal oil–water flow

In this study, a HMW anionic co-polymer of 40:60 wt/wt NaAMPS/acrylamide was used as a drag reducing polymer (DRP) for oil–water flow in a horizontal 25.4 mm ID acrylic pipe. The effect of polymer concentration in the master solution and after injection in the main water stream, oil and water velocities, and pipe length on drag reduction (DR) was investigated. The injected polymer had a noticeable effect on flow patterns and their transitions. Stratified and dual continuous flows extended to higher superficial oil velocities while annular flow changed to dual continuous flow. The results showed that as low as 2 ppm polymer concentration was sufficient to create a significant drag reduction across the pipe. DR was found to increase with polymer concentration increased and reached maximum plateau value at around 10 ppm. The results showed that the drag reduction effect tends to increase as superficial water velocity increased and eventually reached a plateau at U_sw of around 1.3 m/s. At U_sw > 1.0 m/s, the drag reduction decreased as U_so increased while at lower water velocities, drag reduction is fluctuating with respect to U_so. A maximum DR of about 60% was achieved at U_so = 0.14 m/s while only 45% was obtained at U_so = 0.52 m/s. The effectiveness of the DRP was found to be independent of the polymer concentration in the master solution and to some extent pipe length. The friction factor correlation proposed by Al-Sarkhi et al. (2011) for horizontal flow of oil–water using DRPs was found to underpredict the present experimental pressure gradient data.     

Developing structure of two-phase flow in a large diameter pipe at low liquid flow rate

In order to develop the interfacial area transport equation for the interfacial transfer terms in the two-fluid model, accurate data sets on axial development of local parameters such as void fraction, interfacial area concentration, interfacial gas velocity and Sauter mean diameter are indispensable to verify the modeled source and sink terms in the interfacial area transport equation. From this point of view, local measurements of both group 1 spherical/distorted bubbles and group 2 cap/slug bubbles in vertical upward air–water two-phase flow in a large diameter pipe with 200 mm in inner diameter and 26 m in height were performed at three axial locations of z/D = 41.5, 82.8 and 113 as well as 11 radial locations from r/R = 0–0.95 by using four-sensor probe method. Here, z, r, D and R are the axial distance from the inlet, radial distance from the pipe center, pipe diameter and pipe radius, respectively. The liquid flow rate and the void fraction ranged from 0.0505 m/s to 0.312 m/s and from 1.98% to 32.6%, respectively in the present experiment. The flow condition covered extensive region of bubbly flow, cap turbulent flow as well as their transition. The extensive analysis on the radial profiles of local flow parameters and their axial developments demonstrate the development of interfacial structures along the flow direction due to the bubble coalescence and breakup and the gas expansion. The significant decrease in void faction and interfacial area concentration and the increase in Sauter mean diameter and interfacial velocity were observed when the gradual flow regime transition occurred. Finally, the net change in the interfacial area concentration due to the bubble coalescence and breakup was quantitatively investigated in the present paper to reflect the true transfer mechanisms in observed two-phase flows.     

Numerical evaluation of turbulence models for dense to dilute gas–solid flows in vertical conveyor

A two-fluid model (TFM) of multiphase flows based on the kinetic theory and small frictional limit boundary condition of granular flow was used to study the behavior of dense to dilute gas–solid flows in vertical pneumatic conveyor. An axisymmetric 2-dimensional, vertical pipe with 5.6 m length and 0.01 m internal diameter was chosen as the computation domain, same to that used for experimentation in the literature. The chosen particles are spherical, of diameter 1.91 mm and density 2500 kg/m³. Turbulence interaction between the gas and particle phases was investigated by Simonin's and Ahmadi's models and their numerical results were validated for dilute to dense conveying of particles. Flow regimes transition and pressure drop were predicted. Voidage and velocity profiles of each phase were calculated in radial direction at different lengths of the conveying pipe. It was found that the voidage has a minimum, and gas and solid velocities have maximum values along the center line of the conveying pipe and pressure drop has a minimum value in transition from dense slugging to dilute stable flow regime. Slug length and pressure fluctuation reduction were predicted with increasing gas velocity, too. It is shown that solid phase turbulence plays a significant role in numerical prediction of hydrodynamics of conveyor and the capability of particles turbulence models depends on tuning parameters of slip-wall boundary condition.     

Investigation of two-phase flow pattern,liquid holdup and pressure drop in viscous oil–gas flow

An experimental investigation was carried out on viscous oil–gas flow characteristics in a 69 mm internal diameter pipe. Two-phase flow patterns were determined from holdup time-traces and videos of the flow field in a transparent section of the pipe, in which synthetic commercial oils (32 and 100 cP) and sulfur hexafluoride gas (SF₆) were fed at oil superficial velocities from 0.04 to 3 m/s and gas superficial velocities from 0.0075 to 3 m/s.     

Experiments with a Wire-Mesh Sensor for stratified and dispersed oil-brine pipe flow

Two-phase oil–water flow was studied in a 15 m long horizontal steel pipe, with 8.28 cm internal diameter, using mineral oil (having 830 kg/m³ density and 7.5 mPa s viscosity) and brine (1073 kg/m³ density and of 0.8 mPa s viscosity). Measurements of the holdup and of the cross-sectional phase fraction distribution were obtained for stratified flow and for highly dispersed oil–water flows, applying a capacitive Wire-Mesh Sensor specially designed for that purpose. The applicability of this measurement technique, which uses a circuit for capacitive measurements that is adapted to conductive measurements, where one of the fluids is water with high salinity (mimicking sea water), was assessed. Values for the phase fraction values were derived from the raw data obtained by the Wire-Mesh Sensor using several mixture permittivity models. Two gamma-ray densitometers allowed the accurate measurement of the holdups, which was used to validate the data acquired with the capacitive Wire-Mesh Sensor. The measured time-averaged distribution of the phase fraction over the cross-sectional area was used to investigate the details of the observed two-phase flow patterns, including the interface shape and water height. The experiments were conducted in the multiphase-flow test facility of Shell Global International B.V. in the Netherlands.     

Gas–liquid pressure drop in vertical internally wavy 90° bend

Experiments of air water two-phase flow pressure drop in vertical internally wavy 90° bend have been carried out. The tested bends are flexible and made of stainless steel with inner diameter of 50 mm and various curvature radiuses of 200, 300, 400 and 500 mm. The experiments were performed under the following conditions of two-phase parameters; mass flux from 350 to 750 kg/m² s. Gas quality from 1% to 50% and system pressure from 4 to 7.5 bar. The results demonstrate that the effect of the above-mentioned parameters is very significant at high ranges of mass flow quality. Due to the increasing of two-phase flow resistance, energy dissipations, friction losses and interaction of the two-phases in the vertical internally wavy 90° bend the total pressure drops are perceptible about 2–5 times grater than that in smooth bends. Based on the mass and energy balance as well as the presented experimental results, new empirical correlation has been developed to calculate the two-phase pressure drop and hence the two-phase friction factor of the tested bends. The correlation includes the relevant primary parameter, fit the data well, and is sufficiency accurate for engineering purposes.     

Oil mist transport process in a long pipeline on turbulent flow transition region

Internal gas velocity fluctuations and their effects on the mist diffusion process were examined in a long horizontal pipe to understand oil mist transportation, particularly in the laminar-to-turbulent flow transition region. Three hot-wire anemometers and aerosol concentration monitors were used to deduce these effects as the two-phase mist flow gradually developed in the stream-wise direction. We found significant axial mist diffusion at Reynolds numbers (Re) < 1000 because of passive scalar transport by Poiseuille flow. However, this diffusion was restricted by the non-zero inertia of the mist at a Stokes number, O(10⁻⁵), relying on the Brownian motion of the mist. At Re > 2400, a sharp mist waveform was maintained by a turbulent flow with active radial mixing. New data were obtained within the range of 1000 < Re < 2400, which cannot be explained by interpolation between the above-mentioned two states. The mist concentration displays multiple temporal peaks at Re < 2000 owing to perturbations of localized turbulence as well as radial anisotropy as being conveyed more than 2000-diameters in distance. This behavior is caused by intermittent disturbances induced by the pipe wall roughness, which sharply distorts the wall-aligned laminar mist layer left by parabolic axial stretching of local laminar flow.     

Effect of particle size distribution on pressure drop and concentration profile in pipeline flow of highly concentrated slurry

The experiments were conducted in 54.9 mm diameter horizontal pipe on two sizes of glass beads of which mean diameter and geometric standard deviation are 440 μm & 1.2 and 125 μm & 1.15, respectively, and a mixture of the two sizes in equal fraction by mass. Flow velocity was up to 5 m/s and overall concentration up to 50% by volume for each velocity. Pressure drop and concentration profiles were measured. The profiles were obtained traversing isokinetic sampling probes in the horizontal, 45° inclined and vertical planes including the pipe axis. Slurry samples of the mixture collected in the vertical plane were analyzed for concentration profiles of each particle batch constituting the mixture. It was found that the pressure drop is decreased for the mixture at high concentrations except 5 m/s and a distinct change of concentration profiles was observed for 440 μm particles indicating a sliding bed regime, while the profiles in the horizontal plane remains almost constant irrespective of flow velocity, overall concentration and slurry type.     

Flow patterns and pressure drop of ionic liquid–water two-phase flows in microchannels

The two-phase flow of a hydrophobic ionic liquid and water was studied in capillaries made of three different materials (two types of Teflon, FEP and Tefzel, and glass) with sizes between 200 μm and 270 μm. The ionic liquid was 1-butyl-3-methylimidazolium bis{(trifluoromethyl)sulfonyl}amide, with density and viscosity of 1420 kg m⁻³ and 0.041 kg m⁻¹ s⁻¹, respectively. Flow patterns and pressure drop were measured for two inlet configurations (T- and Y-junction), for total flow rates of 0.065–214.9 cm³ h⁻¹ and ionic liquid volume fractions from 0.05 to 0.8. The continuous phase in the glass capillary depended on the fluid that initially filled the channel. When water was introduced first, it became the continuous phase with the ionic liquid forming plugs or a mixture of plugs and drops within it. In the Teflon microchannels, the order that fluids were introduced did not affect the results and the ionic liquid was always the continuous phase. The main patterns observed were annular, plug, and drop flow. Pressure drop in the Teflon microchannels at a constant ionic liquid flow rate, was found to increase as the ionic liquid volume fraction decreased, and was always higher than the single phase ionic liquid value at the same flow rate as in the two-phase mixture. However, in the glass microchannel during plug flow with water as the continuous phase, pressure drop for a constant ionic liquid flow rate was always lower than the single phase ionic liquid value. A modified plug flow pressure drop model using a correlation for film thickness derived for the current fluids pair showed very good agreement with the experimental data.     

The influence of pipe length on thermal statistics computed from DNS of turbulent heat transfer

We present results from direct numerical simulation of turbulent heat transfer in pipe flow at a bulk flow Reynolds number of 5000 and Prandtl numbers ranging from 0.025 to 2.0 in order to examine the effect of streamwise pipe length (πδ ≡ πD/2 ⩽ L ⩽ 12πδ) on the convergence of thermal turbulence statistics. Various lower and higher order thermal statistics such as mean temperature, rms of fluctuating temperature, turbulent heat fluxes, two-point auto and cross-correlations, skewness and flatness were computed and it is found that the value of L required for convergence of the statistics depends on the Prandtl number: larger Prandtl numbers requires comparatively shorter pipe length for convergence of most of the thermal statistics.     

The influence of pipe length on thermal statistics computed from DNS of turbulent heat transfer

We present results from direct numerical simulation of turbulent heat transfer in pipe flow at a bulk flow Reynolds number of 5000 and Prandtl numbers ranging from 0.025 to 2.0 in order to examine the effect of streamwise pipe length (πδ ≡ πD/2 ? L ? 12πδ) on the convergence of thermal turbulence statistics. Various lower and higher order thermal statistics such as mean temperature, rms of fluctuating temperature, turbulent heat fluxes, two-point auto and cross-correlations, skewness and flatness were computed and it is found that the value of L required for convergence of the statistics depends on the Prandtl number: larger Prandtl numbers requires comparatively shorter pipe length for convergence of most of the thermal statistics.     

Equal quality distribution of gas–liquid two-phase flow by partial separation method

This paper proposes a new method for equal quality distribution of gas–liquid two-phase flow by partial separate-phase distribution with a dual-header distributor. The upper and liquid (lower) headers are interconnected with five vertical downward arms. A gas–liquid two-phase mixture enters the distributor from the upper header where most of the liquid of the mixture is removed through the downward arms into the liquid header. Hence, firstly, the remaining gas-rich fluid can be uniformly distributed into the outlet branches, and then secondly, the liquid collected in the liquid header can be uniformly re-distributed into the individual outlet branches. Because both distribution processes are conducted in the condition of single or near single-phase flow, mal-distribution of the two-phase flow is essentially eliminated, and a satisfactory equal quality distribution of gas–liquid two-phase flow is reached. Experiments were conducted in an air–water two-phase flow test loop. The inner diameter of the inlet pipe was 60 mm, the superficial velocity ranges of gas and liquid were 3–32 m/s and 0.02–0.17 m/s respectively, and the quality ranged from 0.02 to 0.44. The flow pattern in the inlet pipe included stratified flow, wavy stratified, slug flow, and annular flow. The experimental results showed that this new method could significantly improve the distribution performance of the two-phase flow. The maximum quality deviation between each outlet branch and the inlet pipe is less than ±1% under the conditions of stratified, wavy stratified and slug flows in the upper header, and less than ±5% in annular flow.     

Turbulent stresses and particle break-up criteria in particle-laden pipe flows

Three-dimensional particle tracking velocimetry (3D-PTV) is applied to particle-laden pipe flows at Reynolds number 10,300, based on the bulk velocity and the pipe diameter. The effects of flow direction (upward or downward) and mean concentration (in the range 0.5 × 10⁻⁵–3.2 × 10⁻⁵) on the production of turbulence are assessed for inertial particles with a Stokes number equal to 2.3, based on the particle relaxation time and viscous scales. The turbulence production and the Kolmogorov constant, both measured for particle laden flows in upflow and downflow, allowed for the derivation of a break-up criterion as a function of the radial coordinate. This criterion predicts the maximum possible particle size before break-up may occur. It is shown that the maximum particle size is bigger at the pipe centerline than in the near-wall zone by more than a factor of 5. Flow direction affects the particle concentration profile, with wall peaking in downflow and core peaking in upflow. This affects both the residence time and the maximum particle size, the latter by 7%.