A numerical strategy for the direct 3D simulation of the expansion of bubbles into a molten polymer during a foaming process

In the framework of the foam process modelling, this paper presents a numerical strategy for the direct 3D simulation of the expansion of gas bubbles into a molten polymer. This expansion is due to a gas overpressure. The polymer is assumed to be incompressible and to behave as a pseudo‐plastic fluid. Each bubble is governed by a simple ideal gas law. The velocity and the pressure fields, defined in the liquid by a Stokes system, are subsequently extended to each bubble in a way of not perturbing the interface velocity. Hence, a global velocity–pressure‐mixed system is solved over the whole computational domain, thanks to a discretization based on an unstructured first‐order finite element. Since dealing with an Eulerian approach, an interface capturing method is used to follow the bubble evolution. For each bubble, a pure advection equation is solved by using a space–time discontinuous‐Galerkin method, coupled with an r‐adaptation technique. Finally, the numerical strategy is achieved by considering a global mesh expansion motion, which conserves the amount of liquid into the computational domain during the expansion. The expansion of one bubble is firstly considered, and the simulations are compared with an analytical model. The formation of a cellular structure is then investigated by considering the expansion of 64 bubbles in 2D and the expansion of 400 bubbles in 3D. Copyright © 2007 John Wiley & Sons, Ltd.     

Direct simulation of liquid–gas–solid flow with a free surface lattice Boltzmann method

Direct numerical simulation of liquid–gas–solid flows is uncommon due to the considerable computational cost. As the grid spacing is determined by the smallest involved length scale, large grid sizes become necessary – in particular, if the bubble–particle aspect ratio is on the order of 10 or larger. Hence, it arises the question of both feasibility and reasonability. In this paper, we present a fully parallel, scalable method for direct numerical simulation of bubble–particle interaction at a size ratio of 1–2 orders of magnitude that makes simulations feasible on currently available super-computing resources. With the presented approach, simulations of bubbles in suspension columns consisting of more than 100,000 fully resolved particles become possible. Furthermore, we demonstrate the significance of particle-resolved simulations by comparison to previous unresolved solutions. The results indicate that fully resolved direct numerical simulation is indeed necessary to predict the flow structure of bubble–particle interaction problems correctly.     

Shock structure in bubbly liquids: comparison of direct numerical simulations and model equations

Shock wave structure in a bubbly mixture composed of a cluster of gas bubbles in a quiescent liquid with initial void fractions around 10% inside a 3D rectangular domain excited by a sudden increase in the pressure at one boundary is investigated using the front tracking/finite volume method. The effects of bubble/bubble interactions and bubble deformations are, therefore, investigated for further modeling. The liquid is taken to be incompressible while the bubbles are assumed to be compressible. The gas pressure inside the bubbles is taken uniform and is assumed to vary isothermally. Results obtained for the pressure distribution at different locations along the direction of propagation show the characteristics of one-dimensional unsteady shock propagation evolving towards steady-state. The steady-state shock structures obtained by the present direct numerical simulations, which show a transition from A-type to C-type steady-state shock structures, are compared with those obtained by the classical Rayleigh–Plesset equation and by a modified Rayleigh–Plesset equation accounting for bubble/bubble interactions in the mean-field theory.      

Robust numerical analysis of the dynamic bubble formation process in a viscous liquid

The dynamics of bubble formation from a submerged nozzle in a highly viscous liquid with relatively fast inflow gas velocity is studied numerically. The numerical simulations are carried out using a sharp interface coupled level set/volume-of-fluid (CLSVOF) method and the governing equations are solved through a hydrodynamic scheme with formal second-order accuracy. Numerical results agree well with experimental results and it is shown that the sharp interface CLSVOF method enables one to reproduce the bubble formation process for a wide range of inflow gas velocities. From numerical results, one can improve their understanding of the mechanisms regarding the dynamics of bubble formation. For example, it is found that for some sets of parameters that the bubble formation process reaches steady state after several bubbles are released from the nozzle. At steady state, bubbles uniformly rise freely in the viscous liquid. It is observed that the fluid flow around a formed bubble has a significant role in determining the overall dynamic process of bubble formation; e.g. the effect of the fluid flow from the preceding bubble can be seen on newly formed bubbles.     

Lattice gas simulations of two-dimensional liquid foams

Liquid foam is a dense random packing of gas bubbles in a small amount of immiscible liquid containing surfactants. The liquid within the Plateau borders, although small in volume, causes considerable difficulties to investigations of the physical properties of foams, and the situation becomes even more complicated if the flow of the liquid through the foam is considered too. Here we propose a fresh approach to tackling these issues by introducing a discrete two-dimensional hybrid lattice gas model of liquid foams. While lattice gas models have been used to model two-phase liquids in the past, their application to the study of liquid foams is novel and proves promising. We represent bubble surfaces by a finite number of nodes, and model the surrounding liquid as a lattice gas (with a finite number of liquid particles). The gas in the bubbles is treated as an ideal gas at constant temperature. The model is tested by choosing an arbitrarily shaped bubble that evolves into a circular shape in agreement with Laplaces law. The model is then employed to simulate periodic ordered and disordered dry and wet foams. Since our model is specifically designed to handle wet foams up to a critical liquid fraction of 0.16 (void fraction of random packing of disks), we are able to compute the variation in coordination number (average number of neighbours of a bubble) over the whole range of liquid fractions, and we find it to be a linear function of the shear modulus.This paper was presented at the first Annual European Rheology Conference (AERC) held in Guimarães, Portugal, 11–13 September 2003.     

Numerical method for unsteady viscous hydrodynamical problem with free boundaries

A finite element method for the transient incompressible Navier–Stokes equations with the ability to handle multiple free boundaries is presented. Problems of liquid–liquid type are treated by solving two coupled Navier–Stokes problems for two separate phases. The possibility to solve problems of liquid–gas, liquid–liquid–gas or liquid–liquid–liquid type is demonstrated too. Surface tension effects are included at deformable interfaces. The method is of Lagrangian type with mesh redefinition. A predictor-corrector scheme is used to compute the position of the deformable interface with automatic control of its accuracy and smoothness. The method is provided with an automatic choice of the time integration step and an optional spline filtration of the truncation error at the free surface. In order to show the accuracy of the method, tests and comparisons are presented. Numerical examples include motion of bubbles and multiple drops.     

Development and elaboration of numerical method for simulating gas–liquid–solid three-phase flows based on particle method

A numerical method for simulating gas–liquid–solid three-phase flows based on the moving particle semi-implicit (MPS) approach was developed in this study. Computational instability often occurs in multiphase flow simulations if the deformations of the free surfaces between different phases are large, among other reasons. To avoid this instability, this paper proposes an improved coupling procedure between different phases in which the physical quantities of particles in different phases are calculated independently. We performed numerical tests on two illustrative problems: a dam-break problem and a solid-sphere impingement problem. The former problem is a gas–liquid two-phase problem, and the latter is a gas–liquid–solid three-phase problem. The computational results agree reasonably well with the experimental results. Thus, we confirmed that the proposed MPS method reproduces the interaction between different phases without inducing numerical instability.     

Gas cluster growth by solute diffusion in porous media. Experiments and automaton simulation on pore network

The study presented in this paper deals with the liquid–gas phase change by pressure decline of supersaturated CO₂ solutions in 2D porous media. The growth of the gas phase is studied experimentally and numerically as a function of supersaturation, wettability and gravity. Experiments are performed on a transparent etched network (micromodel) and simulations with a specific numerical automaton.In the experiments, the nucleation process, i.e. the occurrence of the gas bubbles, as well as the growth of these bubbles are visualised and analysed by means of a micro video camera and an image processing apparatus. The observations confirm the heterogeneous nature of nucleation and the disordered growth pattern of the gas phase. The analysis of the growth rate of a single gas cluster shows that this phenomenon is different from the compact growth of an isolated single bubble in the bulk. As previously predicted, the bubble growth by mass transfer and volume expansion in porous media is characterised by a pattern of the invasion percolation type under normal laboratory conditions.Numerical simulations of the growth pattern and the growth rate of a single gas cluster are performed with a numerical automaton. Based on a pore network modelling technique and a set of hypotheses derived from the observations, this automaton is first validated by comparing the numerical results with the experiments. Then, the automaton is used to conduct a sensitivity study. In particular, the influences of the Jakob number, pressure decline rate, Bond number, wettability and characteristics of the microstructure are investigated.     

垂直上升管内油—气—水三相弹状流压力降的研究

给出一种垂直上升油－气－水三相弹状流压力降的计算模型。该模型考虑弹状流中Ｔａｙｌｏｒ气泡周围下降液膜的变化历程。通过油－气－水弹状流的实验研究发现，该模型的数值模拟结果与低压工况下的实验值符合得较好。本模型是计算垂直油－气－水三相弹状流中液相的连续相为水相时的压力降的有效方法。     

Numerical solution of a two-dimensional fluidized bed model

The numerical solution of a model describing a two-dimensional fluidized bed is considered. The model takes the form of a hyperbolic system of conservation laws with source term, coupled with an elliptic equation for determining a streamfunction. Operator splitting is used to produce homogeneous one-dimensional hyperbolic systems and ordinary differential equations involving the source term. The one-dimensional hyperbolic problems are solved using Roe's method with the addition of an entropy fix. The numerical procedure is second-order in time and first-order in space. Second-order-accuracy in space is obtained using flux limiting techniques. Numerical experiments which show the development of bubbles in the bed are presented. The familiar kidney-shaped bubble, observed experimentally, is found when using the method which is second-order in space. On the same mesh, the first-order method produces bubbles which are no longer kidney-shaped. © 1998 John Wiley & Sons, Ltd.     

Bubble formation in co-fed gas–liquid flows in a rotor-stator spinning disc reactor

The gas–liquid flow in a rotor-stator spinning disc reactor, with co-feeding of gas and liquid, is studied for high gas volumetric throughflow rates and high gas/liquid volumetric flow ratios. High speed imaging and spectral analysis of pressure drop signals are employed to analyse the flow. Two mechanisms of bubble formation are observed, one due to gas overpressure leading to large irregular bubbles, and one due to liquid turbulent vortices leading to small, well-defined bubbles. The two mechanisms lead to three distinct gas dispersion regimes, distinguished by their characteristic oscillations in pressure drop. At low rotational Reynolds numbers (Re_ω < 0.4 · 10⁶), in the gas spillover regime, the gas is dispersed as large bubbles only. Above this critical Re_ω, small bubbles are sheared off as well, thus forming a heterogeneous dispersion. At sufficiently high Re_ω, depending on the gas flow rate, the gas is homogeneously dispersed as small bubbles. The maximum gas flow that can be dispersed as small bubbles is linearly proportional to the local energy dissipation rate. The understanding of the bubble formation mechanisms and pressure signature allows prediction and detection of the prevailing hydrodynamic regime in scaled up spinning disc reactors and for different reaction fluids.     

Simulations of single bubbles rising through viscous liquids using Smoothed Particle Hydrodynamics

The shapes and dynamics of single bubbles rising through viscous fluids are studied using the SPH (Smoothed Particle Hydrodynamics) approach. This fully Lagrangian, particle-based method is applied to compute the complete two-phase flow, both inside the bubbles as well as around them. For that purpose, a multi-phase formulation of the SPH method that can address large density differences is retained, while surface tension effects are explicitly accounted for through a CSF (Continuum Surface Force) model. Numerical simulations have been performed for different regimes (corresponding to different relative importance of surface tension, viscosity and buoyancy effects) and the predicted topological changes as well as the terminal velocity and drag coefficients of bubbles are validated. The numerical outcomes are assessed not only with respect to reference experimental data but also with respect to other numerical methods, namely the Front-Tracking and the Lattice Boltzmann Methods. It is believed that this study corresponds to a new application of SPH approaches for two-phase flow simulations and results reveal the interest of this method to capture fine details of gas–liquid systems with deformable and rapidly changing interfaces.     

Hydrodynamic and mass transfer characteristics of slug flow in a vertical pipe with and without dispersed small bubbles

In this work, we present a numerical study to investigate the hydrodynamic characteristics of slug flow and the mechanism of slug flow induced CO₂ corrosion with and without dispersed small bubbles. The simulations are performed using the coupled model put forward by the authors in previous paper, which can deal with the multiphase flow with the gas–liquid interfaces of different length scales. A quasi slug flow, where two hypotheses are imposed, is built to approximate real slug flow. In the region ahead of the Taylor bubble and the liquid film region, the presence of dispersed small bubbles has less impacts on velocity field, because there are no non-regular intensive disturbance forces or centrifugal forces breaking the balance of the liquid and the dispersed small bubbles. In the liquid slug region, the strong centrifugal forces generated by the recirculation below the Taylor bubble lead to the effect of heterogeneity, which makes the profile of the radial liquid velocity component sharper with higher volume fraction of dispersed small bubbles. The volume fraction has a maximum value in the range of r/R = 0.5–0.6. Meanwhile, it is usually higher than 0.35, which means that larger dispersed bubbles can be formed by coalescences in this region. These calculated results are in good agreement with experimental results. The wall shear stress and the mass transfer coefficient with dispersed small bubbles are higher than those without dispersed small bubbles due to enhanced fluctuations. For short Taylor bubble length, the average mass transfer coefficient is increased when the gas or liquid superficial velocity is increased. However, there may be an inflection point at low mixture superficial velocities. For the slug with dispersed small bubbles, the product scales still cannot be damaged directly despite higher wall shear stress. In fact, the alternate wall shear stress and the pressure fluctuations perpendicular to the pipe wall with high frequency are the main cause for breaking the product scales.     

Numerical simulation of free surface flows with the level set method using an extremely high-order accuracy WENO advection scheme

Three-dimensional dynamic gas–liquid flow simulations that accurately track the phase interface are numerically challenging. This article presents a numerical study of the performance of the level-set phase–interface tracking method when combined with extremely high order (7th to 11th) weighted essentially non-oscillatory (WENO) advection schemes for gas–liquid free surface flows. Comparisons between simulation results and prior benchmark results suggest that such a combination of methods can be satisfactorily applied to the level-set and Navier-Stokes equations for free surface flow simulations when volume conservation is enforced at every time step, and minor numerical oscillations are suppressed through use of an artificial viscosity term. In particular, simulations of solid body rotation, the unsteady flow following an ideal dam break, tank sloshing, and the rise of a single bubble all agree with analytical or experimental results to within ± 3.12% when the level-set method is combined with an 11th order WENO scheme. Furthermore, use of an 11th order WENO advection scheme actually has a computational cost advantage because, for the same accuracy, it can be used on a coarser grid when compared with a more-common second-order advection scheme; computational savings of up to 87% are possible.     

Study on the influences of interaction behaviors between multiple combustion-gas jets on expansion characteristics of Taylor cavities

The purpose of this study is to investigate means of controlling the interior ballistic stability of a bulk-loaded propellant gun(BLPG).Experiments on the interaction of twin combustion gas jets and liquid medium in a cylindrical stepped-wall combustion chamber are conducted in detail to obtain time series processes of jet expansion,and a numerical simulation under the same working conditions is also conducted to verify the reliability of the numerical method by comparing numerical results and experimental results.From this,numerical simulations on mutual interference and expansion characteristics of multiple combustion gas jets(four,six,and eight jets) in liquid medium are carried out,and the distribution characteristic of pressure,velocity,temperature,and evolutionary processes of Taylor cavities and streamlines of jet flow Held are obtained in detail.The results of numerical simulations show that when different numbers of combustion gas jets expand in liquid medium,there are two different types of vortices in the jet flow field,including corner vortices of liquid phase near the step and backflow vortices of gas phase within Taylor cavities.Because of these two types of vortices,the radial expansion characteristic of the jets is increased,while changing numbers of combustion gas jets can restrain Kelvin-Helmholtz instability to a certain degree in jet expansion processes,which can at last realize the goal of controlling the interior ballistic stability of a BLPG.The optimum method for both suppressing Kelvin-Helmholtz instability and promoting radial expansion of Taylor cavities can be determined by analyzing the change of characteristic parameters in a jet flow field.     

Planar dynamics of inclined curved flexible riser carrying slug liquid–gas flows

Flexible risers transporting hydrocarbon liquid–gas flows may be subject to internal dynamic fluctuations of multiphase densities, velocities and pressure changes. Previous studies have mostly focused on single-phase flows in oscillating pipes or multiphase flows in static pipes whereas understanding of multiphase flow effects on oscillating pipes with variable curvatures is still lacking. The present study aims to numerically investigate fundamental planar dynamics of a long flexible catenary riser carrying slug liquid–gas flows and to analyse the mechanical effects of slug flow characteristics including the slug unit length, translational velocity and fluctuation frequencies leading to resonances. A two-dimensional continuum model, describing the coupled horizontal and vertical motions of an inclined flexible/extensible curved riser subject to the space–time varying fluid weights, flow centrifugal momenta and Coriolis effects, is presented. Steady slug flows are considered and modelled by accounting for the mass–momentum balances of liquid–gas phases within an idealized slug unit cell comprising the slug liquid (containing small gas bubbles) and elongated gas bubble (interfacing with the liquid film) parts. A nonlinear hydrodynamic film profile is described, depending on the pipe diameter, inclination, liquid–gas phase properties, superficial velocities and empirical correlations. These enable the approximation of phase fractions, local velocities and pressure variations which are employed as the time-varying, distributed parameters leading to the slug flow-induced vibration (SIV) of catenary riser. Several key SIV features are numerically investigated, highlighting the slug flow-induced transient drifts due to the travelling masses, amplified mean displacements due to the combined slug weights and flow momenta, extensibility or tension changes due to a reconfiguration of pipe equilibrium, oscillation amplitudes and resonant frequencies. Single- and multi-modal patterns of riser dynamic profiles are determined, enabling the evaluation of associated bending/axial stresses. Parametric studies reveal the individual effect of the slug unit length and the translational velocity on SIV response regardless of the slug characteristic frequency being a function of these two parameters. This key observation is practically useful for the identification of critical maximum response.     

Wave dispersion of a gas in a liquid

A novel method of dispersing a gas in a liquid by pressure pulses generated by waves propagating from a hydrodynamic oscillation generator is proposed. Devices that realize this method, wave dispersers, are created and investigated experimentally. The amplitude-frequency characteristics of the wave processes in the dispersers and the size distribution density functions of the gas bubbles are obtained. It is shown that there are optimal pressure values at the disperser inlet at which a minimum bubble size is achieved. The average diameter of the gas bubbles produced by water wave dispersers in the optimal operation regimes varied on the range from 0.3 to 0.6 mm, depending on the gas flow-rate.     

Simulating compressible gas bubbles with a smooth volume tracking 1-Fluid method

The physical relevance of an improved front-capturing 1-Fluid method is investigated considering the behavior of either incompressible or compressible gas bubbles driven by buoyancy in a two-dimensional framework. Through the coupling of a VOF–PLIC technique and a smoothing function of adjustable thickness, the Smooth Volume of Fluid technique SVOF is intended to capture accurately strong interface distorsion with large density and viscosity contrasts between phases, combined with the front-capturing automatic treatment of interface rupture or reconnection. The fundamental idea lies in using the regular VOF–PLIC technique, while applying a smoothing procedure affecting both physical characteristics averaging and surface tension modeling. A thorough assessment procedure is achieved comparing the present method, front-tracking simulations and experiments from Bhaga and Weber that characterize the shape and velocity of single gas bubbles rising into liquid columns. A series of 200 SVOF simulations was necessary to provide a unique set of smoothing and averaging parameters available for any kind of bubble that is stable in an axisymmetric framework. The front-capturing strategy greatly eases the extension to gas injection applications as there is no micro-management required during interface coalescence or break-up, and no volume correction either. Finally the robustness of the 1-Fluid SVOF method is demonstrated in two-dimensions, in the case of compressible or incompressible gas injection into cold metal alloys where the density ratio between phases is greater than 3500.     

Numerical simulation of a single bubble by compressible two‐phase fluids

The present work deals with the numerical investigation of a collapsing bubble in a liquid–gas fluid, which is modeled as a single compressible medium. The medium is characterized by the stiffened gas law using different material parameters for the two phases. For the discretization of the stiffened gas model, the approach of Saurel and Abgrall is employed where the flow equations, here the Euler equations, for the conserved quantities are approximated by a finite volume scheme, and an upwind discretization is used for the non‐conservative transport equations of the pressure law coefficients. The original first‐order discretization is extended to higher order applying second‐order ENO reconstruction to the primitive variables. The derivation of the non‐conservative upwind discretization for the phase indicator, here the gas fraction, is presented for arbitrary unstructured grids. The efficiency of the numerical scheme is significantly improved by employing local grid adaptation. For this purpose, multiscale‐based grid adaptation is used in combination with a multilevel time stepping strategy to avoid small time steps for coarse cells. The resulting numerical scheme is then applied to the numerical investigation of the 2‐D axisymmetric collapse of a gas bubble in a free flow field and near to a rigid wall. The numerical investigation predicts physical features such as bubble collapse, bubble splitting and the formation of a liquid jet that can be observed in experiments with laser‐induced cavitation bubbles. Opposite to the experiments, the computations reveal insight to the state inside the bubble clearly indicating that these features are caused by the acceleration of the gas due to shock wave focusing and reflection as well as wave interaction processes. While incompressible models have been used to provide useful predictions on the change of the bubble shape of a collapsing bubble near a solid boundary, we wish to study the effects of shock wave emissions into the ambient liquid on the bubble collapse, a phenomenon that may not be captured using an incompressible fluid model. Copyright © 2009 John Wiley & Sons, Ltd.