Interpretation of atomization rates of the liquid film in gas-liquid annular flow

For vertical gas-liquid annular flow the fraction of the liquid in the gas is controlled by the rate of atomization of the liquid film flowing along the wall and the rate of deposition of droplets entrained in the gas. Measurements of the rate of atomization are interpreted by a Kelvin-Helmholtz mechanism. Small wavelets on the liquid film are visualized to be entrained when wave-induced variations in the gas pressure cannot be counterbalanced by surface tension effects.     

Liquid fuel droplets entrained in the transient unidimensional gas flow in a pipe

Studies of fuel droplets entrained in air flow are deemed to be important in the understanding of fuel transportation and evaporation in the induction system of spark-ignition engines. So far the studies by other authors were restricted to steady air flow, however, the air flow in the induction system is pulsative unsteady air flow. This paper presents a theoretical model and the computational solution for the fuel liquid droplets entrained in the transient unidimensional air flow in a pipe.     

Entrainment for horizontal annular gas-liquid flow

Measurements of entrainment are presented for air and water flowing in horizontal 2.54 and 5.08 cm pipelines. After the initiation of atomization, entrainment increases with the third power of the gas velocity. At very high gas velocities a fully entrained oendition in reached for which further increases in the gas velocity do not cause a decrease in the flow rate of the wall film. Gas density bas a small effect provided comparisons are made at the same gas velocity rather than at the same mass flowrate. The results are interpreted by asauming that the rate of deposition of droplets on the wall film varies linearly with the concentration of droplets and that the rate of atomization of the wall film varies linearly with its flow rate.     

Transport of salts and micron-sized particles entrained from a boiling water pool

The entrainment of soluble (KI, CsI) and non-soluble (Al₂O₃) substances through droplets, which are produced by disintegrating steam bubbles at the surface of a boiling water pool, is determined in a pilot-scale facility. Integral measurements are conducted at steady-state conditions in an atmosphere of either pure steam or an air–steam mixture. The ratio of the entrained liquid mass flow and the gas mass flow through the pool, the entrainment factor, is determined for air–steam ratios between 0 and 0.47 kg/kg in the gas atmosphere and at constant total pressures between 2 and 6 bar. The influence of the vertical temperature profile in the gas atmosphere on the convective velocity field is demonstrated by phase Doppler anemometry and particle image velocimetry measurements at a location 2.1 m above the pool surface. The influences of nucleation and natural convection are demonstrated during slow de-pressurization of the facility at rates below 420 Pa/s.     

Study of the impacts of droplets deposited from the gas core onto a gas-sheared liquid film

The results of an experimental study on droplet impactions in the flow of a gas-sheared liquid film are presented. In contrast to most similar studies, the impacting droplets were entrained from film surface by the gas stream. The measurements provide film thickness data, resolved in both longitudinal and transverse coordinates and in time together with the images of droplets above the interface and images of gas bubbles entrapped by liquid film. The parameters of impacting droplets were measured together with the local liquid film thickness. Two main scenarios of droplet-film interaction, based on type of film perturbation, are identified; the parameter identifying which scenario occurs is identified as the angle of impingement. At large angles an asymmetric crater appears on film surface; at shallow angles a long, narrow furrow appears. The most significant difference between the two scenarios is related to possible impact outcome: craters may lead to creation secondary droplets, whereas furrows are accompanied by entrapment of gas bubbles into the liquid film. In addition, occurrence of partial survival of impacting droplet is reported.     

Characteristics of flow and liquid distribution in a gas–liquid vortex separator with multi spiral arms

Fischer–Tropsch (F–T) synthesis is an important route to achieve the clean fuel production. The performance of gas–liquid separation equipment involving in the progressive condensation and separation of light and heavy hydrocarbons in the oil-gas products has become a bottleneck restricting the smooth operation of the F–T process. In order to remove the bottleneck, a gas–liquid vortex separator with simple structure, low pressure drop and big separation capacity was designed to achieve the efficient separation between gas and droplets for a long period. The RSM (Reynolds Stress Model) and DPM (Discrete Phase Method) are employed to simulate the flow characteristics and liquid distribution in the separator. The results show that the separation efficiency is influenced by the flow field and liquid phase concentration in the annular zone. The transverse vortex at the top of spiral arm entrains the droplets with small diameter into the upper annular zone. The entrained droplets rotate upward at an angle of about 37.4°. The screw pitch between neighbor liquid threads is about 0.3 m. There is a top liquid ring in the top of annular zone, where the higher is the liquid phase concentration, the lower is the separation efficiency. It is found that by changing the operating condition and the annular zone height the vortex can be strengthened but not enlarged by the inlet velocity. The screw pitch is not affected by both inlet velocity and annular zone height. The liquid phase concentration in the top liquid ring decreases with both the increases of inlet velocity and annular zone height. The total pressure drop is almost not affected by the annular zone height but is obviously affected by the inlet velocity. When the height of annular zone is more than 940 mm, the separation efficiency is not changed. Therefore, the annular zone height of 940 mm is thought to be the most economical design.     

Aerodynamic behavior of liquid sprays

An analysis is presented for the effect of entrained gas flows on drop trajectories and spray distributions from liquid atomizing nozzles. In particular, the effect of the pressure (or density) of the environment into which the liquid is sprayed is examined. The contraction of atomized sprays at elevated pressure which has been observed by various workers is explained, and the analysis is substantially confirmed by their data and by new data presented here. Both the data and the theory show that the amount of spray contraction increases with increasing ambient pressure and nozzle pressure drop, and decreases with increasing nozzle diameter and drop size. The theory examines the entrained gas flow around and into a spray and its subsequent effect on the trajectories of the liquid droplets comprising the spray.     

Modeling transient churn-annular flows in a long vertical tube

This work investigates the transient behavior of high gas fraction gas-liquid flows in vertical pipes (annular and churn flows). Hyperbolic balance equations for mass, momentum and entropy are written for the gas and liquid, which is split between a continuous film and droplets entrained in the gas core. Closure relationships to calculate the wall and interfacial friction and the rates of droplet entrainment and deposition were obtained from the literature. A finite-difference solution algorithm based on a coefficient matrix splitting method was implemented to deal with sharp variations in the spatial and temporal domains, such as pressure and phase holdup waves. The model results were compared with steady-state experimental data from eight different sources, totaling more than 1500 data points for pressure gradient, liquid film flow rate and void/core fraction. The absolute average deviation between the model and the data was 17% for the pressure gradient and 5.8% for the void fraction. A comparison of the model results with fully transient air-water data generated in a 49-mm ID, 42-m long vertical pipe is also presented. The experimental results consist of two outlet pressure-induced and two inlet mass flow rate-induced transient tests. Two main transient parameters are compared, namely the local void fraction and the pressure difference between selected points along the test section and the outlet (taken as a reference). The comparisons between the experiments and the numerical model indicate that the model was capable of describing the transient annular to churn flow transition with absolute average deviations of 14.5% and 7.9% for the pressure difference and void fraction, respectively.     

Prediction of amount of entrained droplets in vertical annular two-phase flow

Prediction of amount of entrained droplets or entrainment fraction in annular two-phase flow is essential for the estimation of dryout condition and analysis of post dryout heat transfer in light water nuclear reactors and steam boilers. In this study, air–water and organic fluid (Freon-113) annular flow entrainment experiments have been carried out in 9.4 and 10.2 mm diameter test sections, respectively. Both the experiments covered three distinct pressure conditions and wide range of liquid and gas flow conditions. The organic fluid experiments simulated high pressure steam–water annular flow conditions. In each experiment, measurements of entrainment fraction, droplet entrainment rate and droplet deposition rate have been performed by using the liquid film extraction method. A simple, explicit and non-dimensional correlation developed by Sawant [Sawant, P.H., Ishii, M., Mori, M., 2008. Droplet entrainment correlation in vertical upward co-current annular two-phase flow. Nucl. Eng. Des. 238 (6), 1342–1352] for the prediction of entrainment fraction is further improved in this study in order to account for the existence of critical gas and liquid flow rates below which no entrainment is possible.Additionally, a new correlation is proposed for the estimation of minimum liquid film flow rate at the maximum entrainment fraction condition. The improved correlation successfully predicted the newly collected air–water and Freon-113 entrainment fraction data. Furthermore, the correlations satisfactorily compared with the air–water, helium–water and air–genklene experimental data measured by Willetts [Willetts, I.P., 1987. Non-aqueous annular two-phase flow. D.Phil. Thesis, University of Oxford]. However, comparison of the correlations with the steam–water data available in literature showed significant discrepancies. It is proposed that these discrepancies might have been caused due to the inadequacy of the liquid film extraction method used to measure the entrainment fraction or due to the change in mechanism of entrainment under high liquid flow conditions.     

Simulation of the primary breakup of a high-viscosity liquid jet by a coaxial annular gas flow

The conversion of low-grade fossil and biogenic energy resources (petcoke, biomass) to a synthesis gas in a high pressure entrained flow gasification process opens a wide spectrum for high efficient energy conversion processes. The synthesis gas can be used for production of methane (SNG), liquid fuels (BtL, CtL) or as fuel for operation of a gas turbine in a combined cycle power plant (IGCC). The production of a tar free high quality syngas is a challenging objective especially due to the fact that typical liquid or suspension fuels for entrained flow gasifiers feature viscosities up to 1000 mPas. Fuel droplet conversion at typical entrained flow gasification conditions is characterized by heat up, evaporation and subsequent degradation of the vapour phase. To guarantee a high fuel conversion rate in the gasifier an efficient atomization of the fuel is required. Mainly twin-fluid burner nozzles are used for atomization of those typically high viscous fuels. The present study is focused on the assessment of the accuracy of CFD computations for the primary breakup of high-viscosity liquids using an external mixing twin fluid nozzle. In a first step experiments were performed with a Newtonian glycerol-water-mixture featuring a liquid viscosity of 400 mPas. Jet breakup was investigated using a high speed camera as well as PIV and LDA-System for a detailed investigation of the flow field. In a second step the experimental results serve as reference data to assess the accuracy of CFD computations. Compressible large eddy simulations (LES) were performed to capture the morphology of the primary breakup as well as the important flow field characteristics. A Volume of Fluid (VOF) approach was used to track the unsteady evolution and breakup of the liquid jet. Comparison of experimental and numerical results showed good agreement with respect to breakup frequency, velocity fields and morphology.     

Numerical simulation of annular two-phase flow considering the four involved mass transfers

In the present study, a numerical model is developed for simulation of annular two-phase flow considering bubbly flow regime in the liquid film along with the four involved mechanisms of mass transfer those are evaporation, entrainment, deposition and condensation. In the numerical approach, liquid film accompanied by fine nucleated bubbles are simulated with innovative model named suction model, the whole domain containing liquid film and the vapor core is simulated by volume of fluid model. While the vapor and the entrained droplets are treated as homogeneous flow. The interface between the liquid and the vapor is traced by level set formulation. The model is then validated by experimental models of Lee & Lee and Stevanovic et al. and shows a good precision such that it predicts the experimental results of Stevanivic et al. Better than their own numerical model. This issue is due to the least possible simplifying assumptions along with considering the effect of boiling in liquid film and all mechanisms of mass transfer in the fluid flow.     

Characterization of plunging liquid jets: A combined experimental and numerical investigation

This paper presents a combined experimental and numerical study of the flow characteristics of round vertical liquid jets plunging into a cylindrical liquid bath. The main objective of the experimental work consists in determining the plunging jet flow patterns, entrained air bubble sizes and the influence of the jet velocity and variations of jet falling lengths on the jet penetration depth. The instability of the jet influenced by the jet velocity and falling length is also probed. On the numerical side, two different approaches were used, namely the mixture model approach and interface-tracking approach using the level-set technique with the standard two-equation turbulence model. The numerical results are contrasted with the experimental data. Good agreements were found between experiments and the two modelling approaches on the jet penetration depth and entraining flow characteristics, with interface tracking rendering better predictions. However, visible differences are observed as to the jet instability, free surface deformation and subsequent air bubble entrainment, where interface tracking is seen to be more accurate. The CFD results support the notion that the jet with the higher flow rate thus more susceptible to surface instabilities, entrains more bubbles, reflecting in turn a smaller penetration depth as a result of momentum diffusion due to bubble concentration and generated fluctuations. The liquid average velocity field and air concentration under tank water surface were compared to existing semi-analytical correlations. Noticeable differences were revealed as to the maximum velocity at the jet centreline and associated bubble concentration. The mixture model predicts a higher velocity than the level-set and the theory at the early stage of jet penetration, due to a higher concentration of air that cannot rise to the surface and remain trapped around the jet head. The location of the maximum air content and the peak value of air holdup are also predicted differently.     

Electro-spray of high viscous liquids for producing mono-sized spherical alginate beads

Alginate beads, often used for controlled release of enzymes and drugs, are usually produced by spraying sodium alginate liquid into a gelling agent using mechanical vibration nozzle or air jet. In this work an alternative method of electro-spray was employed to form droplets with desired size from a highly viscous sodium alginate solution using constant DC voltage. The droplets were then cured in a calcium chloride solution. The main objective was to produce mono-sized beads from such a highly viscous and non-Newtonian liquid (1000-5000 mPa s). The effects of nozzle diameter, flow rate and concentration of liquid on the size of the beads were investigated. Among the parameters studied, voltage had a pronounced effect on the size of beads as compared to flow rate zzle diameter and concentration of alginate liquid. The size of beads was reduced to a minimum value with increasing the voltage in the range of 0-10 kV. At the early stages of voltage increase (I.e. Up to about 4 kV), the rate of size reduction was relatively low, while the dripping mode dominated. However, in the middle part of the range of applied voltage, where the rate of size reduction was high (I.e. About 4-7 kV), an unstable transition occurred between dripping and jetting. At the end part of the range (I.e. 7-10 kV) jet mode of spray was observed. Increasing the height of fall of the droplets was found to improve the sphericity of the beads, because of the increased time of flight for the droplets. This was especially identifiable at higher concentrations of the alginate liquid (I.e. 3 w/v%)     

A two-equation turbulence model for jet flows laden with vaporizing droplets

A two-equation turbulence model for steady incompressible two-phase flows including phase change has been recently developed by Mostafa & Elghobashi (1984). This model is tested for the flow of a turbulent axisymmetric gaseous jet laden with evaporating liquid droplets. To avoid the problem of density fluctuations of the carrier phase at this stage, only isothermal flow is considered and vaporization is assumed to be due to the vapor concentration gradient. The continuous size distribution of the droplets is approximated by finite size groups. Each group is considered as a continuous phase interpenetrating and interacting with the carrier phase. Two test cases have been predicted by the model. The first is for a Freon-11 spray issuing from a round nozzle, where experimental data are available at distances equal to or greater than 170 nozzle diameters. Good agreement between the data and the predictions was achieved. The second is for a methanol spray where no experiments are available yet and the predictions consider the flow region close to the nozzle ($\text{z/D < 40}$). The results of the methanol spray include distributions of the mean velocity, volume fractions of the different phases, concentration of the evaporated material in the carrier phase, turbulence intensity and shear stress of the carrier phase, droplet diameter distribution, and the jet spreading rate. In this case the results are analyzed based on a qualitative comparison with the corresponding single phase jet flow.     

Flow regime transitions due to cavitation in the flow through an orifice

This paper presents both experimental and theoretical aspects of the flow regime transitions caused by cavitation when water is passing through an orifice. Cavitation inception marks the transition from single-phase to two-phase bubbly flow; choked cavitation marks the transition from two-phase bubbly flow to two-phase annular jet flow.

It has been found that the inception of cavitation does not necessarily require that the minimum static pressure at the vena contracta downstream of the orifice, be equal to the vapour pressure liquid. In fact, it is well above the vapour pressure at the point of inception. The cavitation number [σ = (P₃ − P_v)/(0.5 pV²); here P₃ is the downstream pressure, P_v is the vapour pressure of the liquid, ρ is the density of the liquid and V is the average liquid velocity at the orifice] at inception is independent of the liquid velocity but strongly dependent on the size of the geometry. Choked cavitation occurs when this minimum pressure approaches the vapour pressure. The cavitation number at the choked condition is a function of the ratio of the orifice diameter (d) to the pipe diameter (D) only. When super cavitation occurs, the dimensionless jet length [L/(D - d); where L is the dimensional length of the jet] can be correlated by using the cavitation number. The vaporization rate of the surface of the liquid jet in super cavitation has been evaluated based on the experiments.

Experiments have also been conducted in which air was deliberately introduced at the vena contracta to simulate the flow regime transition at choked cavitation. Correlations have been obtained to calculate the critical air flow rate required to cause the flow regime transition. By drawing an analogy with choked cavitation, where the air flow rate required to cause the transition is zero, the vapour and released gas flow rate can be predicted.     

Abnormal rotation of a deformed liquid crystal droplet immersed in an isotropic fluid after transient flow

The morphology evolution of liquid crystal droplets immersed in an isotropic fluid in flow field is found to be different from flexible polymer droplets. In this paper, we investigated the retraction of a liquid crystal droplet after transient flow. It is found that the liquid crystal droplet will rotate during the shape recovery, which has never been observed for an isotropic droplet. The factors that influence the rotational angle of a single liquid crystal droplet during retraction progress were studied, including the temperature, the dimension of the droplets, the time of shear flow, the shear rate, the flow type, and the properties of liquid crystal molecules. The rotation of liquid crystal droplet during shape recovery is ascribed to both the bulk elasticity of liquid crystal droplets and the anisotropic properties of the interface between liquid crystal and isotropic fluid.     

An Eulerian–Lagrangian hybrid model for the coarse-grid simulation of turbulent liquid jet breakup

In this paper we present a numerical model for the coarse-grid simulation of turbulent liquid jet breakup using an Eulerian–Lagrangian coupling. To picture the unresolved droplet formation near the liquid jet interface in the case of coarse grids we considered a theoretical model to describe the unresolved flow instabilities leading to turbulent breakup. These entrained droplets are then represented by an Eulerian–Lagrangian hybrid concept. On the one hand, we used a volume of fluid method (VOF) to characterize the global spreading and the initiation of droplet formation; one the other hand, Lagrangian droplets are released at the liquid–gas interface according to the theoretical model balancing consolidating and disruptive energies. Here, a numerical coupling was required between Eulerian liquid core and Lagrangian droplets using mass and momentum source terms. The presented methodology was tested for different liquid jets in Rayleigh, wind-induced and atomization regimes and validated against literature data. This comparison reveals fairly good qualitative agreement in the cases of jet spreading, jet instability and jet breakup as well as relatively accurate size distribution and Sauter mean diameter (SMD) of the droplets. Furthermore, the model was able to capture the regime transitions from Rayleigh instability to atomization appropriately. Finally, the presented sub-grid model predicts the effect of the gas-phase pressure on the droplet sizes very well.     

Evaporation of bi-component droplets in a heated, highly turbulent flow

This work aims to understand the phenomena that occur in a combustion chamber where multi-component fuel droplets are injected. Many evaporation models exist but the influence of turbulence on spray vaporization is not yet well understood. This study gives a useful database to improve these models. The objective of the work is to measure the dispersion and the evaporation of bi-component (octane/3-pentanone) droplets and the resulting vapor mixing in a well-known, heated, highly turbulent channel flow. The carrier flow shows high turbulence levels, flat profiles for the mean velocity and the velocity fluctuations. The injected droplets have a large variety of behaviors due to the large polydispersion and to the turbulence. The evolution of 3-pentanone liquid concentration, mass flux, and droplet clusters are described. Mean concentration, fluctuations of concentration, and mixing of the vapor phase are characterized.     

Transient flow redistribution in annular two-phase flow

A model is described for the prediction of transient flow redistribution in vertical annular two-phase flow. The model is based on an analysis of the local parameters controlling the flow and takes account of the diffusive motion of entrained droplets and the delay time for change in the wave structure on the film. Comparisons are made with experimental results on inlet effects and it is shown that the wall injection experimental results can be described by the model. The jet injection results are not fitted by the model and it is shown that some additional deposition mechanism must be present.     

Atomized non-equilibrium two-phase flow in mesochannels: Momentum analysis

Two-phase pressure drop measurements are very difficult to make while the fluid is in non-equilibrium condition, i.e. while phase change is taking place. This is further complicated when an atomized liquid is introduced in the system at much higher velocity than other components such as liquid layer, vapor core, and entrained droplets. The purpose of this paper is to develop a model to predict the two-phase pressure characteristics in a mesochannel under various heat flux and liquid atomization conditions. This model includes the momentum effects of liquid droplets from entrainment and atomization. To verify the model, an in-house experimental setup consisting of a series of converging mesochannels, an atomization facility and a heat source was developed. The two-phase pressure of boiling PF5050 was measured along the wall of a mesochannel. The one-dimensional model shows good agreement with the experimental data. The effects of channel wall angle, droplet velocity and spray mass fraction on two-phase pressure characteristics are predicted. Numerical results show that an optimal spray cooling unit can be designed by optimizing channel wall angle and droplet velocity.