Film thickness measurements in liquid–liquid slug flow regimes

At present there is significant interest in the development of small scale medical diagnostic equipment. These devices offer faster processing times and require smaller sample volumes than equivalent macro scale systems. Although significant attention has been focused upon their outputs, little attention has been devoted to the detailed fluid mechanics that govern the flow mechanisms within these devices. Conventionally, the samples in these small scale devices are segmented into distinct discrete droplets or slugs which are suspended in an organic carrier phase. Separating these slugs from the channel wall is a very thin film of the organic carrier phase.The magnitude of this film is the focus of the present study and the effects of sample slug length and carrier phase fluidic properties on the film are examined over a range of Capillary numbers. A non-intrusive optical technique was used to capture images of the flow from which the magnitude of the film was determined.The experimental results show that the film is not constant along the length of the slug; however above a threshold value for slug length, a region of constant film thickness exists. When compared with existing correlations in the literature, the experimental data showed reasonable agreement with the Bretherton model when the Capillary number was calculated based on the mean two phase flow velocity. However, significant differences were observed when the Capillary number was redefined to account for the mean velocity at the liquid interface, i.e., the mean slug velocity.Analysis of the experimental data revealed that it fell into two distinct flow regimes; a visco-capillary regime and a visco-inertial regime. A modified Taylor expression is presented to estimate the magnitude of the film for flows in the visco-capillary regime while a new model is put forward, based on Capillary and Weber numbers, for flows in the visco-inertial regime. Overall, this study provides some novel insights into parameters, such as aqueous slug length and carrier phase fluidic properties, that affect the thickness of the film in liquid–liquid slug flow regimes.     

Experimental investigation of air–oil slug flow using capacitance probes,hot-film anemometer,and image processing

Despite the importance of air–oil slug flows to many industrial applications, their available data reported in the literature are limited compared to air–water slug flows. The main objective of the present study is to explain how air–oil slug flow parameters can be experimentally investigated using hot-film anemometry, capacitance sensors and image processing. Experiments were performed using air–oil slug flow through a horizontal pipe for air superficial velocities ranged from 0.01 m/s to 0.65 m/s and oil superficial velocities ranged from 0.03 m/s to 2.3 m/s. The signal obtained from the hot-film anemometer was used to determine the time-averaged local void fraction and liquid velocity and turbulence intensity for air–oil slug flow. The capacitance signals along with the data obtained by image processing of the flow were used to determine the elongated bubble length and velocity. The measurements techniques used found to describe in detail the internal structure of the slug flow. Finally, the experimental results were compared to existing models and correlations.     

Effect of gas pulsation on long slugs in horizontal gas–liquid pipe flow

Long liquid slugs reaching a length of several hundreds of pipe diameter may appear when transporting gas and liquid in horizontal or nearly horizontal pipelines. These long slugs may cause system vibration, separator flooding, and operational problems for the downstream processing facilities. Although mainly short hydrodynamic slugs have been observed in offshore gas and oil production fields over the past years, the appearance of the long slugs is becoming more common as many production fields are now more mature and reach end of field life, giving reduced production rates and reduced operational pressure.     

Microgravity effects on the rising velocity of bubbles and slugs in vertical pipes of good and poor wettability

Bubbles and slugs rising in vertical pipes of good and poor wettability were observed with a high-speed video camera in normal gravity as well as in microgravity. The wettability of the pipe did not affect the mean rising velocity of bubbles in microgravity. The same was true for the mean rising velocity of slugs in microgravity. An empirical relation was derived for the mean rising velocity of bubbles and slugs in mirogravity as a function of the superficial velocities of gas and liquid.     

Laminar bubbly flow in an open capillary channel in microgravity

The study of a bubbly laminar two-phase flow in an open capillary channel under microgravity conditions was conducted aboard the sounding rocket, Texus-45. The channel consists of two parallel plates of width b = 25 mm and distance a = 10 mm. The flow along the length l = 80 mm is confined by a free surface on one side and a plate on the opposite side. The bubbles are injected at the nozzle of the capillary channel via six capillary tubes of 100 μm in inner diameter. Different liquid and gas flow rates were tested leading to different liquid free surface shape and bubble size.     

Phase and velocity distributions in vertically upward high-viscosity two-phase flow

The two-phase pressure drop in vertical industrial pipes is mainly determined by gravitation and acceleration of the fluid, which means that the void fraction is key an important parameter in any model to predict pressure drops. Typically, these models are applied in industry to size pumps and, e.g., emergency relief systems. There is a shortage of void fraction data in the literature for liquids with a dynamic viscosity above 1000 mPa s. Adiabatic experiments have been performed of mixtures of nitrogen and solutions of polyvinylpyrrolidone (Luviskol^®) in water with dynamic viscosities in the range 900–7000 mPa s. Inner tube diameter was 54.5 mm. Mass flux and quality were varied in a wide range: 8–3500 kg/m²/s and 0–82%, respectively. The corresponding superficial velocities were 0.005–3.4 m/s for the liquid and 0–30 m/s for the nitrogen. For comparison, reference measurements were taken of mixtures of nitrogen with water (1 mPa s). Care has been taken to measure only well-developed flows.     

Bubble migration in a turbulent boundary layer

The wall void peaking distribution observed in an upward turbulent bubbly boundary layer along a flat plate is generated by bubbles that move towards the plate, come into contact with the wall and then slide along it. This transverse ‘migration’ has been studied using flow visualization, high speed video and particle tracking techniques to measure the trajectories of mono-disperse air bubbles at very low void fractions. Investigations have been performed at four Reynolds numbers in the range 280 < Re_θ < 3000, covering both the laminar and turbulent regimes, with mono-disperse bubbles of mean equivalent diameter between 2 mm and 6 mm. Lagrangian statistics calculated from hundreds of trajectories show that the migration only occurs in the turbulent regime and for bubble diameters below some critical value: 3.5 mm < d_eqcrit < 4 mm. Above this size (We > 3), the interface deformation is such that bubbles do not remain at the wall, even when they are released at the surface. Also, bubble migration is shown to be non-systematic, to have a non-deterministic character in the sense that trajectories differ significantly, to increase with Reynolds number and to take place on a short time scale. A series of experiments with isolated bubbles demonstrates that these results are not influenced by bubble–bubble interactions and confirm that two-way coupling in the flow is limited. Flow visualizations show that the migration originates with the capture of bubbles inside the large turbulent structures of the boundary layer (‘bulges’). The bubbles begin to move towards the wall as they cross these structures, and the point at which they reach the wall is strongly correlated with the position of the deep ‘valleys’ which separate the turbulent ‘bulges’. The analysis of the mean Lagrangian trajectories of migrating bubbles confirms these observations. Firstly, the average time of migration calculated from these trajectories coincides with the mean transit time of the bubbles across the structures. Secondly, once the trajectories have been scaled by this transit time and the boundary layer thickness δ, they all have the same form in the region y/δ < 0.4, independent of the Reynolds number.     

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.     

Flow pattern and flow characteristics for counter-current two-phase flow in a vertical round tube with wire-coil inserts

Flow pattern, void fraction and slug rise velocity on counter-current two-phase flow in a vertical round tube with wire-coil inserts are experimentally studied. Flow pattern and slug rise velocity are measured visually with a video camera. The void fraction is measured by the quick-closing valve method. Four kinds of coils with different coil pitches and coil diameters are used as inserts. The presence of wire-coil inserts induces disturbance into gas and liquid flows so that the shape and motion of gas slug or bubbles in a wire-coil inserted tube are quite different from those observed in a smooth tube without insert. The bubbly flow occurs in the low gas superficial velocity region in the wire-coil inserted tube, while the slug or churn/annular flow only appears in the smooth tube without insert over the all test range. The measured slug rise velocity in the wire-coil inserted tube is higher than that in the smooth tube. With modified mean flow velocity calculated with core area, the slug rise velocity in wire-coil tube inserted is in good agreement with Nicklin's correlation. The void fraction in a wire-coil inserted tube is lower than that in a smooth tube in the range of high gas superficial velocities. By introducing a simple assumption on considering the effective flowing area, the measured void fractions in a wire-coil inserted tube are in relatively good agreement with the predicted result based on the drift flux model proposed by others with the correlation for slug rise velocity given by others when the coil pitch is dense.     

On the effect of the nozzle design on the performances of gas–liquid cylindrical cyclone separators

This paper constitutes an experimental study of the separation performances of a gas–liquid cylindrical cyclone (GLCC) separator that interests the oil industry. The global hydrodynamics behavior in the GLCC is characterized by flow visualization under various inflow operating conditions. The effect of the inlet nozzle design on the performances of the separator is studied by using three different nozzles, and it proves to be a key parameter. With an insufficient nozzle restriction, low swirl intensity is imparted to the flow. Due to inadequate centrifugal effects, liquid is prematurely carried over by the gas as flooding occurs in the separator upper part. High amounts of gas are also carried under by the liquid stream. On the other hand, with a too severe nozzle convergence, the important drag applied by the gas leads to liquid “short circuiting” the cyclone toward the gas outlet. In addition to the nozzle design, the separator performances are influenced by phenomena such as liquid bridging or the occurrence of the slug flow regime at the cyclone inlet. This paper leads to a better understanding of the links between the hydrodynamics in the GLCC and its operational limits, which is necessary to enable reliable scaling up tools.     

Prediction of the entrained liquid fraction in vertical annular gas–liquid two-phase flow

The study considers the prediction of the entrained liquid fraction in adiabatic gas–liquid annular two-phase flow in vertical pipes. Nine empirical correlations have been tested against an experimental data bank drawn together in this study containing 1504 points for 8 different gas–liquid combinations and 19 different tube diameters from 5.00 mm to 57.1 mm. The correlation of Sawant, Ishii and Mishima and the one of Oliemans, Pots and Trompé were found to best reproduce the available data. A new correlating approach, derived from both physical intuition and dimensional analysis and capable of providing further physical insight into the liquid film atomization process, was proposed and worked better than any of the existing methods. This new correlation is based on the core flow Weber number that is also a controlling dimensionless group in determining the wall shear stress and associated frictional pressure gradient of annular flows.     

Full-scale two-phase flow measurements on Athena research vessel

Measurements of gas volume fraction, bubble velocity, chord length and bubble size distributions were performed on the research vessel Athena II operating in Saint Andrew Bay in the gulf coast near Panama City, FL. Double tipped sapphire optical local phase-detection probes were used to acquire indicator functions downstream of the breaking bow wave, behind the masker and at the stern. These indicator functions were also taken at different depths, operating speeds and headings respect to the waves. The data processing includes the computation of velocity of individual bubbles and chord lengths, resulting in chord length distributions. These chord length distributions are used to obtain bubble size distributions using a novel procedure described in detail herein. Uncertainty analysis is performed for gas volume fraction, average bubble velocity and chord length. The results indicate that air entrainment increases with ship speed and sailing against the waves at all positions. The bow wave exhibits unsteady breaking that creates bubble clouds, which were characterized and identified by signal processing. At the stern a very strong dependence of bubble size with depth was found, with evidence that small bubbles (smaller than 500 μm) are transported through the bottom of the hull and reach the transom. The roller present at the transom, the associated strong unsteadiness and bubble entrainment are well captured, as indicated by the stern results, showing the frothy nature of the upper layer.     

Interfacial area concentration in gas–liquid bubbly to churn flow regimes in large diameter pipes

This study performed a survey on existing correlations for interfacial area concentration (IAC) prediction and collected an IAC experimental database of two-phase flows taken under various flow conditions in large diameter pipes. Although some of these existing correlations were developed by partly using the IAC databases taken in the low-void-fraction two-phase flows in large diameter pipes, no correlation can satisfactorily predict the IAC in the two-phase flows changing from bubbly, cap bubbly to churn flow in the collected database of large diameter pipes. So this study presented a systematic way to predict the IAC for the bubbly-to-churn flows in large diameter pipes by categorizing bubbles into two groups (group 1: spherical or distorted bubble, group 2: cap bubble). A correlation was developed to predict the group 1 void fraction by using the void fraction for all bubble. The group 1 bubble IAC and bubble diameter were modeled by using the key parameters such as group 1 void fraction and bubble Reynolds number based on the analysis of Hibiki and Ishii (2001, 2002) using one-dimensional bubble number density and interfacial area transport equations. The correlations of IAC and bubble diameter for group 2 cap bubbles were developed by taking into account the characteristics of the representative bubbles among the group 2 bubbles and the comparison between a newly-derived drift velocity correlation for large diameter pipes and the existing drift velocity correlation of Kataoka and Ishii (1987) for large diameter pipes. The predictions from the newly-developed two-group IAC correlation were compared with the collected experimental data in gas–liquid bubbly to churn flow regimes in large diameter pipes and their mean absolute relative deviations were obtained to be 28.1%, 54.4% and 29.6% for group 1, group 2 and all bubbles respectively.     

Slug initiation and evolution in two-phase horizontal flow

A series of two-phase air–water experiments was carried out in order to study the initiation and the subsequent evolution of hydrodynamic slugs in a horizontal pipeline. Experiments were carried out at atmospheric pressure, 4.0 bar(a) and 9.0 bar(a), and the effects of superficial liquid and gas velocities were investigated. The test section used for these experiments is 37 m in length, with an internal diameter of 0.078 m. To study the interfacial development, measurements of interfacial structures were made at 14 axial locations along the test section, with data acquired at a sampling frequency of 500 Hz. A large number of slugs were initiated within the first 3 m of the test section, with the frequency subsequently reducing towards the fully developed value before the end of the pipe. This reduction in frequency was strongly influenced by the magnitude of the gas and liquid velocities. The frequency of slugging was not strongly affected when the system pressure was changed from 1 atmosphere, to 4.0 and 9.0 bar(a), closely similar values being obtained at the 10 downstream locations. However, higher pressure delayed the onset of slug initiation, with “slug precursors” being formed further downstream as the pressure was increased. The statistical distributions of slug lengths and of the time intervals between slug arrivals were examined in detail and compared to several standard distributions. This showed that slug initiation may be reasonably approximated as an uncorrelated Poisson process with an exponential distribution of arrival times. However, once slugs have developed, there is strong correlation and the arrival time intervals, as well as the lengths, are best represented by the log-normal distribution.     

Comparison of void fraction correlations for different flow patterns in horizontal and upward inclined pipes

A comparison of the performance of 68 void fraction correlations based on unbiased data set (2845 data points) covering wide range of parameters than previous assessments was made. A comprehensive literature search was undertaken for the available void fraction correlations and experimental void fraction data. After systematically refining the data, the performance of the correlations in correctly predicting the diverse data sets was evaluated. Comparisons between the correlations were made and appropriate recommendations drawn. The analysis showed that most of the correlations developed are very restricted in terms of handling a wide variety of data sets. Based on the observations made, an improved void fraction correlation which could acceptably handle all data sets regardless of flow patterns and inclination angles was suggested. It was shown that this correlation has the best predictive capability than all the correlations considered in this study.     

Void fraction measurement by X-ray absorption

An X-ray tube and scintillation detectors were mounted on test pipes containing static voids of air–water mixture. Due to fluctuations in the X-ray tube output, void fraction measurements were carried out by using two detectors, one as a reference and the other as a void monitor. The intensity of a narrow (30–100 kV) X-ray beam transmitted through test pipes of different I.D. was measured to obtain the void fraction. The uncertainty in measuring static void fraction, was found to decrease as the void fraction increases, and to increase as X-ray energy increases. It was found that for a certain test-section pipe diameter, there exist an optimum X-ray energy that gives a minimum uncertainty in void fraction measurement.