Predicting gas–liquid flow in a mechanically stirred tank

Computational fluid dynamics (CFD) provides a method for investigating the highly complex fluid flow in mechanically stirred tanks. Although there are quite a number of papers in the literature describing CFD methods for modelling stirred tanks, most only consider single-phase flow. However, multiphase mixtures occur very frequently in the process industries, and these are more complex situations for which modelling is not as well developed. This paper reports on progress in developing CFD simulations of gas–liquid mixing in a baffled stirred tank. The model is three-dimensional and the impeller region is explicitly included using a Multiple Frames of Reference method to account for the relative movement between impeller and baffles. Fluid flow is calculated with a turbulent two-fluid model using a finite-volume method. Several alternative treatments of the multiphase equations are possible, including various expressions for drag and dispersion forces, and a number of these have been tested. Variation in bubble size due to coalescence and break-up is also modelled. The CFD simulation method has been used to model a gas-sparged tank equipped with a Rushton turbine, and simulation results are compared with experimental data. Results to date show the correct pattern of gas distribution and the correct trends in local bubble size in the tank. Further work is needed to improve the quantitative agreement with experimental data.     

Decay of the 3D inviscid liquid–gas two-phase flow model

We establish the optimal \({L^{p}-L^{2}(1 \leq p < 6/5)}\) time decay rates of the solution to the Cauchy problem for the 3D inviscid liquid–gas two-phase flow model and analyze the influences of the damping on the qualitative behaviors of solution. Compared with the viscous liquid–gas two-phase flow model (Zhang and Zhu in J Differ Equ 258:2315–2338, 2015), our results imply that the friction effect of the damping is stronger than the dissipation effect of the viscosities and enhances the decay rate of the velocity. Our proof is based on Hodge decomposition technique, the \({L^{p}-L^{2}}\) estimates for the linearized equations and an elaborate energy method.     

Simulation of a reacting gas–liquid bubbly flow with CFD and PBM: Validation with experiments

In this work we use computational fluid dynamics (CFD) to simulate a reactive gas–liquid bubbly system in a rectangular bubble column, operating at low superficial velocities (i.e. homogeneous regime). The gas bubbles, injected in the column through a sparger, contain one of the reactants, namely CO₂, that via mass transfer moves to the continuous liquid phase, where it reacts with NaOH. A key role is played by the bubble size distribution (BSD) and the specific surface area that define the overall mass transfer rate in the CFD model. In order to correctly predict the BSD and the polydispersity of the bubbly system the population balance equation is solved by the quadrature method of moments (QMOM), within the OpenFOAM (v. 2.2.x) two-fluid solver compressibleTwoPhaseEulerFoam. To reduce the computational time and increase stability, a second-order operator-splitting technique for the solution of the chemically reactive species is also implemented, allowing to solve the different processes involved with their own time-scale. To our knowledge this is the first time that QMOM is employed for the simulation of a real reactive bubbly system and predictions are validated against experiments.     

A note on viscous liquid–gas two-phase flow model with mass-dependent viscosity and vacuum

In this paper, we consider a free boundary value problem for two-phase liquid–gas model with mass-dependent viscosity coefficient; the gas is assumed to be polytropic whereas the liquid is treated as an incompressible fluid, and the fluid velocities are unequal, i.e., $u_g\ne u_l$. The local existence of a weak solution is established when the initial gas mass connects to vacuum continuously.     

Predictions of the gas–liquid flow in wet electrostatic precipitators

Based on Computational Fluid Dynamics (CFD), the present paper aims to simulate several important phenomena in a wet type ESP from the liquid spray generation to gas-droplet flow in electric field. A single passage between the adjacent plates is considered for the simulation domain. Firstly, the electric field intensity and ion charge density are solved locally around a corona emitter of a barbed wire electrode, which are applied to the entire ESP using periodic conditions. Next, the Euler–Lagrange method is used to simulate the gas-droplet flow. Water droplets are tracked statistically along their trajectories, together with evaporation and particle charging. Finally, the deposition density on the plate is taken as the input for the liquid film model. The liquid film is simulated separately using the homogenous Eulerian approach in ANSYS-CFX. In the current case, since the free surface of the thin water film is difficult to resolve, a special method is devised to determine the film thickness.As parametric study, the variables considered include the nozzle pressure, initial spray spreading patterns (solid versus hollow spray) and plate wettability. The droplet emission rate and film thickness distribution are the results of interest. Main findings: electric field has strong effect on the droplet trajectories. Hollow spray is preferred to solid spray for its lower droplet emission. The liquid film uniformity is sensitive to the plate wettability.     

Modelling gas injection of a Peirce–Smith-converter

A commercial CFD-code PHOENICS was used to solve isothermal flow field of gas and liquid in a Peirce–Smith-converter. An Euler–Euler based algorithm was chosen for modelling fluid dynamics and evaluating controlling forces of a submerged gas injection. Predictions were made with a k–ε turbulence model in the body fitted coordinate system. The model has been verified with a 1/4 scale water model, and a parametric study with the mathematical model of submerged gas injection was made for the PS-process and the ladle injection processes. Limits of the modelling technique used were recognised, but calculated results indicate that the present model predicts the general flow field with reasonable accuracy. Predicted bubble distribution, pattern of the flow field and magnitude of flow velocities were used to evaluate scaling factors of physical models and general flow conditions of an industrial PS-converter.     

Chaotic analysis of pressure fluctuation signal in the gas–liquid–solid slurry column

The pressure signal of a slurry column is easily obtained by using a pressure sensor, and a chaotic analysis method is used to analyze these signals in order to indicate the flow pattern of the slurry column. The slopes of the correlation integral curve indicate the flow pattern of the slurry column in various operating conditions. The flow pattern is dispersed bubble regime when the superficial velocity is low and the correlation integral curve has two slopes. The flow pattern changes into transition regime with increase in the superficial velocity, the correlation integral curve has only one slope. In the case of the flow pattern becoming a slugging regime, there are several slopes to the correlation integral curve. So it is convenient to find out the flow pattern in the slurry column by solving the slopes of the correlation integral of the pressure signal. The maximum Lyapunov exponent represents the chaos in a slurry column with various solid holdups. The maximum Lyapunov exponent is nearly similar at different heights when the flow patterns are dispersed bubble regime and slugging regime, but the maximum Lyapunov exponent at the axial height is quite different when the flow pattern is transition regime.     

On the hyperbolicity of the two-fluid model for gas–liquid bubbly flows

The hyperbolicity condition of the system of partial differential equations (PDEs) of the incompressible two-fluid model, applied to gas–liquid flows, is investigated. It is shown that the addition of a dispersion term, which depends on the drag coefficient and the gradient of the gas volume fraction, ensures the hyperbolicity of the PDEs, and prevents the nonphysical onset of instabilities in the predicted multiphase flows upon grid refinement. A constraint to be satisfied by the coefficient of the dispersion term to ensure hyperbolicity is obtained. The effect of the dispersion term on the numerical solution and on its grid convergence is then illustrated with numerical experiments in a one-dimensional shock tube, in a column with a falling fluid, and in a two-dimensional bubble column.     

CFD simulation of gas–solid flow with a cluster structure-dependent drag coefficient model in circulating fluidized beds

To model the effect of clusters on hydrodynamics of gas and particles phases in risers, the interfacial drag coefficient is taken into account in computational fluid dynamic simulations by means of a two-fluid model. The momentum and energy balances that characterize the clusters in the dense phase and dispersed particles in the dilute phase are described by the multi-scale resolution approach. The model of cluster structure-dependent (CSD) drag coefficient is proposed on the basis of the minimization of energy dissipation by heterogeneous drag (MEDHD) in the full range of Reynolds number. The model of CSD drag coefficient is then incorporated into the two-fluid model to simulate flow behavior of gas and particles in a riser. The distributions of volume fraction and velocity of particles are predicted. Simulated results are in agreement with experimental data published in the literature.     

Assessment of turbulence modeling for gas flow in two-dimensional convergent–divergent rocket nozzle

In the present study, the turbulent gas flow dynamics in a two-dimensional convergent–divergent rocket nozzle is numerically predicted and the associated physical phenomena are investigated for various operating conditions. The nozzle is assumed to have impermeable and adiabatic walls with a flow straightener in the upstream side and is connected to a plenum surrounding the nozzle geometry and extended in the downstream direction. In this integrated component model, the inlet flow is assumed a two-dimensional, steady, compressible, turbulent and subsonic. The physics based mathematical model of the considered flow consists of conservation of mass, momentum and energy equations subject to appropriate boundary conditions as defined by the physical problem stated above. The system of the governing equations with turbulent effects is solved numerically using different turbulence models to demonstrate their numerical accuracy in predicting the characteristics of turbulent gas flow in such complex geometry. The performance of the different turbulence models adopted has been assessed by comparing the obtained results of the static wall pressure and the shock position with the available experimental and numerical data. The dimensionless shear stress at the nozzle wall and the separation point are also computed and the flow field is illustrated. The various implemented turbulence models have shown different behavior of the turbulent characteristics. However, the shear-stress transport (SST) k–ω model exhibits the best overall agreement with the experimental measurements. In general, the proposed numerical procedure applied in the present paper shows good capability in predicting the physical phenomena and the flow characteristics encountered in such kinds of complex turbulent flow.     

Nonlinear generalized functions and jump conditions for a standard one pressure liquid–gas model

The mixture of a liquid and a gas is classically represented by one pressure models. These models are a system of PDEs in nonconservative form and shock wave solutions do not make sense within the theory of distributions: they give rise to products of distributions that are not defined within distribution theory. But they make sense by applying a theory of nonlinear generalized functions to these equations. In contrast to the familiar case of conservative systems the jump conditions cannot be calculated a priori. Jump conditions for these nonconservative systems can be obtained using the theory of nonlinear generalized functions by inserting some adequate physical information into the equations. The physical information that we propose to insert for the one pressure models of a mixture of a liquid and a gas is a natural mathematical expression in the theory of nonlinear generalized functions of the fact that liquids are practically incompressible while gases are very compressible, and so they do not satisfy equally well their respective state laws on the shock waves. This modelization gives well defined explicit jump conditions. The great numerical difficulty for solving numerically nonconservative systems is due to the fact that slightly different numerical schemes can give significantly different results. The jump conditions obtained above permit to select the numerical schemes and validate those that give numerical solutions that satisfy these jump conditions, which can be an important piece of information in the absence of other explicit discontinuous solutions and of precise observational results. We expose with care the mathematical originality of the theory of nonlinear generalized functions (an original abstract analysis issued by the Leopoldo Nachbin team on infinite dimensional holomorphy) that permits to state mathematically physical facts that cannot be formulated within distribution theory, and are the key for the removal of “ambiguities” that classically appear when one tries to calculate on “multiplications of distributions” that occur in the differential equations of physics.     

Global strong solutions to the viscous liquid–gas two-phase flow model with slip boundary conditions in 3D exterior domains

This paper is concerned with the viscous liquid–gas two-phase flow model in a three-dimensional exterior domain with the slip boundary conditions. We are able to prove the existence of a global strong solution when the initial total energy is suitably small. The initial masses of liquid and gas are allowed to contain a vacuum, with no extra restriction between the initial masses of liquid and gas. It should be noted here that we consider the slip boundary condition in a three dimensional (3D) exterior domain which is in sharp contrast to result of Yu (2021) where they consider the Cauchy problem.     

Prediction of the bed-load transport by gas–liquid stratified flows in horizontal ducts

Solid particles can be transported as a mobile granular bed, known as bed-load, by pressure-driven flows. A common case in industry is the presence of bed-load in stratified gas–liquid flows in horizontal ducts. In this case, an initially flat granular bed may be unstable, generating ripples and dunes. This three-phase flow, although complex, can be modeled under some simplifying assumptions. This paper presents a model for the estimation of some bed-load characteristics. Based on parameters easily measurable in industry, the model can predict the local bed-load flow rates and the celerity and the wavelength of instabilities appearing on the granular bed.