Pressure Drop in Liquid‐liquid Two Phase Horizontal Flow: Experiment and Prediction

The present study is aimed at an investigation of the pressure drop characteristics during the simultaneous flow of a kerosene‐water mixture through a horizontal pipe of 0.025 m diameter. Measurements of pressure gradient were made for different combinations of phase superficial velocities ranging from 0.03–2 m/s such that the regimes encountered were smooth stratified, wavy stratified, three layer flow, plug flow and oil dispersed in water, and water flow patterns. A model was developed, which considered the energy minimization and pressure equalization of both phases.     

Three‐Dimensional Numerical Simulation of Dense Pneumatic Conveying of Pulverized Coal in a Vertical Pipe at High Pressure

A two‐fluid model based on the kinetic theory of granular flow was used to study three‐dimensional steady state flow behavior of dense phase pneumatic conveying of pulverized coal in a vertical pipe, where the average solid concentration ranges from 11 % to 30 %, and the transport pressure ranges from 2.6 Mpa to 3.3 Mpa. Since the solid concentration is rather high, a k–?–k_p–?_p model which considers the turbulence interaction between the gas and particle phase, was incorporated into the two‐fluid model. The simulation results including profiles of gas and particle phase axial velocity, profiles of solid concentration, profiles of the turbulence intensity of the particle phase, as well as the value of the pressure gradient were reported. Then, the influences of solid concentration and transport pressure on the flow behaviors were discussed. The experiment was also carried out to validate the accuracy of the simulation results which showed that the predictions of pressure gradient were in good agreement with the experimental data. Simulation results indicate that the location of maximal solid concentration deviates from the pipe center and the deviation becomes more obvious with the solid concentration increasing, which is analogous to the phenomenon in the liquid/solid flow. Besides, pressure gradient declines as the transport pressure decreases, which is validated by experiment described in the paper. Moreover, the analysis indicates that it is necessary to consider the turbulence of particles for the simulation of dense phase pneumatic conveying at high pressure.     

Wax deposition modeling of oil/gas stratified smooth pipe flow

Wax deposition modeling is complicated under oil/gas two‐phase pipe flow and therefore remains poorly understood. One‐dimensional empirical heat and mass transfer correlations are unreliably for deposition modeling in stratified flow, due to non‐uniform deposit across the pipe circumference. A mathematical model has been developed to predict the deposit thickness and the wax fraction of deposit in oil/gas stratified pipe flow using a unidirectional flow analysis of non‐isothermal hydrodynamics and heat/mass transfer. The predictions for wax deposition are found to compare satisfactorily with experimental data with three different oils for single phase and oil/gas stratified pipe flow. In particular, the reason that the deposit forming a crescent shape at the cross section of pipe observed in different experiments is revealed, based on the non‐uniform circumferential distributions of two most important parameters for the wax deposition, diffusivity at oil–deposit interface, and the solubility gradient at the oil–deposit interface at different time. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2550–2562, 2016     

Sensor‐based flow pattern detection—gas–liquid–liquid upflow through a vertical pipe

Flow distribution during gas–liquid–liquid upflow through a vertical pipe is investigated. The optical probe technique has been adopted for an objective identification of flow patterns. The probability density function (PDF) analysis of the probe signals has been used to identify the range of existence of the different patterns. Dispersed and slug flow have been identified from the nature of the PDF, which is bimodal for slug flow and unimodal for dispersed flow. The water continuous, oil continuous, and emulsion type flow distributions are distinguished on the basis of the PDF moments. The method is particularly useful at high flow rates where visualization techniques fail. Based on this, a flow pattern detection algorithm has been presented. Two different representations of flow pattern maps have been suggested for gas–liquid–liquid three phase flow. © 2014 American Institute of Chemical Engineers AIChE J, 60: 3362–3375, 2014     

Multi‐scale analysis of acoustic emission signals in dense‐phase pneumatic conveying of pulverized coal at high pressure

Acoustic emission technique in conjunction with multiscale processing method has been utilized to investigate the flow behavior of the dense‐phase pneumatic conveying system at high pressure. A clearly defined classification of microscale, mesoscale, and macroscale signals has been put forward with the aid of wavelet transform and V statistics analysis. The detailed signals d₁–d₄, d₅–d₇, d₈–d₁₀ were recomposed into the microscale, mesoscale, and macroscale signals, respectively, which represent microscale particle‐wall interactions, mesoscale interaction between gas phase and solid phase (such as bubbles, plugs, dunes), and macroscale flow‐induced pipe vibration. Further analysis shows that as the mass flow rate of pulverized coal increases, the energy fraction (energy of detailed signal divided by the energy of original signal) of microscale signals decreases while that of mesoscale signals increases, which indicates that particles are more likely to move as particle aggregates than individual particles when mass flow rate increases. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2635–2648, 2016     

Liquid‐Liquid Stratified Flow through Horizontal Conduits

The stratified configuration is one of the basic and most important distributions during two phase flow through horizontal pipes. A number of studies have been carried out to understand gas‐liquid stratified flows. However, not much is known regarding the simultaneous flow of two immiscible liquids. There is no guarantee that the information available for gas‐liquid cases can be extended to liquid‐liquid flows. Therefore, the present work attempts a detailed investigation of liquid‐liquid stratified flow through horizontal conduits. Gas‐liquid flow exhibits either smooth or wavy stratified orientations, while liquid‐liquid flow exhibits other distinct stratified patterns like three layer flow, oil dispersed in water, and water flow, etc. Due to this, regime maps and transition equations available for predicting the regimes in gas‐liquid flow cannot be extended for liquid‐liquid cases by merely substituting phase physical properties in the equations. Further efforts have been made to estimate the in‐situ liquid holdup from experiments and theory. The analysis considers the pronounced effect of surface tension, and attempts to modify the Taitel‐Dukler model to account for the curved interface observed in these cases. The curved interface model of Brauner has been validated with experimental data from the present work and those reported in literature. It gives a better prediction of liquid holdup in oil‐water flows and reduces to the Taitel‐Dukler model for air‐water systems.     

Liquid‐liquid two‐phase flow patterns in a new helical microchannel device

Flow patterns of liquid‐liquid two‐phase fluids in a new helical microchannel device were presented in this paper. Three conventional systems were considered: kerosene‐water, n‐butyl acetate‐water, and butanol‐water. Six different flow patterns, slug flow, continuous parallel flow, discontinuous deformation parallel flow, discontinuous deformation parallel‐droplet flow, droplet‐slug flow, and filiform‐droplet flow, were observed. The influence of interfacial tension, microchannel structure, and rotation rate on two‐phase flow patterns were studied, and a universal flow pattern map was presented and discussed. The systems without mass transfer (0.1 g/g (10 %) tri‐n‐butyl phosphate (TBP)‐water, 0.2 g/g (20 %) TBP‐water, and 0.8 g/g (80 %) TBP‐water) and the system with mass transfer (0.8 g/g (80 %) TBP‐0.62 g/g (62 %) H₃PO₄) were used to verify the validity of the proposed universal flow pattern map in predicting flow patterns. The results showed that the former compared with the latter can be predicted more accurately by the universal flow pattern map.     

Phase Inversion and Associated Phenomena in Oil‐Water Vertical Pipeline Flow

Phase inversion and its associated phenomena are experimentally investigated in co‐current upward and downward oil‐water flow in a vertical stainless steel test section (38 mm I.D.). Oil (ρ_o=828 kg/m³, µ_o=5.5 mPa s) and tap water are used as test fluids. Two inversion routes (w/o to o/w and o/w to w/o) are followed in experiments where either the mixture velocity is kept constant and the dispersed phase fraction is increased (type I experiments), or the continuous phase flow rate is kept constant and that of the dispersed phase is increased (type II experiments). By monitoring phase continuity at the pipe centre and at the wall it was found that phase inversion does not happen simultaneously at all locations in the pipe cross‐section. In type I experiments, the velocity ratios (U_o/U_w) where complete inversion appeared acquired the same constant value in both flow directions, although the phase inversion points, based on input phase fractions, were different. In contrast to previous results in horizontal flows, frictional pressure gradient was found to be minimum at the phase inversion point. The interfacial energies of the two dispersions before and after phase inversion, calculated from the measured drop sizes, were found to be different in contrast to the previously suggested criterion of equal energies for the appearance of the phenomenon. In type II experiments the phase inversion point was found to depend on mixture velocity for low and medium velocities but not for high ones. In all cases studied an ambivalent region, commonly reported for inversion in stirred vessels, was not observed.     

Gradient‐Direction‐Pattern Transform for Automated Measurement of Oil Drops in Images of Multiphase Dispersions

The automated detection and measurement of oil drops in multiphase fermentation systems are important for mass transfer analysis. A novel computer technique for automated detection of oil drops in images is presented in the context of a stirred tank containing a three‐phase water‐oil‐air dispersion. The technique is an original feature extraction transform designed for the detection of objects with a characteristic appearance. The proposed transform, denominated gradient‐direction‐pattern (GDP) transform, utilizes naturally occurring patterns in the orientation of the local gradient appearing in test images. The GDP transform was used to demonstrate the feasibility of automatically estimating oil drop‐size unbiased distributions which is an important task in the chemical and other related industries.     

Prediction of Phase Split in Horizontal T‐Junctions: Revisited

The prediction of liquid–liquid two‐phase flow at a horizontal dividing T‐junction is re‐investigated, focusing on a stratified orientation of the liquids. Kerosene (as oil) and water as the test fluids of previous studies are used to predict the distribution of oil and water in a 0.025‐m diameter pipe and tee. In addition to the previously studied models, attempts are made to predict the split for liquid–liquid systems by the already known energy minimization. The earlier model, formulated from geometrical considerations and force balance resulting from centripetal as well as inertial forces, is refurbished by the addition of energy minimization for the calculation of phase depth.     

Predicting pressure gradients in heavy oil—water pipelines

Experimental investigations of the flow of water‐heavy oil mixtures at velocities typical of oil‐field gathering systems show that continuous water assisted flow at very low pressure gradients can be achieved. The principal criterion to be satisfied in establishing this desirable flow regime appears to be use of sufficient water, with the velocity also playing a role. It also appears that oil viscosity and water fraction effects on pressure gradient are small provided the beneficial flow regime is established. The flows resemble core‐annular flow, which has been observed previously in Bitumen froth and water‐heavy oil flows, with an oil layer on the pipe wall. However, the correlation for pressure gradient is somewhat different from that reported previously for Bitumen froth flows.     

Pressure drop for single and two‐phase flow of non‐newtonian liquids in helical coils

New experimental results on pressure loss for the single and two‐phase gas‐liquid flow with non‐Newtonian liquids in helical coils are reported. For a constant value of the curvature ratio, the value of the helix angle of the coils is varied from 2.56° to 9.37°. For single phase flow, the effect of helix angle on pressure loss is found to be negligible in laminar flow regime but pressure loss increases with the increasing value of helix angle in turbulent flow conditions. On the other hand, for the two‐phase flow, the well‐known Lockhart‐Martinelli method correlates the present results for all values of helix angle (2.56‐9.37°) satisfactorily under turbulent/laminar and turbulent/turbulent conditions over the following ranges of variables as: 0.57 ≤ n′ ≤ 1; Re′ < 4000; Re_l < 4000; Re_g < 8000; 8 ≤ x ≤ 1000 and 0.2 ≤ De′ ≤ 1000.     

A new mechanistic model to predict gas–liquid interface shape of gas–liquid flow through pipes with low liquid loading

Devising a new mechanistic method to predict gas–liquid interface shape in horizontal pipes is concerned in this article. An experiment was conducted to find the pressure gradients of air–water flow through a 1‐in. pipe diameter. Comparing results of model with some experimental data available in the literature demonstrates that the model provides quite better predictions than existed models do. This model also predicts flow regime transition from stratified to annular flow better than Apparent Rough Surface and Modified Apparent Rough Surface models for both 1‐ and 2‐in. pipe diameters. The model also leads to reliable predictions of wetted wall fraction experimental data. Although one parameter of new model was evaluated based on air–water flow pressure loss experimental data for 1 in. pipe, it was considerably successful to predict pressure drop, liquid holdup, stratified‐annular transition and wetted wall fraction for other gas–liquid systems and pipe diameters. © 2014 American Institute of Chemical Engineers AIChE J, 61: 1043–1053, 2015     

Settling and re‐entrainment of wax particles in near‐gelling systems

Under near‐gelling conditions, the precipitated wax particles can settle down due to gravity and form a bed at the bottom of the pipeline. During restart, the settled waxy bed can increase the pressure drop significantly, and the necessity for pigging and/or addition of chemicals has to be determined to re‐entrain settled wax particles. A laboratory‐scale flow loop, first of its kind, has been built and used to understand the settling and re‐entrainment behavior. The experimental results confirmed the settling of precipitated wax in a pipe under quiescent conditions when the oil temperature falls between wax appearance temperature and pour point. During restart, complete re‐entrainment was attained after reaching a critical flow rate. Solid transport models were able to predict reasonably good results in agreement with experiments. This work emphasizes the importance of understanding the behavior of waxy crude oil during production shutdown and design appropriate startup strategies. © 2017 American Institute of Chemical Engineers AIChE J, 64: 765–772, 2018     

Drag reduction phenomenon in viscous oil‐water dispersed pipe flow: Experimental investigation and phenomenological modeling

An experimental study on drag‐reduction phenomenon in dispersed oil‐water flow has been performed in a 26‐mm‐i.d. Twelve meter long horizontal glass pipe. The flow was characterized using a novel wire‐mesh sensor based on capacitance measurements and high‐speed video recording. New two‐phase pressure gradient, volume fraction, and phase distribution data have been used in the analysis. Drag reduction and slip ratio were detected at oil volume fractions between 10 and 45% and high mixture Reynolds numbers, and with water as the dominant phase. Phase‐fraction distribution diagrams and cross‐sectional imaging of the flow suggested the presence of a higher amount of water near to the pipe wall. Based on that, a phenomenology for explaining drag reduction in dispersed flow in a flow situation where slip ratio is significant is proposed. A simple phenomenological model is developed and the agreement between model predictions and data, including data from the literature, is encouraging. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

On near‐wall jets in a disc‐like gas vortex unit

To clarify the three‐dimensional (3D) structure of near‐wall jets observed in disc‐like gas vortex units (GVUs), experimental and numerical studies are performed. The experimental results are obtained using stereoscopic particle image velocimetry (PIV), laser doppler anemometry, pressure probes and surface oil flow visualization techniques. The first three techniques have been used to investigate the bulk flow hydrodynamics of the vortex unit. Surface oil flow visualization is adopted to visualize streamlines near the end‐walls of the vortex unit. The surface streamlines help to determine the azimuthal and radial velocity components of the radial near‐wall jets. Simulations of the vortex unit using FLUENT^® v.14a are simultaneously performed, computationally resolving the near‐wall jet regions in the axial direction. The simulation results together with the surface oil flow visualization establish the 3D structure of the near‐wall jets in GVUs for the first time in literature. It is also conjectured that the near‐wall jets develop due to the combined effect of bulk flow acceleration and swirl. The centrifugal force diminishes in the vicinity of the end‐walls. The radially inward pressure gradient in these regions, no longer balanced by the centrifugal force, pushes gas radially inward thus developing the near‐wall jets. © 2016 The Authors AIChE Journal published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers AIChE J, 63: 1740–1756, 2017     

High‐Pressure Behavior of Mullite: An X‐Ray Diffraction Investigation

Using synchrotron X‐ray diffraction and diamond anvil cells we performed in situ high‐pressure studies of mullite‐type phases of general formula Al_4+2xSi_2?2xO_10?x and differing in the amount of oxygen vacancies: 2:1‐mullite (x = 0.4), 3:2‐mullite (x = 0.25), and sillimanite (x = 0). The structural stability of 2:1‐mullite, 3:2‐mullite, and sillimanite was investigated up to 40.8, 27.3, and 44.6 GPa, respectively, in quasi‐hydrostatic conditions, at ambient temperature. This is the first report of a static high‐pressure investigation of Al₂O₃–SiO₂ mullites. It was found that oxygen vacancies play a significant role in the compression mechanisms of the mullites by decreasing the mechanical stability of the phases with the number of vacancies. Elevated pressure leads to an irreversible amorphization above ~20 GPa for 2:1‐mullite and above 22 GPa for 3:2‐mullite. In sillimanite, only a partial amorphization is observed above 30 GPa. Based on Rietveld structural refinements of high‐pressure X‐ray diffraction patterns, the pressure‐driven evolution of unit cell parameters is presented. The experimental bulk moduli obtained are as follows: K₀ = 162(7) GPa with K₀′ = 2.2(6) for 2:1‐mullite, K₀ = 173(7) GPa with K₀′ = 2.3(2) for 3:2‐mullite, K₀ = 167(7) GPa with K₀′ = 2.1(4) for sillimanite.     

Numerical modeling of three-phase stratified flow in pipes

The simultaneous flow of water, oil and gas is of practical importance for the oil and gas industry. These three phases are present in varying degrees of concentration in many oil and gas pipelines. In this work, a model has been developed to predict the values of the hold-up and pressure gradient for three-phase stratified flow prevailing in a horizontal pipeline. This information is usually the first step for analyzing the stability of stratified flow and developing transition criteria. The concept of extended velocity has been applied to compute the wall shear stresses in three-phase flow. The effect of process variables such as gas to liquid ratio, pipe diameter, oil viscosity and non-Newtonian character of oil on hold-up and pressure gradient has been studied to simulate the oil well conditions. Structural stability analysis was also carried out to check for the sensitivity of the model.