Experimental and Numerical Analysis of the Viscous Fingering Instability of Shear‐Thinning Fluids

Miscible flow displacements in a rectilinear Hele‐Shaw cell of Newtonian as well as rheologically well‐characterized shear‐thinning fluids are examined through experimental measurements and numerical modelling. Water is used as a displacing fluid while the displaced fluid consists of either a reference Newtonian glycerol solution or shear‐thinning solutions of Alcoflood? polymers of different molecular weights. The experimental measurements revealed that the shear‐thinning behaviour of the non‐Newtonian solutions resulted in more complex instability patterns and new finger structures not previously observed in the case of Newtonian displacements are identified and characterized. An analysis of the effects of the rheological behaviour of the shear‐thinning fluids on instability characteristics such as the finger width and finger tip velocity is presented. Numerical simulations using a pseudo‐spectral method are conducted and allowed to compare the predictions of the mathematical model based on an effective Darcy's law with the experimental measurements.     

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.     

Enhanced Droplet Size Control in Liquid‐Liquid Emulsions Obtained in a Wire‐Guided X‐Mixer

The droplet size in a liquid‐liquid emulsion can be controlled by placing a metal wire along the centerline of an X‐mixer. Droplets gradually form when flowing along the wire, with droplet separation occurring at the tip of the wire rather than at the channel intersection in the X‐mixer. The droplet size is now defined by the Plateau‐Rayleigh instability developing in the axisymmetric annular flow region rather than by a sophisticated and hardly predictable three‐dimensional flow at the channel intersection. The wire‐guided droplet formation allows for fine control of the droplet size by changing the wire diameter, the position of the wire tip, and the flow rates. Further control of the droplet size can be achieved by adjusting the surface tension by adding a surfactant.     

Characteristics of air–water two‐phase flow in a 3‐mm smooth tube

Two‐phase flow pattern and friction characteristics for an air–water system in a 3.17 mm smooth tube are reported in this study. The range of mass flux is between 50 and 700 kg/m²s. The experimental data show that the two‐phase friction multipliers are strongly related to the flow pattern. For a stratified‐wavy flow pattern, a mass‐flux dependence of the two‐phase multipliers is seen. For a non‐stratified flow pattern, the two‐phase frictional multipliers are comparatively independent of mass flux. Correlations of the frictional multipliers are developed for stratified and non‐stratified flow. To use the appropriate correlation in different regime, a simple criterion is proposed.     

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     

Combined effects of internal heat generation and higher order chemical reaction on the non‐darcian forced convective flow of a viscous incompressible fluid with variable viscosity and thermal conductivity over a stretching surface embedded in a porous medium

In this paper, we study the combined effects of internal heat generation and higher order chemical reaction on a steady two‐dimensional non‐Darcian forced convective flow of a viscous incompressible fluid with variable dynamic viscosity and thermal conductivity in a fluid saturated porous medium passing over a linear stretching sheet. Using similarity transformations, the governing nonlinear‐coupled partial differential equations are made dimensionless and solved numerically for similarity solutions using very robust computer algebra software Maple 8. The non‐dimensional velocity, temperature and concentration distributions are presented graphically for various pertinent parameters such as relative temperature difference parameter, Darcy number, porosity parameter, reaction rate parameter and the order of the chemical reaction. The variations of Prandtl number and Schmidt number within the boundary layer are also displayed graphically when the fluid dynamic viscosity and thermal conductivity are temperature dependent. From the present numerical computations it is found that Prandtl number as well as Schmidt number must be taken as variables within the flow domain when the fluid's dynamic viscosity and thermal conductivity are variable. In the presence of internal heat generation, dynamic viscosity and thermal conductivity of the fluid are found to be higher than when it is absent. Increasing Darcy number reduces dynamic viscosity as well as thermal conductivity whereas increasing pore size reduces the Schmidt number and increases the Prandtl number within the boundary layer. For higher order reaction the rate of increase in mass transfer function is less compared to the rate of increase for the lower order reaction. © 2011 Canadian Society for Chemical Engineering     

A Two‐Phase Non‐Isothermal PEFC Model: Theory and Validation

A two‐dimensional, non‐isothermal, two‐phase model of a polymer electrolyte fuel cell (PEFC) is presented. The model is developed for conditions where variations in the streamwise direction are negligible. In addition, experiments were conducted with a segmented cell comprised of net flow fields. The, experimentally obtained, current distributions were used to validate the PEFC model developed. The PEFC model includes species transport and the phase change of water, coupled with conservation of momentum and mass, in the porous backing of the cathode, and conservation of charge and heat throughout the fuel cell. The current density in the active layer at the cathode is modelled with an agglomerate model, and the contact resistance for heat transfer over the material boundaries is taken into account. Good agreement was obtained between the modelled and experimental polarization curves. A temperature difference of 6 °C between the bipolar plate and active layer on the cathode, and a liquid saturation of 6% at the active layer in the cathode were observed at 1 A cm^–2.     

Interfacial instabilities in coextrusion flows of low‐density polyethylenes: Experimental studies

A fundamental investigation into the interfacial instability phenomenon was performed. Coextrusion experiments were carried out using well‐characterized low‐density (LDPE) resins in an effort to gain a better understanding of interfacial instability phenomena. The resins used were chosen carefully and included materials of high and low viscosity as well as broad and narrow molecular weight distributions (MWD). The experiments involved the coextrusion of either the same material in both layers or various combinations of the four materials and the focus of the work was to elucidate the effects of flow rates, molecular weight (MW) and MWD on interfacial instability. The effect of the geometry at the point where the materials merged was also investigated. It was concluded that there are essentially two types of interfacial instabilities and that the MW had the strongest effect on the occurrence of the “zig‐zag” instability due to high interfacial stress while the breadth of the MWD had a strong effect on the appearance of the “wave” instability. Broad MWD materials had a greater tendency to exhibit interfacial instability, which is more due to layer ratio than processing conditions or die geometries. The results suggest that the origin of the “wave” type of interfacial instability is due to an extreme extensional deformation of the minor layer at the merge point and that the viscoelastic properties of adjacent layers determine the instability development.     

A mechanistic model for roll waves for two‐phase pipe flow

A new two‐phase roll wave model is compared with data from high pressure two‐phase stratified pipe flow experiments. Results from 754 experiments, including mean wave speed, wave height, pressure gradient, holdup and wave length, are compared with theoretical results. The model was able to predict these physical quantities with good accuracy without introducing any new empirically determined quantities to the two‐fluid model equations. This was possible by finding the unique theoretical limit for nonlinear roll amplitude and applying a new approach for determining the friction factor at the gas‐liquid interface. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

Three‐Dimensional CFD Simulation of Stratified Two‐Fluid Taylor‐Couette Flow

Two‐fluid Taylor‐Couette flow, with either one or both of the co‐axial cylinders rotating, has potential advantages over the conventional process equipment in chemical and bio‐process industries. This flow has been investigated using three‐dimensional CFD simulations. The occurrence of radial stratification, the subsequent onset of centrifugal instability in each phase, the cell formation and the dependency on various parameters have been analyzed and discussed. The criteria for the stratification, Taylor cell formation in each phase have been established. It can be stated that the analysis of single‐phase flow acts as the base state for the understanding of radial stratification of the two‐fluid flows. The extent of interface deformation also has been discussed. A complete energy balance has been established and a very good agreement was found between dissipation rate by CFD predictions and the energy input rate through the cylinder/s rotation.     

Phase separation of gas–liquid two‐phase stratified and plug flows in multitube T‐junction separators

Using air and water as the working fluids, phase separation phenomena for stratified and plug flows at inlet were investigated experimentally, at a simple T‐junction and specifically designed multitube T‐junction separators with two or three layers. The results show that for these two flow patterns the separation efficiency of the two phases for any multitube T‐junction separator is much higher than that of the simple T‐junction. Increasing the number of connecting tubes in the multitube T‐junction separator can increase the separation efficiency. Generally, for stratified flow, complete separation of the two phases can be achieved by the two‐layer multitube T‐junction separator with five or more connecting tubes and by the three‐layer separator; increasing the gas flow rate, the liquid flow rate, or the mixture velocity under plug flow is detrimental to phase separation with a drop in peak separation efficiency. © 2016 American Institute of Chemical Engineers AIChE J, 63: 2285–2292, 2017     

Three‐Dimensional Simulation of Bubble Formation Through a Microchannel T‐Junction

Three‐dimensional simulations of bubble formation in Newtonian and non‐Newtonian fluids through a microchannel T‐junction are conducted by the volume‐of‐fluid method. For Newtonian fluids, the critical capillary number Ca for the transition of the bubble breakup mechanism is dependent on the velocity ratio between the two phases and the microchannel dimension. For the power law fluid, the bubble diameter decreases and the generation frequency increases with higher viscosity parameter K and power law index n. For a Bingham fluid, the viscous force plays a more important role in microbubble formation. Due to the yield stress τ_y, a high‐viscous region is developed in the central area of the channel and bubbles deform to a flat ellipsoid shape in this region. The bubble diameter and generation frequency are almost independent of K.     

Melt electrospinning writing of three‐dimensional star poly(ϵ‐caprolactone) scaffolds

In the last decade, the melt‐electrospinning technique has gained attention for the production of highly porous microfibrous tissue engineering scaffolds. The possibility of processing polymers without the use of organic solvents is one of the main advantages over solution electrospinning. In this study, computer‐controlled melt‐electrospinning of a commercial poly(?‐caprolactone) and of two batches with different molecular weights of a three‐arm star poly(?‐caprolactone) by means of a screw‐extruder‐based additive manufacturing system is reported. Experimental parameters such as processing temperature, extrusion flow rate and applied voltage were studied and optimized in order to obtain non‐woven meshes with uniform fibre morphology. Applying the optimized parameters, three‐dimensional scaffolds were produced using a layer‐by‐layer approach (0 ? 90° lay‐down pattern). © 2013 Society of Chemical Industry     

Two‐dimensional simulation of hollow fiber membrane fabricated by phase inversion method

In the steady fabricating process, two‐dimensional hollow fiber membrane near the spinneret was numerically simulated using the finite element method (FEM). The unknown positions of free surface and moving interface were calculated simultaneously by the velocity and pressure fields. The effects of seven relevant parameters, i.e., inertia term, gravity term, dope flow rate, bore flow rate, dope viscosity, tensile force, end velocity and non‐Newtonian on the velocity and diameter profile were studied. On the basis of the simulated results, the inertia term in hollow fiber‐spinning process was safely neglected in low speed, while the effect of gravity was not be neglected. Besides, the outer diameter of the fibers increased with an increase of dope flow rate and bore flow rate; Large tensile force or large end velocity could cause large deformation in the air gap; larger viscous dope solution tended to make less deformation in the air gap. It was found that an increase of the dope flow rate at small dope flow rate resulted in an increase of the inner diameter, while at large dope flow rate, it decreased. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 2067–2074, 2006     

Design and fabrication of non‐noble metal catalyst‐based air‐cathodes for metal‐air battery

In this paper, cost‐effective non‐noble metal catalyst‐based air‐cathodes are designed, developed, and fabricated for a metal‐air battery, particularly in a non‐toxic neutral solution environment (sodium chloride). The air‐cathode and its fabrication method comprise two gas diffusion layers (GDLs) bonded on to each side of the current collector (nickel mesh) by a rolling method, and a catalyst layer bonded on one GDL by a spraying method. The GDL paste consists of carbon powder and hydrophobic chemicals, and the catalyst layer contains non‐noble metal catalyst, carbon powder, and hydrophilic chemicals. Several characterization techniques such as DTA/TG thermal analysis, electrochemical impedance spectroscopy, linear sweep voltammetry, and their associated theories are used to understand the properties and performance of the developed air‐cathodes. The advantages of the current method of forming the air‐cathode can decrease the internal electronic resistance and gas flow restriction of the system, and therefore increase air permeability as well as water transportation to the reaction sites. By using such an integrated structure of an air diffusion cathode, the cost‐effectiveness in terms of materials and manufacturing compared to the commercial air‐cathode, and the overall fabrication procedure is achieved, and the method can be easily transferred into a continuous industrial manufacturing process.     

Comparative Investigations of Non‐adiabatic Absorption in Film Flow and Bubble Flow

Comparative non‐adiabatic absorption experiments were carried out using the ammonia–water system under different two‐phase flow regimes. Because of the small thickness of the film, the falling film as a separated two‐phase flow shows an effective dynamic and transport behavior. The hydrodynamics and heat transfer modeling is sufficiently exact and the measurement of the interface temperature allows the discussion of the axial local partial resistance of the heat transfer in the falling film.     

Three‐dimensional simulations of gas‐liquid cocurrent downflow in vertical,inclined, and oscillating packed beds

The hydrodynamic behavior of gas‐liquid downflow in vertical, inclined, and oscillating packed beds related to offshore floating applications was analyzed by means of three‐dimensional unsteady‐state two‐fluid simulations. Angular oscillations of the column between two angled symmetrical positions and between vertical and inclined position were considered while bed non‐uniformity was described using radial porosity distributions. For vertical and slightly inclined columns, two‐phase flow was concentrated in the core area of the bed. However, the two‐phase flow was predicted to deviate significantly from axial symmetry at higher inclinations with prominent liquid accumulation in the bottommost reactor cross‐sectional area. Oscillating packed beds unveiled complex reverse secondary flows radially and circumferentially resulting in oscillatory patterns of liquid holdup and pressure drop whose amplitude and propagation frequency were affected by column inclination angle and travel time between vertical and angled positions. © 2015 American Institute of Chemical Engineers AIChE J, 62: 916–927, 2016     

Drying Kinetics in a Vertical Gas‐Solid System

A one‐dimensional steady‐state two‐fluid model has been developed to demonstrate the drying kinetics in the vertical up‐flow gas‐solid system. The model takes into account mass, momentum, and heat transfer between the continuous and dispersed phases. A set of non‐linear differential equations have been solved numerically for the velocity, moisture content, and temperature of both the continuous and dispersed phases along the dryer length. The effect of operating parameters on drying kinetics has been critically examined and the model simulations are compared with the data reported in the literature.     

Frictional Pressure Drop of Air Non‐Newtonian Liquid Flow through Helical Coils in Horizontal Orientation

Investigations have been carried out to evaluate the two‐phase frictional pressure drop for air non‐Newtonian liquid flow through helical coils in horizontal orientation. The experiments performed using 36 different helical coils and 4 different concentrations of sodium salt of carboxymethyl—cellulose (SCMC) as non‐Newtonian liquids. The effects of air and liquid flow rate, coil diameter, helix angle and liquid properties‐ on two‐phase frictional pressure drop have been discussed. An attempt has been made to fit the experimental two‐phase frictional pressure drop data by the Lockhart and Martinelli, Chem. Eng. Prog. 45 , 39–48 (1949) correlation and the modified Lockhart‐Martinelli correlation as presented by different authors. In another approach, friction factor method was adopted to correlate the experimental data by dimensional analysis. The correlation developed predicts the two‐phase frictional pressure drop with acceptable statistical accuracy.     

The Development of Fibers That Mimic the Core–Sheath and Spindle‐Knot Morphology of Artificial Silk Using Microfluidic Devices

Spider and silkworm produce diverse silk fibers from spinning dopes through smart spinnerets. Spider's capture silk is composed of core thread and periodic spindle‐knots, while silkworm silk consists of fibroin core and sericin outer layer. To mimic the morphologies of natural heterostructured silks, artificial fibers are dry‐spun using a multichannel microfluidic chip, served with a highly viscous core solution of regenerated silk fibroin and low viscosity sheath solution of sericin. Silk fibers with core–sheath, groove, and spindle‐knot structures are obtained by controlling the flow rates and viscosities of the two microfluids depending on the laminar flow, Kelvin–Helmholtz instability, or Plateau–Rayleigh instability.