复合T形管对气液两相流的分离

在诸如天然气、化工、冶金、电力等许多工业过程中广泛存在气液两相流,传统上采用分离罐或旋风分离器等分离两相流,不仅设备成本高、易泄漏,而且维护保养和更新都不方便。T形管分离器具有结构简单、集约、经济、安全、维修更新方便等优点,但缺点是简单T形管的分离效率较低,新型复合T形管是对简单T形管的一种改进,期望能提高两相的分离效率。以空气一水为两相流工作介质,用主管水平侧支管垂直向上的简单T形管和复合T形管作为两相流动的分离器,在层状流和塞状流条件下进行两相流分离实验。结果表明,无论在层状流还是在塞状流条件下,复合T形管气液两相的分离效率都比简单T形管有了显著的提高,增加复合T形管的连接管数,能进一步提高分离效率,一般在层状流时连接管数为5管以上的复合T能完全分离气液两相;而流型进入混合程度较高的塞状流时,采用连接管为5管以上的复合T也能完全分离气液两相流;相同流型下,增加气体或液体的流速,对复合T形管分离效果不利,最大分离效率下降。     

新型复合T型管对液液二相流的分离

T型管分离器是一类新型的二相流分离器,具有集约、连续、简单、经济、安全以及安装、更新、维护方便等优点,缺点是简单T型管作为分离器在分离二相流时的分离效率往往不高,只能起到部分分离的作用。新型复合T型管是对简单T型管的一种改进,以期能提高二相流的分离效率。以煤油和水为液液二相工作介质,用主管水平,侧支管垂直向上的简单T型管和复合T型管作为二相流分离器,在分层流和有混合界面的分层流的二相流型条件下,进行二相流的相分离实验。实验结果表明:2种流型下复合T型管对二相流的分离效果都比简单T型管好,增加复合T型管的连接管数,能进一步提高分离效率;在分层流时连接管数为5管及以上的复合T就能将液液二相完全分离;入口流型中二相的混合程度越高,最高分离效率越低;水相体积分数对分离效率的影响与流型相关。复合T型管分离液液二相流技术具有很好的工业应用前景。     

Bubble splitting under gas–liquid–liquid three‐phase flow in a double T‐junction microchannel

Gas–aqueous liquid–oil three‐phase flow was generated in a microchannel with a double T‐junction. Under the squeezing of the dispersed aqueous phase at the second T‐junction (T2), the splitting of bubbles generated from the first T‐junction (T1) was investigated. During the bubble splitting process, the upstream gas–oil two‐phase flow and the aqueous phase flow at T2 fluctuate in opposite phases, resulting in either independent or synchronous relationship between the instantaneous downstream and upstream bubble velocities depending on the operating conditions. Compared with two‐phase flow, the modified capillary number and the ratio of the upstream velocity to the aqueous phase velocity were introduced to predict the bubble breakup time. The critical bubble breakup length and size laws of daughter bubbles/slugs were thereby proposed. These results provide an important guideline for designing microchannel structures for a precise manipulation of gas–liquid–liquid three‐phase flow which finds potential applications among others in chemical synthesis. © 2017 American Institute of Chemical Engineers AIChE J, 63: 376–388, 2018     

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.     

Direct Numerical Simulations of Three‐Layer Viscosity‐Stratified Flow

Two‐dimensional simulations of flow instability at the interface of a three‐layer, density‐matched, viscosity‐stratified Poiseuille flow are performed using a front‐tracking/finite difference method. This is an extension of the study for the stability of two‐layer viscosity‐stratified flow of Cao et al., Int. J. Multiphase Flow, 30 , 1485‐1508 (2004). We present results for large‐amplitude non‐linear evolution of the interface for varying viscosity ratio m, Weber number We, and phase difference between the perturbations of the two interfaces. Strong non‐linear behaviour is observed for relatively large initial perturbation amplitude. The higher viscosity fluid is drawn out as a finger that penetrates into the lower viscosity layer. The finger originates at the crest of the perturbation at the interface. The simulated interface shape compares well with previously reported experiments. Increasing interfacial tension retards the growth rate of the interface as expected, whereas increasing the viscosity ratio enhances it. The sinuous instability appears to evolve faster than the varicose one. For certain flow parameters the high‐viscosity finger displays a bulbous tip, which is also seen in our previously conducted experiments and two‐layer results, although it is less pronounced. The low‐viscosity intruding finger does not display this curious bulbous tip. Drop formation is precluded by the two‐dimensional nature of the calculations.     

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.     

Gas/liquid/liquid three‐phase flow patterns and bubble/droplet size laws in a double T‐junction microchannel

The double T‐junction microchannel is a classical microstructured chemical device used to generate gas/liquid/liquid three‐phase microflows. An experimental study that focused on the three‐phase flow phenomena and bubble/droplet generation rules in a double T‐junction microchannel was introduced. Based on the published knowledge of gas/liquid and liquid/liquid two‐phase microflows, new flow patterns were carefully defined: bubble cutting flow, spontaneous break‐up and bubble cutting coupling flow, and bubble/droplet alternate break‐up flow. According to the classical correlations of bubble and droplet volumes and their generation frequency ratio, the operating criteria for creating different three‐phase flow patterns were established and a model for the dimensionless average bubble and droplet volumes in the three‐phase microflows was developed. These various three‐phase microflows have great application potential in material science and flow chemistry synthesis. © 2015 American Institute of Chemical Engineers AIChE J, 61: 1722–1734, 2015     

Hydrodynamic considerations on optimal design of a three‐phase airlift bioreactor with high solids loading

The hydrodynamic study of a three‐phase airlift (TPAL) bioreactor with an enlarged gas–liquid dual separator was carried out. Different lengths and diameters of the draft tube were tested to show how the design of the separator zone affects the hydrodynamic performance of the TPAL reactor. Ca‐alginate beads with entrapped yeast biomass at different loadings (0, 7, 14 and 21% v/v) were used in order to mimic the solid phase of conventional high cell density systems, such as those with cells immobilized on carriers or flocculating cells. Important information on multiphase flow and distribution of gas and solid phases in the internal‐loop airlift reactor (ALR) with high solids loading was obtained, which can be used for suggesting optimal hydrodynamic conditions in a TPAL bioreactor with high solids loading. It is finally suggested that the ALR with a dual separator and a downcomer to riser cross‐sectional area ratio (A_D/A_R) ranging from 1.2 to 2.0 can be successfully applied to batch/continuous high cell density systems, where the uniform distribution of solid phase, its efficient separation of particles from the liquid phase, and an improved residence time of air bubbles inside the reactor are desirable. Copyright © 2003 Society of Chemical Industry     

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.     

Distribution of Two‐Phase Flow across 2.7‐mm Vertically Split U‐Type Junctions

A visual observation of the two‐phase flow across vertically split U‐type junctions and its flow redistribution inside two 2.7‐mm diameter smooth tubes with curvature ratios (2R/D) of 3 and 7, respectively, are reported. The range of mass flux is between 100 and 700 kg/m²s and quality (x) ranges from 0.001 to 0.5. The ratio of liquid distribution between the upper and lower outlet legs is related to the inlet flow pattern, but its influence is reduced at higher mass flux. The difference in liquid flow rates in the lower and upper legs is significantly affected by gravity at a small inlet mass flux, but this difference becomes less profound when the inlet mass flux is increased. The difference between the liquid flux in the upper and lower leg is reduced for the smaller curvature radius due to the reduced effect of gravity between the upper and lower legs. However, there is no consistent trend of gas flow distribution across the U‐type junction as compared to liquid flow distribution. The air mass flux in the upper and lower legs always increase with an increase in both gas quality and the total mass flux.     

Experimental Investigation on the Holdup Distribution of Oil‐Water Two‐Phase Flow in Horizontal Parallel Tubes

An experimental investigation was conducted to study the holdup distribution of oil and water two‐phase flow in two parallel tubes with unequal tube diameter. Tests were performed using white oil (of viscosity 52 mPa s and density 860 kg/m³) and tap water as liquid phases at room temperature and atmospheric outlet pressure. Measurements were taken of water flow rates from 0.5 to 12.5 m³/h and input oil volume fractions from 3 to 94 %. Results showed that there were different flow pattern maps between the run and bypass tubes when oil‐water two‐phase flow is found in the parallel tubes. At low input fluid flow rates, a large deviation could be found on the average oil holdup between the bypass and the run tubes. However, with increased input oil fraction at constant water flow rate, the holdup at the bypass tube became close to that at the run tube. Furthermore, experimental data showed that there was no significant variation in flow pattern and holdup between the run and main tubes. In order to calculate the holdup in the form of segregated flow, the drift flux model has been used here.     

Modeling and simulation of conditionally volume averaged viscoelastic two‐phase flows

Conditional volume averaging is used to develop a model capable of simulating two‐phase flows of viscoelastic fluids with surface tension effects. The study is started with the single‐phase mass and momentum balances, which are subsequently conditionally volume averaged. In doing so, we arrive at a set of equations having unclosed interfacial terms, for which closure relations for viscoelastic fluids are presented. The resulting equations possess a structure similar to the single‐phase equations; however, separate conservation equations are solved for each phase. As a result, each phase has its own pressure and velocity over the entire domain. Next, our numerical implementation is briefly outlined. We find that a Poiseuille single‐phase flow is predicted correctly. The closure terms are examined by considering a two‐phase shearing flow and a quiescient cylinder with surface tension. A convergence analysis is performed for a steady stratified two‐phase flow with both phases being viscoelastic. © 2013 American Institute of Chemical Engineers AIChE J, 59: 3914–3927, 2013     

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.     

Effect of tube diameter on two‐phase flow patterns in mini tubes

The effect of tube diameter on two‐phase flow patterns was investigated in circular tubes with inner diameters of 0.6, 1.2, 1.7, 2.6, and 3.4 mm using air and water. The gas and liquid superficial velocity ranges were 0.01–50 and 0.01–3 m/s, respectively. The gas and liquid flow rates were measured and the two‐phase flow pattern images were recorded using high‐speed CMOS camera. The flow patterns observed were dispersed bubbly, bubbly, slug, slug‐annular, wavy‐annular, stratified, and annular flows. These flow patterns were not observed in all the test diameters, but were found to be unique to particular tube diameters, confirming the effect of tube diameter on the flow pattern. The data obtained were compared to existing experimental data and flow regime transition maps which show generally reasonable overall agreement at the larger diameters, but significant differences were observed with the smaller diameter tubes.     

TUBESIDE EXIT CONDITION WITH COMPLETE CONDENSATION IN MULTITUBE CROSS-FLOW HEAT EXCHANGERS

A transition condensate Froude number characterizes the tubeside exit condition or whether condensate fills the tube or is in a stratified flow regime with vapor flowing into the tube exit. The transition Froude number, which defines the boundary between high and low condensate loading conditions, was determined with single-phase water tests and was verified with two-phase tests of large multitube cross-flow heat exchangers. For both cases, the water or condensate is discharged from a tube or tubes into a gas or vapor-filled plenum. With complete condensation and high liquid loading, the flow regimes are progressively annular, slug, and plug followed by the tube running full with subcooled condensate. With complete condensation and low liquid loading, the flow regimes are annular, wavy, and stratified followed by stratified flow with vapor flowing back from the tube exit.     

Use of axial dispersion and plug flow models for determination of axial mixing and mass transfer coefficient in an l‐shaped pulsed packed extraction column

In this study, the volumetric overall mass transfer and phases axial mixing coefficients have been investigated in a pilot plant of an L‐shaped pulsed packed extraction column by using two liquid systems of toluene/acetone/water and n‐butyl/acetone/water. The mass transfer performance has been evaluated using two methods of axial dispersion and a plug flow model. The effect of the operational variables and physical properties, including the dispersed and continuous phases flow rates, pulsation intensity, and interfacial tension, on mass transfer and phases axial mixing coefficients have been considered. It has been found that the pulsation intensity and the continuous phase flow rate seriously affect the mass transfer coefficient, however, the dispersed phase flow rate has a weaker effect. Also, the axial mixing of a phase is strongly affected by the pulsation intensity and the flow rate of the phase itself and it is not affected by the second phase flow rate. Finally, new correlations are proposed to accurately predict the mass transfer and axial mixing coefficients.     

Influence of horizontal return bend on the two‐phase flow pattern in a 6.9 mm diameter tube

The two‐phase flow pattern for air‐water mixtures inside a 6.9 mm U‐tube is reported to have curvature ratios of 3?7.1. At a lower total mass flux of 50 kg/m²·s and a quality of 0.1, or at a larger curvature ratio of 7.1, no influence on the flow patterns is seen. However, if the curvature ratio is reduced to 3, the flow pattern in the recovery region just after the return bend is temporally turned from stratified flow into annular flow. For a quality larger than 0.4, the annular flow pattern prevails in the entire tube. For G = 400 kg/m²·s and x < 0.01, the size of the plug in the downstream is usually larger than that in the upstream due to the coalesce in the return bend. This coalescence phenomenon continues to further increase the total mass flux at the lower quality region. For a total mass flux above 500 kg/m²·s, the bubbly flow pattern in the upstream region may become intermittent.     

Numerical Simulation of Oil‐water Hydrocyclone Using Reynolds‐Stress Model for Eulerian Multiphase Flows

A three‐dimensional oil‐water turbulent flow and oil separation process in a double‐cone liquid‐liquid hydrocyclone (LLHC) is numerically simulated using FLUENT software. The Euler‐Euler approach and Reynolds‐stress model are combined and adopted in this simulation to handle the challenging situation of anisotropic turbulent two‐phase flow with a higher volumetric ratio (over 10%) in the dispersed phase. It is visualized well in the simulation how separation, aggregation and shift of oil and water proceed in the LLHC. The oil separation efficiency is determined based on flow field and phase concentration distribution. The simulation is verified by comparing predicted and measured separation efficiency in the LLHC.     

Analysis of roll wave characteristics under low liquid loading two‐phase flow conditions

An experimental study is conducted using a 0.152‐m ID facility to investigate the wave characteristics of two‐phase stratified wavy flow in horizontal pipelines. The experiments are conducted under low liquid loading condition, which is very commonly observed in wet gas pipelines. The experiments are conducted with water as the liquid phase, and repeated with 51 wt % of monoethylene glycol (MEG) in the aqueous phase to analyze the effects of MEG presence on wave characteristics. The experimental range of this study covers superficial gas velocity, v_Sg, values of 9–23 m/s and superficial liquid velocity, v_SL, values of 0.01–0.02 m/s. Similar test matrices are completed for the cases with and without MEG in the aqueous phase. A conductivity probe system is used to measure the wave characteristics at the liquid–gas interface. These characteristics include the wave celerity, frequency, amplitude, length, and liquid film thickness. The experimental oil–air wave characteristics data of Gawas et al. (Int J Multiphase Flow. 2014;63:93–104) is also used for comparison purposes. The trends in the resulting wave characteristics with respect to input parameters are investigated, for oil, water, or MEG–water mixture as the liquid phase. Common predictive methods for interfacial wave celerity, including shallow water theory, Watson (Proceedings of the 4th International Conference in Multi‐Phase Flows, Nice, France. 1989:495–512), Paras et al. (Int J Multiphase Flow. 1994;20(5):939–956), Al‐Sarkhi et al. (AIChE J. 2012;58(4):1018–1029), and Gawas et al. (Int J Multiphase Flow. 2014;63:93–104) are evaluated in comparison with the experimental data. The results of the wave frequency correlation of Al‐Sarkhi et al. (AIChE J. 2012;58(4):1018–1029) are also compared with the experimental wave frequency data. Lastly, a correlation is developed to predict the relative wave amplitude, as a function of superficial gas Weber number and liquid velocity number. Most of the commonly used two‐phase stratified flow models are developed with the assumption of steady‐state conditions, and neglect the transient wave effects. This study provides valuable experimental results on wave characteristics of stratified wavy flow for different types of liquid phase. Moreover, a comprehensive analysis of the parameters affecting the wave characteristics of stratified wavy flow is presented. © 2017 American Institute of Chemical Engineers AIChE J, 63: 3177–3186, 2017