Benchmark Simulation of Turbulent Flow through a Staggered Tube Bundle to Support CFD as a Reactor Design Tool. Part I: SRANS CFD Simulation

Time-invariant and time-variant numerical simulations of flow through a staggered tube bundle array, idealizing the lower plenum (LP) subsystem configuration of a very high temperature reactor (VHTR), were performed. In Part I, the CFD prediction of fully periodic isothermal tube-bundle flow using steady Reynolds-averaged Navier-Stokes (SRANS) equations with common turbulence models was investigated at a Reynolds number (Re) of 1.8 × 10⁴, based on the tube diameter and inlet velocity. Three first-order turbulence models, standard k-ε turbulence, renormalized group (RNG) k-ε, and shear stress transport (SST) k-ω models, and a second-order turbulence model, Reynolds stress model (RSM), were considered. A comparison of CFD simulations and experiment results was made at five locations along (x, y) coordinates. The SRANS simulation showed that no universal model predicted the turbulent Reynolds stresses, and generally, the results were marginal to poor. This is because these models cannot accurately model the periodic, spatiotemporal nature of the complex wake flow structure.     

扩散角对文丘里管内湍流影响的试验研究

为研究扩散角对文丘里管内湍流的影响,采用立体粒子图像测速技术分别对扩散角度为10°、12.5°、15°以及20°的文丘里管扩散段区域进行了测量,得到了平均速度分布,并通过瞬时速度场的统计分析得到了扩散段湍动能分布情况。研究表明,不同扩散角度的文丘里管扩散段内平均速度在截面直径方向成轴对称的单峰分布,湍动能在截面直径上成轴对称的双峰分布,在各试验工况下扩散段内均发生流动分离现象。随扩散角度增加,湍动能峰值增加,主流区径向宽度未发生变化,分离流区径向宽度增加,但对分离流区所占比例的影响较小,高湍动能区变宽;随着雷诺数的增加,湍动能峰值增加,主要由轴向雷诺应力引起,分离流区所占比例略有降低,但主流区和分离流区分布变化较小。此研究为高雷诺数不同角度的文丘里管流场研究提供了实验基础。      

Two fluid model for two-phase turbulent jets

Eulerian two-fluid models are widely used in nuclear reactor safety and CFD. In these models turbulent diffusion of a dispersed phase must be formulated in terms of the fluctuating interfacial force and the Reynolds stresses. The interfacial force is obtained using the probability distribution function approach by Reeks (1992). This paper is the first application of this force to a case of engineering interest outside homogeneous turbulence. An Eulerian multidimensional two-fluid model for a cylindrical two-phase dispersed particle jet is proposed and compared with experimental data. The averaged conservation equations of mass and momentum are solved for each phase and the turbulent kinetic energy equation is solved for the continuous phase. The turbulent diffusion force and the Reynolds stresses are constituted within the context of the k- model of turbulence. A dissipation term has been added to the k- model for the turbulence modulation by the particles. Once the constitutive relations have been defined, the two-fluid model is implemented in a computational fluid dynamics code. It is shown that when the particles are very small the model is consistent with a convection-diffusion equation for particle transport where the diffusivity is defined according to Taylor's model (Taylor, G.I., 1921. Diffusion by continuous movements. Proc. London Math. Society, A20, pp. 196–211). The two-fluid model is also compared against two experimental data sets. Good agreement between the model and the data is obtained. The sensitivity of the results to various turbulent mechanisms is discussed.     

The structure of turbulent flow in triangular array rod bundles

A wind tunnel study of fully developed uniform-density turbulent flow through triangular array rod bundles is described. Measurements were made for three tube spacings (

Full-size image (<1K)

) over a Reynolds number range of 12 000–84 000. The data include friction factors, local wall shear stresses, and the distributions of mean axial velocity, Reynolds stresses and eddy diffusivities. The secondary flow pattern is from the available evidence.     

Local measurement of interfacial area, interfacial velocity and liquid turbulence in two-phase flow

Double sensor probe and hotfilm anemometry methods were developed for measuring local flow characteristics in bubbly flow. The formulation for the interfacial area concentration measurement was obtained by improving the formulation derived by Kataoka and Ishii. The assumptions used in the derivation of the equation were verified experimentally. The interfacial area concentration measured by the double sensor probe agreed well with one by the photographic method. The filter to validate the hotfilm anemometry for measuring the liquid velocity and turbulent intensity in bubbly flow was developed based on removing the signal due to the passing bubbles. The local void fraction, interfacial area concentration, interfacial velocity, Sauter mean diameter, liquid velocity, and turbulent intensity of vertical upward air–water flow in a round tube with an inner diameter of 50.8 mm were measured by using these methods. A total of 54 data sets were acquired consisting of three superficial gas flow rates, 0.015–0.076 m s⁻¹, and three superficial liquid flow rates, 0.600, 1.00, and 1.30 m s⁻¹. The measurements were performed at the three locations: L/D=2, 32, and 62. This data is expected to be used for the development of reliable constitutive relations which reflect the true transfer mechanisms in two-phase flow.     

Droplet entrainment correlation in vertical upward co-current annular two-phase flow

Upward annular two-phase flow in a vertical tube is characterized by the presence of liquid film on the tube wall and entrained droplet laden gas phase flowing through the tube core. Entrainment fraction in annular flow is defined as a fraction of the total liquid flow flowing in the form of droplets through the central gas core. Its prediction is important for the estimation of pressure drop and dryout in annular flow. In the following study, measurements of entrainment fraction have been obtained in vertical upward co-current air–water annular flow covering wide ranges of pressure and flow conditions. Comparison of the experimental data with the existing entrainment fraction prediction correlations revealed their inadequacies in simulating the trends observed under high flow and high pressure conditions. Furthermore, several correlations available in the literature are implicit and require iterative calculations.Analysis of the experimental data showed that the non-dimensional numbers, Weber number (We = ρ_gj_g²D/σ(Δρ/ρ_g)^1/4) and liquid phase Reynolds number (Re_f = ρ_fj_fD/μ_f), successfully collapse the data. In view of this, simple, explicit correlation was developed based on these non-dimensional numbers for the prediction of entrainment fraction. The new correlation successfully predicted the trends under the high flow and high pressure conditions observed in the current experimental data and the data available in open literature. However, in order to use the proposed correlation it is necessary to predict the maximum possible entrainment fraction (or limiting entrainment fraction). In the current analysis, an experimental data based correlation was used for this purpose. However, a better model or correlation is necessary for the maximum possible entrainment fraction. A theoretical discussion on the mechanism and modeling of the maximum possible entrainment fraction condition is presented.     

Measurement of Liquid Turbulent Structure in Bubbly Flow at Low Void Fraction Using Ultrasonic Doppler Method

Microscopic structure in bubbly flows has been a topic of interest in the study of fluid dynamics. In the present paper, the ultrasonic Doppler method was applied to the measurement of bubbly. The experiments were carried out for an air-water dispersed bubbly flow in a 20 mm × 100 mm vertical rectangular channel having a void fraction smaller than 3%. Two ultrasonic transducers were installed on the outer surface of the test section with a contact angle of 45^° off the vertical axis, one facing upward and the other facing downward. By applying statistical methods to the two directional velocity profiles, Reynolds stress profiles were calculated. Furthermore, to clarify the wake effect induced by the leading bubbles, the velocity profiles were divided into two types of data. The first one is for all of the liquid data and the other is the data which did not include the wake effect. For Re_m ≥1,593, it was observed that the bubbles suppressed the liquid turbulence. Furthermore, comparing with the Reynolds stress profiles in bubbly flow, it was found that Reynolds stress profiles varied with the amount of bubbles present in the flow and the effect of wake causes turbulence in the liquid.     

Two phase flow 1D turbulence model for poly-disperse upward flow in a vertical pipe

A 1D test-solver was developed in recent years for modeling of two phase bubbly flows in pipe geometry. The solver considers a number of bubble classes and calculates bubble-size resolved void fraction profiles in the radial direction. A successful implementation was achieved regarding bubble forces models (non-drag forces). Discrepancies appeared when coalescence and breakup rates were significant. These rates depend upon local turbulence quantities, which are possible reason for discrepancies. Originally the test-solver is equipped by Sato model (Sato, Y., Sadatomi, M., Sekoguchi, K., 1981. Momentum and heat transfer in two-phase bubble flow. I. International Journal Multiphase Flow 7, 167–177 .) which accounts for turbulence via shear- and bubble-induced viscosities calculated out of empirical correlations. One equation for the turbulent kinetic energy was solved, while the dissipation rate was calculated out of a correlation. In order to improve calculation of the local turbulence parameters, a two-phase k– turbulence model was adopted instead. The account for the bubble-induced turbulence was made via a source term taken out of literature. Comparisons between new and old turbulence modeling against experimental data showed better agreement for the new model. The experiments covered a wide range of water and air superficial velocities for upward bubbly flow in two pipe's diameters: 50 and 200 mm. The main feature of the new model is providing more reliable values of turbulence parameters for application in coalescence and breakup models. A comparison with CFX 5.7 calculations in a 50 mm pipe showed better calculation results when the source term was considered in the k– equations. An implementation into CFX is planned.     

Numerical study of a bubble plume generated by bubble entrainment from an impinging jet

The current paper presents the prediction results of a bubbly flow under plunging jet conditions using multiphase mono- and poly-dispersed approaches. The models consider interfacial momentum transfer terms arising from drag, lift, and turbulent dispersion force for the different bubble sizes. The turbulence is modeled by an extended k–? model which accounts for bubble induced turbulence. Furthermore in case of a poly-dispersed air–water flow the bubble size distribution, bubble break-up and coalescence processes as well as different gas velocities in dependency on the bubble diameter are taken into account using the Inhomogeneous MUSIG model. This model is a generalized inhomogeneous multiple size group model based on the Eulerian modeling framework which was developed in the framework of a cooperative work between ANSYS-CFX and Forschungszentrum Dresden-Rossendorf (FZD). The latter is now implemented into the CFD code CFX.According to the correlation on the lateral lift force obtained by Tomiyama (1998); this force changes its sign in dependence on the bubble size. Consequently the entrained small bubbles are trapped below the jet. They can escape from the bubble plume only by turbulent fluctuations or by coalescence. If the size of the bubbles generated by coalescence exceeds the size at which the lift force changes its sign these large bubbles go out from the plume and rise to the surface.A turbulent model based on an additional source term for turbulence kinetic energy and turbulence eddy dissipation equation is compared to the common concept for modeling the turbulence quantities proposed by Sato et al. (1981). It has been found that the large bubble distribution is slightly affected by the turbulence modeling which affects particularly the bubble coalescence and break-up process.     

Simulation of bubbly flow in vertical pipes by coupling Lagrangian and Eulerian models with 3D random walks models: Validation with experimental data using multi-sensor conductivity probes and Laser Doppler Anemometry

A set of two phase flow experiments for different conditions ranging from bubbly flow to cap/slug flow have been performed under isothermal concurrent upward air–water flow conditions in a vertical column of 3 m height. Special attention in these experiments was devoted to the transition from bubbly to cap/slug flow. The interfacial velocity of the bubbles and the void fraction distribution was obtained using 2 and 4 sensors conductivity probes.Numerical simulations of these experiments for bubbly flow conditions were performed by coupling a Lagrangian code with an Eulerian one. The first one tracks the 3D motion of the individual bubbles in cylindrical coordinates (r, ?, z) inside the fluid field under the action of the following forces: buoyancy, drag, lift, wall lubrication. Also we have incorporated a 3D stochastic differential equation model to account for the random motion of the individual bubbles in the turbulent velocity field of the carrier liquid. Also we have considered the deformations undergone by the bubbles when they touch the walls of the pipe and are compressed until they rebound.The velocity and turbulence fields of the liquid phase were computed by solving the time dependent conservation equations in its Reynolds Averaged Transport Equation form (RANS). The turbulent kinetic energy k, and the dissipation rate ? transport equations were simultaneously solved using the k, epsilon model in a (r, z) grid by the finite volume method and the SIMPLER algorithm. Both Lagrangian and Eulerian calculations were performed in parallel and an iterative self-consistent method was developed. The turbulence induced by the bubbles is an important issue considered in this paper, in order to obtain good predictions of the void fraction distribution and the interfacial velocity at different gas and liquid flow conditions.     

Lateral turbulent diffusion for longitudinal flow in a rectangular channel

The turbulent diffusivity for mass transfer in the wide direction of a 0.008 × 0.1 m rectangular duct was determined by continuous tracer injection. A hybrid computation method was used to analyse the axial development of time average lateral concentration distributions. For the investigated Reynolds number range, 30 000–86 000, the turbulent diffusivity of mass can be correlated by = 0.178y₀(τ ) From the diffusivity results one may infer the magnitude of the Lagrangian integral spatial scale of turbulence.     

Geometric effects of 90-degree Elbow in the development of interfacial structures in horizontal bubbly flow

Present study investigates the geometric effects of flow obstruction on the distribution of local two-phase flow parameters and their transport characteristics in horizontal bubbly flow. The round glass tubes of 50.3 mm in inner diameter are employed as test sections, along which a 90-degree Elbow is located at L/D = 206.6 from the two-phase mixture inlet. In total, 15 different flow conditions are examined within the air–water bubbly flow regime. The detailed local two-phase flow parameters are acquired by the double-sensor conductivity probe at four different axial locations. The effect of elbow is found to be evident in both the distribution of local parameters and their development. The elbow clearly promotes bubble interactions resulting in significant changes in interfacial area concentration. It is also found that the elbow-effect propagates to be more significant further downstream (L/D = 250) than immediate downstream (L/D = 225) of the elbow. Furthermore, it is shown that the elbow induces significant oscillations in the flow in both vertical and horizontal directions of the tube cross-section. Characteristic geometric effects due to the existence of elbow are also shown clearly in the transport of one-dimensional interfacial area concentration and void fraction along the flow.     

Benchmark Simulation of Turbulent Flow through a Staggered Tube Bundle to Support CFD as a Reactor Design Tool. Part II: URANS CFD Simulation

In Part II, we described the unsteady flow simulation and proposed a modification of a traditional turbulence flow model. Computational fluid dynamics (CFD) simulations of an isothermal, fully periodic flow across a tube bundle using unsteady Reynolds averaged Navier-Stokes (URANS) equations, with turbulence models such as the Reynolds stress model (RSM) were investigated at a Reynolds number of 1.8 × 10⁴, based on the tube diameter and inlet velocity. As noted in Part I, CFD simulation and experimental results were compared at five positions along (x; y) coordinates. The steady RANS simulation showed that four diverse turbulence models were efficient for predicting the Reynolds stresses, and generally, SRANS results were marginal to poor, using a consistent evaluation terminology. In the URANS simulation, we modeled the turbulent flow field in a manner similar to the approach used for large eddy simulation (LES). The time-dependent URANS results showed that the simulation reproduces the dynamic stability as characterized by transverse oscillatory flow structures in the near-wake region. In particular, the inclusion of terms accounting for the time scales associated with the production range and dissipation rate of turbulence generates unsteady statistics of the mean and fluctuation flow. In spite of this, the model implemented produces better agreement with a benchmark data set and is thus recommended.     

Mechanical integrity analysis of TMI-1 OTSG unplugged tubes

Small I.D. circumferential defects have been identified in many steam generator tubes. The origin of the cracks is known to be chemical, not mechanical. A fracture mechanics evaluation has been conducted to ascertain the stability of tube cracks under steady-state and anticipated transient conditions. A spectrum of hypothetical crack sizes was interacted with tube stresses derived from the load evaluation using the methods of linear elastic fracture mechanics (LEFM). Stress intensities were calculated for part-through wall cracks in cylinders combining components due to membrane stress, bending stress, and stresses due to internal pressure acting on the parting crack faces as the loads are cycled.The LEFM computational code, “BIGIF”, developed for EPRI, was used to integrate over a range of stress intensities following the model to describe crack growth in INCO 600 at operating temperature using the equation (ΔK)^3.5.The code was modified by applying ΔK_Th, the threshold stress intensity range. Below ΔK_Th small cracks will not propagate at all. Appropriate R ratio values were employed when calculating crack propagation due to high cycle or low cycle loading.Cracks that may have escaped detection by ECT will not jeopardize tube integrity during normal cooldown unless these cracks are greater than 180° in extent. Large non-through-wall cracks that would jeopardize tube integrity are not expected to evolve because in axi-symmetric tensile stress fields, cracks propagate preferentially through the tube wall rather than around the circumference. Tube integrity can be demonstrated for mid-span tube regions and for the transition region as well.The as-repaired transition geometry is a design no less adequate than the original. The as-repaired condition represents an improvement in the state of stress due to mechanical and thermal loads as compared to the original.     

Two-group interfacial area transport in vertical air–water flow: I. Mechanistic model

In a companion paper, mechanistic models of major fluid particle interaction phenomena involving two bubble groups have been proposed. The prediction of interfacial area concentration evolution using the one-dimensional two-group transport equation and evaluation with experimental results are performed in the paper. These evaluations are based on solid databases for a 2-inch air–water loop with sufficient information on the axial development and the radial distribution of the local parameters. Model evaluation strategies are systematically analyzed. The predictions for the interfacial area concentration evolution demonstrate satisfactory accuracy. The proposed model predicts a smooth transition across the bubbly-to-slug flow regime boundary and demonstrates mechanisms for the generation and development of the cap/slug bubble group. The two-group interfacial area transport equation covers a wide range from bubbly, slug, to churn turbulent flow regimes for adiabatic air–water upward flow in moderate diameter pipes. The generality of the interfacial transport model is also discussed.     

Effect of Gas Introduction on Temperature Distribution for Tube Flow with Internal Heat Sources

An experimental study has been conducted to investigate the effect of gas introduction on the heat transfer characteristics for turbulent flow of a heat generating liquid in an adiabatic tube 20 mm in inside diameter. Heat generation within the fluid was brought about by passing an alternating current through the working fluid, which was an aqueous solution of sodium chloride mixed with air bubbles. The superficial liquid Reynolds number ranged 3,700–11,000. The quality was varied from 2.6×10^?5 to 3.3×l0^?3. Measurements were made of the temperature distributions in the fluid as well as on the tube wall. The experimental results were compared with theoretical analyses.

In bubbly flow; the introduction of air into liquid brought forth a flat temperature distribution due to a considerable increase of turbulence and a saddle-shaped void distribution, which had a maximum near the tube wall. In slug flow, however, the void distribution changed to a dome-shaped profile with a maximum at the tube center and the rate of heat generation was higher near the wall than in the center region, resulting in a steep temperature distribution.     

CFD analysis of thermal–hydraulic behavior of heavy liquid metals in sub-channels

CFD analysis was carried out for thermal–hydraulic behavior of heavy liquid metal flows, especially lead–bismuth eutectic, in sub-channels of both triangular and square lattices. Effect of various parameters, e.g. turbulence models and pitch-to-diameter ratio, on the thermal–hydraulic behavior was investigated. Among the turbulence models selected, only the second order closure turbulence models reproduce the secondary flow. For the entire parameter range studied in this paper, the amplitude of the secondary flow is less than 1% of the mean flow. A strong anisotropic behavior of turbulence is observed. The turbulence behavior is similar in both triangular and square lattices. The average amplitude of the turbulent velocity fluctuation across the gap is about half of the shear velocity. It is only weakly dependent on Reynolds number and pitch-to-diameter ratio. A strong circumferential non-uniformity of heat transfer is observed in tight rod bundles, especially in square lattices. Related to the overall average Nusselt number, CFD codes give similar results for both triangular and square rod bundles. Comparison of the CFD results with bundle test data in mercury indicates that the turbulent Prandtl number for HLM flows in rod bundles is close to 1.0 at high Peclet number conditions, and increases by decreasing Peclet number. Based on the present results, the SSG Reynolds stress model with semi-fine mesh structures is recommended for the application of HLM flows in rod bundle geometries.     

Analytical prediction of friction factors and Nusselt numbers of turbulent forced convection in rod bundles with smooth and rough surfaces

A simple analytical method was developed for the prediction of the friction factor, f, of fully developed turbulent flow and the Nusselt number, Nu, of fully developed turbulent forced convection in rod bundles arranged in square or hexagonal arrays. The friction factor equation for smooth rod bundles was presented in a form similar to the friction factor equation for turbulent flow in a circular pipe. An explicit equation for the Nusselt number of turbulent forced convection in rod bundles with smooth surface was developed. In addition, we extended the analysis to rod bundles with rough surface and provided a method for the prediction of the friction factor and the Nusselt number. The method was based on the law of the wall for velocity and the law of the wall for the temperature, which were integrated over the entire flow area to yield algebraic equations for the prediction of f and Nu. The present method is applicable to infinite rod bundles in square and hexagonal arrays with low pitch to rod diameter ratio, P/D<1.2.     

Novel porous media formulation for multiphase flow conservation equations

Multiphase flows consist of interacting phases that are dispersed randomly in space and in time. An additional complication arises from the fact that the flow region of interest often contains irregularly shaped structures. While, in principle, the intraphase conservation equations for mass, momentum, and energy, and their initial and boundary conditions can be written, the cost of detailed fluid flow and heat transfer analysis with explicit treatment of these internal structures with complex geometry and irregular shape often is prohibitive, if not impossible. In most engineering applications, all that is required is to capture the essential features of the system and to express the flow and temperature field in terms of local volume-averaged quantities while sacrificing some of the details. The present study is an attempt to achieve this goal by applying time averaging after local volume averaging.Local volume averaging of conservation equations of mass, momentum, and energy for a multiphase system yields equations in terms of local volume-averaged products of density, velocity, energy, stresses, and field forces, together with interface transfer integrals. These averaging relations are subject to the following length scale restrictions:

dℓL,