Gas–Liquid Two-Phase Flow Evolution in a Long Microchannel

A pair of optical void sensors and a high-speed video camera were used to investigate the evolution of adiabatic gas–liquid two-phase flow in a long microchannel. Experiments were conducted with a 1676-mm-long, circular microchannel with an inner diameter of 100 μm. Two-phase flow patterns, void fraction, and velocities of gas plug/slug and liquid slugs were measured at different axial locations between the gas–liquid mixer and microchannel exit. The pressure decreased linearly in the first half of the microchannel, and more rapidly and nonlinearly in the second half of the test section. As a result, the flow accelerated significantly in the second half of the microchannel such that the void fraction and liquid slug velocity increased nonlinearly. The measured mean void fraction and mean velocity of liquid slugs also agreed well with the homogeneous flow model predictions when the liquid flow rate was constant and the mass velocity of the gas was low.     

Droplet and slug formation in polymer electrolyte membrane fuel cell flow channels: The role of interfacial forces

A microfluidic device is employed to emulate water droplet emergence from a porous electrode and slug formation in the gas flow channel of a PEM fuel cell. Liquid water emerges from a 50 μm pore forming a droplet; the droplet grows to span the entire cross-section of a microchannel and transitions into a slug which detaches and is swept downstream. Droplet growth, slug formation, detachment, and motion are analyzed using high-speed video images and pressure-time traces. Slug volume is controlled primarily by channel geometry, interfacial forces, and gravity. As water slugs move downstream, they leave residual micro-droplets that act as nucleation sites for the next droplet-to-slug transition. Residual liquid in the form of micro-droplets results in a significant decrease in slug volume between the very first slug formed in an initially dry channel and the ultimate “steady-state” slug. A physics-based model is presented to predict slug volumes and pressure drops for slug detachment and motion.     

Optimization of gas hydrate reactors with slug flow

A model of heat transfer during gas hydrate formation at a gas-liquid interface in gas-liquid slug flow with liquid plugs containing small bubbles is suggested. Under the assumption of perfect mixing of liquid in liquid plugs, recurrent relations for temperature in the n-th liquid plug and heat and mass fluxes from the n-th unit cell in a gas-liquid slug flow are derived. The ratio of the total mass flux during gas hydrate formation in a cluster with N unit cells to the mass flux in a cluster with an infinite number of unit cells is determined. The number of unit cells that yield 95% of the total amount of gas hydrates in an infinite cluster of unit cells is calculated and formula for an optimal length of a gas hydrate slug flow reactor is derived.     

Mass Transfer during gas absorption from a linear cluster of slugs in the presence of inert gases

A model of mass transfer during isothermal gas absorption in the presence of inert gas from a slug rising in a channel filled with liquid is suggested. The work studies the case of a small amount of soluble gas inside a slug and employs the approximation of a thin concentration boundary layer. Theoretical results of mass transfer analysis for a single gas slug are applied for determination of mass transfer rate in gas liquid slug flow. In the assumption of a perfect mixing of the dissolved gas in liquid plugs, recurrent relations for the dissolved gas concentration in the n-th liquid plug and mass flux from the n-th gas slug are derived. The mass transfer coefficient in gas-liquid slug flow is determined. In the limiting case the derived formulas for mass transfer in the presence of inert admixtures recover the obtained expressions for mass transfer during absorption of a pure gas. Theoretical results are compared with available experimental data.     

Two models of fluid flow and mass transfer at the trailing edge of a gas slug

Two theoretical models for fluid flow and mass transfer at the trailing edge of a gas slug for small and large Reynolds numbers are suggested. In the case of small Reynolds numbers the creeping fluid flow at the trailing edge of a slug near a corner formed by a plane rigid wall and gas liquid interface is investigated. The flow is caused by in-plane motion and by a fluid in the gap between a rigid wall and a gas-liquid interface. Using this model the rate of mass transfer from the bottom of a slug during gas absorption is determined. In the case of high Reynolds numbers the vortex flow at the trailing edge of the gas slug is investigated. A model of a fluid flow and mass transfer in a vortex flow in cavities is applied for the investigation of vortex formation at the trailing edge of a gas slug.     

The role of the gas diffusion layer on slug formation in gas flow channels of fuel cells

Water drops emerge from large pores of the hydrophobic Gas Diffusion Layers (GDL) into the cathode gas flow channel of Polymer Electrolyte Membrane (PEM) Fuel Cells. The drops grow into slugs that span the cross-section of the flow channels. The slugs detach and are forced out the gas flow channel by the air flow. An acrylic micro-fluidic flow cell with a 1.6 mm gas flow channel and a 100 μm liquid pore through a carbon paper GDL has been used to quantitatively determine slug volumes, velocity of slug motion, and the force required to move slugs as functions of the gas and liquid flow rates. In a channel with 4 acrylic walls, slugs detach immediately upon formation. A porous GDL wall allows gas flow to bypass the slugs, thus allowing slugs to continue to grow after spanning the open area of the channel. The differential pressure to detach and move slugs is equal to the dynamic interfacial force on a slug normalized by the cross-sectional area of the channel. The dynamic interfacial force is equal to the difference between the downstream (advancing) and upstream (receding) contact lines of the water with the channel walls. Slugs will stop moving if the differential pressure drop for gas flow to bypass the slug and flow through the GDL under the rib separating the channels is less than the differential pressure required to move the slug. The results improve our physical insight into the state of water hold up in PEM fuel cells.     

Transient flow patterns and bubble slug lengths in parallel microchannels with oxygen gas bubbles produced by catalytic chemical reactions

Transient flow patterns and bubble slug lengths were investigated with oxygen gas (O₂) bubbles produced by catalytic chemical reactions using a high speed camera bonded with a microscope. The microreactor consists of an inlet liquid plenum, nine parallel rectangular microchannels followed by a micronozzle, using the MEMS fabrication technique. The etched surface was deposited by the thin platinum film, which is acted as the catalyst. Experiments were performed with the inlet mass concentration of the hydrogen peroxide from 50% to 90% and the pressure drop across the silicon chip from 2.5 to 20.0 kPa. The silicon chip is directly exposed in the environment thus the heat released via the catalytic chemical reactions is dissipated into the environment and the experiment was performed at the room temperature level. It is found that the two-phase flow with the catalytic chemical reactions display the cyclic behavior. A full cycle consists of a short fresh liquid refilling stage, a liquid decomposition stage followed by the bubble slug flow stage. At the beginning of the bubble slug flow stage, the liquid slug number reaches maximum, while at the end of the bubble slug flow stage the liquid slugs are quickly flushed out of the microchannels. Two or three large bubbles are observed in the inlet liquid plenum, affecting the two-phase distributions in microchannels. The bubble slug lengths, cycle periods as well as the mass flow rates are analyzed with different mass concentrations of hydrogen peroxide and pressure drops. The bubble slug length is helpful for the selection of the future microreactor length ensuring the complete hydrogen peroxide decomposition. Future studies on the temperature effect on the transient two-phase flow with chemical reactions are recommended.     

Study of Phase Splitting at a Micro-T-Junction

Small T-junctions are frequently applied in various devices, such as microreactors and compact heat exchangers. However, when a gas–liquid two-phase flow passes through a T-junction, uneven distribution of the phases will take place among the branching channels, which can cause reductions in both thermal and fluid-dynamic performances. An experiment has been carried out to study the transient behavior of water–nitrogen slug flow through a horizontal T-junction with square cross section (500 μm × 500 μm). It is observed that the distribution of liquid and gas at the inlet is changed with the gas taken off from the branch side. The merge of liquid slugs at the inlet occurs frequently at high gas taken off due to the decrease of slug velocity. At median gas taken off in the branch side, the system is highly unstable owing to the easier change of gas acceleration. However, the liquid split is not dramatically influenced by a wide range of values of gas taken off but depends more on the liquid superficial velocity. When the mixture velocity in the main branch is lower than the liquid superficial velocity, the liquid rapidly flow back from the main branch to the side branch.     

Characteristics of interfacial profiles in upward and downward gas-liquid two-phase plug flow

Gas-liquid interfacial profiles in plug flow for both upward and downward flows were obtained using semi-supermultiple point-electrode probes, comprising 67 sensing tips arranged on a tube diameter. Typical interfacial profiles are demonstrated for both flows. Close inspection of the profiles reveals that four zones exist in a pair of gas and liquid slugs for upward plug flow and a high slip velocity region in downward plug flow. The lengths of the swelling liquid front zone and the wake zone were determined. The length of the wake zone strongly depends on the relative velocity between the liquid film around the gas slug and the liquid phase in the liquid slug. Characteristic distributions of bubbles within liquid slugs were found, i.e., three types of radial distributions of void fraction, namely saddle-shaped, trapezoidal and bullet-shaped distributions, exist for upward flow. The two types for downward flow exclude the saddle-shaped distribution. © 1997 Scripta Technica, Inc. Heat Trans Jpn Res, 25 (8): 568–579, 1996     

An experimental study of the statistical parameters of gas–liquid two-phase slug flow in horizontal pipeline

Experiments were performed in a horizontal test loop with inner diameter 50 mm to study the gas–liquid slug flow. The translational velocities of elongated bubbles, lengths of liquid slugs and elongated bubbles, and slug frequencies were measured using two pairs of conductivity probes. Correlations are presented for elongated bubble translational velocity, length of elongated bubble and slug frequency, respectively. It was found that the translational velocity of elongated bubble is not only dependent on Froude number, but also is significantly affected by the distance from the entrance of pipeline in the higher mixture velocity range. Mean liquid slug length is relatively insensitive to the gas and liquid flow rates in the higher mixture velocity range, however in the lower mixture velocity range, the mean liquid slug length is affected by the mixture velocity. Mean slug frequency clearly increases as the liquid superficial velocity increases but it weakly depends on the gas superficial velocity.     

The effect of liquid film evaporation on flow boiling heat transfer in a micro tube

Flow boiling in micro channels is attracting large attention since it leads to large heat transfer area per unit volume. Generated vapor bubbles in micro channels are elongated due to the restriction of channel wall, and thus slug flow becomes one of the main flow regimes. In slug flow, sequential bubbles are confined by the liquid slugs, and thin liquid film is formed between tube wall and bubble. Liquid film evaporation is one of the main heat transfer mechanisms in micro channels and liquid film thickness is a very important parameter which determines heat transfer coefficient. In the present study, liquid film thickness is measured by laser focus displacement meter under flow boiling condition and compared with the correlation proposed for an adiabatic flow. The relationship between liquid film thickness and heat transfer coefficient is also investigated. Initial liquid film thickness under flow boiling condition can be predicted well by the correlation proposed under adiabatic condition. Under flow boiling condition, liquid film surface fluctuates due to high vapor velocity and shows periodic pattern against time. Frequency of periodic pattern increases with heat flux. At low quality, heat transfer coefficients calculated from measured liquid film thickness show good accordance with heat transfer coefficients obtained directly from wall temperature measurements.     

Flow pattern of boiling in micro-channel by numerical simulation

Boiling flows of R-134a and R-22 fluids in a 0.50 mm circular channel have been simulated to analyze bubbly flow, bubbly/slug flow, slug flow and slug/semi-annular flow depending on bubble evolution. The vapor–liquid interface was captured using VOF method. We studied the behavior of bubble growth and coalescence related to flow pattern transitions (bubbly/slug flow to slug flow, slug flow to slug/semi-annular flow) and analyzed the effect of fluid properties on transition lines. Some parameters, including heat flux, mass velocity, ONB point, vapor velocity, bubble lifting diameter, growth rate and generation frequency, have been analyzed in detail. The results show that bubble growth and coalescence are important factors for flow pattern transitions. The flow patterns at the micro-channel outlet predicted by simulation were in agreement with phenomena observed in experiments for bubbly/slug flow, slug flow and slug/semi-annular flow. In addition, the peak bubble frequency at the outlet was predicted and the general shape of the bubble frequency distribution at the outlet from simulation was found to be consistent with the achieved experimental results.     

Dynamic water transport and droplet emergence in PEMFC gas diffusion layers

The dynamics of liquid water transport through the gas diffusion layer (GDL) and into a gas flow channel are investigated with an ex situ experimental setup. Liquid water is injected through the bottom surface of the GDL, and the through-plane liquid pressure drop, droplet emergence and droplet detachment are studied. The dynamic behaviour of water transport in and on the surface of the GDL is observed through fluorescence microscopy, and the through-plane liquid pressure drop is measured with a pressure transducer. With an initially dry GDL, the initial breakthrough of liquid water in the GDL is preceded by a substantial growth of liquid water pressure. Post-breakthrough, droplets emerge with a high frequency, until a quasi-equilibrium liquid water pressure is achieved. The droplet emergence/detachment regime is followed by a transition into a slug formation regime. During the slug formation regime, droplets tend to pin near the breakthrough location, and the overall channel water content increases due to pinning and the formation of water slugs. Droplets emerge from the GDL at preferential breakthrough locations; however, these breakthrough locations change intermittently, suggesting a dynamic interconnection of water pathways within the GDL. The experiments are complemented by computational fluid dynamics (CFD) simulations using the volume of fluid method to illustrate the dynamic eruption mechanism.     

Effect of Channel Length on the Gas–Liquid Two-Phase Flow Phenomena in a Microchannel

An optical measurement system was used to investigate the effect of microchannel length and inlet geometery on adiabatic gas–liquid two-phase flow. Experiments were conducted with 146-mm- and 1571-mm-long, circular microchannels of 100 μm diameter. Void fraction and gas and liquid plug/slug lengths and their velocities were measured for two inlet configurations for gas–liquid mixing: (a) reducer and (b) T-junction. The superficial gas velocity was varied from 0.03 to 14 m/s, and superficial liquid velocity from 0.04 to 0.7 m/s. The test section length was found to have a significant effect on the two-phase flow characteristics measured at the same axial location (37 mm from the inlet) in both microchannels. The mean void fraction data for the short (146 mm) microchannel with the reducer inlet agreed well with the equation previously proposed by Kawahara et al. (2002). On the other hand, the mean void fraction data for the long (1571 mm) microchannel obeyed the homogeneous flow model and Armand's equation for both the reducer and T-junction inlet configurations. Many long and rapidly moving gas plugs/slugs and long, slowly moving liquid plugs/slugs were observed in the short microchannel compared to the long microchannel, leading to the differences in the time-averaged void fraction data. The mean velocity of liquid plugs/slugs generally agreed well with Hughmark's equation and the homogeneous flow model predictions, regardless of the inlet configurations and microchannel lengths. Thus, both the microchannel length and inlet geometry were found to significantly affect the two-phase flow characteristics in a microchannel.     

CFD simulations of hydrodynamic characteristics in a gas–liquid vertical upward slug flow

Computational fluid dynamics (CFD) simulations are conducted using the volume-of-fluid (VOF) method to investigate the hydrodynamic characteristics of slug flow and the mechanism of slug flow induced CO₂ corrosion. The hydrodynamic characteristics are significantly affected by the viscous, interfacial, and inertial forces. In inertia dominated flows, the velocity of fully developed falling liquid film is increased with increased Taylor bubble rising velocity. The developing falling liquid film is formed at about the length of 0.5 diameter from the Taylor bubble nose, the fully developed falling liquid film is reached at about the length of 1.5–2.1 diameter from the Taylor bubble nose. The average mass transfer coefficient in the falling liquid film is always higher than that in the Taylor bubble wake zone. The iron ion near wall mass transfer coefficient is higher than that of hydrogen ion. The wall shear stress is increased with increased Taylor bubble rising velocity in fully developed falling liquid film zone, and the wall shear stress has a large fluctuation due to the chaotic and turbulent vortexes in Taylor bubble wake zone. The formation and the damage mechanism of the corrosion product scale are proposed for the gas–liquid two-phase vertical upward slug flow induced CO₂ corrosion. It is found that the wall shear stress of upward gas–liquid slug flow is alternate with high frequency, which is the key factor resulting in the corrosion product scale fatigue cracking. The CFD simulation results are in satisfactory agreement with previous experimental data and models available in literature.     

注聚井分级注入浓度段塞的现场应用

一直以来,聚合物驱的设计和实施普遍采用＂分阶段、统一段塞＂的注入方式,即同一阶段内,注聚区的所有注入井注相同浓度的聚合物溶液段塞,不同阶段,聚合物溶液的浓度不同。这种方式没有区别各井（区）不同的地层参数,使有的井因黏度太低而仍存在聚合物窜流,而有的井则因黏度太高注不进去。根据孤东油田六区西北部Ng5-6层的注聚过程中暴露出的问题,提出并实施了＂分级注入浓度＂聚合物段塞,井与井之间、同一井的不同时段,其注入段塞也不相同。为了实现这一点,根据流动系数、单井注入压力、吸水指数、启动压力、大孔道分布等5个条件,设计了5种段塞,在不同井、不同时段注入。2008年8月起在六区西北部Ng5-6层的35口井上实施,26口井见效,到2009年4月,比原聚合物驱多增油10190t;在三四区推广实施3个月,也取得明显增油降水效果。     

Numerical simulation of thermofluid characteristics of two-phase slug flow in microchannels

A fundamental study of heat transfer characteristics of two-phase slug flow in microchannels is carried out employing the Volume-of-Fluid (VOF) method. Despite of the fact that numerical simulations of two-phase flows in microchannels have been attempted by many investigators, most efforts seem to have failed in correctly capturing the flow physics, especially those pertaining to the slug flow regime characteristics. The presence of a thin liquid film in the order of 10 μm around the bubble is a contributing factor to the above difficulty. Typically, liquid films have a significant effect on the flow field and heat transfer characteristics. In the simulations reported in this paper, the film is successfully captured and a very high local convective heat transfer coefficient is observed in the film region. A strong coupling between the conductive heat transfer in the solid wall and the convective heat transfer in the flow field is observed and characterized. Results showed that unsteady heat transfer through the solid wall in the axial direction is comparable to that in the radial direction. Results also showed that a fully developed condition could be achieved fairly quickly compared to single-phase flows. The fully developed condition is defined based on the Peclet number (Pe) and a dimensionless length of the liquid slug. Local and time-averaged Nusselt numbers for slug flows are reported for the first time. It was found that significant improvements in the heat transfer coefficient could be achieved by short slugs where the Nusselt number was found to be 610% higher than in single-phase flows. The study revealed new findings related to slug flow heat transfer in microchannels with constant wall heat flux.     

Two-phase hydrodynamics in a miniature direct methanol fuel cell

We present controlled experiments on a miniature direct methanol fuel cell (DMFC) to study the effects of methanol flow rate, current density, and void fraction on pressure drop across the DMFC anode. We also present an experimental technique to measure void fraction, liquid slug length, and velocity of the two-phase slug flow exiting the DMFC. For our channel geometry in which the diameter of the largest inscribed sphere (a) is 500 μm, pressure drop scales with the number of gas slugs in the channel, surface tension, and a. This scaling demonstrates the importance of capillary forces in determining the hydrodynamic characteristics of the DMFC anode. This work is aimed at aiding the design of fuel pumps and anode flow channels for miniature DMFC systems.     

Gas–liquid two-phase flow patterns in a miniature square channel with a gas permeable sidewall

Characteristics of air–water two-phase flow patterns in a miniature square channel having a gas permeable sidewall were investigated experimentally. Water was fed into the channel from its entrance, while air was injected uniformly into the channel along the permeable sidewall. This configured two-phase flow problem is encountered in direct feed methanol fuel cells. Flow patterns in both vertical upward and horizontal flows were identified using a high-speed motion analyzer. The visualization shows that the typical flow pattern encountered in the conventional co-current gas–liquid two-phase flow, such as bubbly flow, plug flow, slug flow and annular flow were also observed in the present work. However, unlike the conventional co-current gas–liquid two-phase flow in a channel with gas and liquid uniformly entering from one of its ends, for the flow configuration considered in this work, the stratified flow and wavy flow were not found in horizontal flow. And a so-called “single layer bubbly flow” was found in vertical upward flow, which is characterized by a mono small-gas-bubble layer existing adjacent to the surface of the permeable sidewall with the reminding space occupied by the liquid phase. Four transitional flow patterns such as bubbly-plug flow, bubbly-slug flow, plug–slug flow, and slug-annular flow, were found to exist between the distinct flow patterns. Finally, the flow regime maps for various liquid volumetric fluxes are presented in terms of mass quality versus the volumetric flux of gas phase.     

Transition from annular flow to plug/slug flow in condensation of steam in microchannels

A visualization study has been conducted to investigate the transition from annular flow to plug/slug flow in the condensation of steam in two different sets of parallel microchannels, having hydraulic diameters of 90 μm and 136 μm, respectively. The steam in the parallel microchannels was cooled on the bottom by forced convection of water and by natural convection of air from the top. It is found that the location, where the transition from annular flow to plug/slug flow takes place, depends on mass flux and cooling rate of steam. The effects of mass flux and cooling rate on the occurrence frequency of the injection flow in a single microchannel, having a hydraulic diameter of 120 μm and 128 μm, respectively, are investigated. It is found that two different shapes of injection flow occur in the smooth annular flow in microchannels: injection flow with unsteady vapor ligament occurring at low mass flux (or high cooling rate) and injection flow with steady vapor ligament occurring at high mass flux (or low cooling rate). It is also found that increase of steam mass flux, decrease of cooling rate, or decrease of the microchannel diameter tends to enhance instability of the condensate film on the wall, resulting in occurrence of the injection flow further toward the outlet with an increase in occurrence frequency.