Indian Journal of Engineering & Materials Sciences

Vol. 13, December 2006, pp. 477-483

Pressure drop for the flow of high concentration solid-liquid mixture across 90°
horizontal conventional circular pipe bend
Abhai Kumar Vermaa, S N Singh b* & V Seshadrib
Civil Engineering Department, Kamla Nehru Institute of Technology, Sultanpur, 228 118, India
Applied Mechanics Department, Indian Institute of Technology, New Delhi 110 016, India
Received 16 December 2005; accepted 6 October 2006

Pressure drop across a 90° horizontal bend for fly ash slurry at high concentrations is reported in the present study. The
pressure drop across the bend has been measured at five concentrations in the range of 50-65% (by weight) and the data has
been analyzed to obtain the relative pressure drop, bend loss coefficient and permanent pressure loss. Measurements show
that the relative pressure drop across the pipe bends increases with increase in concentration at low velocity. However, at
any given concentration relative pressure drop is independent of velocity over the range tested. The bend loss coefficient at
any velocity increases with increase in concentration. The permanent pressure loss increases marginally with concentration
and velocity. The contribution of disturbed flow conditions downstream of the bend to the total pressure loss is much less in
the case of highly concentrated slurries as compared to that in water.

IPC Code: G01F 1/34

Pipe bends are an integral part of any pipeline network additional pressure losses, relative pressure drop, bend
system. They cause obstruction to the flow resulting in loss coefficient and permanent pressure loss. However,
additional pressure losses. The flow characteristics in these studies have been basically carried out at low to
the bend for single phase fluid (water) have been medium solid concentrations, and there is hardly any
critically reviewed by Ito1,2, adopting more mechanistic study at high concentrations (Cw > 50%, by weight). In
approach for analysis. A few systematic studies on the recent years, for the disposal of the fly ash and
bends commercially available for two-phase flow have other industrial wastes, high concentration slurry
also been reported3-5. The literature on two-phase flow disposal system is being increasingly used to reduce
through pipe bends is limited. The limited literature the specific energy consumption and avoid wastage of
available for flow of solid-liquid mixtures through pipe water. In the light of these facts, it is essential to
bends has shown strong dependence of pressure loss establish pressure loss characteristics for pipe bends at
across the bend on concentration of solid particles, the high concentrations (Cw > 50% by weight). The
pipe diameter, the mean flow velocity, radius of emphasis in the present study is directed towards this
curvature of bend, bend angle, specific gravity of the aspect. Effort has been made to generate the basic
solids and general configuration of the bend. Semi- data on pressure drop across pipe bend at high
empirical models to predict the pressure drop in concentration for fly ash slurry flow using pilot plant
straight pipeline are available. However no such test loop.
models are available for pipe bends and as such one
has to resort to experimental estimation using pilot Pilot Plant Test Loop (50 mm NB)
plant loops. The flow characteristics in bends are The schematic layout of the pilot plant test loop is
further complicated due to generation of the secondary shown in Fig. 1. It consists of a closed circuit mild
flows as a result of centrifugal forces created due to the steel pipe test loop of 30 m length. The set-up
bend curvature. The literature review shows that some comprises of 53 mm diameter (50 mm NB) pipeline,
studies6-8 in the recent past have been carried out on connected to mixing and measuring tank forming the
slurry flow characteristics through pipe bends and a closed re-circulating pipe test loop. The slurry is
comprehensive methodology is given to estimate the prepared in the hopper shaped mixing tank having a
___________
capacity of 2.73 m3, which is provided with suitable
*For correspondence(E-mail: sidhnathsingh@hotmail. Com) stirring arrangement for keeping the slurry well
478 INDIAN J. ENG. MATER. SCI., DECEMBER 2006

Fig. 1—Schematic diagram of the pilot plant test loop

mixed. The slurry is drawn from the mixing tank into Physical properties of material used
53 mm diameter pipe loop by a "50K WILFLEY" The solid material used in the study is fly ash
(Make: Hindustan Dorr Oliver Limited) model slurry obtained from a thermal power plant. The fly ash
pump having Ni-hard impeller and casing. The pump sample used has a specific gravity of 2.06 and pH
is driven by an induction motor of 22 kW, 415 V and value of 7.1 at 60% solid concentration. The
40 A (Type: ILA 2174-4, Make: M/s Siemens maximum and the minimum particle sizes are 300 μm
Limited). The capacity of the pump is sufficient to and 3 μm respectively with 84.4% particles are finer
cover the entire range of head and discharge needed than 75 μm. The weighted mean diameter (dwm) and
for simulating the conditions in the prototype the medium diameter (d50) for the fly ash particles are
pipeline. The flow rate in the loop can be varied over 34.5 and 24.0 μm respectively which show that the fly
a wide range by suitably operating the plug valves ash particles are largely finer in size. The final static
provided in the pipe loop and the bypass pipeline. The settled concentration of the fly ash slurry was 67.6%
operation of the bypass line also helps in keeping the by weight.
slurry well mixed in the mixing tank. For continuous Geometry of the bend
monitoring of the flow rate, a pre-calibrated electro- A commercially available circular mild steel pipe
magnetic flow meter is installed in the vertical pipe bend having 90° turn angle and radius ratio of 5.6
section of the loop as shown in Fig. 1. The test loop is fitted in a horizontal plane is used to generate the
provided with an efflux sampler fitted with a plug pressure drop data experimentally. The detailed
valve in the vertical pipe section near the discharge geometrical configuration of the test bends as well as
end for collection of the slurry sample to monitor the the location of the pressure taps are given in Fig. 2.
solid concentration. The average efflux concentration
is evaluated using the measured correlation between Experimental Procedure
the slurry specific gravity and the solid concentration. The pressure loss across the 90° horizontal bend
Deposition velocity is estimated by visual observation having a nominal size of 50 mm is determined by
of the flow in the transparent observation chamber. incorporating the bend in the pilot plant test loop. To
Different instruments and measuring systems such as measure the pressure drop across the bend, pressure
isokinetic sampling tube for concentration taps with separation chambers are provided at a
measurement, separation chamber for pressure distance of 2-pipe diameters both on the up-stream
measurement and a diverter for flow rate and the down-stream sides of the bend (Figs 1 and 2).
measurement have been provided in the test loop. To establish the permanent pressure loss across the
 VERMA et al.: PRESSURE DROP ACROSS 90° HORIZONTAL BEND FOR FLY ASH SLURRY 479

Fig. 3—Variation of pressure drop across the test bend with flow
velocity in 50 mm NB

flow velocities are in the range of 0.5 m/s (minimum

measurable value) to 3.0 m/s (maximum achievable
Fig. 2—Geometric details of 90° horizontal circular mild steel test value). The uncertainties in the pressure drop and flow
bend rate measurements are ± 2% and ± 0.5% respectively.
bend for the slurry flow at high concentrations,
additional pressure taps are also provided at the Results and Discussion
distances of 32-diameters (reference point) on up- Pressure drop characteristics across the bend
stream side and 64-diameters on the downstream side Pressure drop across the bend is defined as the
(Figs 1 and 2). In order to account for the disturbed pressure differential measured between pressure taps
flow conditions downstream of the bend, two pressure at –2D and +2D locations. To quantify the pressure
taps are provided in the horizontal plane at each drop across the conventional bend as a function of
location, one on the inner side and the other on the flow velocity and solid concentration, pressure drop is
outer side and an average value of pressure is measured first for the water and then at the five efflux
measured. The pressure tap locations selected to concentrations over the total range of flow velocities
establish the pressure drop across the bend and the (0.5-3.0 m/s) achievable. Figure 3 shows the pressure
permanent pressure loss are based on the findings of drop across the conventional bend as a function of
Kaushal6 and Kumar et al.9. For the comparative flow velocity. It is seen that at any given solid
study of flow through the pipe bends and the straight concentration, pressure drop increases with increase
pipeline, the pressure drop is also measured over a in the flow velocity. For all ranges of solid
straight length of 4 m for fully developed flow. The concentrations, it is observed that the pressure drop is
head loss values obtained between different pairs of always more than the single-phase water flow. It is
pressure taps are non-dimensionalized using dynamic also seen that at any concentration, the rate of
head. The loss characteristics for the test bend is increase of pressure drop is higher at higher
evaluated at selected flow velocities by suitably velocities. It is further seen that pressure drop across
operating the plug valves provided in the pipe loop the bend at a given flow velocity increases with
and the bypass line (Fig. 1). increasing efflux concentration, the rate of increase
being higher at higher efflux concentration. This can
Range of parameters studied be attributed to the steep increase in density and
The aim of the study is to evaluate the pressure viscosity of the slurries with increase in the efflux
drop characteristics for conventional pipe bend for concentration. It is known from the literature that
slurry flow at high solid concentrations. The pressure presence of solid particles results in the suppression
drop is measured across the bend at five efflux of secondary flows, which is even depicted by the
concentrations namely 50.42, 54.76, 60.06, 62.2 and present results. There is no significant difference in
65.0 % (by weight). The analysis is also carried out pressure drop for 50.42% efflux slurry as compared to
for the estimation of the permanent pressure loss as a water more so at low velocities. The trends are similar
function of Reynolds number (1.5×103-2.0×105). The to the ones reported by Mishra et al.10. At higher efflux
480 INDIAN J. ENG. MATER. SCI., DECEMBER 2006

concentrations, there is significant increase in pressure

drop even at low velocities, which could be attributed
to abnormal increase in viscosity of the slurry.

Relative pressure drop

In order to analyze the results more quantitatively
relative pressure drop in bend (PRB) is calculated as:

ΔPb
PRB = … (1)
ΔPst
where, ΔPb is pressure drop across the bend, (P1-P2),
ΔPst is pressure drop in straight pipe having a length
equal to the distance between the two pressure taps 1 Fig. 4—Pressure drop variations in 50 mm NB diameter pipeline
and 2. for fly ash slurry with flow velocity at different concentrations
(% by weight)
Both ΔPb and ΔPst are measured for the same slurry
at the same velocity. Thus, PRB is a measure of
increase in the pressure drop due to the bend. The
pressure drop for the straight pipeline was measured
over a distance of 4.0 m (Fig. 4) and ΔPst is calculated
from this data. Figure 5 shows the variation of relative
pressure drop at selected flow velocities for the five
efflux concentrations. It is seen that for water flow the
relative pressure drop is almost constant at all
velocities and it is close to 1.3. This value agrees with
the values reported in literature10. The minor variation
in the values is due to the experimental uncertainties.
The relative pressure drops for the solid
concentrations below 60% by weight are less than that Fig. 5—Variation of relative pressure drop across the bend with
of water flow at the lowest flow velocity of 1.0 m/s flow velocity for different efflux concentrations
tested whereas at all other concentrations and flow Bend loss coefficient
velocities, the relative pressure drop is higher than The parameter, which represents the effect of
that for water flow. The variation observed at lower density and viscosity of the fluid on the pressure drop
velocities corroborates the fact that the presence of across the bend, is the bend loss coefficient. For slurry
solid particles suppresses secondary flows in the flow, bend loss coefficient (Kb) can be defined as:
bend, thereby resulting in lower pressure drop
compared to water. Further, it is observed that for a ΔPb V2
given efflux concentration, the relative pressure drop = ΔH b = K b × m … (2)
approaches a constant value as the flow velocity ρm g 2g
increases. This trend is observed at all efflux
concentrations tested. In the lower ranges of flow where, ΔPb is pressure loss in bend in N/m2 = (P1-P2),
velocities, it is observed that the relative pressure drop ρm is density of slurry in kg/m3, ΔHb is pressure drop
increases with increase in the efflux concentration. across bend in ‘m’ of slurry column, Vm is mean flow
This rate of increase diminishes at higher velocities, velocity of slurry in m/s
and at the highest selected velocity (3.0 m/s) the The bend loss coefficient as a function of efflux
relative pressure drop is almost independent of the concentration and flow velocity is shown in Fig. 6.
efflux concentration and it approaches almost a For water flow, the bend loss coefficient decreases
constant value of 1.4 with a variation of ±0.1. The from 0.219 to 0.156 with increase in the flow
trend is similar as observed by Mishra et al.10 at lower velocity. The trends are in agreement with the data
concentrations. For efflux concentrations of more than available in literature9,10. For slurry flow the trends
60%, the relative pressure drop is nearly constant. observed are similar to that observed for the water
 VERMA et al.: PRESSURE DROP ACROSS 90° HORIZONTAL BEND FOR FLY ASH SLURRY 481

Fig. 6—Bend loss coefficient as a function of flow velocity Fig. 7—Bend loss coefficient as a function of Reynolds number

flow at different efflux concentrations and it is Hence, Kb has been plotted as a function of Reynolds
always higher than the corresponding water data. At number in Fig. 7. For fly ash slurries, Bingham
a given velocity, the bend loss coefficient increases Reynolds number (Bingham viscosity is used in
with increase in the efflux concentration. It is Reynolds number) is used for the plot and the details
observed that the rate of increase with efflux of calculation are available elsewhere13. It is seen
concentration is maximum at the lowest velocity and from the figure that the value of ‘Kb’ decreases with
minimum at the highest velocity. This variation increasing Reynolds number, with the data points
could be attributed to the change in the rheological corresponding to all concentrations more or less
characteristics of the slurry. So, in general it can be falling on a single curve. Thus, the effect of solid
concluded that for the fly ash slurry flow, the bend concentration on Kb appears to be some what
loss coefficient at any given velocity increases with secondary and the effect of the Reynolds number is
increase in efflux concentrations and decreases with predominant.
increase in the average flow velocity. The increase in Permanent pressure loss
the bend loss coefficient with increase in the efflux Permanent pressure loss due to bend is of interest
concentrations is due to the higher increase in the to a pipeline designer. For this purpose, two pressure
pressure drop across the pipe bend which is taps, one at 32D (P3) on the up-steam side and other
attributed to the change of rheological nature of the at 64D (P4) on the downstream side of the bend are
slurry at higher concentrations. For fly ash slurries, provided. The pressure drop between these locations
experience shows that the slurry above a solid is measured. It was observed that this pressure drop
concentration of 60% (by weight) exhibits strongly is higher in comparison to the pressure drop
non-Newtonian behaviour and the viscosity of the measured in straight pipeline over the same length
suspension increases exponentially which causes an without the bend. The net increase in the pressure
increase in the pressure drop in the pipe network, drop due to the introduction of the bend is therefore
i.e., both across the pipe bend as well as in the determined. The non-dimensionalized form of the
straight pipeline. The bend loss coefficient decreases net increase in the pressure drop due to the
with increase in the flow velocity for both water and introduction of the bend is termed as permanent
slurry flow. It is well known that in single phase pressure loss coefficient. The permanent pressure
fluid flow through bend, the loss coefficient depends loss coefficient (KP) is defined as:
on Reynolds number generally showing a decreasing
trend with increasing Reynolds number, attaining a ΔPBEND − ΔPSt .
constant value at very high Reynolds numbers. KP = ...(3)
1
Further, the nature of the flow (laminar/turbulent) ρ mVm 2
has also a major effect on the values of Kb. It is to be 2
noted that at any given velocity, Reynolds number
reduces as solid concentration increases due to where, ΔPBEND = (P3-P4), with bend, in N/m2, ΔPSt. is
increase in viscosity. Hence, increasing trend of Kb pressure drop in a straight pipeline of equal length, in
with concentration at any given velocity could be N/m2, ρm is density of slurry in kg/m3, Vm is mean
partially due to decrease in Reynolds number. flow velocity of slurry in m/s
482 INDIAN J. ENG. MATER. SCI., DECEMBER 2006

Figure 8 has been plotted to show the variation of

pressure drop between the locations at 32D on the up-
stream side and 64D on downstream side from the test
bend at selected flow velocities. The trends are similar
to the ones observed just across the bend (2D
upstream and 2D downstream) with higher
magnitudes.
Figure 9 shows the variation of the permanent
pressure loss coefficient, (KP) as a function of average
flow velocity. At any given flow velocity the
permanent pressure loss coefficient increases with the
increase in the solid concentration. It is also seen that Fig. 8—Variation of pressure drop between 32D u/s and 64D d/s
for the flow of water, the permanent pressure loss is of test bend with flow velocity at various fly ash concentrations
minimum, which gradually increases as the fly ash
solid is added and the increase is of the order of 50% at
the lowest velocity (1.5 m/s), to 25% at the highest
velocity (3.0 m/s) tested. Figure 9 also shows that the
permanent pressure loss increases almost linearly with
the average flow velocity for any given solid
concentration, with increase being steeper at higher
concentrations. These trends are in agreement with the
data given by Kumar9, Mishra10 and Ahmed11. Further,
the values of bend loss coefficient for water are in good
agreement with the data available in literature1,2.

Effect of bend on flow on downstream pipe

Fig. 9—Permanent pressure loss coefficient as a function of
Flow of slurry inside the pipe bend is very much average velocity
complex due to the presence of secondary flows.
Secondary flows play a dominant role in determining Table 1— The values of KP and Kb at higher velocities obtained
the flow regime, i.e., homogeneous or heterogeneous, for various concentrations
within the pipe bend. The presence of bend also Coefficient 0% 50.42 54.76 60.02 62.2 65.06
affects the flow behaviour in the downstream side in (water) % % % % %
the pipeline where the flow is disturbed due to the Vm= 2.5 m/s
bend. It is very difficult to analyze this phenomenon KP 0.173 0.185 0.201 0.203 0.223 0.230
mathematically. However, Ito1,2 and Kumar9 have Kb’ 0.154 0.177 0.200 0.212 0.227 0.239
shown that the disturbances downstream to the bend Vm= 3.0 m/s
exist up to the distance of the order of 40 to 50 pipe KP 0.193 0.201 0.214 0.238 0.245 0.254
diameters from the exit of the bend. Since the flow in Kb’ 0.132 0.206 0.209 0.218 0.223 0.255
this region is disturbed, the pressure drop will be
different from the corresponding value in a fully pressure loss across the bend only. Since the upstream
developed flow in a straight pipe. The analysis is effect of the bend is usually small, the difference in
based on the comparison of permanent pressure loss the value of KP and Kb is a measure of additional
coefficient, KP (Eq. 3) and excess pressure loss losses in the downstream of the bend due to
coefficient, Kb, defined as, disturbances caused by it. The values of KP and Kb at
comparatively higher velocities (Vm= 2.5 and 3.0 m/s)
ΔPb − ΔPst obtained for all concentrations tested are given in
Kb =
'
... (4) Table 1.
1
ρ mVm 2 The data shows that in the case of water the
2 permanent pressure loss coefficient is much higher
It is to be noted that KP is a measure of total than the excess pressure loss coefficient for the bend.
pressure loss due to the bend whereas Kb represents This implies that the additional pressure loss due to
 VERMA et al.: PRESSURE DROP ACROSS 90° HORIZONTAL BEND FOR FLY ASH SLURRY 483

the flow disturbances downstream of the bend also concentration, the dependence of relative
contributes significantly to the total permanent loss pressure drop on velocity is rather weak.
due to the bend. Due to the curvature of the bend, (ii) The bend loss coefficient shows a reducing
centrifugal forces are generated, which create large trend with increase in flow velocity (over the
disturbances resulting in skewed velocity profile range tested) for the slurry flow at all
downstream of the bend. Hence, the pressure loss in concentrations tested. The bend loss
this region contributes significantly to the total coefficient is predominantly decided by the
pressure loss due to the disturbed flows conditions. Reynolds number of the flow.
For slurry flow the presence of solids suppresses the (iii) The permanent pressure loss coefficient for
secondary flows leading to lower pressure losses in bends increases marginally with the increase in
the bend at low concentrations11,12. Further as the flow velocity at all concentrations tested.
concentration increases, viscous effects also increase, The increase in bend permanent loss with
resulting in higher loss across the bend. The concentration is more at lower velocity as
contribution of the downstream disturbance, to the compared to that at higher velocity.
permanent pressure loss reduces at higher (iv) The flow disturbances downstream of the
concentrations of the solids, since flow tends to pipe bend result in additional losses and their
stabilize much faster due to increased viscous effects. contribution to permanent pressure loss is
At higher concentrations, both pressure drop in the substantial for single phase fluids. However, in
bend region as well as at the downstream side the case of highly concentrated slurries, this
increases but increase in the former is at higher rate contribution is rather insignificant.
than the latter, and at any concentration for instance,
Cw = 50.42% the difference between the permanent References
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