ChE 205 Fluid Mechanics

Module 11

L2/TII Chemical Engineering, BUET

Topic: Multiphase Flow

Course Instructor:
Dr. Iftheker Ahmed Khan
Associate Professor, Dept. of Chemical Engineering,
Bangladesh University of Engineering & Technology

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Multiphase Flow

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What is a Multiphase Flow?
• In the broadest sense, it is a flow in which two or more phases of matter are
dynamically interacting
• Distinguish multiphase and/or multicomponent
• Gas/Liquid
• Gas/Solid
• Liquid/Liquid
• Technically, two immiscible liquids are “multi-fluid”, but are often
referred to as a “multiphase” flow due to their similarity in behavior
Single component Multi-component
Water
Single phase Air
Pure nitrogen
Water + Oil emulsions
Steam bubble in H20
Multi-phase Coal particles in the air
Ice slurry
Sand particles in Water
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Two-phase Fluid Flow
• A multiphase flow can be a simultaneous
• By definition, multiphase flow is the flow of:
interactive flow of two or more distinct
Materials with different states or
phases with common interfaces in, say, a
phases (e.g., water-steam mixture).
conduit. Each phase, representing a
volume fraction (or mass fraction) of Materials with different chemical
solid, liquid, or gaseous matter, has its properties but in the same state or
properties, velocity, and temperature. phase (e.g., oil droplets in water).
• There are many combinations in
industrial processes, but the most
common is the simultaneous flow
of steam and liquid water (as
encountered in steam
generators and condensers).

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Importance of Multiphase Flow Systems
• Multiphase flow is of critical importance due to its widespread prevalence in various industrial
applications and natural phenomena.
• Its significance stems from several key factors:
• Industrial Applications: Multiphase flow plays a crucial role in numerous industries.
 Power Generation: It's essential in steam turbines, combustion processes, and nuclear reactors.
 Oil and Gas: Multiphase flow is fundamental in oil recovery systems, involving the simultaneous
flow of oil, water, and natural gas.
 Chemical and Process Engineering: It's vital in reactors, separators, scrubbers, and mixers.
 Food and Beverage: Multiphase flow is crucial in filling, packaging, and drying.
 Automotive and Aerospace: It's important in fuel injection systems, exhaust systems, and tank
filling.
• Environmental and Natural Phenomena: Multiphase flow is also significant in various
environmental processes
 Sediment transport in rivers
 Groundwater flow through porous media
 Blood flow in living organisms
 Wave breaking and tidal movements

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Flows categorized by the distribution of the components
Interfacial Flow
• “Separated” or “Interfacial”
• both fluids are more or less contiguous (i.e., in
contact) throughout the domain
• “Dispersed”
 One of the fluids is dispersed as non-contiguous
isolated regions within the other (continuous)
phase
 The former is the “dispersed” phase, while the
latter is the “carrier” phase
• One can now describe/classify the geometry of the
dispersion: geometry, size, and its distribution, Dispersed Flow
volume fraction Carrier Phase Dispersed Phase
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Physical Effects in Dispersed Systems
• Hydrodynamics:
• Change in shape
• Diameter
• Particle-wall collision
• Particle-particle collision
• Coalescence
• Breakup
• Turbulence
• Other transport phenomena:
• Heat transfer
• Mass transfer

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Coupling Between Phases
• One-way coupling: Sufficiently dilute such that fluid
feels no effect from the presence of particles. Particles
move in dynamic response to fluid motion.
• Two-way coupling: Enough particles are present such
that momentum exchange between the dispersed and
carrier phases alters the dynamics of the carrier phase.
• Four-way coupling: Flow is dense enough that
dispersed phase collisions are significant momentum
exchange mechanism
 Depends on particle size, relative velocity, volume
fraction

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Multi-phase flow regimes
• Flow regimes in mixed-phase flow systems describe the spatial distribution and
interaction of different phases within a flow.
• These regimes are crucial for understanding and predicting the behavior of
multiphase flows in various industrial applications.
• The main types of flow regimes in mixed-phase systems include:

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Gas-Liquid Flow Regimes
• Bubble Flow
 Liquid is the continuous phase
 Gas is dispersed as discrete bubbles within the liquid
 Typically occurs at low gas flow rates and high liquid
flow rates
• Slug or Plug Flow
 Characterized by large bullet-shaped bubbles
alternating with liquid slugs
 Bubbles approach the diameter of the pipe
 Common in horizontal or slightly inclined pipelines
• Churn Flow
 An unstable regime where slug flow breaks down
 Exhibits oscillatory motion of the liquid
 Often seen as a transition between slug and annular
flow in vertical pipes

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Gas-Liquid Flow Regimes
• Annular Flow
 Liquid flows as a film on the pipe wall
 Gas flows in the center core
 May contain entrained liquid droplets in the gas core
 Occurs at high gas velocities
• Stratified Flow
 Liquid flows at the bottom of the pipe, gas at the top
 Clear separation between phases by a relatively
smooth interface
 Common in horizontal pipes at low flow rates
• Wavy Flow
 Similar to stratified flow, but with waves at the gas-
liquid interface
 Occurs as gas velocity increases in horizontal flows

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Gas-Liquid Flow Regimes Solid-Liquid Flow Regimes

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 Ref:
Al-Dogail, A.S. and R.N. Gajbhiye,
Effects of density, viscosity and surface
tension on flow regimes and pressure
drop of two-phase flow in horizontal
pipes. Journal of Petroleum Science and
Engineering, 2021. 205: p. 108719.

https://www.sciencedirect.com/science/article/pii/S092041052100379X

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 A flow pattern map for gas-
liquid flow in horizontal pipes
References:
1. Mandhane, J.M., G.A. Gregory, and K.
Aziz, A flow pattern map for gas—
liquid flow in horizontal pipes.
International Journal of Multiphase
Flow, 1974. 1(4): p. 537-553.
2. Al-Dogail, A.S. and R.N. Gajbhiye,
Effects of density, viscosity and surface
tension on flow regimes and pressure
drop of two-phase flow in horizontal
pipes. Journal of Petroleum Science and
Engineering, 2021. 205: p. 108719.

Q(m 3 / s)
Superficial Velocity : vsg (m / s ) =
A(m 2 )

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Approximate sequence of
flow patterns in a vertical
heat pipe evaporator

Reference:
Zohuri, B., Heat Pipe Theory and Modeling, in Heat
Pipe Design and Technology: Modern Applications
for Practical Thermal Management, B. Zohuri,
Editor. 2016, Springer International Publishing:
Cham. p. 43-166.

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 Reference:
1. Zohuri, B., Heat Pipe Theory and Modeling, in
Heat Pipe Design and Technology: Modern
Applications for Practical Thermal Management,
B. Zohuri, Editor. 2016, Springer International
Publishing: Cham. p. 43-166.
2. Mehta, R. and T. Jayachandran, Numerical
analysis of transient two phase flow in heat
pipe. Heat and mass transfer, 1996. 31(6): p.
383-386.

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Multi-phase flow regimes

The schematic of observed flow regimes in

the vertical microchannels:
(a,b) bubbly flow,
(c,d) Taylor or segmented flow,
(e) transitional flow from slug to churn,
(f) churn flow,
(g) annular-film flow,
(h) mist-annular or wispy-annular flow.

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 Multiphase Flow Regimes
Section A
• Bubbly flow: discrete gaseous bubbles
Class in a continuous liquid
Lecture • Droplet flow: discrete fluid droplets in
a continuous gas
• Particle-laden flow: discrete solid slug flow bubbly flow
particles in a continuous fluid droplet flow
particle-laden flow
• Slug flow: large bubbles in a
continuous liquid
• Annular flow: continuous liquid along
walls, gas in the core
• Stratified and free-surface flow:
immiscible fluids separated by a clearly annular flow free-surface flow
defined interface

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 (Slurry) Bubble Column Systems
Gas

• A bubble column is a liquid pool sparged by

a process stream Liquid
• A gas sparger at the bottom of a cylindrical
or square-shaped column introduces gas
into a liquid or liquid-catalyst medium, Liquid
causing the gas to rise as bubbles. Pool 2 < L/D < 20
• This mixes the gas and liquid phases, which
can be used for various processes. UG,sup up to 50 cm/s

UG,sup >> UL,sup

Sparger

Liquid/Slurry Inlet
Gas
Gas Inlet

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Bubble Columns: Flow Regimes

Bubbly Flow

Churn-Turbulent
Flow
(“Heterogeneous”)

Flow Regime Map (Deckwer, 1980)

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Fluidized-Bed Systems
• When a fluid flows upward through a bed of solids beyond a
certain fluid velocity, the solids become suspended. The
suspended solids:
• has many of the properties of a fluid,
• seeks its level (“bed height”),
• assumes the shape of the containing vessel.
• Bed height typically varies between 0.3m and 15m
• Particle sizes vary between 1 mm and 6 cm. Small particles can
agglomerate. Particle sizes between 10 mm and 150 mm
typically result in the best fluidization and the least formation of
large bubbles. Adding finer-sized particles to a bed with coarse
particles usually improves fluidization.
• Superficial gas velocities (based on the cross-sectional area of
the empty bed) typically range from 0.15 m/s to 6 m/s.

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Fluidized Bed Uses
• Fluidized beds are generally used for gas-solid contacting.
• Typical uses include:
• Chemical reactions:
• Catalytic reactions (e.g. hydrocarbon cracking)
• Noncatalytic reactions (both homogeneous and heterogeneous)
• Physical contacting:
• Heat transfer: to and from fluidized bed; between gases and solids;
temperature control; between points in bed
• Solids mixing
• Gas mixing
• Drying (solids or gases)
• Size enlargement or reduction
• Classification (removal of fines from gas or fines from solids)
• Adsorption-desorption
• Heat treatment
• Coating
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Fluidization Regimes

Umf Umb Uch

U U

Solids Return

Solids Return
Solids Return
Gas
Fixed Particulate Bubbling Slug Flow Turbulent Fast Pneumatic
Bed Regime Regime Regime Regime Fluidization Conveying

Increasing Gas Velocity

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Modeling Multiphase Flows
• What is the goal of the simulation?
• Which effects are important?
• Controlled by which hydrodynamic effects?
• Controlled by which other transport phenomena effects?
• All these factors influence which model to choose for the analysis.

Flow Specific Process Specific Model Specific

• Bubbly • Separation • Lagrangian Dispersed
• droplet • Filtration • Phase Algebraic Slip
• particle-laden • Suspension • Eulerian
• slug • Evaporation • Eulerian Granular
• annular • Reaction • Volume of Fluid
• stratified/free surface
• rapid granular flow

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 Modeling Approaches
• Empirical Correlations
• Lagrangian
Increased complexity

• Track individual point particles

• Particles do not interact
• Algebraic Slip Model
• Dispersed phase in a continuous phase
• Solve one momentum equation for the mixture
• Two-Fluids Theory (multi-fluids)
• Eulerian models
• Solve as many momentum equations as there are phases
• Discrete Element Method
• Solve the trajectories of individual objects and their collisions, inside a continuous phase
• Fully Resolved and Coupled
- (Separated fluids/ Discontinuous -Single fluid) Solve conservation laws in the coupled domains

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Model Overview

Particle relaxation time is the time it takes for a particle to

adjust its velocity to a new set of forces. It's a measure of
how quickly a particle can adapt to a new environment.
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Characteristics of Multiphase Fluid Flow
• All multiphase flow problems have features that are characteristically different from those found in
single-phase problems.
• In the case of steam and liquid water, the density of the two phases differs by a factor of about 1000.
Therefore, the influence of gravitational body force on multiphase flows is of much greater importance
than in the case of single-phase flows.
• The sound speed changes dramatically for materials undergoing a phase change and can be orders of
magnitude different. This significantly influences a flow through an orifice.
• The relative concentration of different phases is usually a dependent parameter of great importance in
multiphase flows, while it is a parameter of no consequence in single-phase flows.
• The phase change means flow-induced pressure drops can cause further phase change (e.g.,, water can
evaporate through an orifice), increasing the relative volume of the gaseous, compressible medium and
increasing efflux velocities, unlike single-phase incompressible flow where decreasing of an orifice
would decrease efflux velocities.
• The spatial distribution of the various phases in the flow channel strongly affects the flow behavior.
• There are many types of instabilities in multiphase flow.

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