Real Flows: (Continued)

1
Faith A. Morrison, Michigan Tech U.

Real Flows (continued)
So far we have talked about internal flows
ideal flows (Poiseuille flow in a tube)
real flows (turbulent flow in a tube)
Strategy for handling real flows: Dimensional analysis and data
correlations
How did we arrive at correlations? non-Dimensionalize ideal flow; use to
guide expts on similar non-ideal
flows; take data; develop empirical
correlations from data
What do we do with the correlations? use in MEB; calculate pressure-drop
flow-rate relations
Empirical data correlations
friction factor (P) versus Re (Q) in a pipe
4000 Re 4 . 0 Re log 0 . 4
1
turbulent
10 Re 4000 Re 079 . 0 turbulent
2100 Re
Re
16
laminar
10
5 25 . 0
=
=
< =
f
f
f
f
correlation equations
(flow in a pipe)
(Geankoplis
3rd ed)
from Denn, Process Fluid Mechanics,
Prentice-Hall 1980; p35
graphical correlations
(flow in a pipe)
2
rough pipes - need an additional dimensionless group
k - characteristic size of the surface roughness
D
k
- relative roughness (dimensionless roughness)
28 . 2
Re
67 . 4
log 0 . 4
1
10
+
|
|
.
|
\
|
+ =
f D
k
f
Colebrook correlation (Re>4000)
Other internal flows:
k
Drawn tubing (brass,lead, glass, etc.) 1.5x10
-3
Commercial steel or wrought iron 0.05
Asphalted cast iron 0.12
Galvanized iron 0.15
Cast iron 0.46
Wood stave 0.2-.9
Concrete 0.3-3
Riveted steel 0.9-9
Material k (mm)
Surface Roughness for Various
Materials
3
( )
H H
R D 4
perimeter wetted
) area sectional cross ( 4
=

Empirically, it is found that f vs. Re correlations for circular
conduits matches the data for noncircular conduits if D is
replaced with equivalent hydraulic diameter D
H
.
Hydraulic radius
Equivalent hydraulic
diameter
flow through noncircular conduits
Flow Through Noncircular Conduits
f
Re
Flow through
equilateral
triangular
conduit
f and Re
calculated
with D
H
solid lines
are for
circular pipes
Note: for some shapes the correlation is
somewhat different than the circular pipe
correlation; see Perrys Handbook
4
Non-Circular Cross-
sections have application
in the new field of
microfluidics
Chemical & Engineering News, 10 Sept
2007, p14
5
entry flow in pipes
flow through a contraction
flow through an expansion
flow through a Venturi meter
flow through a butterfly valve
etc.
see Perrys Handbook
calculate drag - superficial velocity
relations
Now, we will talk about external flows
ideal flows (flow around a sphere)
real flows (turbulent flow around a sphere, other obstacles)
Strategy for handling real flows: Dimensional analysis and data
correlations
How did we arrive at correlations? non-Dimensionalize ideal flow; use to
guide expts on similar non-ideal
flows; take data; develop empirical
correlations from data
What do we do with the correlations?
6
y
z
(r,,)

flow
g
Steady flow of an
incompressible, Newtonian
fluid around a sphere
Creeping Flow
spherical coordinates
symmetry in the dir
calculate v and drag
force on sphere
neglect inertia
upstream

= v v
z
(equivalent to
sphere falling
through a liquid)
Steady flow of an
incompressible,
Newtonian fluid around
a sphere
Creeping Flow
r
r
v
v
v
|
|
.
|
\
|
=
0
r
g
g
g
|
|
.
|
\
|
=
0
sin
cos
) , ( r P P =
g v P v v
t
v
+ + = |
.
|
\
|
+
2
steady
state
neglect
inertia
SOLVE
BC1: no slip at sphere surface
BC2: velocity goes to far from sphere
v
Eqn of
Motion:
Eqn of
Continuity:
( )
0
sin
sin
1 1
2
2
=
|
|
.
|
\
|
v
r r
v r
r
r
7
SOLUTION: Creeping Flow
around a sphere
cos
2
3
cos
2
0
|
.
|
\
|
=

r
R
R
v
gr P P
( ) [ ]
T
v v + =
all the stresses can be
calculated from v
r
r
R
r
R
v
r
R
r
R
v
v
|
|
|
|
|
|
|
|
|
.
|
\
|
(
(
|
.
|
\
|

(
(
|
.
|
\
|
+
=

0
sin
4
1
4
3
1
cos
2
1
2
3
1
3
3
0
Bird, Stewart, Lightfoot, Transport Phenomena,
Wiley, 1960, p57; complete solution in Denn
evaluate at the
surface of the
sphere
( ) [ ]

=
=

2
0 0
2
sin
d d R I P r F
R r
SOLUTION: Creeping Flow
around a sphere
What is the total z-direction
force on the sphere?
total stress
at a point in
the fluid
vector stress on a
scopic surface of
unit normal r
integrate over
the entire
sphere surface
total vector
force on
sphere
F k =
total z-
direction
force on the
sphere
8
Force on a sphere (creeping flow limit)

+ + = = Rv Rv g R F F k
z
4 2
3
4
3
buoyant
force
comes from
pressure
friction drag
kinetic terms stationary terms
(=0 when v=0)
Stokes law:
kinetic force

= Rv F
kin
6
comes from shear
stresses
form drag
Bird, Stewart,
Lightfoot,
Transport
Phenomena,
Wiley, 1960, p59
Steady flow of an
incompressible,
a sphere
Turbulent Flow
* *
2
* * * * * *
*
*
1
Re
1
g
Fr
v P v v
t
v
+ + =
|
|
.
|
\
|
+
Nondimensionalize eqns of change:

Nondimensionalize eqn for F
kin
:
define dimensionless
kinetic force
|
.
|
\
|
= =
2
2
,
2
1
4
v
D
F
C f
kinetic z
D
conclude f=f(Re) or
C
D
=C
D
(Re)
drag
coefficient
take data, plot, develop correlations
9
Steady flow of an
incompressible,
a sphere
Turbulent Flow
( )
Re
24
2
1
4
6
2
2
=
|
.
|
\
|
= =
v
D
Rv
C f
D
take data, plot, develop correlations

Laminar flow:
Stokes law
Turbulent flow:
Calculate CD from terminal velocity of a falling sphere
(see BSL p182; Denn p56)
( )
2
sphere
3
4
= =
v
Dg
C f
D

all
measurable
quantities
Steady flow of an incompressible, Newtonian
McCabe et al., Unit Ops of Chem
Eng, 5th edition, p147
Re
24
graphical correlation
10
Steady flow of an incompressible, Newtonian
BSL, p194
correlation equations
000 , 200 Re 500 44 . 0 turbulent
500 Re 2 Re 5 . 18 turbulent
10 . 0 Re
Re
24
laminar
60 . 0
=
=
< =
f
f
f
use correlations in engineering practice
particle settling
entrained droplets in distillation columns
particle separators
drop coalescence
(See Denn,
BSL,
Perrys)
rough spheres
objects of other shapes
flows past walls
airplane flight
Other external flows:
11
internal flows (flow in a conduit)
external flow (around obstacles)
Now, weve done two
classes of real flows:
We can apply the techniques we have learned to
more complex engineering flows.
We will discuss two examples briefly:
1. Flow through packed beds
2. Fluidized beds
ion exchange columns
packed bed reactors
packed distillation
columns
filtration
flow through soil
(environmental issues,
enhanced oil recovery)
fluidized bed reactors
Flow through Packed Beds
voids
voids
solids
solids
solids
(
=
(
bed of section - x
solid area sectional - x
1
bed of section - x
voids area sectional - x
If the hydraulic diameter D

H
concept works for this flow, cross-
section then we already know f(Re) from pipe flow.
12
What is pressure-drop versus flow rate for flow through an
unconsolidated bed of monodisperse spherical particles?
More Complex Applications I: Flow through Packed Beds
flow
D
p
=sphere diameter
or for irregular particles:
v
p
a
D 1
particles of area surface
particles of volume
6
=
We will choose to model the flow
resistance as flow through tortuous
conduits with equivalent hydraulic
diameter D
H
=4R
H
.
Hagen-Poiseuille equation:
We will choose to model the flow
resistance as flow through tortuous
conduits with equivalent hydraulic
diameter D
H
=4R
H
.
( )
L
D P P
v
L
32
2
0
=
average
velocity in the
interstitial
regions
bed entire of section - x
voids of area sectional - x
0
Q
v
Q
v
=
v v v =
(
=
bed of section - x
voids area sectional - x
0
void
fraction
superficial
velocity
BUT, what are D
H
and average velocity
in terms of things
we know about the
bed?
0
v
v =
13
(
= =
surface wetted total
flow for available volume
4
H
H
R
D
BUT, what is D
H
in terms of things we know about the bed?
) 1 ( 6 ) 1 (
bed of volume
surface wetted
bed of volume
voids of volume
=
(
(
(
(
|
.
|
\
|
|
.
|
\
|
=
p
v
D
a
from Denn, Process Fluid
Mechanics, Prentice-Hall
1980; p69
|
.
|
\
|
|
|
.
|
\
|
bed of volume
particles of volume
particles of volume
surface particle
( )
=
1 3
2
p
H
D
D
Now, put it all together . . .
1980; p69
0
v
v =
( )
=
1 3
2
p
H
D
D
( )
L
D P P
v
L
32
2
0
=
( )
|
.
|
\
|
|
|
.
|
\
|

=
2
0
0
2
1
4
1
v
D
L
P P
f
p
L
analogous to f for
for pipes we write:
( )
L
P P
D
v f
L
p
=
0
2
0
2
14
Now, put it all together . . .
1980; p69 2
2 2
0
0
) 1 ( 36

=
p
D v f v
) 1 (
2
72
1
) 1 (
3
0

=
f
D v
p
Now we follow
convention and
define this as 1/Re
p
and this as f
p
p
p
f
72
1
Re
1
=

p
p
f
72
1
Re
1
=
When we check this relationship with experimental data we find that a
better fit can be obtained with,
p
p
f = + 75 . 1
Re
150
Ergun Equation
A data correlation for pressure-drop/flow rate data
for flow through packed beds.
1980; p69
) 1 (
2
) 1 (
Re
3
0
f
f
D v
p
p
p
15
p
f
p
Re
from Denn, Process Fluid Mechanics, Prentice-Hall 1980; p709;
original source Ergun, Chem Eng. Progr., 48, 93 (1952).
p
p
f = + 75 . 1
Re
150
What did we do?
We assumed the same functional form for P and
Q as laminar pipe flow with,
hydraulic diameter substituted for diameter
hydraulic diameter expressed in measureables
resulting functional form was fit to experimental data (new Re and f
defined for this system)
scaling was validated by the fit to the experimental data
we have obtained a correlation that will allow us to do design
calculations on packed beds
16
Can we use the Ergun equation (for pressure drop versus flow rate in
a packed bed) to calculate the minimum superficial velocity at which
a bed becomes fluidized?
More Complex Applications II: Fluidized beds
flow
In a fluidized bed reactor, the flow
rate of the gas is adjusted to
overcome the force of gravity and
fluidize a bed of particles; in this
state heat and mass transfer is good
due to the chaotic motion.
v
p
p
f = + 75 . 1
Re
150
The P vs Q
relationship can
come from the Ergun
eqn at small Re
p
neglect
Now we perform a force balance on the bed:
Real Flows (continued) More Complex Applications II: Fluidized beds
pressure
(Ergun eqn)
gravity
buoyancy
A P
net effect of
gravity and
buoyancy is:
( )( )ALg
p
1
( )AL 1
bed volume =
When the forces
balance,
incipient
fluidization
17
Real Flows (continued) More Complex Applications II: Fluidized beds
( )( )ALg A P
p
= 1
When the forces balance, incipient fluidization
p
p
f =
Re
150
eliminate P;
solve for v
0
( )
( )

=
1 150
3 2
0
p p
gD
v
velocity at the point of
incipient fluidization
Real Flows SUMMARY
internal flows (pipes, pumping)
external flow (packed beds, fluidized bed reactors)
REAL
ENGINEERING
UNIT OPERATIONS
internal flows (Poiseuille flow in a pipe)
external flow (flow around a sphere)
IDEAL
FLOWS
internal flows (f vs Re)
external flow (C
D
vs Re)
REAL
FLOWS
nondimensionalization
scopic
balances
apply engineering approximations using reasonable
concepts and correlations obtained from experiments.

Real Flows: (Continued)

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1

Faith A. Morrison, Michigan Tech U.

Faith A. Morrison, Michigan Tech U.

Nondimensionalize eqns of change:

take data, plot, develop correlations

If the hydraulic diameter D

Faith A. Morrison, Michigan Tech U.

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