1

INTRODUCTION TO
MULTIPHASE FLOW
Mekanika Fluida II
-Haryo Tomo-
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Definitions
Multiphase flow is simultaneous flow of
Matters with different phases( i.e. gas, liquid or solid).
Matters with different chemical substances but with the same phase
(i.e. liquid-liquid like oil-water).

Primary and secondary phases

One of the phases is considered continuous (primary) and others
(secondary) are considered to be dispersed within the continuous
phase.
A diameter has to be assigned for each secondary phase to calculate its
interaction (drag) with the primary phase (except for VOF model).

Dilute phase vs. Dense phase;

Refers to the volume fraction of secondary phase(s)

Volume of the phase in a cell/domain

Volume fraction of a phase =
Volume of the cell/domain

Why model multiphase flow?
Multiphase flow is important in
many industrial processes:
Riser reactors.
Bubble column reactors.
Fluidized bed reactors.
Scrubbers, dryers, etc.
Rushton CD-6
3
Typical objectives of a modeling
analysis:
Maximize the contact between
the different phases, typically
different chemical compounds.
Flow dynamics.
BT-6
 Two-phase Flow Applications
The practical importance in many common
engineering and industrial applications are:

Steam generators and condensers, steam turbines ( Power

Plants ).
Refrigeration .
Coal fired furnaces .
Fluidized bed reactors .
Liquid sprays .
Separation of contaminants from a carrier fluid
 Free surface flows, where sharp interfaces exist .
pumping of slurries .
pumping of flashing liquids .
raining bed driers .
oil industry two phase flow occurs in pipelines carrying oil and
natural gas.
energy conversion .
paper manufacturing .
food manufacturing .
medical applications .
The laws governing two phase flow are identical
to those for single phase flow. However, the
equations are more complex and/or more
numerous than those of single phase flow.
The description of the two-phase flow is
complicated due to the existence of
interface between the phases depending
on a large number of variables such as :
1. quality (x).
2. phase physical properties .
3. flow patterns .
4. pipe geometry .
5. orientation of flow .
A general classifications divide two-phase flow into four
groups depending on the mixtures of phases in the flow.
The four groups are the flow of gas-liquid, gas-solid,
liquid-solid and immiscible liquid-liquid mixtures. The last
case is technically not a two-phase mixture, it is rather a
single phase two-component flow, but for all practical
purposes it can be considered as a two-phase mixture.
 Flow Regimes In Horizontal Flow
1. Bubble flow .
2. Plug flow .
3. Stratified flow (layered, separated) .
4. Wavy flow (ripple flow, cresting) .
5. Slug flow .
6. Semi-annular flow .
7. Annular flow (ringed) .
8. Spray flow (mist, froth, dispersed) .
 11

Flow Regimes in Vertical Flow

Multiphase flow can be classified by
the following regimes:
1. Bubbly flow: Discrete gaseous or fluid
bubbles in a continuous fluid
2. Droplet flow: Discrete fluid droplets in
a continuous gas
3. Particle-laden flow: Discrete solid
slug flow bubbly flow
particles in a continuous fluid
droplet flow
4. Slug flow: Large bubbles (nearly filling particle-laden
cross-section) in a continuous fluid flow
5. Annular flow: Continuous fluid along
walls, gas in center
6. Stratified/free-surface flow:
Immiscible fluids separated by a
clearly-defined interface annular flow free-surface flow
Slug Bubble Separated Annular
 Two Phase Flow Regimes Mapping
Mapping of flow patterns that occur in pipe flow has
always been a popular means of describing the
behaviors of flow at different conditions. The
superficial velocity of the gas and liquid are usually
put on the two different axes, and supply an efficient
method of comparing and contrasting the effects of
different flow conditions .
 15

Flow regimes: vertical gas-liquid flow

Q(m 3 / s )
Superficial Velocity : vsg (m / s)
A(m 2 )
Q(m 3 / s )
Evaporator Q(VVM ) 60
V (m 3 )
 16

Multiphase flow regimes

User must know a priori the characteristics of the flow.
Flow regime, e.g. bubbly flow, slug flow, annular flow, etc.
Only model one flow regime at a time.
Predicting the transition from one regime to another
possible only if the flow regimes can be predicted by the
same model. This is not always the case.
Laminar or turbulent.
Dilute or dense.
Secondary phase diameter for drag considerations.
 17

Modeling approach

Increased complexity
Empirical correlations.
Lagrangian.
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.
 18

Coupling between phases

One-way coupling:
Fluid phase influences particulate phase via aerodynamic drag and
turbulence transfer.
No influence of particulate phase on the gas phase.
Two-way coupling:
Fluid phase influences particulate phase via aerodynamic drag and
turbulence transfer.
Particulate phase reduces mean momentum and turbulent kinetic
energy in fluid phase.
Four-way coupling:
Includes all two-way coupling.
Particle-particle collisions create particle pressure and viscous
stresses.
 19

Modeling multiphase flows

What is the goal of the simulation?
Which effects are important?
Controlled by which hydrodynamic effects?
Model Specific
Controlled by which other transport
phenomena effects? Lagrangian Dispersed
Phase Algebraic Slip
All these factors influence which model to
Eulerian
choose for the analysis.
Eulerian Granular

?
Flow Specific Volume of Fluid
bubbly
droplet
particle-laden Process Specific
slug Separation
annular Filtration
stratified/free surface Suspension
rapid granular flow Evaporation
Reaction
 20

Physical effects in dispersed systems

Hydrodynamics:
Change in shape.
Diameter.
Particle-wall collision.
Particle-particle collision.
Coalescence.
Dispersion and breakup.
Turbulence.
Inversion.
Other transport phenomena:
Heat transfer.
Mass transfer.
Change in composition.
Heterogeneous reactions.
 21

Multiphase formulation
Two phases

Fluid

Solids

Fluid
Three phases
Solids - 1

Solids - 2
 22

Sediment transport under unidirectional flows

I. Classification of sediment load

The sediment that is transported by a current.

Two main classes:

Wash load: silt and clay size material that remains in suspension even during low flow
events in a river.

Bed material load: sediment (sand and gravel size) that resides in the bed but goes into
transport during high flow events (e.g., floods).

Bed material load makes up many arenites and rudites in the geological record.
 23

Three main components of bed material load.

Contact load: particles that move in contact with the bed by sliding or rolling over it.
 24

Saltation load: movement as a series of hops

along the bed, each hop following a ballistic
trajectory.
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When the ballistic trajectory is disturbed by turbulence the motion is referred to as

Suspensive saltation.
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Intermittent suspension load: carried in suspension by turbulence in the flow.

Intermittent because it is in suspension only during high flow events and otherwise
resides in the deposits of the bed.

Bursting is an important process in initiating suspension transport.

 27

II. Hydraulic interpretation of grain size

distributions

In the section on grain size distributions we

saw that some sands are made up of several
normally distributed subpopulations.

These subpopulations can be interpreted in

terms of the modes of transport that they
underwent prior to deposition.
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The finest subpopulation represents the wash

load.

Only a very small amount of wash load is ever

stored within the bed material so that it makes
up a very small proportion of these deposits.
 29

The coarsest subpopulation represents the

contact and saltation loads.

In some cases they make up two

subpopulations (only one is shown in the
figure).
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The remainder of the distribution, normally

making up the largest proportion, is the
intermittent suspension load.

This interpretation of the subpopulations gives

us two bases for quantitatively determining
the strength of the currents that transported
the deposits.
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The grain size X is the coarsest sediment

that the currents could move on the bed.

In this case, X = -1.5 f or

approximately 2.8 mm.

If the currents were weaker, that grain size

would not be present.

If the currents were stronger, coarser

material would be present.

This assumes that there were no limitations

to the size of grains available in the system.
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The grain size Y is the coarsest sediment

that the currents could take into suspension.

In this case, Y = 1.3 f or

approximately 0.41 mm.

Therefore the currents must have been just

powerful enough to take the 0.41 mm
particles into suspension.

If the currents were stronger the coarsest

grain size would be larger.

This assumes that there were no limitations

to the size of grains available in the system.
 33

To quantitatively interpret X we need to

know the hydraulic conditions needed to just
begin to move of that size.

This condition is the threshold for sediment

movement.

To quantitatively interpret Y we need to

know the hydraulic conditions needed to just
begin carry that grain size in suspension.

This condition is the threshold for

suspension.
The threshold for grain movement on the bed. 34

Grain size X can be interpreted if we know what flow strength is required to just move
a particle of that size.

That flow strength will have transported sediment with that maximum grain size.

Several approaches have been taken to determine the critical flow strength to initiate
motion on the bed.
Hjulstroms Diagram 35

Based on a series of experiments using unidirectional currents with a flow depth of 1

m.

The diagram (below) shows the critical velocity that is required to just begin to move
sediment of a given size (the top of the yellow field).

It also shows the critical velocity for deposition of sediment of a given size (the bottom
of the yellow field).
 36

Note that for grain sizes coarser than 0.5 mm the velocity that is required for transport
increases with grain size; the larger the particles the higher velocity that is required for
transport.

For finer grain sizes (with cohesive clay minerals) the finer the grain size the greater the
critical velocity for transport.

This is because the more mud is present the greater the cohesion and the greater the
resistance to erosion, despite the finer grain size.
 37

The problem is that the forces that are required to move sediment are not only related
to flow velocity.

Boundary shear stress is a particularly important force and it varies with flow depth.

to = rgDsinq

Therefore, Hjulstroms diagram is reasonably accurate only for sediment that has been
deposited under flow depths of 1 m.
Shields criterion for the initiation of motion 38

Based on a large number of experiments Shields criterion considers the problem in

terms of the forces that act to move a particle.

The criterion applies to beds of spherical particles of uniform grain size.

Forces that are important to initial motion:

1. The submerged weight of the particle ( ( r r ) gd 3 ) which

s
resists motion. 6

2. to which causes a drag force that acts to

move the particle down current.

3. Lift force (L) that reduces the effective

submerged weight.
Whats a Lift Force? 39

The flow velocity that is felt by the particle varies from approximately zero at its base to
some higher velocity at its highest point.
 40

Pressure (specifically dynamic pressure in contrast to static pressure) is also imposed

on the particle and the magnitude of the dynamic pressure varies inversely with the
velocity:

Higher velocity, lower dynamic pressure.

Maximum dynamic pressure is

exerted at the base of the particle
and minimum pressure at its highest
point.
 41

The dynamic pressure on the particle varies symmetrically from a minimum at the top to
a maximum at the base of the particle.
 42

This distribution of dynamic pressure results in a net pressure force that acts upwards.

Thus, the net pressure force (known as the Lift Force) acts oppose the weight of the
particle (reducing its effective weight).

This makes it easier for the flow to

roll the particle along the bed.

The lift force reduces the drag

force that is required to move the
particle.
A quick note on saltation 43

If the particle remains immobile to the flow and the velocity gradient is large enough so
that the Lift force exceeds the particles weight.it will jump straight upwards away from
the bed.

Once off the bed, the pressure

difference from top to bottom of the
particle is lost and it is carried down
current as it falls back to the bed.

following the ballistic trajectory of

saltation.
 44

Example: bubble column design

Gas

A bubble column is a liquid

pool sparged by a process Liquid
stream.

2 < L/D < 20

UG,sup up to 50 cm/s

Liquid UG,sup >> UL,sup

Pool

Sparger
Liquid/Slurry Inlet

Gas Gas Inlet

 45

Bubble columns: flow regimes

Bubbly Flow Churn-Turbulent Flow (Heterogeneous)

Flow Regime Map (Deckwer, 1980)

 46

Bubble column design issues

Design parameters:
Gas holdup. Directly related to rise velocity. Correlations of the form
a ~ usgarlbscmld are commonly used.
Mass transfer coefficient kla. Correlations of the form
kla ~ usgarlbscmld mgeDfDrg are commonly used.
Axial dispersion occurs in both the liquid and gas phase, and
correlations for each are available.
Mixing time. Correlations are available for a limited number of systems.
Volume, flow rates and residence time.
Flow regime: homogeneous, heterogeneous, slug flow.
 47

Bubble column design issues - contd

Accurate knowledge of the physical properties is
important, especially the effects of coalescence and mass
transfer affecting chemicals.
Although good correlations are available for commonly
studied air-water systems, these are limited to the ranges
studied.
Correlations may not be available for large scale systems
or systems with vessel geometries other than cylinders
without internals.
Furthermore, experimental correlations may not
accurately reflect changes in performance when flow
regime transitions occur.
 48

Bubble size
At present, bubble column reactors are modeled using a
single effective bubble size.
Coalescence and breakup models are not yet mature.
Statistical approach. Solve equation for number density.
Population balance approach.
Application of population balance with two-fluid models with initial
focus on gas-liquid.
The gas phase is composed of n bubble bins and share the same
velocity as the second phase.
The death and birth of each bubble bin is solved from the above
models.
 49

Example - gas-liquid mixing vessel

Combinations of multiple
impeller types used.
Bottom radial flow turbine
disperses the gas.
Top hydrofoil impeller provides
good blending performance in
tall vessels.
 50

Eulerian-granular/fluid model features

Solves momentum equations for each phase and
additional volume fraction equations.
Appropriate for modeling fluidized beds, risers, pneumatic
lines, hoppers, standpipes, and particle-laden flows in
which phases mix or separate.
Granular volume fractions from 0 to ~60%.
Several choices for drag laws. Appropriate drag laws can
be chosen for different processes.
Several kinetic-theory based formulas for the granular
stress in the viscous regime.
Frictional viscosity based formulation for the plastic
regime stresses.
Added mass and lift force.
 51

Eulerian-granular/fluid model features

Solves momentum equations for each phase and
additional volume fraction equations.
Appropriate for modeling fluidized beds, risers, pneumatic
lines, hoppers, standpipes, and particle-laden flows in
which phases mix or separate.
Granular volume fractions from 0 to ~60%.
Several choices for drag laws. Appropriate drag laws can
be chosen for different processes.
 52

Granular flow regimes

Elastic Regime Plastic Regime Viscous Regime
Stagnant Slow flow Rapid flow
Stress is strain Strain rate Strain rate dependent
independent dependent
Elasticity Soil mechanics Kinetic theory
 53

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 own 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. Very 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. Addition of finer size particles to a
bed with coarse particles usually improves fluidization.
Superficial gas velocities (based on cross sectional area of
empty bed) typically range from 0.15 m/s to 6 m/s.
 54

Fluidized bed example

 55

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.
 56

Typical fluidized bed systems - 1

Gas

Gas and entrained solids

Dust

Freeboard
Solids Feed Separator
Disengaging Space
(may also contain a
cyclone separator)

Dust

Bed depth
Fluidized Bed

Gas in
Solids Discharge

Windbox or plenum chamber Gas distributor or constriction plate

 57

Typical fluidized bed systems - 2

Gas + solids

Riser section of
a recirculating
fluidized bed

Solids

Bed with central jet

Gas
Uniform Fluidization
 58

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

 59

Fluidized bed design parameters

Main components are the fluidization vessel (bed portion,
disengagement space, gas distributor), solids feeder, flow
control, solids discharge, dust separator, instrumentation, gas
supply.
There is no single design methodology that works for all
applications. The design methodologies to be used depend on
the application.
Typical design parameters are bed height (depends on gas
contact time, solids retention time, L/D for staging, space
required for internal components such as heat exchangers).
Flow regimes: bubbling, turbulent, recirculating, slugs. Flow
regime changes can affect scale-up.
Heat transfer and flow around heat exchanger components.
Temperature and pressure control.
Location of instrumentation, probes, solids feed, and
discharges.
 60

Fluidized bed - input required for CFD

CFD can not be used to predict the:
minimum fluidization velocity,
and the minimum bubbling velocity.
These depend on the:
particle shape,
particle surface roughness,
particle cohesiveness, and the
particle size distribution.
All of these effects are lumped into the drag term. Hence
we need to fine tune the drag term to match the
experimental data for minimum fluidization or minimum
bubbling velocity.
 61

Fluidized bed - when to use CFD

If the drag term is tuned to match the minimum fluidization
velocity, CFD then can be used to predict:

bed expansion effects of inlet and outlets

gas flow pattern
solid flow pattern
bubbling size, frequency and
population
short circuiting
effects of internals
hot spots
reaction and conversion rates
mixing of multiple particle size
residence times of solids and gases
backmixing and downflows (in risers)
solids distribution/segregation