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ANNUAL TRANSACTIONS OF THE NORDIC RHEOLOGY SOCIETY, VOL. 20, 2012
ABSTRACT This paper describes initial experiments
that are done at the University of Stavanger in a new flow rig for study of gas lift under static and flowing conditions. Lift efficiency is determined from lift of a liquid column under various experimental conditions, while bubble rise velocity and bubble sizes are determined using high speed video recordings. For the experiments water, and also PAC (polyanionic cellulose) are used as fluids. Both static lift and air-circulation experiments involving polymers is found to be more time dependent than with water, due to different accumulation of gas bubbles.
INTRODUCTION
Gas-lift techniques are based on injection of gas into fluids to be transported in vertical upward flows in pipes and circulation systems. Gas reduces the mixture density and lowers the hydrostatic pressure gradient. It is used as a pumping technique often also for enhancement of chemical reactions via interfacial mass transfer and turbulence. It is used in a variety of engineering applications, as well as environmental cleaning and bioreactor systems, which generally involves non-Newtonian fluids 1,3,4.
Gas lift is also very important in oil production. A substantial fraction of drilled
oil wells worldwide are “helped” by gas lift, and may increase production rates very much. Basically two applications are well known for petroleum. One is “gas lift production”, where usually produced natural gas is injected through gas-lift valves into the production tubing at the bottom of the well. The bottom-hole pressure (BHP) is reduced and thereby the inflow from the producing reservoir is increased. In this case the liquid is usually oil which is predominantly Newtonian, or an oil-water mixture which has a complex rheological nature not easily described by common non-Newtonian models. Another application is the addition of gas into drilling mud for so-called “underbalanced drilling”. The aim is to reduce the pressure at the bottom of the well to slightly below the reservoir pressure. The purpose is to avoid reservoir fracture and loss of lubrication drilling fluid into the reservoir formation. Drilling mud is usually non-Newtonian.
The gas-lift efficiency depends on the in-situ gas fraction for a given amount of injected gas. The lift process leads to increase in liquid flow-rate and thus the total flow-rate and mixture velocity will increase. However a number of parameters play a role in the overall process, where the rise velocity or “slip” is one of the most important. Additional factors involve solubility of the gas into the liquid, and also the total mixture velocity. Solubility is
An Experimental Study of Gas Lift Efficiency in Polymer Systems
Rune W. Time and A.H. Rabenjafimanantsoa
University of Stavanger, Norway
59
difficult to know in petroleum systems since the produced natural gas is most often used as gas source, and this aspect is not covered here since air and water based systems are used, with only minor interfacial mass transfer.
Rheology of the liquid is likely to have a major impact on the lift efficiency, in particular in conjunction with the suspended bubbles. The power-law behavior of the polymer solutions will not necessarily be the same in a gas-liquid system, like with shear rate versus shear stress in a vertical pipe. The rise velocity is closely connected to the bubble size but in non-Newtonian flows this is not a simple connection. It depends very much on the rheological parameters of the fluid. Furthermore it is found1 that even for the same fluid the rise velocity depend in a more non-linear way on bubble size than in Newtonian flows. Finally, the bubble size in multiphase flow is in general a “self-organized” quantity. It is influenced by upstream injection or mixing history, and also by the turbulence intensity. The latter is a challenge to determine in polymer liquids with dispersed gas bubbles.
THEORY
The gas-lift efficiency is basically determined by the in-situ gas fraction which controls the hydrostatic pressure gradient. The gas fraction is for a given flow rate of gas directly connected to the slip velocity or the slip ratio S = uG/uL. Here uG and uL are the gas and liquid phase velocities respectively.
For low mixture velocity systems like in a bubbling column, it is more convenient to use the bubble rise velocity instead of the slip ratio, since uL is practically zero and S would become very large. This is a common parameter to use also in drift-flux models for numerical simulation. In the drift-flux formulation the gas fraction can be determined theoretically by equating the two equations for the “drift flux” (Zuber and Findlay, 1965 and Wallis, 1969):
(1 )nGM G G Tj U (1)
and
(1 )GM G GS G LSj U U (2)
Eq. (1) is referred to as the “dynamical
equation” since fluid flow dynamics controls the rise velocity uT while n is a system dependent parameter. The equation also includes effective rise velocity in a system of bubbles with gas fraction G as compared to terminal velocity for the bubbles. UT is the stabilized rise velocity for one single bubble in a large tank. Equation (2) called the “kinematic equation” is theoretically just a connection between the superficial velocities in a fixed reference frame to the so-called “drift–flux” jGM. This is the superficial velocity in a system following the mixture velocity, which again is the sum of the superficial velocities
mix GS LSU U U (3)
For pure bubble column mode with
liquid circulation ULS=0, and the equations simplify to solving
n 1 GS
G GT
U(1 )
U (4)
Alternatively if the gas fraction is
known, it possible to derive the average bubble terminal velocity UT using
GST n 1
G G
UU
(1 )
(5)
However the rise velocity may be very
different for single bubbles in a big tank compared to in pipes with high gas fraction and complex velocity profiles. One objective of this study is to investigate also the effect of non-Newtonian liquids on the
60
bubble velocity
Goocan beexperimmore comput EXPER
Themotivatdynamiapplica“productransposurfacedrillingtranspothe dril
It wflow ri“Riser”two hoas showalso a applica
Figurdefini
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focus ontational mod
RIMENTALe particulated by neics for
ations. Gas-ction” will
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” and “Doorizontal crown in Fig. very gener
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re 1. Sketchitions of “R
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L SETUP ar setup weed to dete
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d to build o 5 m high wncomer”, ossover pip1. In this w
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net bubble
gas-lift systst focuses the other transfer
was originermine gas
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ith and
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It is quite emical reacirculation ossover pipeans of valv
Gas liftingir) bubbles ag. 1. A clothe insert oly partly coinjectors o
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A problemassive” spang on to tflation stagameters largtlet.
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However
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ves. g is obtainedat the bottomose up of thof Fig. 2. ontrollable wr “spargers”us injector al particles,oscope pictu
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2. Picture oan electrone. Magnificidth is appro
even if the10-100 mr bubbles thing to the or by coal
e they are ree spargers a
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hat bubblespenings duay becomeopenings o
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61
bubbles either by a strong cross flow, or by using a fast mechanical scraper mechanism to wipe the bubbles off the surface. EXPERIMENTS
Experiments were planned and carried out to determine the following issues: 1) flow regimes in the riser, crossovers and downcomer pipe, 2) gas-liquid fractions as a function of superficial gas velocity, 3) flooding limit for gas bubbles in the downcomer pipe in terms injected gas, 4) bubble size for given gas sparging unit as a function of gas flow rate, 5) pressure gradients versus flowrates for different configurations of valve openings, and finally 6) velocity profiles of liquid and gas in riser and downcomer. Determination of the velocity profile in the downcomer could also enable calculation of the liquid flow-rate.
There are already quite a lot of data generated from these initial experiments. They have been acquired during a very busy experimental campaign the last month. This has left less time to carry out all the planned analysis, so only some few examples will be presented and discussed here. More will be presented at the conference and in later papers.
Experimental program
The different tests were grouped as i) Static column bubbling ii) Gas-lifted circulation Static bubbling was used to determine
liquid height as a function of gas flow rate. The goal was to determine gas fraction. This was done both for water and PAC. Flow regime determination and a feasibility study to find bubble sizes gas fraction distributions was also part of this study.
Circulation with fully opened valves was carried out to study dynamic lift, both in Newtonian and non-Newtonian flow. As described later a direct comparison between the experimental modes was influenced by the gradual entrainment of bubbles especially in the non-Newtonian case.
The lift efficiency can be measured from the pressure gradient in the riser, but it is representative only in the initial period when gas bubbles still have not reached the downcomer pipe. On the measurement program was also the flooding limit for gas bubbles in the downcomer, both for water and PAC
Flow aspects regarding the tests
The “static 1” experiments were carried out with the crossover pipes closed These tests reveal the potential lift properties of a full circulating the gas-lift system. It is also possible to close just the upper valve to aloe inflow from the bottom into the riser. These tests mainly shift the column level to a slightly higher level, but do in principle not add much more information.
The circulating fully dynamic tests also involve flow friction. Both in two-phase flow, and in single-phase non-Newtonian system this is important to determine. A comment on the static versus circulating test regards the analogous equivalent when measuring the voltage difference between the poles of a battery when not loaded. The circulation tests give the corresponding voltage when current flows in an external circuit. In his case the voltage is reduced due to internal losses in the battery. The friction in the left downcomer leg corresponds to the internal loss.
Instrumentation
The flow loop has been set up to give a best possible access to vital information to determine lift dynamics and efficiency. Transparent pipes give excellent information about flow regimes, bubble size and velocities, and also liquid rise levels. Pressure is measured at the gas flowmeter with a Honeywell sensor. Also the pressure difference P between the two locations shown in Fig. 1 was measured, using a Rosemount transmitter 3051C. It has a range of 62 mbar and time resolution 100ms. Finally the gauge pressure is measured at
62
the lowP sensensor used. Pfast dat12 bit)profilesspeed vthat reresolutirecord resolutifor 82ImagesGigaBidedicat(“Motio
Fluids
Basused; concen(PAC) of distiPAC 20PAC rheomecone pl
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Static e
Forclosed, more ithe bub
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(Crystal Pressures artalogging ca). Phase ds are measuvideo camerecords up ion 512x5
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eter of typelate configuC is chosenarency. The law fluids 3.
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h the gas flo
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63
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64
since thand 2 tfractionwater apipe (1Fig. 7.given tIt is althougpressurfractionvolumeto the rconnec
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This assumption in preste as shown
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his is a reapected sincite complex
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hows a linnd then a ibuted to ine gas flowrtailed calcu
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he bubble risusing the lier. This is en that foer 0.008 mirly constan
asonable vace the bubx for the hig
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near increassharper ris
ncreased turrate is measulation of R
analysis um. A fullbo, but very fe
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se velocitiedrift-flux
shown in For superfic
m/s the bubnt around 0alue, and sobble intera
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se up to se which rbulence. sured for Reynolds using the re liquid ew if any feasible; c for gas
s may be model
Fig. 9. It cial gas bble rise 0.15 m/s. omewhat action is wrates.
65
Figure
PAC 4
At bubble becauseand in trains opipe wvisibly of the Coanda
For kind ofviscousdecreasshear deformmore su
Finastatic cFig. 10for the0.012 mseems t
Experim
Whallowedlevels seem toin this ngas todownco
e 9. Averag400, based o
gas flow lrise velo
e the bubblefairly stra
of bubbles wall, where
much highpipe. This
a effect. the shear
f dynamics s dampingses the col
thinning mation, and
usceptible tally conside
cases, all th0. From the e superficim/s. For hto be slightl
ments with hen the vad to circulais reached.
o the same anew situatioo the cromer. Impo
ge bubble rison drift-flux
lower than ocities are es move wi
aight paths. were devel
e the bubbher than in t
is very lik
thinning PAis modified
g of the llision stren
also incrthus mak
o coalescenering the co
he tests are graph thereial gas vehigher flowly higher fo
open valveslves are o
ate until a n. At first as the staticon the liquidrossover prtant new re
se velocity fx model (Eq
0.007 m/s much hig
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oped alongble speed the central kely a kind
AC system d due to hig
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kes the bubnce. olumn lift in
summarizee is clear treelocities be
w rates, the r water.
s - circulatioopen, liquidnew equilibrsight this m case. Howd may transpipe and egimes occu
for q.5).
the gher, sions tests
g the was part
d of
this gher hich ever bble
ubble
n the ed in ends elow lift
on d is rium may ever
sport the
ur
whas
infratpipgraredgascirgasdo(diin De
accanalarbehpipforgra
detvaldopipbub
Figure 10. C
static bub
hen the liquin the examThe diffe
fluence thete. The equipes reflect adient. Gasduce the mis-lift effect rculation ves to ventiwncomer.ifference inthe riser wh
ensity variatWith PA
cumulation alysis somerger bubblhavior maype. This pipr the liquadually redu
To some termined anlves and cwncomer wpe which bbles.
Column liftbling - with
uid start to mple Fig. 11
rent flow gas fracti
librium liquthe diffe
s bubbles ixture densiis lost. This
elocity and ilate out aIt is only gas fractio
hich sets up
tions with tiAC, over
in the liquewhat, in ples with y continue ipe is supposuid densityuced.
extent thnd accountecomparing with the levecontains on
t for all the hout circula
flood the g1. regimes th
ion and ciruid levels inerence in in the dowity and mucs in turn redallows mor
at the topy the “exceon in the tw a lift effect
ime time t
uid complicparticular si
unpredictabinto the dowsed to be a ry, which
his effect ed for usinliquid leveel in a thirdnly liquid
fluids, ation.
gas down
hat arise rculation n the two pressure
wncomer ch of the duces the re of the
of the ess gas”
wo pipes) t.
he gas cates the ince also ble rise wncomer reference is then
can be ng closed el in the d thinner
without
66
Figuredow
bubbleconstan
In separatdowncoin the changephase) counterspecificpolymesmall blarge briding”the wvariatioscale imflow co Floodin
In teffects the wavelocityforces amiddle
e 11. Floodiwncomer wits agglomerantly varying
fr
circulation tion effectomer pipe. Triser. The of flow rand flow dyrcurrent floc and diffeer flows. Ibubbles flobubbles cau effect - th
wake of thons in Fig. mpact of thonditions in
ng dynamicthe downcopresent; 1)
all decreasy. For noa higher do(“core”) pa
ng of gas buth PAC 400ate, rotate ag patterns. Irom video.
mode als
ts takes This is diffeimmediate
regimes (siynamics in ows. This erent effectsn the riser
ow side by uses a type he small bubhe larger 12 mainly
he pressurethe riser an
s in downcoomer pipe bubbles inse the neaon-Newtoniownward liqart of the pip
ubbles into 0 liquid. Theand rearrangImage snaps
so bubble place in erent from fe reason is ingle and tconcurrent again sets
s in water both large sides, and of “piggyb
bbles followbubbles. show the l
e gradients nd downcom
omer there are
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quid flow inpe. 2) This
the e
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size the
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Fr
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Lift
hei
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(mm
)Li
ft h
eigh
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Lift
hei
ght
(mm
)
Figure 12. Driser and dowow rate. Circopened valv
(middle
0 0.000
100
200
300
400
500
600Liqui
Sup
R
D
0 0.000
100
200
300
400
500
600P20
Sup
R
D
0 0.000
100
200
300
400
500P40
Sup
R
D
Difference iwncomer asculation expes using wa
e) and PAC4
05 0.01 0
d (water) rise vers
perficial gas veloc
iser
owncomer
05 0.01 0
00 Liquid rise vers
perficial gas veloc
iser
owncomer
05 0.01 0
00 Liquid rise vers
perficial gas veloc
iser
owncomer
in liquid hes a functionperiments water (top), P400 (bottom
0.015 0.02
sus gas flowrate
city UGS (m/s)
0.015 0.02
us gas flowrate
city UGS (m/s)
0.015 0.02
us gas flowrate
city UGS (m/s)
ight in n of gas with fully AC200
m).
0.025
0.025
0.025
67
causes a “pinch” effect so that there is higher shear further away from the wall than for water. Since PAC is shear thinning this causes a reduction of apparent viscosity in the main flow of the pipe. So even though the downflow is stronger in the core, the reduced liquid viscosity in some cases may cause enhanced counter current upwards bubble flow compared to with water circulation.
Similar phenomena are seen in the riser, but with opposite effect. Bubbles rise faster close to the wall causing a positive feedback with increased wall shear stress and reduced apparent viscosity. As an example, this is as reflected in Fig. 9.
The high speed camera is particularly useful for this study. It enables both calculation of the liquid phase velocity with the addition of small tracer particles. It also visualizes the velocity profile, bubble size and bubble fractions profile, as well as bubble shape. CONCLUSIONS
Two different modes of operation were used, with and without external circulation, often referred in literatures to as bubble column and gas-lift mode. In this work the bubble column mode is mainly used as an indicator of the gas rise velocity as reflected in the gas fraction.
It was found that gas-lift with Newtonian and non-Newtonian liquids differ in several ways. Fig. 10 and 12 illustrate the overall behavior in various ways. These are not conclusive until a more detailed analysis from high-speed recordings is done. The lift in the non-Newtonian PAC 200 case is slightly higher for low gas flow rates than the corresponding Newtonian case, even though the overall viscosity of water is lower.
The interpretation is therefore not straightforward, since the lift process dynamics involves both the liquid viscosity and the density. The main mechanisms seems to be the reduced rise velocity of the
gas bubbles which increases gas fraction as seen in the “static” experiments where both of the crossovers valves were closed. Reduced density should in the case of equal viscosity lead to higher flow. However for PAC the viscosity is higher and friction increases. The flowing case (circulation mode) is in accordance with this conclusion, but is complicated by the gradual saturation of small and microscopic bubbles over time.
The effect of gas bubble size is for the present initial study difficult to estimate, since bubble size was not easily controllable. Similar conclusions are given in most publications too; that diameter of gas sparger orifices has small effect on the overall gas fraction and pressure drop. We conclude this from a theoretical point of view; the bubble rise velocity approaches zero for small bubbles, and thus the gas fraction would increase with smaller diameter. This would be even more pronounced with shear thinning fluids like PAC.
For the bubble column mode this would lead to accumulation of time until the gas creates a foamy mixture at the sparger, eventually leading to slugging when the foam breaks. For the gas-lift mode a similar effect is expected, although taking much longer time and leading to a more even gas distribution.
Friction is modified by the bubbly flow as compared to single phase flow for both the Newtonian and the non-Newtonian case, in accordance with the general conclusion in most published works8. ACKNOWLEDGMENTS
We greatly acknowledge the work of bachelor students Bjørn Holien and Knut Jørgen Brodahl. They have contributed very much experimentally to this work, with flow loop building, pictures and data recording.
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