Titolo presentazione sottotitolo Solid volume fraction [-] Slurry 5 Gianandrea Vittorio Messa, FluidLab Group, DICA How to investigate slurry pipeline flows? Physical modelling Predominant

$Page 1: Titolo presentazione sottotitolo Solid volume fraction [-] Slurry 5 Gianandrea Vittorio Messa, FluidLab Group, DICA How to investigate slurry pipeline flows? Physical modelling Predominant$
Titolo presentazione

sottotitolo

Milano, XX mese 20XX

Slurry flows in pipeline systems

modelling and management

Gianandrea Vittorio Messa

FluidLab Group

Dept. Civil and Environmental Engineering

Politecnico di Milano, Milano, Italy

Seminars organized by the DICA Scientific Commission, V cycle

www.fluidlab.polimi.it

http://www.fluidlab.polimi.it/

Gianandrea Vittorio Messa, FluidLab Group, DICA

Why are slurry flows so interesting?

Several applications involved

Mining industry

Chemical industry

Food industry

Oil and gas

…and many others

Attractive for academia

Complex system

Many physical mechanisms

Challenge is linking scientific research (physical understanding and

modelling) with practical purposes (design and management)

Drying/separatorsSlurry pipelines

Oil sands processing

2


Research approach and milestones

2010 2013 2014 2015 2016 2018

Slurry flow modelling years…

Impact erosion years…

Key features of research @ FluidLab group:

Synergy of numerical and experimental

Always a look to the engineering needs

3


Keynote outline

Slurry pipeline flows

The impact erosion issue

Current and future developments

1

2

3


Keynote outline

1

2

3





The slurry flow team and its partners

Stefano me

Dr. Michael Malin

CHAM Limited

London UK

Prof. Vaclav Matousek

Czech Technical University in Prague

Prague CZ

4


Basic questions

What is a slurry pipeline?

A pipeline used to transport granular material

mixed with water

What are the main concerns?

Reduce the energy consumption

Protect the particles against degradation

Protect the pipeline agains E/C

Reduce water consumption?

What is to be predicted?

Pressure losses

Particle distribution

Velocity field

Pre

ssure

gra

dient

Slurry velocity

Single-phase

SlurrySolid volume fraction [-]

5


How to investigate slurry pipeline flows?

Physical modelling

Predominant approach

High economic cost

Technical issues even for simple flows

Size limitations

"Conceptual" modelling

Effective way for straight pipe flows

Many simplifying assumptions

Sometimes not so easy to implement

Not applicable to other geometries

Numerical modelling

Very complex models

Pending issues (particle accumulation)

Many parameters involved

Numerical problems

Potentially applicable to complex geometries and large scale systems

Pecker and Helvaci (2008)

https://sites.ualberta.ca/~turb/facilities.html

Ekambara et al. (2009)

6


A new predictive modelDefining the fundamental assumptions…

What type of model?

Euler-Euler, two-fluid model approach

Other approaches (e.g. Euler-Lagrange) not

pratically applicable to dense flows in

complex geometries

What type of slurry flows?

Fully-suspended flow (no particle accumulation)

Slurry

Liquid phase

Solidphase

Fully-suspended flow Flow with a moving bed Flow with a stationary bed

7


Overview of two-fluid model equations

Mass and momentum conservation equations

1

tf f f f f

tp p p p p

p f

T

f f f f f f f f

tf f p f f f f

T

p p p p p p p p

tp p f p p p p

p

p

u

u

u u T T

g M u

u u T T

g M u

2

1 2

t

f f tf f f f f

k

tf f f f k

f f tf f f f f

tf f f f k

kC

kk k

t

k P

t

C P Ck

u

u

Turbulence modelling

3

2

0.687

22 2 ,

3

2.5 1exp

1 1

6

1

2 4

24max 1 0.15Re ,0.44 Re

Re

T

j j j j j j t j j

m f f

p m f

p pp

p

p f f p d l vm

p

p

d d f p f p f

f p f p

d p p

p m

l

k j f p

d

dC

dC

T S T S I

M M F F F

F u u u u

u u

F 3

3

6

p

l f p f p f vm vm f f f p p

dC d C

u u u F u u u u

Constitutive equations and closures

Wall boundary conditions for the solid phase

/ / / /

, ,1 ,2

2//

,1 ,

, ,1

0.30.75 //

0.25

,2 , ,

1

Reln Re

0.3105Re Re

w p p p p p p p p

p p

p w y

pw y p

p p pp mp w d w d

f f

s s s s

ys

E s

dds

l

u u

u

u

8


A typical pipe flow solution 9

0 3.600.90 2.701.80

Velocity of solid phase [m/s]

0.270 0.3200.283 0.3080.295

Solid volume fraction

0 3.600.90 2.701.80

Velocity of liquid phase [m/s]

y

αp

Pressure profile

Solution on pipe cross section

Flow

Chord averageconcentration profile


Main features of the two-fluid model

Modelling of turbulent dispersion1

Friction, mixture viscosity-related parameter2,3

Modelling of wall shear stress due to particles3

Parabolic solution algorithm for straight pipe flows4

ACCURATE: good agreement vs experiments

ROBUST: just one tuning, particle shape-related parameter

FAST: 40" for straight pipes, 2-3 days for a valve

NUMERICALLY STABLE: smooth solution, no oscillations

1 Spalding, in Recent Advancements in Numerical Methods in Fluids, Pineridge, 1980.2 Messa et al., Powder Technol., 256 (2014), 61-70.3 Messa and Malavasi, Powder Technol., 270 (2015), 358-367.4 Patankar and Spalding, Int. J. Mass Transfer, 15 (1972), 1787-1806.

0 3.600.90 2.701.80

Axial velocity of solid phase [m/s]

0.270 0.3200.283 0.3080.295


10


Application to slurry pipeline flows

Validated against about 80 pipe experiments1-6

Pressure gradient accuracy within ±10%

Good match of solid volume fraction profiles

Consistent slurry velocity distributions

Cvd=0.11 Cvd=0.21

0.00 0.500.13 0.380.25


Cvd=0.31

1 Roco and Shook, Can. J. Chem. Eng. 61 (1983), 494-5032 Gillies et al., Can. J. Chem. Eng. 82 (2004), 1060-10653 Matousek, Exp. Therm. Fluid Sci. 26 (2002), 692-704 Shaan et al, Can. J. Chem. Eng. 78 (2000), 717-7255 Lee at al., Terra et Aqua 99 (2005), 3-10 6 Shaan and Shook, Can. J. Chem. Eng. 78 (2000), 726-730

11


Application to horizontal pipe bends1,2

INLET

OUTLET

S1S2 S3

S4S5

S6

1 Kaushal et al., Int. J. Multiphase Flow, 52 (2013), 71-91.2 Messa and Malavasi, Eng. Appl. Comput. Fluid Mech., 8(3) (2014), 356-372.

0 0.500.13 0.380.25


12


Application to more complex geometries

… and flow control valves2

Backward-facing step1…

1 Messa and Malavasi, J. Hydrol. Hydromech., 62(3) (2014), 234-240.2 Messa and Malavasi, PVP2013, Paris, France, 14-18 July 2013.

0 0.320.08 0.240.16


0 4.501.13 3.382.25

Fluid velocity magnitude [m/s]

13


Keynote outline




1

2

3


The impact erosion team and its partners

Stefano me

Prof. Josè Gilberto Dalfrè Filho

University of Campinas

Campinas, Sao Paulo, Brasil

Prof. Armando Carravetta

Dr. Oreste Fecarotta

Università Federico II di Napoli

Napoli

Marco Yongbo

14


Basic questions

What is the slurry impact erosion?

The loss of material from hydraulic

components due to the impingement of

solid particles carried by a liquid

Where is impact erosion likely to occur?

Straight pipes and connections

Hydraulic devices (pumps, valves…)

How may research help?

Improve the design of the components

Enhance the management of the system

Develop protective coatings

How does our research develop?

Start with the impact erosion in dilute flow

Move on with impact/abrasion erosion in dense flows

Valve needle

Gate valve

15


First challenge: the EPICO project

EPICO project: "Erosion Prediction In Control Operation"

GOAL: Development of methods for estimating

the useful life of valves subjected to erosive

wear in fields with sand production

Experimental

(two new setups @ LIF)

Numerical

(in-house code)

16


Two experimental facilities @ LIF

Angle choke valve

nozzle

specimen

E-loop DIT

Gate valve

2" to 4" testing line

Up to 28 bar

Up to 160 m3/h

Inconel 718 GRE

17


Numerical approach: Eulerian-Lagrangian modelling 18

Fluid simulation: solution of the Reynolds-averaged Navier-Stokes equations (RANS)

Output:

- Mean fluid pressure

- Mean fluid velocity

- Fluid turbulence variables

Erosion modelFluid simulation Particle tracking

coupling

350 21 28


147

Re

Re

0

+ turbulence model for

pP

U

U U U g S

Additional source

due to particles



Particle tracking: solution of the Lagrangian particle equations of motion

400 20 30

Particle velocity magnitude [m/s]

10


coupling

Output:

- Particle trajectories

- Particle-wall impacts characteristics

2

@ @ *

1

8

3.0844

p f p f p d p f p

p p p

f p

p p

dc W d C W

dt

d D mW c J

dt Dt d

vw w g

u uω w

ω


Impact

wear

scar


Erosion model: material removal by each particle-wall impingement and sum

Output:

- Mass losses


coupling

Input data:

Impact velocity

Impact angle

Properties of materials

e.g. E/CRC

0.750 0.50

Erosion depth [mm]

0.25

imp imp imp

na

pM C m BH v f


Numerical modelling

CAD

Volume

Meshing

Surface

Meshing

CFD

simulation

Erosion

estimation

E-code

E-code

Cage

SleeveRetaining

sleeve

Body

Flow

mmeroded

1.0

0.0

0.2

0.4

0.6

0.8

In-house tool for erosion prediction

Specifically intended for complex geometries

Multi-component analysis

Effect of selective coating

21


Combine our experiments to literature data

Assess the reliability of the prediction model3

Validate a target-oriented model

nozzle

specimen

DIT

E-code

E-code

1 Messa et al., Int. Conf. on Wear of Materials, Long Beach, US-CA, 20172 Gorini et al., Offshore Mediterranean Conference, Ravenna, Italy, 2017 3 Messa and Malavasi, Wear, 370-371 (2017), 59-72.

Research strategy1-3

Direct impact testing

RANS simulation of water flow

350 21 28


147

DPM particle tracking

400 20 30

Particle velocity magnitude [m/s]

10

22



Valve testing and validation

Erosion valve testing in the E-loop

Validation of the prediction model

1 Messa et al., Int. Conf. on Wear of Materials, Long Beach, US-CA, 2017 2 Gorini et al., Offshore Mediterranean Conference, Ravenna, Italy, 2017 3 Malavasi at al., ASME PVP 2018, Prague, CZ, 2018. Under review.4 Messa at al., AIMETA 2017, Salerno, IT, 2017.

mmeroded

1.0

0.0

0.2

0.4

0.6

0.8

Cage

SleeveRetaining

sleeve

Body

Flow

FlowFlow

54321

mm/d

0

Gate valve

Choke valve

0

2

4

6

8

10

12

14

16

18

20

0.00 2.00 4.00 6.00 8.00 10.00

[g]

[h]

Mass loss history of valve cage

E-loop

E-code

23



Virtual experiments and data analysis

Erosion valve simulation in different conditions

Database collection

Sensitivity analysis

Identification of the most relevant parameters

Engineering failure analysis

1 Messa et al., Int. Conf. on Wear of Materials, Long Beach, US-CA, 2017 2 Gorini et al., Offshore Mediterranean Conference, Ravenna, Italy, 2017 3 Malavasi at al., ASME PVP 2018, Prague, CZ, 2018. Under review.4 Messa at al., AIMETA 2017, Salerno, IT, 2017.

E-code

Useful life-time

Type of valve

Size of valve

Valve opening

Flow conditions

Abrasive load

24


Keynote outline




1

2

3


Towards the modelling of dense slurry erosion

1 Messa et al., ASME Pressure Vessels and Piping Conference, Anaheim, US-CA, 2015. 2 Messa et al., Wear, 398-399 (2018), 127-145.3 Messa and Malavasi, 9th Int. Conference on Multiphase Flow, Firenze, Italy, 2016.4 Messa and Malavasi, Wear, 398-399 (2018), 127-145.

Particle-particle interactions become important

Self-induced geometry changes may become important

Computational burden of

Eulerian-Lagrangian

approach grows

exponentially! No practically

feasible for complex flows

IDEA: Mixed EE-EL model with self-updating boundary1-4

EL subdomain

EE domainInterface

25


Investigation of concrete erosion1-3

ExperimentalE-code

1 Malavasi et al., XX SBRH, Bento Gonçalves, Brazil, 2013.2 De Lima Branco et al., XXII SBRH, Florianopolis, Brazil, 2017.3 Messa et al., J. Hydrol. Hydromech., 66 (2018), 121-128.

E-CODE for non-homogeneous materials

Experiments / simulation

Cooperation with UNICAMP, Brazil

26


Impact erosion in devices with moving components

1 Fecarotta et al., 3rd Efficient Water Systems Conference, Lefkada, Greece, 2018. Under review.

E-CODE for rotating bodies

Application to Pumps As Turbines1 and Valves

Cooperation with UNINA

E-code

Pump used as turbine

Gate valve

Stirred tank

27


Towards a more general view of slurry systems

Keyword: sustainability of the process

Accounting for water saving?

Multidisciplinary design and management

Energy

Water

Durability

28


Thank you for your attention

www.fluidlab.polimi.it

Gianandrea Vittorio Messa

Assistant Professor

FluidLab Group

Dept. Civil and Environmental Engineering

Politecnico di Milano

Piazza Leonardo da Vinci, 32

20133 Milano (Italy)

e-mail: [email protected]

Tel. +39 02 2399 6287

http://www.fluidlab.polimi.it/

mailto:[email protected]

Documents

Titolo presentazione sottotitolo Solid volume fraction [-] Slurry 5 Gianandrea Vittorio Messa, FluidLab Group, DICA How to investigate slurry pipeline flows? Physical modelling Predominant