Feasibility study of coal-hydrocarbon slurries
by James Brent Blazek
A thesis submitted in partial fulfillment of the requirements for the degree of MASTER OF SCIENCE
in Chemical Engineering
Montana State University
© Copyright by James Brent Blazek (1975)
Abstract:
Finely ground coal-hydrocarbon slurries were studied to determine their properties. The research was
separated into two parts, an initial phase to determine if the slurries would set up under pipeline
pressure conditions and a more detailed look at a crude oil—coal slurry. Brookfield and Stormer
viscometers were used to measure viscosities.
It was found that the viscosities of most coal-hydrocarbon slurries did tend to increase after
pressurization to 500 and 1000 psig for several weeks. However, it was felt that this viscosity increase
was not severe enough to eliminate any of the liquid carriers.
Rheograms obtained from a Brookfield rotational viscometer for a range of coal—crude oil slurries
from 0% to 50% by weight showed four distinct rheological models.
Slurries of crude oil and coal were pumped through a one inch schedule 40 pipe to determine their flow
characteristics. Various methods were used to compare the effective viscosities obtained from the
pipeloop’s pressure drop to the apparent viscosities measured by the Brookfield viscometer. The
agreement was not good. A method derived for Bingham plastics to predict pipeline pressure drops
from viscometer data was tried. Its success in predicting pressure drops was found to be limited. STATEMENT OE PERMISSION TO CORY
In p re s e n tin g t h is
t h e s i s i n p a r t i a l f u l f i l l m e n t o f t h e r e q u i r e m e n ts
f o r a n a d v a n c e d d e g r e e a t M ontana S t a t e U n i v e r s i t y , I a g r e e t h a t t h e
L i b r a r y s h a l l m ake i t f r e e l y - a v a i l a b l e f o r i n s p e c t i o n ..
I f u r th e r a g re e
t h a t p e r m i s s i o n f o r e x t e n s i v e c o p y in g o f t h i s t h e s i s f o r s c h o l a r l y
p u r p o s e s may b e g r a n t e d b y my m a jo r p r o f e s s o r , o r , i n h i s a b s e n c e , b y
th e D ire c to r o f L ib r a r ie s .
p u b l i c a t i o n on t h i s
I t i s u n d e r s t o o d t h a t a n y c o p y in g o r
t h e s i s f o r f i n a n c i a l g a i n s h a l l n o t b e a llo w e d
w i t h o u t my w r i t t e n p e r m i s s i o n .
FEASIBILITY STUDY Of COAL-HYDROCARBON
SLURRIES■
by
JAMES BRENT BLAZEK
A t h e s i s s u b m i t te d i n p a r t i a l f u l f i l l m e n t
o f t h e r e q u i r e m e n ts f o r t h e d e g re e
■
of
MASTER OF SCIENCE
tn
C h e m ic a l E n g in e e r in g
A p p ro v e d :
C h a irm a n , E x a m in in g C o m m ittee
H ead , M a jo r DepartifferTl
G r a d u a te B ean
MONTANA STATE UNIVERSITY
B ozem an, M ontana
J u n e , 1975
UJL
ACKNOWLEDGMENT
The a u t h o r w is h e s t o t h a n k t h e s t a f f o f t h e C h e m ic a l E n g in e e r in g
D e p a rtm e n t o f M o n tan a S t a t e U n i v e r s i t y f o r t h e i r a i d w h i c h 'l e d to t h e
c o m p le tio n o f t h i s p r o j e c t .
A s p e c i a l th a n k s g o e s to D r. L lo y d B e rg ,
d i r e c t o r o f t h i s r e s e a r c h , f o r h i s g u id a n c e d u r in g t h i s p r o j e c t .
th a n k s a l s o g o e s t o D r. G i l e s C o k e le t f o r t h e u s e o f
and h i s h e l p f u l i d e a s .
A
h i s v i s c o m e te r
The a s s i s t a n c e o f M r. Jam es T i l l e r y a n d M r.
S i l a s Huso, i n t h e c o n s t r u c t i o n . o f t h e e q u ip m e n t n e c e s s a r y t o c o m p le te
t h is p r o je c t i s g r e a tly a p p re c ia te d .
The a u t h o r i s a l s o i n d e b t e d t o t h e B u r l i n g t o n N o r t h e r n R a i l r o a d
I
f o r t h e i r f i n a n c i a l s u p p o r t an d f o r b e in g g iv e n t h e o p p o r t u n i t y to
conduct th is in v e s tig a tio n .
v!
a
iv
. TABLE OF CONTENTS
' Page
VITA
ii
ACKNOWLEDGMENT...........................................................................................
iii
LIST OF TA B LES.............................
vi
LIST OF FIGURES.............................................................................
v ii
ABSTRACT . ...................................................................................................................................... v i i i
I.
INTRODUCTION AND BACKGROUND............................. ■ . . ..............................
II.
RESEARCH OBJECTIVES ..................................
III.
x
6
OBJECTIVES .................................................
6
V II.
. . . . . . . . . . . .
MATERIALS, EQUIPMENT ANDPROCEDURES .......................................................
8
MATERIALS. . ............................................................
8
EQUIPMENT. ............................................ i
8
. ......................................
. .......................................................... ....
.
12
RESULTS AND DISCUSSION.................................................................. ' . . . . .
18
PRELIMINARY PHASE........................ . . . . . ' ...........................................
18
RHEOLOGICAL PHASE....................................... ' .........................
23
PIPELOOP DATA............................................ .... ................................. ...
PREDICTING PRESSURESDROPS
V.
6
PURPOSE.................................. .... ........................■...................................................
PROCEDURE............................. ....
IV .
. . . . . . . . . . . .
-I
. ..
. . .
26
.......................................................
35
CONCLUSIONS.................................
62
RECOMMENDATIONS FOR.FUTURE STUDY.
V
. . ................................................
63
V
TABLE OF CONTENTS ( C o n t ) .
P age
V III.
A PPEND IX........................ ......................................................... ....
64
NOMENCLATURE............................................................... ■..................................7 0
ix.
b ib l io g r a p h y :
. . ' ............................. ' .
. .................................. ....
72
vi
LIST OF TABLES
TABLE
P ag e
I.
S l u r r y C a r r i e r M a t e r i a l s T e s t e d ................................................ ....
II.
V i s c o s i t y C hanges a t 7 0 ° F ........................................................................................ 20
III.
A p p a re n t V i s c o s i t i e s 'o f C rude O i l - C o a l S l u r r i e s ...................................... 24
IV .
C o a l P a r t i c l e S iz e D i s t r i b u t i o n .
V.
P r e s s u r e Drop P r e d i c t i o n s U sin g t h e M ooneyR a b in o w its c h - W e is s e n b e r g E q u a tio n .........................................
V I.
9
..................................................................... 30
P r e s s u r e Drop P r e d i c t i o n s U sin g The G e n e r a l iz e d
R e y n o ld s N um ber..................................................... ....
47
V °
. I .
50
V II.
P r e s s u r e Drop P r e d i c t i o n s U sin g a T u r b u le n t V i s c o s i t y .
54
V III.
P r e d i c t e d P r e s s u r e D rops fro m V is c o m e te r D a ta ......................................... 59
v ii
' LIST OF FIGURES
FIGURE
RAGE
1
The P ip e S e c t i o n s and R o l l e r A s s e m b ly .................................................
11
2
The P i p e lo o p
.................................................■........................................................
13
3
Rheogram fro m B r o o k f i e l d V is c o m e te r ......................................................
27
4
R heogram fro m B r o o k f i e l d V is c o m e te r . . ... ..........................................
28
5
T ypes o f F l u i d s ..........................................................................
29
6
P ip e lo o p P r e s s u r e D r o p .......................................................... •......................
31
7
P ip e lo o p P r e s s u r e Drop ..........................................................
32
8
T h e o r e t i c a l Flow P a t t e r n s .
9
0% S l u r r y . ....................................... ....
. . . . .
. . ..............................................................
34
. . .....................................................
38
10....
5?. S l u r r y .......................................................... .... ...........................................' . .
39
11
10% S l u r r y
40
12
15% S l u r r y .................................. ' ....................................... ■................................
41
13
20% S l u r r y ............................................ • .......................... ■..............................
42
14
25% S l u r r y ......................................
43
15
30% S l u r r y ........................
44
16
35% S l u r r y .........................................................................• . ' ......................... ....
45
17
40% S l u r r y ............................. ' .................................. ................................. ....
.
46
18
S to rm e r V is c o m e te r R heogram f o r 500 Grams D r ie d C o a l 600 M i l l i l i t e r s FMC S y n t h e t i c C rude S l u r r y A f t e r
. P r e s s u r i z a t i o n to 500 p s i g . . ....................................................................
65
S to rm e r V is c o m e te r Rheogram f o r 500 Grams D r ie d C o a l 600 M i l l i l i t e r s FMC S y n t h e t i c C ru d e S l u r r y A f t e r
P r e s s u r i z a t i o n to 1000 p s i g ....................................................................
66
19
...................................................................
v iil
ABSTRACT
F i n e l y g ro u n d c o a l- h y d r o c a r b o n s l u r r i e s w e re s t u d i e d t o ..d e te r m in e
th e ir p ro p e rtie s .
The r e s e a r c h w as s e p a r a t e d i n t o two p a r t s , a n i n i t i a l
p h a s e to d e te r m in e i f t h e s l u r r i e s w o u ld s e t up u n d e r p i p e l i n e p r e s s u r e
c o n d i t i o n s a n d a m ore d e t a i l e d lo o k , a t a c ru d e o i l —c o a l s l u r r y .
B r o o k f i e l d a n d S to rm e r v is c o m e te r s , w e re u s e d t o m e a s u re v i s c o s i t i e s .
I t w as fo u n d t h a t t h e v i s c o s i t i e s o f
d i d te n d t o i n c r e a s e a f t e r p r e s s u r i z a t i o n
s e v e r a l w e e k s . H o w ev er, i t was f e l t t h a t
n o t s e v e r e enough to e lim in a te any o f th e
m o st c o a l- h y d r o c a r b o n s l u r r i e s
t o 500 and 1000 p s i g f o r
t h i s v i s c o s i t y i n c r e a s e was
liq u id c a r r ie r s .
R heogram s o b t a i n e d fro m a B r o o k f i e l d r o t a t i o n a l v i s c o m e t e r f o r
a r a n g e o f c o a l —c ru d e o i l s l u r r i e s fro m 0% t o 50% b y w e i g h t show ed
f o u r d i s t i n c t r h e o l o g i c a l m o d e ls .
S l u r r i e s o f c r u d e o i l an d c o a l w e re pumped th r o u g h a one in c h
s c h e d u l e 40 p i p e t o d e te r m in e t h e i r f lo w c h a r a c t e r i s t i c s .
V a rio u s
m eth o d s w e re u s e d t o com pare t h e e f f e c t i v e v i s c o s i t i e s o b t a i n e d from
t h e p i p e l o o p ’ s p r e s s u r e d ro p to t h e a p p a r e n t v i s c o s i t i e s m e a s u re d b y
th e B ro o k fie ld v is c o m e te r.
The a g re e m e n t w as n o t g o o d . A m ethod
d e r i v e d f o r B ingham p l a s t i c s to p r e d i c t p i p e l i n e p r e s s u r e d r o p s fro m
v i s c o m e te r d a t a was t r i e d .
I t s s u c c e s s i n p r e d i c t i n g p r e s s u r e d ro p s
w as fo u n d t o b e l i m i t e d .
INTRODUCTION AND BACKGROUND
A m a jo r f a c t o r i n d e te r m i n in g w h ic h m i n e r a l d e p o s i t s h a y e b e e n f i r s t
e x p l o i t e d h a s b e e n t h e t r a n s p o r t a t i o n c o s t s o f t h e .ra w m a t e r i a l s .
The
s o u r c e s o f raw m a t e r i a l s w h ic h w e re m o st a c c e s s i b l e a r e now d e p l e t e d
o r a l r e a d y c o m m itte d t o t h e m a r k e t .
A t t h e sam e t i m e , i n d u s t r i a l
e x p a n s io n h a s b e e n g r e a t w o r ld w id e , w h ic h h a s c r e a t e d a n i n t e n s e
demand f o r raw m a t e r i a l s .
T h is h a s m e a n t t h a t t h e m o re i n a c c e s s i b l e raw
m a t e r i a l s h a v e b e g u n t o b e d e v e lo p e d ,
T h is s i t u a t i o n i s e s p e c i a l l y t r u e i n t h e U n ite d S t a t e s w h ic h
consum es a b o u t 40 p e r c e n t o f t h e w o r l d 's e n e r g y and i s e x p e r i e n c i n g a
r a p i d g ro w th r a t e i n e n e rg y demand w h i l e t h e a c c e s s i b l e p r o v e n r e s e r v e s
a r e d r o p p in g .
The B u re a u o f M ines h a s p r e d i c t e d a 3 .5 p e r c e n t y e a r l y
i n c r e a s e i n e n e r g y demand u n t i l t h e y e a r 2 0 0 0 .
A t t h e sam e t i m e , t h e r e i s i n c r e a s e d p r e s s u r e w i t h i n t h e U n ite d
S t a t e s t o becom e e n e r g y i n d e p e n d e n t .
The r e c e n t A rab o i l em bargo
v i v i d l y p o i n t e d o u t how u n d e p e n d a b le f o r e i g n i m p o r t a t i o n o f raw
m a t e r i a l s f o r e n e rg y c a n b e .
P r o j e c t In d e p e n d e n c e w h ic h c a l l s on t h e
n a t i o n t o b e e n e r g y i n d e p e n d e n t by t h e y e a r 1985 h a s b e e n e n d o r s e d by
b o t h P r e s i d e n t s N ix o n an d F o r d ;
F o rtu n a te ly ,
t h e U n ite d S t a t e s h a s m a s s iv e r e s e r v e s o f c o a l ,
p r i m a r i l y i n t h e W e s te rn p a r t o f t h e c o u n t r y .
The U n ite d S t a t e s h a s
a p p r o x i m a t e ly 40 p e r c e n t o f t h e w o r l d 's known c o a l r e s e r v e s . ' A lth o u g h
coal is ,
o f c o u rs e , a n o th e r f i n i t e r e s o u rc e i t
c a n p r o v i d e a m a jo r
p h a s e o f t h e n a t i o n 's e n e r g y f o r a tim e o f a b o u t 50 t o 100 y e a r s ;
T h is
2
tim e c a n t h e n b e u s e d t o d e y e l o p . o t h e r lo n g te rm s o l u t i o n s t o t h e e n e r g y
p ro b le m such, a s s o l a r e n e rg y an d n u c l e a r f u s i o n .
The c o a l i n t h e E a s t e r n p a r t o f t h e c o u n t r y h a s a h i g h s u l f u r
c o n t e n t and i s e x p e n s i v e t o m in e .
a m uch lo w e r s u l f u r c o n t e n t ,
W e s te rn c o a l , on t h e o t h e r h a n d , h a s
(• 5 p e r c e n t o r l e s s com pared t o 2 t o 3
p e r c e n t f o r m o st E a s t e r n c o a l ) ,
it
c a n b e b u rn e d i n p r e s e n t d a y b o i l e r s
a n d m e e t t h e 1975 EPA e m i s s io n r e q u i r e m e n t s .
o f W e s te rn c o a l i s
A n o th e r a t t r a c t i v e f e a t u r e
t h e f a c t t h a t i t i s r e l a t i v e l y c l o s e to t h e s u r f a c e
w i t h o n l y a b o u t t h i r t y t o f o r t y f e e t o f o v e r b u r d e n w i t h seam s t h a t ru n
a s t h ic k , a s 100 f e e t .
T h is i s o p p o se d t o E a s t e r n seam s w h ic h h a v e m ore
o v e r b u r d e n an d a r e n o t t h i c k .
Y e t t h e E a s t e r n r e s e r v e s h a v e b e e n much
m ore f u l l y d e v e lo p e d , m a in ly b e c a u s e o f t r a n s p o r t a t i o n c o s t s .
One o f t h e m a jo r d ra w b a c k s o f t h e W e s te rn c o a l r e s e r v e s i s i t s
d i s t a n c e from t h e m a jo r m a r k e ts .
The M id w est o f f e r s s e v e r a l l a r g e
c o a l m a r k e ts a t a d i s t a n c e o f a b o u t 500 t o 1000 m il e s fro m t h e W e s te rn
rese rv es.
I t c a n b e e a s i l y s e e n t h a t t r a n s p o r a t i o n c o s t s a r e th u s a
m a jo r f a c t o r .
I n c r e a s e d t r a n s p o r t a t i o n c o s t s a r e r e f l e c t e d i n an
i n c r e a s e i n t h e p r i c e o f e n e r g y , w h ic h i n t u r n i s r e f l e c t e d i n
i n c r e a s e d p r o d u c t i o n c o s t s f o r a lm o s t a l l goods o r s e r v i c e s i m a g in a b l e .
I t i s t h e r e f o r e n e c e s s a r y t o t r a n s p o r t t h e W e s te rn c o a l t o i t s m a rk e ts
by t h e m o st e c o n o m ic a l m eans p o s s i b l e ,
One o f t h e l a t e s t a p p ro a c h e s t o t h i s p ro b le m h a s b e e n t o t r a n s p o r t
th e c o a l as a s l u r r y in a p ip e lin e .
T h is m eth o d h a s r e c e n t l y b e e n
T 3
s e r i o u s l y c o n s i d e r e d a s a v i a b l e a l t e r n a t i v e t o t b e . o t h e r two lo n g
d i s t a n c e la n d t r a n s p o r t a t i o n a l t e r n a t i v e s , u n i t t r a i n s an d e x t r a h i g h
v o l t a g e (EKV) t r a n s m i s s i o n .
S e v e r a l s u c h l i n e s a r e now i n o p e r a t i o n and a p p e a r t o b e v e r y
p r o m is in g e c o n o m i c a l ly .
t h e B la c k Mesa
Two o f t h e l a r g e s t l i n e s now i n e x i s t e n c e a r e
P i p e li n e and th e G i l s o n i t e P i p e li n e .
The G i l s o h i t e P i p e l i n e w e n t i n t o o p e r a t i o n on A p r i l 1 5 , 1 9 5 7 .
It
i s a 6 i n c h l i n e t r a v e r s i n g 72 m il e s an d an 8 ,5 0 0 f o o t m o u n ta in p a s s
b e tw e e n A m e ric an G i l s o n i t e Companyt S m in e a t B o n a n z a , U ta h , and i t s
p e tr o le u m r e f i n e r y n e a r G rand J u n c t i o n , C o lo r a d o .
I t t r a n s p o r t s 700 to n s
p e r d ay o f m in u s 8-m esh g i l s o n i t e a s a w a t e r s l u r r y .
" h y d ro c a rb o n fo u n d o n l y i n t h e U i n t a B a s in o f U ta h .
(G ils o n ite i s a
I t i s te c h n ic a lly
an a s p h a l i t e w i t h a s p e c i f i c g r a v i t y a b o u t 5 p e r c e n t g r e a t e r t h a n w a t e r ) .
The B la c k M esa p i p e l i n e w e n t I n t o o p e r a t i o n i n 1 9 7 0 .
I t pumps
c o a l a s a s l u r r y w i t h w a t e r 273 m il e s th r o u g h an 18 i n c h l i n e .
The
c o a l s l u r r y i s pum ped a t a s o l i d s ’ c o n c e n t r a t i o n o f 45 t o 55 p e r c e n t
by w e i g h t .
The s i z e o f t h e p a r t i c l e s i s m in u s 14 m esh .
The l i n e
h a n d le s 4 .8 m i l l i o n to n s p e r y e a r .
C o a l s l u r r y l i n e s h a v e s e v e r a l a d v a n ta g e s o v e r o t h e r m odes o f
tra n s p o ra tio n .
i t is in s ta lle d .
A p ip e lin e re q u ire s v e ry l i t t l e
I t is
la b o r to o p e ra te once
th e r e f o r e c a p i t a l in te n s iv e r a t h e r th a n la b o r
i n t e n s i v e and t h u s l e s s s e n s i t i v e
to i n f l a t i o n a r y p r e s s u r e s .
A
p i p e l in e i s a ls o a t t r a c t i v e a e s t h e t i c a l l y s in c e I t i s u n d e rg ro u n d .
k'
4
A n o th e r i m p o r t a n t f a c t o r i s r e l i a b i l i t y .
P ip e lin e s a re n o t a f f e c te d ■
b y a d v e r s e w e a t h e r c o n d i t i o n s apd a r e n o t g r e a t l y a f f e c t e d b y l a b o r
d is p u te s .
A l s o , p i p e l i n e s h a y e e n a b le d m i n e r a l s to b e t r a n s p o r t e d o v e r
p re v io u s ly u n a c c e s s I b le t e r r a i n .
S e v e r a l f a c t o r s h a v e b e e n p r e s e n t e d b y J . C. H o n t f o r t , M anager o f
t h e B la c k M esa P i p e l i n e , i n d i c a t i n g when c o a l s l u r r y l i n e s w o u ld b e
e c o n o m ic a lly f e a s i b l e .
T h e se a r e I ) w hen no o t h e r t r a n s p o r t a t i o n
p r e s e n t l y e x i s t s , 2) m ovem ents i n v o l v e lo n g d i s t a n c e s a n d h i g h
t o n n a g e s , 3) t h e r e i s
a lo n g te rm r e q u i r e m e n t , 4) few p o i n t s o f o r i g i n
a n d d e s t i n a t i o n , 5) t h e t e r r a i n i s ru g g e d a n d t h e p i p e l i n e c a n a c h ie v e
a s h o r t e r r o u t e s i n c e p i p e l i n e s c a n b e l a i d on s t e e p e r s l o p e s , and
6) a s u i t a b l e c a r r i e r i s a v a i l a b l e .
Cl)
A lth o u g h t h e r e i s a c o n s i d e r a b l e am ount o f l i t e r a t u r e a v a i l a b l e
i
on c o a l s l u r r i e s ,
m a te ria l.
c a rrie r.
it
i s d o m in a te d b y t h e u s e o f w a t e r a s t h e s l u r r y i n g
A ll th e e x is tin g c o a l s lu r r y p ip e lin e s u se w a te r a s th e
T h i s , o f c o u r s e , m eans t h a t t h e s l u r r y m u st u n d e rg o a
s e p a r a t i o n s t e p a t t h e end o f t h e l i n e b e f o r e t h e c o a l c a n b e f i r e d .
I t may b e p o s s i b l e t o b y p a s s t h i s s t e p i f
t h e c o a l w as s l u r r i e d w i t h a
l i q u i d t h a t w o u ld a ll o w t h e e n t i r e s l u r r y t o b e f i r e d .
The e x i s t i n g c o a l - w a t e r s l u r r y p i p e l i n e s co m bine t h e s e p a r a t i o n
and g r i n d i n g s t e p s .
I f th e e n t i r e s l u r r y i s to b e b u rn ed th e
g r i n d i n g w i l l o f n e c e s s i t y t a k e p l a c e a t t h e b e g in n in g o f t h e l i n e s .
T h is w i l l ,
t h e r e f o r e , a l s o i n v o l v e t h e pum ping o f a s l u r r y w i t h c o a l
p a r t i c l e s o f s i g n i f i c a n t l y s m a lle r s i z e
■‘RESEARCH..' OBJECTIVES
■
PURPOSE
.The p u r p o s e o f t h i s r e s e a r c h i s
t o o b t a i n som e f u n d a m e n ta l d a t a
a b o u t f i n e l y g ro u n d c o a l - h y d r o c a r b o n s l u r r i e s .
T he c u r r e n t l i t e r a t u r e
f o c u s e s a lm o s t e x c l u s i v e l y on w a t e r a s t h e c a r r i e r f l u i d f o r s l u r r y i n g .
A ls o t h e r e i s l i t t l e
l i t e r a t u r e a v a i l a b l e on c o a l g ro u n d to a s f i n e a
m esh s i z e a s i s u s e d i n t h i s r e s e a r c h .
The r e s e a r c h i s i n t e n d e d to b e a fu n d a m e n ta l l o o k a t t h e f e a s i b i l i t y
o f such a s lu r r y ,
i n a d d i t i o n , i t i s i n t e n d e d t o g a i n some u n d e r ­
s t a n d i n g o f t h e r h e o l o g y o f t h e s e s l u r r i e s and t o s e e w h a t s p e c i a l
c h a ra c te ris tic s
t h e y may h a v e o r s p e c i a l p ro b le m s t h e y may p r e s e n t .
I t i s i n t e n d e d to b e u s e d a s t h e b a s i s f o r f u r t h e r r e s e a r c h , i n t h i s a r e a .
OBJECTIVES
The f i r s t o b j e c t i v e o f t h i s r e s e a r c h w as t o l o o k a t v a r i o u s ty p e s
o f h y d ro c a rb o n s to s e e i f
t h e r e was som e r e a s o n th e y w o u ld n o t b e
s u ita b le as a s lu rry in g f lu id .
w o u ld b e a te n d e n c y f o r t h i s
The p r im a r y c o n c e r n h e r e w as t h a t t h e r e
f i n e l y g ro u n d c o a l , u n d e r p r e s s u r e
c o n d i t i o n s e x p e r i e n c e d i n a p i p e l i n e , t o a b s o rb t h e f l u i d a n d to s e t
up so t h a t i t s v i s c o s i t y w o u ld no l o n g e r b e i n a n a c c e p t a b l e pum ping
ran g e .
T h is w o u ld e l i m i n a t e any f u r t h e r t e s t i n g o f u n a c c e p t a b l e f l u i d s .
O nce t h i s q u e s t i o n was r e s o l v e d , i t w as h o p e d t h a t som e ju d g m e n t
c o u ld b e m ade a s to w h a t t h e m o st s u i t a b l e c a r r i e r s - may b e .
The
r h e o l o g i c a l p r o p e r t i e s o f a c o a l s l u r r y u s i n g o n e o f t h e f l u i d s w as
7 "
t h e n t o b e s t u d i e d i n m ore d e t a i l , . T h is s t u d y w as t o b e d o n e i n two
p h a s e s ; a v i s c o m e t e r p h a s e and a p i p e l o o p p h a s e ,
A t h i r d o b j e c t i v e o f t h i s r e s e a r c h , w as t o t r y t o d e te r m i n e how
w e l l t h i s d a t a c o u ld b e c o r r e l a t e d t o p r e d i c t p r e s s u r e d r o p s from
e i t h e r v is c o m e te r o r p ip e lo o p d a ta .
M eth o d s u s e d f o r o t h e r s l u r r i e s
and n o n -N e w to n ia n f l u i d s w e r e t o b e t e s t e d f o r t h e i r a c c u r a c y i n
p r e d ic tin g p re s s u re d ro p s.
■ MATERIALS, EQUIPMENT AND PROCEDURES
MATERIALS
The c o a l u s e d d u r in g t h e m a j o r i t y o f t h i s i n y e s t l g a t I o n was
s u b - b itu m in o u s c o a l w hich.' I s p r e s e n t l y b e in g m ined a t C o ls t r i p , M o n ta n a ,
Some l i g n i t e fro m S a v a g e , M ontana w as a l s o u s e d d u r in g t h e I n t i a l p a r t
o f th e i n v e s t ig a t io n .
A num ber o f p e tr o l e u m l i q u i d s w e re t e s t e d a s p o s s i b l e l i q u i d
c a rrie rs .
T h e i r d e s c r i p t i o n a n d o r i g i n a r e g iv e n i n T a b le I .
Tap
w a t e r was u s e d a s t h e s o u r c e o f w a t e r .
EQUIPMENT
F o r t h e i n i t i a l s t a g e s o f t h e i n v e s t i g a t i o n , a T h o m a s-S to rm e r
v is c o m e te r
was u s e d t o m e a s u re v i s c o s i t i e s .
A B r o o k f i e l d v i s c o m e te r
was u s e d i n t h e l a t t e r s t a g e s o f t h e r e s e a r c h .
A S to rm e r v i s c o m e t e r
b a s ic ia lly
c o n s is ts o f a r o to r th a t tu rn s
i n s i d e o f a t e s t cup f i l l e d w i t h t h e l i q u i d to b e t e s t e d .
i s p o w e re d by a d r i v i n g w e i g h t - p u l l e y s y s te m .
The r o t o r /
The d r i v i n g w e ig h t i s
f i l l e d w i t h re m o v a b le s h o t s o t h a t t h e r a t e o f r o t a t i o n c a n b e v a r i e d .
The r o t o r i s a t t a c h e d t o a r e v o l u t i o n c o u n t e r .
The t e s t cup s i t s
i n s i d e o f a w a te r o r o i l b a th to keep th e te m p e ra tu re c o n s ta n t.
The v i s c o s i t y i s d e te r m in e d b y t im in g how lo n g I t t a k e n f o r t h e
r o t o r to make IOQ r e v o l u t i o n s w i t h a s to p w a tc h .
com pared t o t h e tim e i t
T h is tim e
i s th e n
t a k e s t h e r o t o r t o m ake 100 r e v o l u t i o n s i n a
f l u i d w i t h a known v i s c o s i t y . -
TABLE I
FLUID
SLURRY CARRIER MATERIALS TESTED
ORIGIN
1 , 2 , 3 , '4 T e t r a h y d r o n a p h t h a le n e
A ld r ic h . C h e m ic a l Company '
M ilw a u k e e , W is c o n s in
C ru d e O il
Amoco O i l Company
M andan, N o r th D a k o ta
#4 C ut A n th r a c e n e O i l
R e i l l y T a r and C h e m ic a l C o rp .
C l e v e la n d , O hio
Dubb U n it R e s i d u a l T a r
U n io n O i l CompanyC ut B ank, M ontana
P a ra -x y le n e
COMMENTS
T e c h n ic a l G ra d e
■J
T e c h n ic a l G rad e
M edium A ro m a tic C ut
Exxon O i l Company
B i l l i n g s , M ontana
A ro m a tic C o n c e n t r a te
Exxon O i l Company
H o u s to n , T exas
EMC S y n t h e t i c C ru d e O i l
FMC C o r p o r a t i o n
P r i n c e t o n , New J e r s e y
P ro d u c e d fro m
U tah A-searn c o a l
i
'-4
:10
The B r o o k f i e l d v i s c o m e t e r c o n s i s t s o f a, c o n e t h a t r o t a t e s I n s i d e
o f th e t e s t cup.
The c o n e I s p o w ered b y an e l e c t r i c m o to r .
o f r o ta tio n i s a d ju s ta b le .
The r a t e
The v i s c o m e t e r h a s a s c a l e t h a t m e a s u re s
t h e am ount o f t o r q u e e x e r t e d on t h e c o n e a s i t r o t a t e s i n t h e t e s t
m a te ria l.
T h e v i s c o s i t y c a n t h e n b e m e a s u re d b y c o m p a rin g t h e t o r q u e
.
e x e r t e d on t h e c o n e i n t h e t e s t m a t e r i a l w i t h t h a t o f a known v i s c o s i t y .
The t e s t cup h a s a l i q u i d c i r c u l a t i n g s t a g e a t t a c h e d t o a t e m p e r a t u r e
c o n t r o l l e r to k e e p t h e t e m p e r a t u r e c o n s t a n t .
For t h e f i r s t p h a se o f .'the i n v e s t i g a t i o n , 11 in c h s e c t i o n s o f two
in c h s c h e d u le 40 p ip e w ere capped on b o th e n d s .
. --VWith a v a l v e on one o f t h e cap s so t h a t i t
The p ip e was c o n s tr u c t e d
c o u ld b e p r e s s u r i z e d .
The
■•■-jpipe s e c t i o n s w ere c a p a b le o f w it h s ta n d in g p r e s s u r e s up t o ab ou t
1000 p s i g .
T h e se p i p e s e c t i o n s w e re t h e n p l a c e d on r u b b e r r o l l e r s
,
p o w e re d by a m o to r s o t h a t th e y c o u ld b e c o n t i n u a l l y a g i t a t e d w h i l e
th e y w e re u n d e r p r e s s u r e .
The. r o l l e r s y s te m and p i p e s e c t i o n s a r e
show n i n F i g u r e I .
A d r i e r was a l s o c o n s t r u c t e d to d r y som e o f t h e c o a l s a m p le s u n d e r
a n i t r o g e n a tm o s p h e r e .
I t c o n s is te d o f a s te a m -ja c k e te d p ie c e o f
tw o - in c h p i p e 23 i n c h e s i n l e n g t h p l a c e d v e r t i c a l l y on a s t a n d .
p i p e w as c a p p e d a t e a c h e n d .
t o b e b lo w n th r o u g h .
The
E a c h cap h a d a v a l v e a ll o w i n g n i t r o g e n
A p i e c e o f f i l t e r p a p e r w as s a n d w ic h e d b e tw e e n
•two p i e c e s o f s c r e e n a t t h e b o tto m en d o f t h e p i p e t o k e e p t h e c o a l
fro m f a l l i n g
th ro u g h .
G round c o a l c o u ld t h u s b e p l a c e d i n t h e p i p e
SCHEDULE 4 0 STEEL
FIFE
NTTROGEN
DRIVE BELT
RUBBER ROLLERS
KOTOR
FIGURE I .
The P i p e S e c t i o n s an d R o l l e r A ssem bly
an d n i t r o g e n c o u ld b e b lo w n th ro u g h , fro m a s t a n d a r d g a s c y l i n d e r . /
T he p i p e l o o p c o n s i s t e d o f a b o u t 9Q f e e t o f o n e -in c h , s c h e d u l e 40
s te e l p ip e .
s lu rry .
A o n e h o r s e p o w e r c e n t r i f u g a l pump was u s e d t o pump th e
F low r a t e s c o u ld b e v a r i e d b y a b y - p a s s v a l v e s y s te m .
The
t e s t s e c t i o n c o n s i s t e d o f a. h o r i z o n t a l s e c t i o n 30 f e e t lo n g w i t h
s t a n d a r d m an o m eter t a p s .
p re s s u re d ro p s.
A m e rc u ry f i l l e d m an o m eter m e a s u re d t h e
A b l e e d v a l v e a llo w e d t h e l i n e s fro m t h e m anom eter
'to . b e b l e d p e r i o d i c a l l y .
F low r a t e s w e re d e te r m in e d by m e a s u r in g
t h e m ass v e l o c i t y o f t h e s l u r r y w i t h a b u c k e t an d s to p w a tc h . . The
lo o p e m p tie d i n t o a c y l i n d e r fro m w h ic h t h e s l u r r y was o n c e a g a i n
■'■-pumped i n t o t h e l o o p .
The c y l i n d e r w as c o n s t r u c t e d s o t h a t i t
.
c o u ld b e c o v e r e d f o r lo n g r u n s .
The p i p e l o o p i s shown i n F i g u r e 2 .
A m o r t a r a n d p e s t l e w as u s e d t o g r i n d t h e c o a l t o m in u s 200 a n d
m in u s 325 m esh .
v
F o r t h e l a r g e r am ounts o f c o a l r e q u i r e d f o r t h e
p i p e l o o p , a b a l l m i l l w as u s e d t o c r u s h t h e c o a l .
The c o a l- was
a n a ly z e d w i t h a s t a n d a r d T y l e r s c r e e n u s in g a R o-Tap t e s t i n g s i e v e
sh a k er.
PROCEDURE
For th e i n i t i a l p h ase o f th e in v e s tig a tio n , a s l u r r y o f c o a l o r
l i g n i t e a n d t h e c h o s e n l i q u i d w as c a r e f u l l y p r e p a r e d .
The c o a l was
g ro u n d by a c o m b in a tio n o f m o r t a r an d p e s t l e a n d b a l l m i l l t o t h e d e s i r e d
m esh s i z e .
The v i s c o s i t y o f t h e s l u r r y was m e a s u re d W ith a S 'form er
BLEED
LINE
30 FT
BfPASS
SHTEM
RECEIVING
CYLINDER
FIGURE 2
The B ip e lo o p
v i s c o m e te r f o l l o w i n g t h e o p e r a t i n g i n s t r u c t i o n s . • Care, w as t a k e n t o
b e c e r t a i n t h e s l u r r y w as w e l l m ix ed b e f o r e a n y r e a d in g s , w e r e t a k e n .
A minimum o f f o u r r e a d i n g s w e re t a k e n to m ake s u r e t h e y w e re
c o n s is te n t.
An a v e r a g e o f t h e r e a d i n g s was u s e d .
The v i s c o m e t e r w as c a l i b r a t e d p e r i o d i c a l l y w i t h d i s t i l l e d w a t e r
and g l y c e r o l.
S in c e t h e S tO rm er v i s c o m e t e r I s p o w e re d b y a d r i v i n g
w e ig h t w i t h re m o v a b le s h o t , i t w as i m p o r ta n t t h a t t h e c a l i b r a t i o n and
t e s t r u n s w e re m ade u n d e r I d e n t i c a l c o n d i t i o n s .
A ls o , a s f a r a s i t
was p o s s i b l e , t o i n c r e a s e t h e a c c u r a c y o f t h e r e a d i n g s , s h o t was
rem oved i f
added i f
t h e tim e f o r IOQ r e v o l u t i o n s w as l e s s t h a n 20 s e c o n d s an d
t h e m ovem ent o f t h e r o t o r w as v e r y s lo w .
The s l u r r y was t h e n p l a c e d i n t h e p i p e s e c t i o n s and p r e s s u r i z e d
w ith n itr o g e n .
The p i p e s e c t i o n s w e re p l a c e d on t h e r o l l e r s y s te m
w h ic h w as l o c a t e d on t h e r o o f o f Ryon L a b o r a t o r y and r o l l e d f o r a m in ­
imum o f 20 d a y s .
T h e se r u n s w e re m ade d u r in g t h e w i n t e r m o n th s and
i t was f e l t t h a t i n t h i s way an y a d v e r s e e f f e c t o f c o ld t e m p e r a t u r e
on t h e s l u r r y c o u ld b e d e te r m in e d .
W here i n d i c a t e d , some o f t h e c o a l an d l i g n i t e s l u r r i e s w e r e d r i e d
b e f o r e t h e s l u r r i e s w e re m ade u p .
p ip e d r i e r .
T h is w as d o n e i n t h e s te a m j a c k e t e d
The d r i e r was c o n n e c te d t o a n i t r o g e n c y l i n d e r and n i t r o g e n
w as b lo w n s lo w ly t h r o u g h t h e c o a l w h i l e i t w as d r y i n g .
The c o a l
s a m p le s w e re d r i e d f o r a t l e a s t 48 h o u r s .
'
The s e c o n d p h a s e o f t h e I n v e s t i g a t i o n c o n s i s t e d o f a m ore d e t a i l e d _
— 15 —>
l o o k a t a n Amoco c r u d e o i l - c o a l s l u r r y .
F i r s t the. c o a l w as p l a c e d i n
a l a r g e b a l l m i l l w h ich .'w as a llo w e d t o r u n f o r 24 h o u r s .
The b a l l m i l l
w as e m p tie d and t h e c o a l was s c r e e n e d w i t h a 10 mesh, s c r e e n to s e p a r a t e
t h e c o a l fro m t h e c e ra m ic b a l l s and l a r g e r p a r t i c l e s .
A s a m p le o f t h e
c o a l w as th e n t a k e n and a n a ly z e d w i t h s t a n d a r d T y l e r s c r e e n a n d a R oTap t e s t i n g s i e v e s h a k e r .
The p i p e lo o p w as f i l l e d w i t h p u r e c r u d e o i l .
o i l n e c e s s a r y t o f i l l t h e l i n e w as n o t e d .
T he w e ig h t o f t h e
E nough g ro u n d c o a l was th e n
w e ig h e d a n d a d d e d t o t h e lo o p t o g i v e t h e d e s i r e d w e ig h t p e r c e n t s l u r r y .
To t e s t t h e n e x t h i g h e r c o n c e n t r a t i o n o f c o a l i n t h e s l u r r y , a d d i t i o n a l
c o a l was m e r e ly a d d e d t o t h e e x i s t i n g s l u r r y .
T h is w as d o n e b e c a u s e
o f t h e l a r g e am ount o f s l u r r y t h a t w o u ld h a v e b e e n r e q u i r e d t o r e f i l l
t h e lo o p e a c h t im e .
T he c o n c e n t r a t i o n was d e te r m in e d b y t h e f o l l o w i n g ^
f o r m u la :
C =
w
C-
X
W +
X
)
w h e re ,
C = m ass f r a c t i o n o f c o a l
w
w = known w e ig h t o f o i l i n t h e lo o p
x = w e ig h t o f c o a l t h a t n e e d e d t o b e ad d ed
A f t e r t h e a d d i t i o n o f c o a l , t h e pump was t u r n e d on a n d t h e
b y - p a s s v a l v e w as c l o s e d s o t h a t t h e s l u r r y was b e in g pumped a t i t s
f a s t e s t f lo w r a t e .
The s l u r r y w as a llo w e d t o pump f o r a p p r o x i m a t e ly
-
16
o n e h o u r t o i n s u r e c o m p le te m ix in g o f t h e c o a l .
v a l v e s to t h e m an o m eter t a p s w e re o p e n e d .
At t h i s tim e , th e
T he b l e e d v a l v e s w e re a l s o
o p e n e d to m ake s u r e t h e l i n e from t h e m an o m eter t a p s to t h e m anom eter
w e re f r e e o f a i r and w e re n o t c lo g g e d .
The b l e e d v a l v e s w e re th e n
c lo s e d and t h e v a l v e s t o t h e m anom eter w e re o p e n e d .
T he p r e s s u r e d ro p
was t h e n m e a s u re d .
Flow r a t e s w e re m e a s u re d b y r u n n in g t h e s l u r r y i n t o a b u c k e t .
tim e r e q u i r e d t o f i l l t h e b u c k e t was m e a s u re d w i t h a s to p w a tc h .
The
The
w e ig h t o f t h e b u c k e t p l u s t h e s l u r r y m in u s t h e w e ig h t o f t h e b u c k e t
was d i v i d e d by t h e tim e r e q u i r e d to g e t t h e . m ass . . f l o w - r a t e <
T h is
p r o c e s s was r e p e a t e d a t l e a s t two tim e s a t e a c h flo w r a t e t o a s s u r e
c o n s is te n c y .
The flo w r a t e s w e re a v e r a g e d .
The b y —p a s s v a l v e w as t h e n o p e n e d f u l l y so . t h e s l u r r y w o u ld b e a t
its
s lo w e s t f lo w r a t e .
20 -m in u te s s o t h a t i t s
th e re a d in g s f o r t h i s
The s l u r r y was a llo w e d to pump f o r a p p r o x im a te ly
f lo w p a t t e r n , c o u l d becom e f u l l y d e v e lo p e d b e f o r e
c o n c e n t r a t i o n w e re t a k e n .
T h is p r o c e d u r e w as th e n r e p e a t e d f o r t h e o t h e r f lo w r a t e s r e c o r d e d
fo r each s lu r r y .
F o r a m j a o r i t y o f t h e s l u r r i e s , d a t a w as t a k e n a t
f i v e d i f f e r e n t flo w r a t e s .
A m e a s u re d s a m p le o f t h e s l u r r y was t a k e n fro m t h e p i p e a t t h e
c o m p le tio n o f e a c h r u n t o d e te r m in e i t s
d e n s ity .
R h e o l o g ic a l d a t a w as a l s o t a k e n f o r e a c h c o n c e n t r a t i o n u s in g a
B ro o k fie ld v is c o m e te r b y u s in g th e m a n u f a c tu r e r ’s o p e r a tin g I n s t r u c t i o n s .
17 "
B e s t r e s u l t s w e re o b t a i n e d w hen t h e s l u r r i e s , w e re m ade up f p e s h ,
W here
p o s s i b l e , d a t a was t a k e n a t s h e a r r a t e s o£ 3 7 . 5 , 7 5 , 1 5 0 , 30.0, 750 and
1500 s e c o n d s
-
I
.
an d w e re a v e r a g e d .
2 0°C .
'
'
■ •
A t l e a s t 1f o u r r e a d i n g s w e re ta k e n a t e a c h s h e a r r a t e
The s l u r r y was- k e p t a t a c o n s t a n t t e m p e r a t u r e o f
'
■ RESULTS AND DISCUS STON
PRELIMINARY' PHASE
I n t h i s p h a s e o f t h e I n v a s t i g a t L p n , a l l y i s c o s i t y d a t a w as ta k e n
b y a S to rm e r v i s c o m e t e r .
T he S to rm e r v i s c o m e t e r i s w e l l s u i t e d to
h a n d le s l u r r i e s b e c a u s e o f i t s
r e l a t i v e l y l a r g e gap ( 0 .1 8 cm) b e tw e e n
t h e r o t o r and s t a t i o n a r y b a f f l e d c u p .
The p e r f o r a t e d h o l lo w r o t o r a l s o
c a u s e s some pum ping a c t i o n t o h e lp k e e p t h e s l u r r y w e l l m ix e d .
m ain d ra w b a c k i s t h a t i t
Its
i s d i f f i c u l t t o a d j u s t t o a g i v e n s h e a r r a t e . ..
The m ain c o n c e r n i n t h i s p o r t i o n o f t h e i n v e s t i g a t i o n was t h a t
t h e c o a l w o u ld a b s o r b s o m uch o f t h e s l u r r y i n g l i q u i d t h a t i t w o u ld '
s e t up l i k e a g e l .
I f t h i s h a p p e n e d , t h e r e w ould, b e no s e n s e i n
f u r t h e r c o n s i d e r a t i o n o f t h i s s y s te m .
I n t h i s m an n er i t w as h o p ed t h a t
an y u n a c c e p t a b l e s y s te m s c o u ld b e q u i c k l y e l i m i n a t e d .
I t was f e l t t h a t t h e r e w e re s e v e r a l f a c t o r s i n c o n s i d e r i n g w h ic h
l i q u i d h y d r o c a r b o n s h o u ld b e t e s t e d .
One was i t s v i s c o s i t y . „ As t h e
v i s c o s i t y o f t h e l i q u i d i n c r e a s e s , t h e pow er r e q u i r e m e n ts to ) pump i t
w o u ld a l s o i n c r e a s e .
A t t h e sam e tim e i t was f e l t t h a t t h e h e a v i e r t h e
l iq u i d w as, th e le s s th e p r o b a b ility o f th e c o a l s e t t l i n g
or
s t r a t i f i c a t i o n on s t a n d i n g o r f a l l i n g o u t i n t h e l i n e w o u ld b e .
p ro x im ity o f th e l i q u i d
t o c o a l w as a l s o c o n s id e r e d i m p o r t a n t .
The
It
w as a l s o f e l t t h a t t h e h y d r o c a r b o n s h o u ld b e a p e tr o le u m l i q u i d so
t h a t i t c o u ld b e b u r n e d a lo n g w i t h t h e c o a l .
' The s t a b i l i t y
o f . t h e s l u r r y a l s o w o u ld d ep en d on t h e p a r t i c l e s i z e
o f t h e c o a l to a l a r g e e x t e n t .
S m a lle r p a r t i c l e s i z e w o u ld r e s u l t i n
19 a m ore s t a b l e s l u r r y .
A lso s i n c e t h e g r i n d i n g s t e p xzas to . b e e l i m i n a t e d
a t t h e ' en d o f t h e l i n e ,
t h e c o a l s h o u ld b e g ro u n d , to a s i z e t h a t , c o u ld
e a s i l y be b u rn ed .
■ A s l u r r y was a l s o m ade up w i t h d i s t i l l e d w a t e r t o a c t a s a
refe re n c e .
T a b le T I g i v e s a sum m ary o f t h e v i s c o s i t y c h a n g e s .
T h e re a r e s e v e r a l i n t e r e s t i n g p o i n t s a b o u t T a b le T I .
one i s
t h a t a lm o s t a l l o f t h e s l u r r i e s
in v is c o s ity a f te r p re s s u riz a tio n .
Amoco c r u d e o i l a n d c o a l .
The f i r s t
t e s t e d show ed a d e f i n i t e i n c r e a s e
The m o st " r e a c t i v e ^ c o m b in a tio n w as
The r u n s m ade w i t h d r i e d c o a l a n d l i g n i t e
w e re m ade b e c a u s e i t was f e l t t h a t t h i s w o u ld p r o b a b l y b e t h e s y s te m
r t h a t w o u ld m o st l i k e l y
a b so rb th e f l u i d .
t o m ake a g r e a t d e a l o f d i f f e r e n c e .
500 t o 1000 p s i g a l s o
H ow ever, t h i s d i d n o t seem
I n c r e a s i n g t h e p r e s s u r e fro m
d i d n o t seem t o h a v e m uch o f a n e f f e c t .
The a n t h r a c e n e o i l s l u r r i e s w e re r a t h e r i n t e r e s t i n g i n t h a t th e y
seem ed t o e x h i b i t t h e g r e a t e s t t e m p e r a t u r e a f f e c t s .
When i t was
rem oved fro m t h e p r e s s u r i z e d p i p e s e c t i o n s i t w as e x tr e m e ly t h i c k .
As
i t warm ed i t w o u ld b e g i n t o b u b b le n o t i c e a b l y and t h e v i s c o s i t y w ould
d e c re a s e as e x p e c te d .
No' o t h e r s l u r r y a c t e d t h i s w ay.
F u r t h e r i n v e s t i g a t i o n o f a n t h r a c e n e o i l s l u r r i e s w as c o n d u c te d
b y p r e s s u r i z i n g p i p e s e c t i o n s , c o n t a i n i n g p u r e a n t h r a c e n e an d a s l u r r y
o f 300 m i l l i l i t e r s o f a n t h r a c e n e o i l w i t h 100 gram s o f "3 2 5 m esh c o a l
t o 500 p s i g .
T he p i p e s w e re p l a c e d i n a f r e e z e r a t a t e m p e r a t u r e o f
TABLE L I .
(
.
S lu rry
VISCOSITY CHANGES AT 7 0 0F
O rig in a l
A p p a re n t
I P re ssu re
Days
V is c o s ity
PSIG
R o lle d
Ib /fts e c
New
A p p a re n t
V is c o s ity
Ib /fts e c
%
In c re a se
f 00097
.0 0 1 0 0
3 .1
300 m l t e t r a h y d r o n a p h t h a l e n e
100 g ram s —200 m esh c o a l
500
300 m l t e t r a h y d r o n a p h t h a l e n e
200 gram s —200 m esh c o a l
500
23
.0 0 1 9
.0 0 2 2
1 5 .8
300 m l Amoco c r u d e o i l
200 gram s —200 m esh c o a l
500
20
.2 0
.3 7
85
300 m l Amoco c r u d e o i l
250 gram s —200 m esh c o a l
500
20
.5 4
.9 7
80.
25
'
I
600 m l #4 c u t a n t h r a c e n e o i l
200 gram s 325 m esh c o a l
500
20
300 m l d i s t i l l e d w a t e r
100 gram s —200 m esh c o a l
500
81
500
21
50 m l Dubbs u n i t r e s i d u a l t a r
150 m l T e t r a h y d r a n a p h t h a l e n e
200 .gram s -3 2 5 m esh c o a l
300 m l p - x y l e n e
200 gram s - 3 2 5 m esh c o a l
300 m l Amoco c ru d e
300 gram s -2 0 0 m esh d r i e d c o a l
600 m l medium A ro m a tic c u t (E xxon)
500 gram s - 2 0 0 m esh d r i e d l i g n i t e
.
2 .7 1
2 .7 3
.0 0 0 5 6
.0 0 0 6 2
.5 9
.6 7
.7 4
1 0 .7
1 3 .5
■
500
21
1000
500
.0 0 1 4
2 .0 8
13
.3 0 0
.0 0 1 3
- 7 .1
3 .7 7
8 1 .3
.2 9 0
(7 5 °F )
- 3 .3
O
,
TABLE I I
(c o n t) .
S lu rry
VICOSITY CHANGES A'I 70°F
O rig in a l
A
p p aren t
i-'
P re ssu re
Days
V is c o s ity
PSIG
R o lle d
Ib /fts e c
New
A p p a re n t
V is c o s ity
Ib /fts e c
%
In c re a se
300 m l Amoco c r u d e
200 gram s —200 m esh d r i e d c o a l
500
15
.1 7
.3 0
7 6 .5
600 m l s y n t h e t i c c r u d e (EMC)
500 gram s — 200 m esh d r i e d l i g n i t e
500
12
.3 0
.4 9
6 3 .3
1000
26
.3 0
.5 0
6 6 .7
500
25
.2 2
.2 6
1 8 .2
28
.2 2
.2 9
3 1 .8
13
.3 1
600 m l s y n t h e t i c c r u d e (EMO)
500 gram s - 2 0 0 m esh d r i e d l i g n i t e
600 m l >EMC s y n t h e t i c c ru d e
500 gram s d r i e d - 2 0 0 m esh c o a l .
600 m l EMC s y n t h e t i c c ru d e
500 gram s d r i e d —220 m esh c o a l
1000
600 m l medium A ro m a tic c u t (E xxon)
500 gram s —200 m esh d r i e d l i g n i t e
1000
•
'
300 m l Amoco c r u d e
250 gram s - 2 0 0 m esh d r i e d c o a l
1000
21.
.5 4
•
.3 0
( 7 5 0F)
- 3 .2
.9 3
7 2 .2
.22.
- 1 3 ° F f o r 24. h o u r s .
B o th t h e s l u r r y and p u r e o i l w e r e f r o z e n when t h e
p i p e s w e re u n lo a d e d .
They b o th ; h a d p o u r p o i n t s o f a b o u t 4 1 0F ,
I
B u b b lin g
was a g a in , n o t i c e a b l e a n d i t seem ed t o i n c r e a s e u n t i l t h e t e m p e r a t u r e
r e a c h e d a b o u t 5 9 0F .
B o th t h e p u r e o i l an d s l u r r y r e t u r n e d t o t h e i r
o r i g i n a l v i s c o s i t i e s a t 70 °F .
The t e m p e r a t u r e e f f e c t oh t h e v i s c o s i t y o f t h e o t h e r s l u r r i e s was
n o t e x a m in e d .
dependence.
None o f t h e s l u r r i e s e x h i b i t e d su c h a d r a m a ti c te m p e r a t u r e
I t w as f e l t t h a t t e m p e r a t u r e s h o u ld b e h e l d c o n s t a n t f o r
th is in v e s tig a tio n .
T h is i s s o m e th in g t h a t s h o u ld b e s t u d i e d i n
fu tu re in v e s tig a tio n s .
A n o th e r i n t e r e s t i n g
f e a t u r e o f b o t h t h e Amoco c r u d e o i l and FMC
...crude o i l s l u r r i e s w as t h a t t h e y w o u ld s e t up n o t i c e a b l y w hen l e f t
ex p o sed to a i r .
F o r i n s t a n c e , a s l u r r y o f 250 gram s o f d r i e d -2 0 0 m esh
c o a l a n d 300 m i l l i l i t e r s
o f Amoco c r u d e o i l l e f t u n c o v e re d f o r o n e w eek
i n c r e a s e d i n v i s c o s i t y fro m 1 .9 3 I b / f t s e c
to 4 .8 0 I b / f t s e c .
t h a t t h i s was d u e to e v a p o r a t i o n o f t h e o i l .
e x h i b i t e d t h e sam e t r e n d .
I t w as f e l t
C rude o i l s a n d s l u r r i e s
A lso 90 m i l l i l i t e r s o i l w as p l a c e d in ' a
g r a d u a t e d c y l i n d e r an d l e t s t a n d o p e n f o r . 72 h o u r s .
I t w as fo u n d t h a t
t h e l i q u i d l e v e l d ro p p e d t o 8 7 .5 m i l l i l i t e r s i n t h i s t im e .
A d d i t i o n a l e f f e c t s o f e x p o s u r e t o a i r f o r FMC s y n t h e t i c c r u d e o i l
s l u r r i e s a r e shown i n F i g u r e s 18 and 19 i n t h e a p p e n d ix .
I t was f e l t t h a t a lth o u g h , t h e v i s c o s i t i e s o f m any o f t h e s l u r r i e s
d i d i n c r e a s e u n d e r1 p r e s s u r i z a t i o n , t h i s d i d n o t h a p p e n t o a g r e a t
.
23
.
i
enough, d e g r e e to c a u s e any o f tH e l iq u i d s .- t o b e e l i m i n a t e d fro m f u r t h e r
■ c o n s id e ra tio n .
F o r t h i s r e a s o n , i t was d e c id e d to e n d t h i s p h a s e o f
i n v e s t i g a t i o n a n d t o g e t m ore d e t a i l e d r h e o l o g i c a l an d p i p e l o o p d a ta ..
RHEOLOGICAL PHASE
A lth o u g h t h e Amoco c r u d e o i l s l u r r i e s seem ed t o h a v e t h e g r e a t e s t
te n d e n c y t o s e t u p , i t w as f e l t to b e t h e s l u r r y i n g m a t e r i a l m o st
l i k e l y to b e u s e d i n a c o m m e rc ia l o p e r a t i o n .
W i l l i s t o n B a s in w hich, i s i n f a i r l y
o f E a s t e r n M o n ta n a .
The c r u d e came from t h e
c lo s e p ro x im ity to th e c o a l f i e l d s
A ls o , I t I s r e a d i l y a v a i l a b l e a n d I s n o t t i e d t o
a p l a n t o r r e f i n e r y t S c a p a c ity to p ro d u ce i t .
For th e s e re a s o n s ,
. .Amoco c r u d e o i l — c o a l s l u r r i e s w e re c h o s e f o r m ore d e t a i l e d s t u d i e s .
A W e l l s - B r o o k f i e l d H y n c h o - L e c tr ic V is c o m e te r w as u s e d t o t a k e t h e
v i s c o s i t y re a d in g s f o r t h i s p h a se o f th e i n v e s t ig a t io n .
The r a t e o f
s h e a r c o u ld b e c o n t r o l l e d much e a s i e r an d m ore a c c u r a t e l y th a n i t
c o u ld b e w i t h t h e S to rm e r v i s c o m e t e r .
The v i s c o m e t e r w as c a l i b r a t e d w i t h a s t a n d a r d o i l .
w e re t a k e n a t 2 0 ° C.
A ll re a d in g s
C a re was t a k e n t h a t t h e s l u r r i e s w e re w e l l m ixed
b e f o r e th e y w e re p l a c e d i n t h e t e s t c u p .
S l u r r i e s o f - 2 5 0 m esh c o a l i n Amoco c r u d e , o i l w e re t e s t e d a t
w e ig h t c o n c e n t r a t i o n s o f c o a l fro m 0% t o 50% i n 5% i n c r e m e n t s .
T a b le I I I show s how t h e a p p a r e n t v i s c o s i t y o f . t h e s l u r r i e s v a r i e d
w ith th e s h e a r r a t e
'
24.
TABLE L IT . - APPARENT VISCOSITIES Of CRUDE OIL-COAL SLURRIES
W e ig h t % C o a l •
R a te o f S h e a r s e c
- 'I
Ih
A p p a re n t V i s c o s i t y f t . s e c .
0
3 7 .5
•75
150
300
750
1500
5
3 7 .5
75
150
300
750
1500
.0 1 3 3
.0 0 9 2 1
.0 0 7 8 0
.0 0 7 1 2
.0 0 6 1 2 _
.0 0 5 1 7
10
3 7 .5
75
150
300
750
1500
.0 1 7 9
' 3 7 .5
75
150
300
750
1500
.0 2 3 4
.0 1 5 0
15
20
25
- '"
.
'
.0 0 6 0 7
.0 0 4 7 6
.0 0 4 8 0
.0 0 4 4 8
■ .0 0 4 1 8
.0 0 4 1 8
.0110
.0 1 0 9
.0 1 0 3
.0 0 9 3 2
.0 0 6 6 3
’
.0120
.0 1 0 7
.0 0 9 3 5
,0 0 8 2 4
3 7 .5
75
150
300
750
■ .0 3 9 8
.0 2 5 7
.0 1 9 3
.0 1 4 8
.0 1 1 7
3 7 .5
75
150
300
■ 750
.0 5 4 8
.0 2 9 2
,0 2 3 0
,0 1 7 0
.0 1 3 6
■
:
(
— 25
TABLE I I I
W e ig h t % C o al
(c e n t),
APPARENT VISCOSITIES' OF CRUDE OIL-COAL SLURRIES
R a te o f S h e a r s e c
—I
" ' ' V -Ih
A p p a re n t V i s c o s i t y f t . s e c .
- 3 7 .5
75
150
300
750
.0 5 3 7
.0 3 3 4
.0 2 5 4
,0 2 0 6
.0 1 5 5
3 7 .5
75
150
300
750
.0 6 7 0
.0 3 3 6
.0 2 7 8
.0 2 2 2
.0 1 7 1
3 7 .5
75
150 '
300
.0.672
.0 3 3 6
.0 2 8 4
.0 2 7 0
3 7 .5
75
150
300
.1 3 8
.0 7 5 1
.0 6 1 8
.0 4 0 9
15
3 7 .5
75
150
.1 3 7
.1 4 3
.0 9 9 5
.0 8 3 2
The r e a d i n g s a r e n o t r e c o r d e d a t t h e h i g h e r s h e a r r a t e s f o r t h e
m ore c o n c e n t r a t e d s l u r r i e s b e c a u s e t h e y i s c o m e te r w e n t o f f s c a l e .
The
r e a d i n g s a t t h e lo w e r s h e a r r a t e s a r e n o t a s a c c u r a t e a s t h o s e o f t h e
h i g h e r s h e a r r a t e s b e c a u s e t h e r h e o l o g i c a l d a t a a t lo w e r r a t e s h ad
m ore s c a t t e r .
I t was v e r y d i f f i c u l t t o g e t a c c u r a t e r e a d in g s , b e lo w
\
-26. x:
3 7 .5 s e c o n d s
F i g u r e s 3 a n d 4 show: t h e ' rh e o g ra jn s c a l c u l a t e d fro m t h e B r o o k f i e l d
v is c o m e te r d a ta .
F i g u r e 5 i s a t y p i c a l rheogpam sh o w in g f i v e d i f f e r e n t
c la s s e s o f f lu i d s .
I t c a n b e s e e n fro m t h e s e r h e o gram s t h a t t h e 'p u r e c r u d e o i l a p p e a r s
t o c l o s e l y r e s e m b le a N e w to n ia n f l u i d .
c l o s e l y r e s e m b le a p s u e d o p l a s t i c .
a p p e a r to b e r e a l p l a s t i c s .
C o n c e n t r a t i o n s up t o 10% m ost,
C o n c e n t r a ti o n s fro m 10% t o 40%
A bove 40% t h e s l u r r i e s a p p e a r t o a p p r o x i ­
m a te a B ingham p l a s t i c .
PIFEL00P DATA
V'
T h e p i p e l o o p was l o c a t e d i n Ryon L a b o r a t o r y .
a t room t e m p e r a t u r e .
A l l r u n s w e re m ade
S p e c i a l c a r e w as t a k e n t o k e e p t h e r e c e i v i n g
c y l i n d e r c o v e r e d w hen t h e p i p e l o o p w as n o t i n u s e a n d d u r in g lo n g r u n s
b e c a u s e o f c ru d e o i l ’ s a p p a r e n t te n d e n c y t o e v a p o r a t e .
P ip e lo o p d a t a w as t a k e n f o r s l u r r i e s
5% i n c r e m e n t s .
H ow ever, a t a 45% s l u r r y ,
sh o w in g a te n d e n c y t o p l u g u p .
fro m 0% t o 50% b y w e ig h t i n
t h e m anom eter l i n e s b e g a n
The l i n e s w e re c l e a r e d b u t b e f o r e e a c h
r u n b u t t h e d a t a s t i l l seem ed to b e e r r a t i c .
a p ro b le m a t c o n c e n t r a t i o n s b e lo w 45%,
T h is d i d n o t seem t o b e
F o r t h i s r e a s o n , d a ta i s o n ly
p r e s e n t e d f o r c o n c e n t r a t i o n s up. t o 40%,
■ T a b le IV
g iv e s th e a v e ra g e s iz e d i s t r i b u t i o n p f th e c o a l p a r t i c l e s
a s a n a ly z e d w i t h s t a n d a r d T y l e r s c r e e n s and a R o-Tap t e s t i n g s i e v e
Shear S tre s s ( lb f . / f t . 2 )
Tooo
S h e a r R a te ( S e c ." I )
FIGURE 3 .
Rheogram from B r o o k f ie ld V isc o m e te r
1200
Shear S tre s s (I b f . / f t
V
3#
S h e a r R a te ( S e c . ” 1 )
i
FIGURE 4 .
Rheogram from B r o o k f ie ld V isc o m e te r
-2 9
-
R a te o f S h e a r
FIGURE 5 .
T ypes o f F l u i d s
- 30 sh a k er.
TABLE IV .
COAL PARTICLE SIZE DISTRIBUTION
S c re e n S iz e
..
W e ig h t % C o al
—10 t o + 150 m esh
1 .2
- 1 5 0 t o + 200 m esh
5 .4
- 2 0 0 t o +325 m esh.
6 7 .8
- 3 2 5 m esh
2 5 .5
F i g u r e s 6 an d 7 show how t h e p r e s s u r e d ro p v a r i e d w i t h v e l o c i t y .
The p r e s s u r e d r o p s , e s p e c i a l l y a t t h e lo w e r flo w r a t e s , seem to
re m a in f a i r l y
w e ig h t.
c o n s t a n t w i t h c h a n g e s i n c o n c e n t r a t i o n up t o 30% by
A t a w e ig h t p e r c e n t o f 30 p e r c e n t t h e r e s e e m s .to b e a d e f i n i t e
b re a k in th e g ra p h s .
T h is i n d i c a t e s t h a t t h e v i s c o s i t y o f t h e s l u r r y
b e g in s to i n c r e a s e m ore r a p i d l y a t a 30% c o n c e n t r a t i o n .
o b s e rv a tio n s have been re p o rte d f o r c o a l-w a te r s l u r r i e s
S im ila r
(4 ).
The s o l i d l i n e r e p r e s e n t s t h e b e s t c u r v e f o r t h e c a r r i e r m a t e r i a l
a lo n e .
I t i s ',in te n d e d t o show how t h e s l u r r y p r e s s u r e d r o p s d e v i a t e d
fro m t h e p u r e c r u d e o i l .
T h re e t h e o r e t i c a l f lo w ty p e s h a v e b e e n p r e s e n t e d i n t h e l i t e r a t u r e
fo r s lu rrie s :
f lo w .
(2 )
(3 ).
hom ogeneous s l u r r i e s , h e te r o g e n e o u s s l u r r i e s , and p lu g
E ach h a s . i t s own c h a r a c t e r i s t i c flo w p r o p e r t i e s .
I n hom ogeneous s l u r r i e s ,
th e s o l i d p a r t i c l e s a r e u n ifo rm ly
d i s t r i b u t e d i n t h e l i q u i d m e d ia .
T h o se s l u r r i e s a r e u s u a l l y
c h a r a c t e r i z e d b y h i g h s o l i d c o n c e n t r a t i o n an d f i n e p a r t i c l e s i z e s .
H e te ro g e n e o u s s l u r r i e s h a v e c o n c e n t r a t i o n g r a d i e n t s a lo n g t h e
v e r t i c a l a x is o f th e p ip e .
The c o n c e n t r a t i o n of. s o l i d s i s g r e a t e r a t
P r e s s u r e D ro p ( l b f . / f t
800
■
600 --
V e lo c ity ( f t . / s e c . )
FIGURE 6 .
P ip e lo o p P r e s s u r e Drops
O
2 #
V e lo c ity ( f t . / s e c . )
FIGURE 7
PIPELOOP PRESSURE DROPS
/
T 33 —
t h e b o tto m o f t h e p i p e th a n i t i s a t t h e t o p . . T h e se s l u r r i e s a r e
u s u a l l y o f lo w e r s o l i d s c o n c e n t r a t i o n an d h a v e l a r g e r p a r t i c l e s i z e s
t h a n hom ogeneous s l u r r i e s .
P lu g flo w t h e o r y h a s b e e n p r e s e n t e d t o e x p l a i n t h e f a c t t h a t t h e
s l u r r i e s h a v e on o c c a s i o n h a d a lo w e r p r e s s u r e d ro p t h a n t h e p u r e
l i q u i d a t t h e sam e f lo w r a t e .
I t s t a t e s t h a t when f o r c e i s a p p l i e d ,
I
th e m ix tu re i s
c o m p re s se d and t h e l i q u i d i s s q u e e z e d o u t to t h e
p e rip h e ry o f th e p lu g .
T h e r e f o r e t h e s o l i d s te n d t o m ove a lo n g t h e
c e n t e r o f t h e p i p e a s a p lu g and l i q u i d s e r v e s a s a l u b r i c a n t b e tw e e n
t h e p lu g a n d th e p i p e w a l l .
t u r b u l e n t f lo w .
o c c u r, s lu r r ie s
T h is c a n o c c u r i n b o t h l a m in a r and
I t i s v e ry in te r e s tin g in th a t i f
t h i s d o e s in d e e d
c a n b e t r a n s p o r t e d i n t h e la m in a r f lo w r e g i o n w h ic h
r e d u c e s t h e pow er r e q u i r e m e n t s .
Much o f t h e l i t e r a t u r e s t a t e s
th a t
th e s l u r r i e s h av e to b e t r a n s p o r t e d i n th e tu r b u le n t r e g io n to keep
th e s o l i d p a r t i c l e s in s u s p e n s io n .
. P lu g flo w h a s a l s o b e e n p o s t u l a t e d t o o c c u r, i n t h e t u r b u l e n t
flo w r e g i o n .
I n t h i s c a s e , t h e s o l i d p lu g a l s o t e n d s t o s u p p r e s s t h e
t u r b u l e n c e i n t h e m id d le c o r e .
s o l i d p lu g o r s h e a r s
The m id d le c o r e m oves e i t h e r a s a
l a m i n a r l y i n a t e l e s c o p i c m a n n e r.
T he o u t e r
a n n u lu s i s i n t u r b u l e n t s h e a r , . T his, a c c o u n t s f o r p r e s s u r e d r o p s f o r
s lu rrie s
t h a t a r e lo w e r t h a n f o r t h e p u r e l i q u i d .
The t h e o r e t i c a l f lo w p a t t e r n s a r e show n i n F i g u r e 8 .
I n a c t u a l a p p l i c a t i o n , t h e s l u r r i e s w i l l p r o b a b l y b e o f a m ixed
HOMOGENEOUS SLURRY
HETEROGENEOUS SLURRY
I
Ui
PLUG FLOW
FIGURE 8
THEORETICAL FLOW PATTERNS
I
-35 ■
c h a ra c te r.
T h is - i n c r e a s e s t h e d i f f i c u l t y i n p r e d i c t i n g p r e s s u r e d r o p s .
Two lo n g r u n s w e re m ade d u r in g t h e i n v e s t i g a t i o n t o s e e i f a n y
s e t t l i n g w as o c c u r r i n g i n t h e l i n e .
t i o n s o f 30% and 50%.
T h e se r u n s w e re m ade a t c o n c e n t r a ­
T h e ib y - p a s s v a l v e w as s e t w id e o p e n so t h e flo w
r a t e s w e re t h e s lo w e s t a t t a i n a b l e .
a n d t h e 50% s l u r r y f o r 11 d a y s .
The 30% s l u r r y w as r u n f o r 10 d ay s
A t t h e en d o f e a c h r u n , t h e p ip e lo o p
was t a k e n a p a r t t o d e te r m in e i f a l a y e r o f c o a l h a d fo rm e d on t h e
b o tto m .
No e v id e n c e o f s e t t l i n g w as fo u n d i n e i t h e r c a s e .
A ls o , t h e
p r e s s u r e d ro p r e m a in e d a p p r o x im a te ly c o n s t a n t d u r in g t h e 30% r u n .
The
m an o m eter l i n e s p lu g g e d w i t h t h e 50% s l u r r y so t h e p r e s s u r e d ro p c o u ld
h o t h e m easu red .
The pump h a d t o b e r e p a c k e d o n c e d u r in g t h e i n v e s t i g a t i o n .
B o th
t h e pump an d p i p e w e re c h e c k e d f o r a n y s i g n s o f w e a r a t t h e e n d o f th e '
in v e s tig a tio n .
No s i g n o f e x c e s s i v e w e a r was f o u n d .
■PREDICTING. PRESSURE DROPS
P ip e lo o p d a t a was f i r s t a n a ly z e d u s i n g t h e M o o n e y -R a b in o w itsc h W e is s e n b e r g e q u a t i o n (.see a p p e n d ix ) .
A p l o t o f 8 V/D v e r s u s Tq s h o u ld
b e u n iq u e r e g a r d l e s s o f t h e p i p e d i a m e te r u s e d .
The r a t e o f s h e a r i s
g iv e n by
.
• , dV\
™(h d F " )
o
.3
= ■—
,
8V
c~
d
x
) ■+
I
—
T
' d ( 8 V/D)
°
z r
o
— 36 —
w h e re
^ ^ — I s th e s lo p e o f th e c u rv e a t th e g iy e n v a lu e o f
o ■
■D AE ■■
—^
and T
o
tq
4L.
In th e above e q u a tio n s ,
V
= b u lk v e lo c i ty
D
= i n s i d e d i a m e te r
AP
= p r e s s u r e d ro p
L
= le n g th o f p ip e
T
= s h e a r s t r e s s a t w a ll
o f th e p ip e
The e f f e c t i v e v i s c o s i t y , i s t h e n fo u n d b y
'to
u
Be
e
=
-------------------d v /d r
=
e ffe c tiv e v is c o s ity
=
g r a v i t a t i o n a l c o n s ta n t
w h e re
p
g^
The p r e s s u r e d ro p c a n b e t h e n c a l c u l a t e d u s in g
i n t h e R ey n o ld s num ber c a l c u l a t i o n s „
good f o r a R ey n o ld s
2100.
T h is m ethod i s s u p p o s e d t o b e
n u m b e r, c a l c u l a t e d i n t h i s m a n n e r, o f l e s s th a n
The f r i c t i o n f a c t o r i s t h e r e f o r e 1 6 /R e and t h e p r e s s u r e d ro p
c a n b e c a l c u l a t e d u s in g P o i s e u L l l e ' s e q u a t i o n .
AP
2f V2 L p
8c D
w h e re ,
vT a s t h e v i s c o s i t y
- 37AP
=
p r e s s u r e d ro p
p.
=
d e n s i t y o f th.e s l u r r y
F i g u r e s 9 th ro u g h . 17 a r e t h e p l o t s o f 8 V/D v e r s u s Tq f o r s l u r r i e s
fro m 0% t o 40%.
T a b le V show s th e. p r e d i c t e d p r e s s u r e d r o p s com pared
t o t h e m e a s u re d .
The m eth o d seem s t o b e o n l y goo<3 t o i
25%.
The p r e d i c t e d p r e s s u r e
d ro p s a t h i g h e r f lo w r a t e s a r e c o n s i s t e n t l y h i g h e r t h a n t h e m e a su re d
p re s s u re d ro p s.
The m eth o d o n l y g i v e s a p p r e c i a b l y lo w p r e d i c t i o n s a t
t h e lo w e r v e l o c i t i e s .
The c h a n g e i n t h e s h a p e o f t h e c u r v e b e tw e e n t h e p u r e o i l and
s l u r r i e s may i n d i c a t e a t r a n s i t i o n fro m t u r b u l e n t t o l a m i n a r f lo w , a
dam ping o f t h e t u r b u l e n c e , o r a d i f f e r e n t f l u i d c h a r a c t e r i z a t i o n .
U sin g
t h e v i s c o s i t y f o r p u r e o i l a s d e te r m in e d b y t h e B r o o k f i e l d v is c o m e te r
t h e R e y n o ld s . num ber f o r t h e p u r e o i l r a n g e s fro m 7991 t o 4 3 1 6 .
T h is i n d i c a t e s t h a t t u r b u l e n t flo w p r o b a b l y d o e s e x i s t i n t h e p ip e
e x p l a i n i n g why t h e e f f e c t i v e v i s c o s i t i e s , f o r p u r e o i l ,
c a l c u l a t e d from
t h e p i p e l o o p d a t a a r e h i g h e r th a n t h o s e c a l c u l a t e d fro m t h e
B r o o k f i e l d v is c o m e te r ,.
A p l o t o f D AP/4L v e r s u s 8 y/D on l o g a r i t h m i c c o o r d i n a t e s o f t e n
g iv e s a s t r a i g h t l i n e .
n l an d i s
The s l o p e o f t h i s l i n e i s g iv e n t h e sym bol
t h e f lo w - b e h a v i o r i n d e x .
v a l u e o f D AP/4L f o r 8 V/D = I .
The c o n s i s t e n c y in d e x k* i s
.
th e
W
CO
FIGURE 9 .
0% S lu r r y
O
FIGURE 1 0 .
5% S lu r r y
T
FIGURE 1 1 .
O
10% S lu r r y
O
O
O
O
VO
8V
D
O
O
VTX
O
O
_ l ____________________ I____________________ I____________________I
0.1
0 .2
0 .3
T
FIGURE 1 2 ,
O
15% S lu r r y
0 .4
0 .5
O
FIGURE 13
20% S lu r r y
FIGURE 14
25% S lu r r y
FIGURE 1 5 .
30% S lu r r y
O
O
FIGURE 1 6 .
35% S lu r r y
O
£ -
O
O
N3
8V
D
I
o
o
<r>
I
O
O
-d"
0 .1
0 .2
FIGURE 1 7 .
I
0 .3
40% S lu r r y
0 .4
0 .5
- 47 TABLE V.
PRESSURE DROP PREDICTIONS USING THE MOONEY-RABINOWITSCH
WEISSENBERG EQUATION
S V /D sec- ^ T - 1^ . . d v / d r
o f
^
Ib
f f SPP
lb f
.r lb f
AP^ E 2 -
Re
% dev.
0%
742 .
655
587
526
401
.3 8 5
.3 4 5
.3 0 8 .
.2 6 2
.1 4 5
.
797
656
560
477
334
.0 1 5 5
,0 1 6 9
.0 1 7 7
.0 1 7 7
.0 1 4 0
_
473
443
397
239
2310
1870
1599
1434
1381
480
423
346
204
.■
5%
706
671
566
460
309
_
- 1 .5
4 .7
1 4 .7
1 7 .1
—
.3 9 1
.3 6 2
.2 8 5
.2 3 0
.1 6 6
642
■ 615
536
457
344
.0 1 9 6
.0 1 8 9
.0 1 7 1
.0 1 6 2
.0 1 5 5
1797
1771
1651
1418
996
590
541413
318
205
550
487
416
331
226
.3 8 9
.3 5 0
.2 9 5
.2 4 8
.2 0 8
590
577
. 543
513
462
.0 2 1 2
.0 1 9 5
.0 1 7 5
.0 1 5 6
.0 1 4 5
1634
1698
1700
1729
1469
617
542
437
353
259
578
462
414
342
296
6 .7
1 7 .3
■ 5 :5 6
3 .2 2
- 1 2 .5
.0 2 3 1
.0 2 0 2
.0 1 8 2
.0 1 6 0
.0 1 3 6
1534
1623
1664
1522
1520
676
547
455
328
232
571
465
408
328
301
1 8 .4
1 7 .6
1 1 .5
0
- 2 2 .9
■,0 2 1 6
,0 1 9 2
.0 1 6 8
.0 1 6 0
.0 1 5 6
1735
. 1725
1,626
1412
1435
660
519
375
295
285
582
473
384
302 .
272
.
7 .3
1 1 .1
.7 2
' - 3 .9
- 9 .3
10%
682
652
.586
531
419
15%
-
.685
634
586
480
400
.4 2
.3 5
.3 0 2
.2 4
.2 1 5
584
557
535
484.
510
.4 2 4
.3 4 1
.2 6 4
.2 1 5
.2 1 0
632
572 .
506
433
434 •
20%
717
633
523
432
428
v
1 3 .4
9 .7
- 2 .3
, - 2 .3
4 ,8
I
a m
48 TABLg V- C c o n tj
M
hB
■d y / d r .
8V /D sec ■*" T
o ft^
• lb
- Re
f t sec
■
Ib f
'
,£Fp ' f t 2 ‘ %
Ib f '
t ? % dev‘
25%
717 .
625
565
442
.4 2 1
.3 4 2
.2 9 8
.2 3 2 .
641
580
544 .
452
.4 5 9
.4 3 5
.3 7 8
.3 6 5
.2 6 5
.0 2 1 1
.0 1 9 0
.0 1 6 5
1816
1760
1716
1433
645
507
424
312
586
576
558
551
505
.0 2 5 2
.0 2 4 2
.0 2 1 8
.0 2 1 3
.0 1 6 9
1489
1516
1568
1567
1430
.4 5 5
.4 2 5
.3 9 2
.3 2 8
.2 7 4
561
566
577
554
529
.0 2 6 1
.0 2 4 2
.0 2 1 9
.0 1 9 0
.0 1 6 7
1441
1520 .
1600
1577
1382
.4 8 3
.4 5 3
.3 8 8
.3 3 3
.2 8 6
561
573
582
540
488
.0 2 7 7
.0 2 5 4
.0 2 1 4
.0 1 9 8
.0 1 8 9
1383
1486
1622
1491
1239
'
' .0 1 7 6
.
1 589
473
409
331
9 ,5
7 .2
3 .7
- 5 .7
738
693
581
555
319
664
573
506
501
.374
1 1 .1
2 0 .9
1 4 .8
' 1 0 .7
- 1 4 .7
747
677
584 ^
433
294
663
575
525
451
372
1 2 .7
1 7 .7
1 1 .2
- 4 .0
- 2 0 .9
688
607
518
437
406
1 5 .7
1 8 .5
7 .7
.2 2
- 1 8 .2 3
.
30%
686
671
625
610
442
.
35%
671
656
625
534
412
40%
674
664
610
517
412.
796
719
• 558
438
332
— 49 —
T h is m eth o d w as t r i e d
f o r th e s l u r r i e s
t e s t e d b u t i t was fo u n d
t h a t t h e p l o t d i d n o t g iv e a s t r a i g h t l i n e .
H ow ever, v a l u e s f o r n '
and k ' c o u ld b e o b t a i n e d fro m t h e f o l l o w i n g f o r m u la s .
n* =
dx ■
__________
d(8V /D )
8V
TqD
k ' = xo /(8 V /D ) n
From t h e s e v a l u e s a g e n e r a l i z e d R e y n o ld s num ber c o u ld b e
c a lc u la te d by:
Re =
2 -n l
D
V
w h e re
v = g ck* 8n
1
T a b le VI g i v e s t h e p r e s s u r e d ro p p r e d i c t i o n s u s i n g t h e
g e n e r a l i z e d R e y n o ld s n u m b er.
T h is m eth o d g i v e s p r e d i c t e d p r e s s u r e d r o p s t h a t a r e w i t h i n
- 10% o f t h e m e a s u re d d r o p s .
I f t h e s l u r r y i s n o t h o m o g en e o u s, t h e g e n e r a l i z e d R e y n o ld s
num ber c r i t e r i a o f 2100 a s t h e t r a n s i t i o n fro m l a m in a r t o t u r b u l e n t
f lo w may n o t b e t r u e .
T h is w o u ld m ean t h a t t h e a s s u m p tio n t h a t
t h e s h e a r s t r e s s i s j u s t a f u n c t i o n o f s h e a r r a t e may n o t b e t r u e .
I f i t i s assum ed t h e s l u r r y i s i n t u r b u l e n t f lo w , P e r r y
(5 ) recom m ends
c o m p u tin g a t u r b u l e n t v i s c o s i t y from t h e p r e s s u r e d ro p d a t a a n d .th e
f r i c t i o n - f a c t o r v e r s u s R e y n o ld s num ber p l o t .
P r e s s u r e d r o p s com puted
PRESSURE DROP PREDICTIONS USING THE GENERALIZED
TABLE VI
8V/D
WEIGHT
T
n, _
'
O
T
8V
D
O
8T
, ,
d(8V /D
_
T0
v
(8V /D )U
)
.
=
g^k*8
REYNOLDS NUMBER
n ’- l
D ^ U 2-
Re
' ,
V
COAL
%
0%
74.2
.3 8 5
.7 7 1
2 .3 6 x IO- 3
4 .7 2 x IO " 2
2140
655
.3 4 5
.9 9 1
5 .5 8 x IO " 4
1 .7 6 x 10~ 2
1869
587
.3 0 8
1 .2 3
1 .2 1 x IO " 4
6 .2 8 x IO " 3
1679
526
.2 6 2
1 .5 9
1 .2 3 x IO " 5
1 .3 5 x IO " 3
401
.1 4 2
3 .0 4
1 .7 3 x IO "9
3 .8 7 x IO " 6
AP
P
lb f
ftz
T
“r a
'
ftz
........................
.%
•
•
1591
1702
I
.d e v ..
0
1
530
8V/D
T
473
480
- 1 .4 5
422
423
- 0 .2 3
358
346
3 .4 7
194
204
- 4 .9 0
O
nl
kl
v .
Re
AP
lb £
P f t i-
AP
lb
ftif t z
—
%
dev.
5%
706
.3 9 1
1 .5 6
1 .4 1 x 10~5
1 .4 5 x IO " 3
1977
536
550
- 2 .5
671
.3 6 2 •
1 .5 0
2 .0 8 x K f 5
1 .8 9 x IO " 3
1934
496
487
1 .8
566
.2 8 5
1 .2 7
9 .0 9 x IO " 5
5 .1 3 x 10~ 3
1743
391
416
- 6 .0
V
TABLE VI ( C o n t ) .
lb f
8V/D
T
O
n'
k'
Re
V
Ibf
APp ^ r - APa - f ^
% dev.
5% ( c o n t )
309
.1 6 6
10%
1 .0 3
.6 8 7
4 .1 6 x
1 .4 2 x 10“ 2
3 .2 3 x 10 3
5 .4 2 x 1Q~2
'
1433
315
331
894
228
226
—4 .8
CO
oo
.2 3 0
O
i—
I
460
■
682
.3 9 8
2 .1 7
7 .7 5 x IO " 7
1 .0 0 8 x IO " 4
1894
532
578
652
.3 5 0
1 .8 4
2 .3 2 x IO " 6
4 .2 8 x 10 " 4
1920
479
462
586
.2 9 5
1 .4 2
3 .4 6 x IO " 5
2 .6 7 x 10 ~ 3
1836
405
414
- 2 .2
531
.2 4 8
1 .1 6
1 .7 1 x
O
H
7 .6 7 x 10 ~ 3
1797
340
342
-
419
.2 0 8
.7 0 7
2 .9 1 x
io
5 .0 9 x 10 " 2
1334
286
296
- 3 .4
- 7 .9
■
3 .7
T
“3
15%
.5 8
i
5 .0 6 x IO " 8 •
3 .2 5 x IO "5
1796
577
571
1 .0 5
.3 5
1 .9 4
1 .2 8 x IO " 6
2 .9 1 x IO "4
1848
480
465
3 .2 2
586
.3 0 2
1 .5 2
1 .8 7 x IO "5
1 .7 7 x
1835
412
408
.9 8
480
.2 4 0
1 .8 6 x 10 2
1574
324
328
- 1 .2
1 .3 5 x IO "1
1194
295
301
- 2 .0
3 .3 2 x 10 4
1975
580
582
-
1 .1 0 x IO " 3
1917
467
473
- 1 .2 7
.9 6 4
6 .2 4 x
H
O
° l
H
I
634
Lo
CM
2 .4 4
685
.4 7 5
1 .2 5 x
717
.4 2 4
1 .9 0
1 .5 9 x
633
.3 4 1
1 .6 3
9 .2 6 x
.
O
I—I
T
.2 1 5
400
H
O
I
Ox
20%
.3 4
I
Ln
H
: I
VD
O
rH
I
TABLE VL (C o n t)
8V/D
T
O
n'
k'
Re
V
.
AR
• lb f
P f t 2
<7 Qev
AmT •
- /o
20% ( c o n t )
523
.2 6 4
1 .1 5
1 .9 7 x 10~4
8 .6 6 x IO- 3
1686
432
.2 1 5
. .9 8 7
5 .3 9 x IO 04
1 .6 9 x 10“ 2
428
.2 1 0
.
361
384
- 5 .9 9
1408
296
302
- 1 .9 9
.4 2 1
1 .7 4
4 .5 3 x IO- 6
. 6 .7 9 x 10~4
2028
578
.589
- 1 .9
625
.3 4 2
1 .4 1
3 .9 1 x IO- 5
2 .9 5 x 10“ 3
1898
470
473.
565
.2 9 8
1 .1 8
1 .6 9 x IO- 4
7 .9 0 x H T 3
1777
410
409
.2 4
442
.2 3 2
8 .8 1 x 10“ 4
3 .3 8 x 10~ 2
984
227
331
- 3 .1 4
630
664
- 5 .1 2
.9 1 5
Co
Ch
717
I
25%
30%
686
.4 5 9
2 .3 9
7 .6 4 x I d - 8
4 .4 2 x IO ^ 5 ' ' ' • 1743
671
.4 3 5
2 .3 0
1 .3 7 x IO- 7
6 .5 8 x IO- 5
1760
. 596
573
4 .0 1
625
.3 7 8
1 .7 5
4 .8 4 x IO- 6
7 .4 1 x K f 4
1755
519
506
2 .5 7
1735
501
501
.0
1253
364
374
- 2 .6 7
610
.3 6 5
1 .6 4
9 .8 7 x 10 0
1 .2 0 x 10
442
.2 6 5 '
.6 3 8
5 .4 4 x 10
8 .2 4 x 10
-3
-2
TABLE VI (C o n t)
8V/D
To
n ’
Tc*
K.
..
■y
Re .
lb f
AT
ZXr
p-f t ^ — a f t 2 % dev,
35%
.4 5 5
2 .9 1
2 .7 0
X
IO "9 .
656
.4 2 5
1 .9 1
1 .7 7
X
IO " 6
625
.3 9 2
1 .4 4
3 .6 9
X
534
.3 2 8
.8 6 8
1 .4 1
412
.2 7 4
.4 6 8
674
.4 8 3
664
4 .6 1
X
I O '6
1728
623
663
- 6 .0 3
3 .7 8
X
IO " 4
1764
584
575
1 .6
IO *5
2 .9 6
X
IO " 3
1739.
537
525
2 .3
X
IQ " 3'
3 .4 5
X
IO " 2
1512
452
451
.2 2
1 .6 4
X
io " 2
1 .7 5
X
IO "1
1074
378
372
1 .6 1
3 .0 5
1 .1 4
X
IO "9
2 .6
X
IO " 6
1666
661
688
- 3 .9
.4 5 3
2 .2 2
2 .4 6
X
H
O
671
I
X
IO " 4
1722
620
607
2 .1
610
.3 8 8
1 .2 2
1 .5 5
X
io " 4
7 .8 8
X
IO " 3
1698
533
518
2 .9
517
.3 3 3
.8 4 9
1 .6 5
X
IO *3
3 .8 8
X
io " 2
1428
459
437
' 5 .0 3
412
.2 8 6
.5 7 6
8 .9 2
X
io " 3
1 .1 9
X
io " 1
1047
393
406
- 3 .2 0
'
I
40%
.
54
by t h i s p r o c e d u r e s h o u ld b e a c c u r a t e w i t h i n % 25%.
T a b le V I I shows,
t h e p r e s s u r e d ro p s p r e d i c t e d b y t h i s m e th o d .
TABLE V I I .
W eig h t V e l o c i t y
C oal
ft/s e c
PRESSURE DROP PREDICTIONS USING A TURBULENT VISCOSITY
'.
' ^t
1V
I b f■C Cr/ J}„
•yv't)"
* Ar
. . P ft% . a f t * ■■'"•dcv
N 529
529
0
' 480
486
1 .3
398
423
- 5 .9
331
346
- 4 .3
213
4 .4
204
’ . Ib
— . bXixe.. .
f t sec
0
8 .1 1
7 .1 6
. 6 .4 1
5 .7 6
4 .3 8
5
7 .7 1
7 .3 3
6 .1 8
5 .0 3
3 .3 8
.0 0 5 4
6521
6200
5227
4255
2859
563
484
387
274 .
153
550
487
416
331
226
2 .4
- .6 1
- 7 .0
- 1 7 .2
- 3 2 .3
10
7 .4 5
7 .1 2
6 .4 0
5 .8 0
4 .5 8
.0 0 5 9
5871
5611
5044
4571
3609
554
512
423
363
238
587
462
417
342
296
- 4 .1 5
1 0 .8
2 .1 7
■6.14
- 1 9 .6
.0 0 5 2 .
'
6885
6078 '
5442
.4 8 8 1
3718
15
7 .4 9
6 .9 3
6 .4 0
5 .2 5
4 .3 7
.0 0 6 0
5898
5464
5046
4140
3446
568
499
430
312
243
571
465
408
328
301
.5 3
7 .3
5 .4
- 5 .1 3
- 1 9 .3
20
7 .8 3
6 .9 2
5 .7 1
4 .7 2
4 .6 8
.0 0 5 5
6812
6020
4977
4107
4142. .
601
492
348
252
251
582
473
384
302
272
3 .3
4 .0 2
- 9 .4
- 1 6 .6
- 7 .7
7 .8 3
6 .8 3
. 6 .1 7
4 .8 3
.0 0 4 9
593
474 .
391
259
589
473
409
331
.6 8
,2 1
- 4 .4
- 2 1 .7
25
I
■\
7822
6823
6164 .
4825.
.
-
TABLE'V I I ( C o n t ) .
W e ig h t V e l o c i t y
C oal
F t/s e c
Mt
. .I b f
- AP - l b f
■ % dey
.p., f t z ' ■ APa f t 2
Ib
f t sec
30
7 .5 0
7 .3 3
6 .8 3
6 .6 7
4 .8 3
.0 0 6 8 .
5519 5394
5026
4908
3554 .
611
591
518
494
299
-664
573
-506
501
374
35
7 .3 3
7 .1 7
6 .8 3
5 .8 4
4 .5 0
.0 0 7 4
5081
4970
4734
4041
3119
612
586
549
417
279
663
575
525
451
372
- 1 2 .4
3 .5
6 .0
—4 .6
- 2 5 .0
40
7 .3 6
7 .2 5
6 .6 7
5 .6 7
4 .5 0
.0 0 7 8
4912
4838
4452
3784
3003
626
614
543
408
283
688
607
518
437
406
- 9 .0 1
1 .1 5
4 .8 0
—6 .6
- 3 0 .3
'
- 7 .9 8
3.-14
2 .4 0
- 1 .4
- 2 0 .0 5
I n a l l c a s e s , th e a y e ra g e tu r b u le n t v i s c o s i t y I s th e a v e ra g e v a lu e
c a l c u l a t e d fro m t h e f r i c t i o n f a c t o r s t h a t i n d i c a t e t h e f lo w i s
tu rb u le n t.
In a l l c a s e s , e x c ep t th e p u re o i l ,
t h e s l o w e s t f lo w r a t e s
f r i c t i o n f a c t o r s i n d i c a t e th e y a r e i n t h e l a m in a r f lo w r e g i o n .
T h is
i s p r o b a b ly why t h e y g i v e v a l u e s t h a t a r e c o n s i s t e n t l y s o lo w .
I t is in te re s tin g
t o n o t e how t u r b u l e n t v i s c o s i t i e s i n c r e a s e up
t o 20%, b e g i n t o d e c r e a s e and th e n i n c r e a s e s h a r p l y a g a i n a t 30%.
The
d e c r e a s e a t 20% m ay b e b e c a u s e t h e d am pening e f f e c t s o f t h e s l u r r y on
th e tu rb u le n c e a r e o v e rr id in g th e in c r e a s e in a p p a re n t v i s c o s i t y .
The
s h a r p i n c r e a s e a t 30% I n d i c a t e s , o n c e a g a i n , t h a t t h e v i s c o s i t y b e g in s
t o i n c r e a s e m a r k e d ly a t t h i s c o n c e n t r a t i o n .
" -56 —C om paring t h e t u r b u l e n t v i s c o s i t i e s w i.th ' th e . a p p a r e n t v i s c o s i t i e s
lis te d
i n T a b le I i i p o i n t s ' o u t some i n t e r e s t i n g f e a t u r e s ';
T h e re i s
good a g re e m e n t b e tw e e n t h e t u r b u l e n t v i s c o s i t y and B r o o k f i e l d
v is c o m e te r v a lu e s f o r p u re o i l .
H ow ever, t h e v a l u e s fro m t h e
v i s c o m e t e r i n c r e a s e a t a m uch m ore r a p i d r a t e th a n t h e t u r b u l e n t
v is c o s itie s do.
T h is o n c e a g a in p o i n t s o u t t h e d am pening e f f e c t s o f
th e s l u r r y .
■' .
M ethods p r o p o s e d by A u d e, C ow per, Thom pson, and H asp (3 ) w e re
u s e d t o p r e d i c t t h e p r e s s u r e d ro p fro m v i s c o m e t e r d a t a f o r hom ogeneous
a n d h e te r o g e n o u s f lo w .
The m eth o d f o r hom ogeneous f lo w w as d e v e lo p e d f o r s l u r r i e s
e x h i b i t i n g B ingham p l a s t i c c h a r a c t e r i s t i c s .
The R e y n o ld s num ber i s
c a lc u la te d by th e e q u a tio n ,
Re = DY p /n
w h e re
n = c o e ffic ie n t o f r ig id ity .
The c o e f f i c i e n t o f r i g i d i t y f o r a Bingham p l a s t i c i s
th e s lo p e o f a
l i n e g iv e n b y p l o t t i n g t h e r a t e o f s h e a r v e r s u s t h e s h e a r s t r e s s .
T h is w as a p p ro x im a te d by t a k i n g t h e s l o p e o f t h e s t r a i g h t p o r t i o n s
o f rh e o g ra m s show n i n F i g u r e s 3 and 4 ,
The t r a n s i t i o n v e l o c i t y i s d e f i n e d a s t h e v e l o c i t y w h e re t h e f lo w
'm ak es i t s
tra n s itio n
fro m la m in a r to t u r b u l e n t f lo w .
Tt i s r e la te d
.V-Xiek
~ 5 7 —to t h e E e d s tro m num ber b y a c u r y e p u r p o s e d b y H anks (3 ) ,• The
H e d stro m num ber i s d e f i n e d a s
if
\
P Sg
,2
H ankt S c u r v e i s
n u m b e r.
;
T
= y ie ld s tr e s s
-
a p l o t o f c r i t i c a l R e y n o ld s num ber v e r s u s t h e H e d stro m
Once t h e v a l u e o f t h e H e d stro m num ber i s known t h e c r i t i c a l
/
R e y n o ld s num ber c a n b e d e te r m in e d fro m H an k t S c u r v e .
v e lo c ity is
The c r i t i c a l
th e n c a lc u la te d by :
. .Re . n
______ C
Uc
Dp
w here.
■
Uc
=
c r i t i c a l v e lo c ity
Rec = c r i t i c a l R e y n o ld s num ber
F o r h e te r o g e n e o u s f lo w , t h e D u ran d c o r r e l a t i o n i s u s e d t o c o r r e l a t e
t h e F ro u d e num ber t o v o l u m e t r i c s o l i d s c o n c e n t r a t i o n .
The a u t h o r s
p r e s e n t a g r a p h o f t h e \ c r i t i c a l F ro u d e num ber v e r s u s t h e v o l u m e t r i c
s o lid s c o n c e n tra tio n .
c ritic a l
The d e s p o s i t i o n v e l o c i t y i s r e l a t e d t o t h e
F ro u d e num ber b y ;
Ud = ( F r ) c
CgcD )1 /2
w h e re
Ud
=
d e s p o s itio n v e lo c ity
F r ■= c r i t i c a l F ro u d e num ber
c
.
- 58
H e te ro g e n e o u s ^ f r i c t i o n f a c t o r s are. t h e n c a l c u l a t e d b'y D u r a n d 's
.
e m p iric a l r e l a t i o n s h i p ;
1; ‘3D . -
f =
[I + 82 (-
..
■P - P a
p
.3 /2 .
V
-3 /4
w h e re ,
f
=
f r i c t i o n f a c t o r c a l c u l a t e d u s in g t h e v i s c o s i t y o f t h e
p u re l iq u i d
d e n s ity o f th e p u re liq u id
P,
p
=
d e n s ity o f th e s o lid
C^
=
v o lu m e tric c o n c e n tra tio n
c^
.=
d rag c o e f f ic i e n t
The d r a g c o e f f i c i e n t was t a k e n t o b e c o n s t a n t a t .4 4 . ■ The w e ig h t
c o n c e n t r a t i o n was c o n v e r t e d t o t h e v o l u m e t r i c c o n c e n t r a t i o n b y :
'v
c
w.
pc
,
T
1 -c
w
po
w h e re ,
cw
=
w e ig h t c o n c e n t r a t i o n
Pc
=
d e n s ity o f th e c o a l
Po
=
d e n s ity o f th e o i l
The d e n s i t y o f t h e c o a l w as t a k e n t o b e 79 p o unds- p e r c u b ic f o o t .
59.
The d e n s ity " o f t h e o i l was 5 0 .5 p o u n d s p e r c u b i c f o o t .
T a b le V I I I g i v e s t h e p r e d i c t e d p r e s s u r e d r o p s c a l c u l a t e d b y
t h e s e two m e th o d s .
TABLE V I I I .
W eig h t %
C o al
U
ft
sec
v
PREDICTED PRESSURE DROPS FROM VISCOMETER DATA
HomoH e te ro ­
geneous
, geneous
M e asu re d
ft
c sec
- lb f
.AP ' f t 2
AP
—
' 530
485
366
260
134
550
487
416
331
226
617
575
465
419
286
511
473
' 399
337
223
578
462,
414
342
296
3 .0 2
680
609
.544
398
—
526
457
404
286
211
571
465
408
328
301
576
462
335
242
238
582
473
384
302
272
591
463
394
261
589
473
409
331
TT f t
d sec
7 .7 1
7 .3 3
6 .1 8
5 .0 3
3 .3 8
4 .0 6
7 .4 5
7 .1 2
6 .4 0
5 .8 0
4 .5 8
4 .6 9
7 .4 9
6 .9 3
6 .4 0
5 .2 5
4 .3 7
4 .6 9
20
7 .8 3
6 .9 2
5 .7 1
4 .7 2
4 .6 8
5 .4 3
' 3 .1 9
716
615
438
325
320
25
7 .8 3
6 .8 3
6 .1 7
4 .8 3
6 .4 7
3 ,3 5
806
657
569
5
•V
10:
-. •
. V- .
15
2 .5 1
AR
.
2 .7 0
,
lb f
ftz
629
569
426
388
,
—
<
-
lb f
ft%
— 60 ■'->
TABLE V I I I (C o n t)
W e ig h t %
C o al
U
ft
sec
Homogeneous
' u
uC
ft
sec
■u
ft
ud ' s e c
lb f
AP . ' f t 2 '
. H e te r o c
geneous
AR
M easu red
)
lb f
ft^
lb f
AP f t 2
30
7 .5 0
7 .3 3
6 .8 3
6 .6 7
4 .8 3
6 .0 6 '
3 .5 2
773
755
661
630
—
559 ,
541
478
457
270
664
573 '
506
501
374
35
7 .3 3
7 .1 7
6 .8 3
5 .8 4
4 .5 0
6 .9 4
3 .5 2
773
756
701
534
-
554
531
491
382
261
663
575
525
451
372
7 .3 6
7 .2 5
6 .6 7
5 .6 7
4 .5 0 ,
9 .0 6
3 .7 0
573
557
483
378
273
688
607
518
437
406
40
.
—
-
—.
The v a l u e s t h a t a r e n o t p r e s e n t e d f o r t h e hom ogeneous
flo w
c a s e a r e t h o s e t h a t g a v e a R e y n o ld *s num ber l e s s t h a n 2 1 0 0 .
c o r r e l a t i o n i s n o t m ea n t to c o v e r l a m in a r f lo w .
The
The f r i c t i o n
fa c to r
f o r p u r e o i l was o b t a i n e d u s in g a v i s c o s i t y o f .0 0 4 8 I b / f t . s e c .
T h e re a r e s e v e r a l d i f f i c u l t i e s i n u s in g , t h i s m e th o d .
c o u rse , i s
O ne, o f
t h a t f o r t h e m o st p a r t t h e s l u r r i e s do n o t a p p e a r t o b e
Bingham p l a s t i c s .
A p p ro x im a tio n b y u s in g t h e s l o p e o f t h e s t r a i g h t
s e c t i o n s o f t h e rh e o g ra m s i s c r u d e a t . b e s t .
A n o th e r i s
t h a t th e y ie ld
s t r e s s i s e x tr e m e l y d i f f i c u l t t o m e a s u r e .
I t may v e r y w e l l b e t h a t
s l u r r i e s do n o t e v e n h a v e a y i e l d s t r e s s ,
t h e rh e o g ra m s o f F i g u r e s 3
'I
J
- 61 - ■
an d 4 may s im p ly c u r v e down t o a z e r o v a l u e . . The b e s t t h a t c o u ld h e
d o n e was to e x te n d t h e sm ooth, c u r v e to t h e y - a x i s .
A t b e s t , t h i s m eth o d a p p e a r s o n ly t o g i v e a r a n g e th a ,t t h e
p r e s s u r e d ro p w i l l p r o b a b l y f a l l i n t o .
T he hom ogeneous m e th o d g i v e s
c o n s i s t a n t l y h i g h v a l u e s f o r t h e p r e s s u r e d ro p w h i l e t h e h e te r o g e n e o u s
v a l u e s a r e c o n s t a n t l y lo w .
The s t u d y c o n f ir m s t h a t t h e s l u r r i e s h a v e m ix ed f l o w c h a r a c t e r i s t i c s
in th e ra n g e o f v e l o c i t i e s t e s t e d .
No i d e a l f lo w t y p e was fo u n d to
c o r r e l a t e a l l th e d a ta .
j
CONCLUSIONS
The f o l l o w i n g c o n c l u s i o n s c a n b e m ade from t h i s i n v e s t i g a t i o n .
1.
T he f i n e c o a l - c r u d e o i l s l u r r i e s w e re fo u n d t o c o n fo rm t o
fo u r
r h e o l o g i c a l m o d e ls .
P u re c ru d e o i l a p p e ars
t o b e N e w to n ia n , c o n c e n t r a t i o n up to 10% p s u e d o p l a s t i c ,
c o n c e n t r a t i o n s fro m 10% t o 40% r e a l p l a s t i c s , a n d fro m 40%
t o 50% B ingham p l a s t i c .
2.
The f lo w p a t t e r n a p p e a r s t o b e m i x t u r e o f t h r e e i d e a l t y p e s ,
hom ogeneous f lo w , h e te r o g e n e o u s f lo w , and p l u g f lo w .
3.
A p p a re n t v i s c o s i t i e s / m e a s u r e d b y a B r o o k f i e l d v i s c o m e te r
i n c r e a s e d much m ore r a p i d l y t h a n do t h e t u r b u l e n t v i s ­
c o s itie s
A-.
c a l c u l a t e d fro m t h e p i p e lo o p d a t a .
'^ - i s c o m e t e r d a t a c a n a t b e s t g i v e a ro u g h e s t i m a t e a s t o
w hat ra n g e th e p r e s s u r e d ro p s w i l l f a l l i n t o .
5.
The v i s c o s i t y o f t h e s l u r r i e s i n c r e a s e s r a p i d l y a t a w e ig h t
c o n c e n t r a t i o n o f 30 p e r c e n t .
RECOMMENDATIONS IOR FUTURE STUDY
A l a r g e r d i a m e te r p l p e l o o p s h o u ld b e c o n s t r u c t e d t o d e te r m in e
how a c c u r a t e l y t h e p l p e l o o p d a t a c a n b e s c a l e d , u p ,
A d e t a i l e d s t u d y o f th e S lu r r y t S f lo w p a t t e r n s h o u ld b e
I
c o n d u c te d .
The s l u r r y ’ s a b r a s i v e n e s s s h o u ld b e s t u d i e d i n g r e a t e r d e t a i l .
The h i g h e s t p e r c e n t a g e o f c o a l t h a t c a n b e e c o n o m i c a l ly c a r r i e d
i n t h e s l u r r y s h o u ld b e d e te r m in e d .
C r i t i c a l v e l o c i t i e s , a t w h ic h t h e c o a l s e t t l e s i n t h e l i n e ,
Z
s h o u ld b e d e te r m in e d .
APPENDIX
2.0
0
R a te o f F low ( r e v . / s e c . )
^
r e a d i n g s a f t e r s i t t i n g u n c o v e re d f o r tw o d a y s
i n i t i a l re a d in g s
D r i v i n g W e ig h t (g ra m s )
FIGURE 1 8 .
S to rm e r V is c o m e te r R heogram f o r 500 Grams D r ie d C o a l-6 0 0 M i l l i l i t e r s
FMC S y n t h e t i c C rude S l u r r y A f t e r P r e s s u r i z a t i o n to 500 p s i g
r e a d i n g s a f t e r s i t t i n g u n c o v e re d f o r tw o d a y s
A
i n i t i a l re a d in g s
R a te o f F lo w ( r e v . / s e c . )
O
________________ J -------------------------- J-------------------------- 1---------------------------L------------------------#6
- 80
120
160
D r i v i n g W e ig h t (g ra m s )
FIGURE 1 9 .
S to rm e r V is c o m e te r Rheogram f o r 500 Grams D r ie d C o a l-6 0 0 M i l l i l i t e r s
FMC S y n t h e t i c C rude S l u r r y A f t e r P r e s s u r i z a t i o n to 1000 p s i g
— 67 —
M ooney-'R a b in o w its c h —W e is s e n b e rg E q u a tio n :
JL
2irrV d r = 2ir
x
rv dr
x
J o
w h e re ,
Q = v o l u m e t r i c f lo w r a t e
In te g ra te by p a rts
.o .
r
r r o,
■r '
2 r
- 2
2" )
J
B u t, we know t h a t
_
To
-T l-
If 8 = f(r)
ro
Q =
- 2 tt I
=
r
dTr x
(k e y a s s u m p tio n )
dr .
r
.2
2
(
( °—) T r x
(. 2 ) f ( x ) d r
T
o
r
;
C -T ^-)
-2 TT
t O
Jo
Tr x
ic V x5
.
T.
tt.
T - ^ x
O
. .r
•
3
■. • Tr X2 '
-TT
°
d trx
V=
T
r o
2
I
V 3
f ^ r x 1 dTr x
fu n c tio n o f
Jo
So, a p lo t o f
w f ilc h .'is j u s t a
------ —
irr
o
v s To s h o u ld b e a u n iq u e f u n c t i o n ,
e v e n i f d a t a a r e c o l l e c t e d fro m t u b e s o f v a r i o u s s i z e s .
D e f in e
-fiV
-
S o , p r e v i o u s e q u a t i o n becom es
T
o
T
rx
2
f (t
rx
)
dr
rx
Jn ■
D i f f e r e n t i a t e <i> w i t h r e s p e c t t o t h e u p p e r , l i m i t , Tq J
T
'O
d
<f>
Tr x 2 f & r x ! dTr x
Jo
<t>1 ----- --I • C- <f>) +
o
O
t
--1:- £(".t 0 )
1O
+
" V
■T
[ t o 2 f f t O5 1
— 69 —
f (Tq) =
(j)1 + 3(j)
t h e s h e a r r a t e - w hich, c o r r e s p o n d s
to
I n te rm s o f e a s i l y m e a s u re d q u a n t i t i e s :
V = b u lk v e l o c i t y
A
'irr
o
So
J z
D
o
H t 0)
..S o
-
f(? o ) = -?o
So
- c-
3
4
-)
-) +
dx
0
and o f c o u rs e ,
T
o
=
D AP
Q
4L
o
NOMENCLATURE
D rag C o e f f i c i e n t
d im e n s io n l e s s
V o lu m e tr ic C o n c e n t r a ti o n
d i m e n s io n l e s s
W e ig h t C o n c e n t r a ti o n
d i m e n s io n l e s s
I n s i d e d i a m e te r
ft.
I n s i d e d i a m e t e r i n M o o n e y -R a b in o w itsc h
W e is s e n b e r g E q u a tio n
ft.
F ric tio n fa c to r
d i m e n s io n l e s s
F r ic tio n f a c to r o f p u re liq u id
d i m e n s io n l e s s
G r a v ita tio n a l, c o n s ta n t
I b m/ l b
C o n s is te n c y in d e x
f t/s e c
2
lb ^ /ft^ (s e c n )
L e n g th
Flow b e h a v i o r in d e x
d im e n s io n le s s
P r e s s u r e d ro p
Ib f Z ft2
E x p e r im e n ta l p r e s s u r e d ro p
Ib f Z ft2
P r e d i c t e d p r e s s u r e d ro p
I b f Z ft2
.
R a d iu s
I n s i d e r a d i u s i n M o o n e y -R a b in o w its ch—
W e is s e n b e r g E q u a tio n
ft.
D e p o s i ti o n v e l o c i t y
ft/s e c .
C r itic a l v e lo c ity
ft:/s e c .
V e lo c ity
ft/s e c .
S M " '- !
w e ig h t
( I b m/ f t . s e c
)se c
- 71 ■NOMENCLATURE (C o n t) .
Fr
F ro u d e Number , V^/Qg
d im e n s io n l e s s
He
2
2
H e d stro m N um ber, D T ^P g^/n
d im e n s io n l e s s
Re
R e y n o ld s N um ber, V D p/.p'
d i m e n s io n l e s s
T
S h ear S tr e s s a t th e w a ll
ib f/ft2
Y ie ld s t r e s s
lb f / f t 2
V is c o s ity
lb / f t . s e c
m
E ffe c tiv e v is c o s ity
lb / f t . s e c
O
T
y
U
^e
Wt
P
pe
n
TH
.
T u r b u le n t v i s c o s i t y '
D e n s ity
' D e n s i ty o f p u r e l i q u i d
C o e ffic ie n t o f r i g i d i t y
lb / f t . s e c
m
1
V f t3
. Ib / f t 3
m
■
I b m/ f t . s e c .
BIBLIOGRAPHY'
1.
M o n t f o r t , J . G ., " C o a l S l u r r y P i p e l i n i n g " H e a r t o f A m e ric an
S e v e n th . A n n u a l P i p e l i n e O p e r a tio n and M a in te n a n c e I n s t i t u t e .
Novem ber 16 a n d 1 7 , 1 9 7 1 , S i b e r a l , K ansas
2.
S t e p a n o f f , A. J . , "Pum ping S'o I I d - L i q u i d M ix t u r e s " , M e c h a n ic a l
E n g i n e e r i n g , S e p te m b e r 1 9 6 4 , p p . 2 9 - 3 5 .
'
3.
A ude, T. C ., C opw er, N. T . , ’Thom pson, T. L . , W asp, E . J . ,
" B l u r r y P i p i n g S y s t e m s : . T re n d s D e s ig n M e th o d s , G u i d e l i n e s " ,
C h e m ic a l E n g i n e e r i n g , J u n e 2 8 , 1 9 7 1 , p p . 74—9 0 .
4.
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I n t e r n a t i o n a l C o n f e re n c e on t h e H y d r a u li c T r a n s p o r t - o f S o l i d ,
i n P ip e s , 1 5 t h - 1 7 t h May, 1 9 7 4 . C r a n f i e l d , B e d f o r d , E n g la n d
5.
P e r r y , R. K.", C h i l t o n , C. H ., K i r k p a t r i c k , S . D ., C h e m ic a l
E n g in e e r s H andbook,
F o u r t h E d i t i o n , pp 5 - 3 5 , 5 -4 5
6.
W asp, E. J . , R e g a n , T . J . , W i t h e r s , J . , Cook, P .D .C ., C la n c y , J . T . ,
" C r o s s C o u n tr y C o a l P ip e L in e H y d r a u l i c s " , P i p e L in e News,
J u l y , 1 9 6 3 , p p . 2 0 -2 7
7 . . .W asp, E. J . , "W hat S l u r r y P i p e l i n i n g i s A l l A b o u t" , P i p e l i n e
E n g in e e r in g I n t e r n a t i o n a l . N ovem ber, 1 9 6 9 .
8.
L o v e , T . H ., "T he B la c k M esa S t o r y " , P i p e l i n e E n g in e e r in g
I n t e r n a t i o n a l , N o v e m b e r ,1 9 6 9 .
9.
W asp, E . J . , " S t a t e o f t h e A r t i n S o l i d s P i p e l i n i n g " , P i p e l i n e
E n g i n e e r in g I n t e r n a t i o n a l , N ovem ber, 1 9 6 9 .
10.
D u ra n d , R ., C o n d o l i o s , E . , "T he H y d r a u li c T r a n s p o r t o f C o al and
S o l i d M a t e r i a l s i n P i p e s " , P a p e r IV .
j
11.
B ond, R. K ., " D e s ig n in g t h e G I L s o r iite P i p e l i n e " , C h e m ic a l
E n g i n e e r i n g , O c to b e r , 1 9 5 7 , p p , 249-254..
12.
W asp, E . J . , Thom pson, T, L ,,A u d e , T. C ., " S l u r r y P i p e l i n e
E conom ics and A p p l i c a t i o n " F i r s t I n t e r n a t i o n a l C o n f e re n c e
on t h e H y d r a u li c T r a n s p o r t o f S o l i d s i n P i p e s , 1 s t — 4 th .
S e p te m b e r, 1 9 7 0 , U n i v e r s i t y o f W arw ick
13.
A lv e s , G. E . , B o u c h e r, D. T . , P i g f o r d , R; L . , " P i p e - l i n e D e sig n
f o r N o n -N e w to n ia n S o l u t i o n s a n d S u s p e n s io n s " , C h e m ic a l
-
73-
E n g i n e e r in g P r o g r e s s , V o l. 4 8 , No. 8 , 1 9 5 2 ,, p p , '3 8 5 -3 9 3 .
14.
W asp, E. J . , Thom pson, T. L . , " S l u r r y P i p e —l i n e s — E n e r g y M overs
o f t h e F u t u r e " , I n t e r p i p e 73 C o n f e r e n c e , Novem ber I , 1 9 7 3 ,
H o u s to n , T ex as
.
1762
tri-TV I IRRfcMES
IU U ia v u ^
~