CFD simulation of velocity distribution of water-air two-phase flows in vertical helical coils Hamid Saffari1, Rouhollah Moosavi, Edris Gholami LNG Research Laboratory, School of Mechanical Engineering, Iran University of Science and Technology, Narmak, Tehran 16844, Iran Abstract CFD simulation for single and two-phase flow and distribution of velocity and void fraction of fluid flow in vertical helical coils by varying coil parameters has been investigated. The considered Reynolds number is in the range of 16000 < Re < 80000, and the void fraction is in the range of 0.01 < α < 0.09. To simulate the water-air two-phase flow in this article, the Eulerian-Eulerian model was employed. The 3-D governing equations of continuity and momentum have been solved by using the finite volume method. To calculate the turbulent fluctuations, the k-ε realizable turbulence model has been used. Also, the SIMPLE algorithm was employed to solve the velocity and pressure fields. The close correlation between the obtained numerical results and the numerical and empirical results of other researchers confirms the accuracy of the applied method in mesh generation and in numerically solving the governing equations. Keywords: Numerical study; Flow field distribution; Bubbly flow; Eulerian-Eulerian Nomenclature a tube radius dynamic viscosity d tube diameter kinematic viscosity Dc curvature diameter density 1 Corresponding author: Hamid Saffari, Ph.D., Associate Professor of School of Mechanical Engineering, Iran University of Science and Technology, Narmak, Tehran 16844, Iran. Tel./Fax: +98 21 77491228/ +98 21 77240488, E-mail address: Saffari@iust.ac.ir 1 De Dean number helix angle F force term f frictional factor subscripts g gravity acceleration l liquid phase H coil pitch lg from phase l to phase g P pressure g gas phase Rc curvature radius k phase(liquid or gas) Re Reynolds number m mixture S source term pq from phase p to phase q u velocity TD turbulence dissipation V volume vm virtual mass Greek letters void fraction curvature ratio 2 Introduction Helical coil tubes are used in various industries, including the food industry, nuclear reactors, chemical processing, compact heat exchangers, heat recovery systems, low value heat exchange, and medical equipment [1-3]. In comparison to straight pipes, coiled pipes have a larger surface area and enjoy higher heat transfer and friction coefficients. The influence of curvature and torsion on fully developed turbulent flow characteristics in straight, curved and helically coiled pipe a direct numerical studied by Huttle et al. [4,5]. The results have shown that the torsion effect is weaker than the curvature effect and performed several DNS of fully developed flow through toroidal and helical pipes. Lin [6] studied the effects of inlet turbulence on the development turbulent flow in the entrance region of a helically coiled pipe. They found that bulk temperature kinetic energy for from the entrance is not affected by the inlet turbulence level. Also Lin [7] investigated laminar forced flow and heat transfer in the entrance region of helical pipes using a numerical method. For measuring the velocity in coiled pipes an electrochemical technique was used by Sylvain Galier [8]. They observed that the high shear rate was found at the outside and lowest value on the inside of the curve. Litster et al.[9] have 3D numerical simulated the hydrodynamics and mass transfer inside helically wound hollow-fiber membranes for the effect of the centrifugally induced Dean vortices on the mass transfer and secondary swirling flow. They suggested a non-orthogonal pseudo-stream function to visualize the flow. The optimal Reynolds number for fully developed laminar forced convection in a helically coiled tube have found by Shokouhmand and Salimpour [10]. Monisha and Nigam [11] studied the pressure drop and heat transfer of turbulent flow in the tube in the tube helical heat exchanger. They have proposed a relation for the friction coefficient and nusselt for the inner and 3 outer tubes. Banerjee et al. [12] the graph presented the effect of liquid velocity on the pressure drop coefficient, especially for low-speed, liquid and gas show. Czop et al. [13] carried out experiments on the adiabatic two-phase flow through a helically coiled tube and investigated pressure drops, wall shear stress and void fraction. They have been observed in experiments that the pressure drop in two-phase flow is very much different from Lokhart-Martinelli correction but fairly good agreement with the Chisholm [14] correlation. Two-phase flow air-water in helically coiled tube has been studied by Whalley et al. [15]. They have studied the flow pattern transition between stratified and annular flow and also the local film thickness and pressure drop for air-water flow has been measured. The effects of coil geometry and air and water flow rates on the pressure loss of two-phase flows in horizontal and vertical helical pipes with three different inside and outside diameters have been investigated by Xin et al. [16]. Frictional pressure drops of a single and two-phase flow have been studied by Liejne et al. [17]. They found that helix axial angles have little influence on the single phase frictional pressure drop, while a variation of two-phase flow is high. In this article, the numerical solution of fluid flow in a coiled heat exchanger pipe, in the single-phase and two-phase (water-air) cases, has been investigated. The k-ε realizable turbulence model has been used for calculating the turbulent fluctuations. Pipe diameter, coil diameter, coil curvature, Reynolds number and void fraction on velocity profile and distribution of void fraction in pipe have been studied. Problem’s Geometry The considered geometry, related coordinate systems and the mesh configuration used in the problem have been shown in Fig. 1. The coiled pipe under investigation consists of 4 coil pitches 4 with a diameter “a” (d = 2a) and dimensionless curvature radius “Rc” (Dc = 2Rc). δ is the amount of curvature, and H is the dimensionless coil pitch. The considered coil is installed vertically and the two-phase fluid flows inside of it from bottom to top. It is worth mentioning that in these types of coiled pipes, the cited geometrical features are constant throughout the coil. Similar to the Reynolds number which is used for flows in straight pipes, the Dean’s number is employed for flows inside helical pipes. The dimensionless Reynolds number and the Dean’s number are defined as follows: Re = ρUi (2a) 2μ De = Re√r⁄R (1) (2) c Governing equations The governing equations of the two-phase flow comprise the volume fraction, continuity, momentum and energy equations. The volume fraction of each phase includes the volume it occupies from the total phase volume. (3) Vk = ∫ αk dV where the sum of both phases is equal to 1. αl + αg = 1 (4) Continuity Equation 𝜕𝜌𝑘 𝛼𝑘 + 𝛻. (𝜌𝑘 𝛼𝑘 𝑉𝑘 ) = ∑ ( 𝛤𝑝𝑞 − 𝛤𝑞𝑝 ) + 𝑆𝑘 𝜕𝑡 (5) 𝑝=𝑙,𝑔 5 Where Γpq − Γqp denotes the change of one phase to another; and since no phase change occurs here, its value is zero. Also Sk is generation where its value is zero. Momentum Equation 𝜕𝜌𝑘 𝛼𝑘 𝑉𝑘 + ∇. (𝜌𝑘 𝛼𝑘 𝑉𝑘 𝑉𝑘 ) 𝜕𝑡 (6) 𝑒𝑓𝑓 = −𝛼𝑘 ∇𝑃 + 𝛼𝑘 𝜌𝑘 𝑔 + ∇. [𝛼𝑘 𝜇𝑘 (∇𝑉𝑘 + (∇𝑉𝑘 )𝑇 ] + ∑ (Γ𝑝𝑞 𝑉𝑝𝑞 − Γ𝑞𝑝 𝑉𝑞𝑝 ) + 𝐹𝑙𝑔 𝑝=𝑙,𝑔 where 𝐷 𝐿 𝑉𝑀 𝑇𝐷 𝐹𝑙𝑔 = 𝐹𝑙𝑔 + 𝐹𝑙𝑔 + 𝐹𝑙𝑔 + 𝐹𝑙𝑔 (7) Turbulent Kinetic Energy Equation 𝜕 𝜇𝑡,𝑚 (𝜌𝑚 𝑘) + ∇. (𝜌𝑚 𝑢𝑚 𝑘) = ∇. ( ∇𝑘) + 𝐺𝑘,𝑚 − 𝜌𝑚 𝜀 𝜕𝑡 𝜎𝑘 (9) Dissipation Rate of Turbulent Kinetic Energy 𝜕 𝜇𝑡,𝑚 𝜀 (𝜌𝑚 𝜀) + ∇. (𝜌𝑚 𝑢𝑚 𝜀) = ∇. ( ∇ε) + (𝐶1 𝐺𝑘,𝑚 − 𝐶2 𝜌𝑚 𝜀) 𝜕𝑡 𝜎𝜀 𝑘 (10) As density and velocity average obtained from the following equations: 𝑁 (11) 𝜌𝑚 = ∑ 𝛼𝑖 𝜌𝑖 𝑖=1 𝜐𝑚 = ∑𝑁 𝑖=1 𝛼𝑖 𝜌𝑖 𝜐𝑖 ∑𝑁 𝑖=1 𝛼𝑖 𝜌𝑖 (12) Viscosity turbulence: 6 𝜇𝑡,𝑚 = 𝜌𝑚 𝐶𝜇 𝑘2 𝜀 (13) Turbulent kinetic energy generation term: 𝐺𝑘,𝑚 = 𝜇𝑡,𝑚 (∇𝜐𝑚 + (∇𝜐𝑚 )𝑇 ): ∇𝜐𝑚 (14) Results and Discussion Table 1 shows the type of coil geometries used in this article. Diameter, coil pitch and coil radius have been the considered parameters. There have been different inlet boundary conditions based on the inlet velocity and void fraction, and the pressure gradient of zero has been considered as the outlet boundary condition. Changes of pressure and shear stress in the singlephase and two-phase cases have been measured. These measurements have been taken initially for the single-phase case from the Reynolds of 16000 to 80000; which according to Ito’s proposed relation for critical Reynolds in coils, fall in the fully turbulent range. Location of maximum velocity in the helical pipe In all the geometries and flow cases (from the perspective of void fraction changes) in twophase (air-water) bottom-to-top flows, the maximum velocity point is observed at the outer section of coiled pipe. In Fig 2, for coil No. 7 (with void fraction of 0.09 and Re = 72000), the air velocity contour has been plotted at various cross sections for each of the phases at the inlet of the pipe. In straight pipes, the central region of the pipe is where the maximum velocity forms in single-phase flows. The reason for this phenomenon is that with the entrance of fluid into the pipe, boundary layers are formed on pipe walls, and as the flow advances, these boundary layers gradually develop and extend further. 7 The shear stress has a maximum value at the wall, and it decreases by moving towards the pipe’s axis. As the flow advances inside the pipe, the boundary layers converge at the center of the pipe; from this point on, the flow has a developmental state and the velocity profile assumes a constant and unchanging form. Therefore, fluid velocity is higher in the central region of pipe, which is less influenced by the shear stress of the wall; and the maximum velocity location in straight pipes is on the pipe’s axis (central section of pipe). However, in helical pipes, centrifugal forces affect the velocity field and cause the fluid elements to move with different velocities along the pipe; in other words, the velocity profile is not uniform in these types of pipes. In curved pipes, the fluid adjacent to the pipe’s outer wall (due to having a larger curvature radius) generally has a higher velocity compared to the fluid near the inner wall of the pipe. The centrifugal forces also affect the distribution of phases inside the pipe. Regarding the two-phase (liquid-gas) flow, the process of phase distribution in the pipe is significantly governed by the centrifugal forces that operate on the liquid phase. The shape of velocity contours and void fraction at various pipe cross sections can provide a broader view on the physics of the problem. The pipe curvature results in the creation of a centrifugal force which affects the flow. This leads to a higher fluid velocity at the outer section of pipe, contrary to flows within straight pipes in which the high velocity region is located at the center of the pipe. As can be observed in Fig. 2, flow profile changes as we move forward in the coiled pipe. As we advance through the pipe, centrifugal forces become more prominent and their impacts on the flow become more obvious. These forces cause the fluid flowing in the outer region of coil to have a higher velocity compared to the fluid that flows near the inner wall of the coil. Also, contrary to straight pipes in which the flow is symmetrical, the fluid flow in a coiled pipe is 8 asymmetrical, and due to the influence of centrifugal forces, the phases are somewhat separated from each other; in other words, the flow approaches a laminar flow. Figures 3 and 4, the velocity profiles at different sections of the first and second coil and the horizontal and vertical center line sections show. As is clear from the figures, the maximum velocity is shifted towards the outer wall of the coil. In the helical tubes, due to the curvature of the coil, and then the effect of the centrifugal force and the formation of secondary flow, the velocity profiles are asymmetric and the radial direction this asymmetry can be seen as well. Also can be seen as well as the effect of the return flow, as it is clear that we encounter in the range of 0.4 r 0.4 to drop rapidly. a Impact of pipe diameter on velocity field Figure 5 shows the air velocity diagrams for two pipes with diameters of 25 and 40 mm and with the same coil radius of 200 mm, at two identical cross sections (outlet cross section). In two spiral pipes with the same coil diameters and different pipe diameters, the one with the larger pipe diameter has more curvature. Therefore, the centrifugal forces in this larger diameter pipe are stronger due to the larger curvature, and they cause a larger difference between the velocities of fluids near the outer and inner walls of the pipe. So the 40 mm diameter pipe has more curvature compared to the pipe with 25 mm diameter, and stronger centrifugal forces are created in this pipe as a result of its larger curvature. As is shown in Fig. 5, there is a larger difference between the velocities of fluids near the outer and inner pipe walls in the 40 mm diameter pipe than in the 25 mm diameter pipe. Also, because of the strong centrifugal force, the maximum velocity that can be attained by the fluid in the larger diameter pipe is higher, which is clearly seen in Fig. 5. The air velocity contours in two coiled pipes with the same coil radius of 200 mm 9 and different pipe diameters have been shown in Fig. 6 and 7, respectively. In the larger diameter pipe, because of more curvature and a stronger centrifugal force, a stronger secondary flow is created, which makes the fluid unstable and gives it a rotational motion. Therefore, as can be seen from these two figures, in the smaller diameter coiled pipe, because of smaller curvature and consequently, weaker centrifugal force, the flow develops sooner; meaning that it has a shorter hydrodynamic inlet length. Effect of coil diameter on velocity field With the increase of coil radius, the curvature of the coiled pipe becomes smaller and consequently, the centrifugal forces and their influence diminish as well. The larger the coil radius gets, the smaller the pipe curvature becomes and the helical pipe turns more into a straight pipe. As Fig. 8 illustrates, the air velocity profiles at two identical pipe cross sections are different in two helical pipes with different coil diameters. The pipe with a smaller coil diameter develops a stronger centrifugal force which causes a larger difference between minimum and maximum values of flow velocity in the pipe’s cross section. This stronger centrifugal force also causes the maximum velocity in the pipe with smaller coil diameter to be higher than the maximum velocity in the pipe with larger coil diameter. Fig. 8 illustrates the flow velocity contours in two helical pipes (pipes No. 5 and 8), both with a pipe diameter of 25 mm, coil pitch of 60 mm, but with different coil radiuses. When the coil radius changes, the velocity profiles will not be the same for different coils at identical θ angles; in other words, the flow development lengths will be different. As the coil radius gets larger, the formation of the high velocity region towards the outer section of coil starts at smaller values of θ, due to the reduction of the centrifugal force. Therefore, in pipes with 10 a larger coil radius, because the curvature is small and the centrifugal forces arising due to curvature are weak, the fluid gets to the high velocity region sooner. Effect of Reynolds number on void fraction distribution Fig. 9 shows the void fraction distribution in coil No. 3 at different Reynolds numbers. In fluid flow inside coiled pipes, the centrifugal force tends to carry the fluid towards the outer wall of the coil and the force of gravity tends to pull down the fluid towards the bottom section. The equilibrium between these two forces is expressed by the Froud number. A low Froud number means that the force of gravity has overcome the centrifugal force. As is observed, air distribution at low Reynolds numbers is more uniform and air is dispersed throughout most of the pipe’s cross section. Although the centrifugal force in helical pipes causes the denser fluid to move towards the outer section of pipe, here at low Reynolds numbers, it is observed that the centrifugal force has a lower influence compared to the force of gravity, and the gas phase of the fluid is dispersed towards the upper section. The distribution of void fraction at Re = 16000 indicates that, as a result of low flow velocity and thus the minor effect of the centrifugal force, with the increase of angle along the coil’s length, water (being denser and heavier) is pulled by the force of gravity towards the bottom section of pipe, and air (with less density) occupies the upper half of the pipe’s cross section. When the Reynolds number increases, the centrifugal force exerts more influence and as a result, with the increase of angle θ, the liquid phase tends to move towards the outer section of pipe. At θ = 270º, when Re = 16000, it is observed that the liquid is at the bottom and the air is at the top of the pipe’s cross section; while at Re = 48000, the liquid phase moves more towards the outer region of the pipe. As Fig. 9 shows, with the increase of Reynolds number, the centrifugal forces influence the distribution of phases throughout the pipe 11 and cause the air bubbles to move away from the outer section of coiled pipe and get closer to the inner section as the fluid moves along the pipe. These forces also cause the water phase, which has a higher density relative to air, to be present at the outer region of helical pipe. Velocity and pressure profiles in the two-phase case In all the geometries and flow cases (from the perspective of void fraction changes) in twophase (air-water) bottom-to-top flows, the maximum velocity point is observed at the outer section of coiled pipe. In Fig 10, for coil No. 7 (with void fraction of 0.09 and Re = 72000), the air velocity contour has been plotted at various cross sections for each of the phases at the inlet of the pipe. In straight pipes, the central region of the pipe is where the maximum velocity forms in single-phase flows. The reason for this phenomenon is that with the entrance of fluid into the pipe, boundary layers are formed on pipe walls, and as the flow advances, these boundary layers gradually develop and extend further. The shear stress has a maximum value at the wall, and it decreases by moving towards the pipe’s axis. As the flow advances inside the pipe, the boundary layers converge at the center of the pipe; from this point on, the flow has a developmental state and the velocity profile assumes a constant and unchanging form. Therefore, fluid velocity is higher in the central region of pipe, which is less influenced by the shear stress of the wall; and the maximum velocity location in straight pipes is on the pipe’s axis (central section of pipe). However, in helical pipes, centrifugal forces affect the velocity field and cause the fluid elements to move with different velocities along the pipe; in other words, the velocity profile is not uniform in these types of pipes. In curved pipes, the fluid adjacent to the pipe’s outer wall (due to having a larger curvature radius) generally has a higher velocity compared to the fluid near the inner wall of the pipe. The centrifugal forces also affect the distribution of phases inside the pipe. 12 Regarding the two-phase (liquid-gas) flow, the process of phase distribution in the pipe is significantly governed by the centrifugal forces that operate on the liquid phase. The shape of velocity contours and void fraction at various pipe cross sections can provide a broader view on the physics of the problem. The pipe curvature results in the creation of a centrifugal force which affects the flow. This leads to a higher fluid velocity at the outer section of pipe, contrary to flows within straight pipes in which the high velocity region is located at the center of the pipe. As can be observed in Fig. 10, flow profile changes as we move forward in the coiled pipe. As we advance through the pipe, centrifugal forces become more prominent and their impacts on the flow become more obvious. These forces cause the fluid flowing in the outer region of coil to have a higher velocity compared to the fluid that flows near the inner wall of the coil. Also, contrary to straight pipes in which the flow is symmetrical, the fluid flow in a coiled pipe is asymmetrical, and due to the influence of centrifugal forces, the phases are somewhat separated from each other; in other words, the flow approaches a laminar flow. Fig. 11 illustrates the contours of pressure at different angles from pipe surface. Angle θ is measured from the pipe inlet cross section. The centrifugal forces that act on the fluid inside the pipe cause a high pressure region near the outer wall of the pipe. The decreasing trend of pressure along the pipe, at various cross sections, can be observed in this figure. Conclusion In this paper, the numerical solution of fluid flow and distribution of void fraction in a coiled heat exchanger pipe, in the single-phase and two-phase (water-air) cases, has been investigated. With regards to the effect of the centrifugal force resulting from curvature in coiled pipes, which causes the velocity profile to become asymmetrical and makes the heavier fluid to move towards 13 the outer section of pipe and the maximum velocity point to shift in the same direction. Pipe diameter, coil diameter, coil curvature, Reynolds number and void fraction on velocity profile and distribution of void fraction in pipe have been studied. Numerical results indicate that with the increase of curvature effect, friction coefficient increases due to the increase of the centrifugal force. By increasing the pipe diameter and keeping the coil pitch and diameter constant, the radius of coil curvature increases and as a result, the centrifugal force becomes stronger. The impact of coil diameter on velocity field has also been examined. With the increase of Reynolds number in a given coiled pipe, the centrifugal forces affect the distribution of phases throughout the pipe and cause the gas phase bubbles to approach the inner section of pipe and the liquid phase (with a higher density relative to gas) to move towards the outer region as the flow advances inside the pipe. The higher the Reynolds number gets, the higher the percentage of gas phase moving towards the inner wall of the pipe and of the liquid phase moving towards the outer wall will become. References [1] Berger SA. Talbot L. Yao LS. 1983. Flow in curved pipes. Ann. Rev. Fluid Mech., Vol. 15, pp. 461-512. [2] Rabin Y. Korin E. 1996. Thermal analysis of a helical heat exchanger for ground thermal energy storage in arid zones. International Journal of Heat and Mass Transfer, Vol. 39(5), pp.1051-1065. [3] Bai B. Guo L. Feng Z. Chen X. 1999. Turbulent heat transfer in a horizontally coiled tube. 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[9] Litster S, Pharoah JG. Djilali N. 2006. Convective mass transfer in helical pipes: effect of curvature and torsion, Heat Mass Transfer, Vol. 42, pp. 387–397. [10] Shokouhmand H. Salimpour MR. 2007. Optimal Reynolds number of laminar forced convection in a helical tube subjected to uniform wall temperature. Int Comm Heat Mass Transf, Vol. 34(6), pp. 753–761. [11] Mandal MM. Nigam KDP. 2009. Experimental Study on Pressure Drop and Heat Transfer of Turbulent Flow in Tube in Tube Helical Heat Exchanger, Ind. Eng. Chem. Res. Vol. 48, pp. 9318–9324. [12] Banerjee S. Rhodes E. Scott DS. 1969. Studies on concurrent gas–liquid flow in helically coiled tubes – I, Flow patterns, pressure drop and holdup, Can J Chem Eng, Vol. 47(5), pp. 445–453. 15 [13] Czop V. Barbier D. Dong S. 1994. Pressure drop, void fraction and shear stress measurements in an adiabatic two-phase flow in a coiled tube, Nuclear Engineering and Design, Vol. 149(1-3), pp. 323-333. [14] Chisholm D. 1967. 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International journal of heat and mass transfer, Vol. 44, pp. 2601-2610. 16 Table 1- Geometrical characteristics of studied cases Case No. PCD [mm] Pitch [mm] Diameter [mm] 1 100 20 16 2 100 40 16 3 100 60 16 4 200 60 16 5 200 60 25 6 200 60 40 7 300 60 25 8 400 60 25 17 Fig. 1- Geometry and mesh configuration of the problem 18 0 45 90 135 180 225 270 360 450 540 765 900 1125 1260 1440 Fig. 2- Velocity distribution [m/sec] at different angles 19 Fig. 3 Air velocity profiles in the radial direction 20 Fig. 4 Air velocity profiles in the direction perpendicular to the radius of the coil 21 Fig.5- air velocity in two different diameter pipes 22 θ=450 θ =900 Fig. 6- air velocity in helical coil with diameter 25 mm in two different sections 23 θ=450 θ =900 Fig. 7- air velocity in helical coil with diameter 25 mm in two different sections 24 Case 8 Case 5 45 90 135 45 90 135 Fig. 8 - Effect of coil diameter on velocity [m/s] distribution 25 Re = 16000, 270 360 540 630 360 540 630 360 540 630 Re= 48000, 270 Re= 80000, 270 Fig. 9 - Void fraction distribution at different Reynolds numbers 26 Fig. 10- the air velocity contours in the helical coil 27 Fig. 11- the pressure contours in the helical coil 28