Oil Velocity Research Articles

CFD simulation of crude oil fouling from laboratory- to industrial-scale heat exchangers using a weak coupling approach

Crude oil fouling is described as an accumulation of unwanted materials such as asphaltene and metallic salt on a heat transfer surface in a pre-heat train of the crude distillation unit in oil refineries, causing an economic loss of 1–1.2 billion U.S. dollars per year in 2019. Computational fluid dynamics is one of the useful simulation tools for numerical research on this topic. However, crude oil fouling is a long-term phenomenon; therefore, the time scale is longer than general computational fluid dynamics problems. The fouling layer in oil refineries grows over several months to several years despite the small pipe diameter of several or several tens of millimetres. For this reason, it is not easy to satisfy the Courant–Friedrichs–Lewy condition. To overcome this problem, we developed a new algorithm based on a weak coupling approach, validated this scheme, and exhibited the application of this technology. In the new algorithm, momentum and pressure fields and enthalpy and mass fraction fields are solved separately. The algorithm was implemented as FoulingFOAM, a crude oil fouling simulator based on OpenFOAM v2006. Then, the solver was first validated with the lab-scale measurements, showing good agreement with the experimental data. Next, industrial-scale data in the two refineries were simulated for validation. It was possible to predict the peak fouling resistance against time. Finally, for both lab- and industrial-scale simulations, the predictions of our numerical tool showed that fouling resistance increased with higher wall temperature, lower crude oil velocity, and higher concentration of fouling species, which were identical to previous measurements. Hence, we concluded that the weak coupling approach is promising for investigating crude oil fouling problems.

Experimental study of oil-water two-phase flow patterns in a vertical large diameter pipe

The flow structure and the phase inversion have great influence on the flow measurement in vertical upward oil-water two-phase flow. This paper attempts to investigate the flow patterns in oil-water flows through a vertical upward large pipe with the designed mini-conductance array probes measurement system and the vertical multi-electrode array (VMEA) measurement system. According to the output waveform of the mini-conductance array probes, the oil-in-water flow, transition flow and water-in-oil flow can be identified effectively. The fluctuating signals of the VMEA is processed by the recurrence plot and the time-frequency representation, the results show that the VMEA conductance signal with average measurement characteristics can realize an effective identification of the above three flow patterns, which has a good agreement with the results of the mini-conductance array probes. Finally, via comparing with previous published flow pattern transition boundary models in different pipe diameters, it is founded that the boundary line of the transition to oil-in-water based on the kinematic wave-based model and the observation-based model in the same diameter pipe are consistent with our experimental data. And the pipe diameter affects the flow pattern transition, compared with the boundary in small diameter pipe, the phase inversion requires a larger oil velocity, and the transition zone becomes narrower in large diameter pipe.

Investigating lubricant behavior in a partially flooded tapered roller bearing: Validation of a multiphase CFD solver for aerated oil sump via particle image velocimetry studies and high-speed camera acquisitions

In the recent years, the efficacy of utilizing sapphire outer rings as a viable tool for experimentally observing oil flows within rolling bearings has been demonstrated. However, in previous studies, such approach was applied under fully-flooded lubrication conditions exclusively. This paper presents the outcomes of observations and measurements conducted under oil-bath lubrication conditions of a vertical-axis Tapered Roller Bearing (TRB). The experimental work encompasses four operational speeds ranging from 1000 min−1 to 2500 min−1, and two oil levels, i.e. 10% and 100% of the bearing width. Pictures were captured using an High-Speed Camera (HSC) for a qualitative inspection. Particle Image Velocimetry (PIV) measurements were conducted for a quantitative assessment of the oil velocity fields. The findings reveal specific lubricant flows, highlight aeration, and show particular vorticity patterns that intensify with increasing speed. These experimentally obtained results align with Computational Fluid Dynamics (CFD) simulations conducted using a specially developed model in OpenFOAM®, leveraging a solver that accounts for aeration.

Calculation of Some Crude Oil Flow Parameters in A Cylindrical Tube and Their Modelization in Small and Great Variable Radius

In this work, we establish the kinematic of flowing of crude oil inside a cylindrical tube which is rare in the literature. From velocity expression, we find kinematic. Pressure, temperature and heat distribution of crude oil flowing are also find from equations in the literature. Silmilation of these expressions shows that Kinematic of crude oil is similar to a flow of a fluide with a small viscosity what is true in the reality. Velocity of crude oil is not similar in any points during the flowing but increasing and decreasing according to the position point and seams like to be more fast in the border than in the center with a small radius and more fast in the center than in the border with a great radius. Temperature of the crude oil is not similar in any points during the flowing. It is more elevated in the the border than in the center. Pressure in small radius is more important in the center than in the border contrarily in great radius. results are more conformable in the reality in small than in great radius. Results of the heat is more conformable in the reality in small than in great radius.

Occurrence and Flow Behavior for Oil Transport in Mixed Wetting Nanoscale Shale Bedding Fractures.

Shale reservoirs are characterized by an abundance of nanoscale porosities and microfractures. The states of fluid occurrence and flow behaviors within nanoconfined spaces necessitate novel research approaches, as traditional percolation mathematical models are inadequate for accurately depicting these phenomena. This study takes the Gulong shale reservoir in China as the subject of its research. Initially, the unique mixed wetting characteristics of the Gulong shale reservoir are examined and characterized using actual micropore images. Subsequently, the occurrence and flow behavior of oil within the nanoscale bedding fractures under various wettability scenarios are described through a combination of microscopic pore image and molecular dynamics simulations. Ultimately, a mathematical model is established that depicts the velocity distribution of oil and its apparent permeability. This study findings indicate that when the scale of the shale bedding fractures is less than 100 nm, the impact of the nanoconfinement effect is significant and cannot be overlooked. In this scenario, the state of oil occurrence and its flow behavior are influenced by the initial oil-wet surface area on the mixed wetting walls. The study quantifies the velocity and density distribution of oil in mixed wetting nanoscale shale bedding fractures through a mathematical model, providing a crucial theoretical basis for upscaling from the nanoscale to the macroscale.

Study on flow field of oil‐cooling permanent magnet synchronous motor with hairpin winding using porous medium model

AbstractThe oil cooling method has been widely used in the permanent magnet synchronous motor with hairpin winding. Because of the irregular shape of the hairpin end winding, there are complex oil circuits in the fluid domain, resulting in a large number of grids and a high computational cost. It is still a challenge to calculate the oil‐cooling performance of the hairpin end winding. Therefore, the porous medium model (PMM) is first proposed to replace the real hairpin end winding to analyse the oil‐cooling performance. By comparing oil volume fraction and velocity at different oil‐supplied conditions using three methods: experiments, real model (the non‐equivalent fluid domain model based on the real hairpin end winding) and PMM, the feasibility of using the PMM to calculate the oil‐cooling performance on the end winding is verified. The oil distribution of three methods is the same. The use of the PMM saves 80% of the number of grids, which improves the simulation efficiency. Relationships between the porosity, permeability and resistance coefficient and the geometry parameters of windings are determined. The results show that the flow field changes greatly with changes in porosity, permeability and resistance coefficient.

Nonequilibrium molecular dynamics investigation on friction behavior of organic friction modifiers under dynamic load

The evolution of lubricating oil containing additives under dynamic conditions is very significant, since its oil film structure, velocity distribution, and adsorption characteristic have an obvious impact on friction and wear. In this work, a boundary lubrication (BL) and elastohydrodynamic lubrication (EHL) models under sinusoidal load were carried out by nonequilibrium molecular dynamics (NEMD), using iron oxide as the substrate, hexadecane, and stearic acid molecules as lubricants. It was discovered that the friction in the BL regime is positively correlated with the degree of additive’s solidification. The greater the solidification degree of additive layers, the less the interlacing between them, making the relative motion between them easier and reducing compression oscillation within them, thus diminishing friction in the BL regime. The degree of liquefaction of base oil and additive regions, as well as the velocity difference within their interlacing zones, are connected to the friction force in the EHL regime. At high frequencies as well as large amplitudes, the oil film has a very high degree of liquefaction, which facilitates internal shear in it, and there is essentially no relative motion between the base oil and additives, resulting in low friction.

Experimental Study on Flow Characteristics of Oil-Water Two-Phase Flow in Single-Node Cross Fracture

Single-node cross fracture is the basic unit of discrete fracture network. In this paper, the flow characteristics of oil-water two-phase flow in single-node cross fracture model are investigated by experimental method. The model was divided into sixteen groups according to different angles, the oil and water phase flow rates were changed sequentially in each group and the velocity of oil and water phase were controlled to be in the low velocity flow rate range all the time during the experiment. The fluid flow process was recorded during the experiment by using the high-speed camera and the results were analyzed in detail. Under the condition of low velocity flow, oil-water two phases were slug flow in fracture. Effects of fracture crossing angle and oil-water phase velocity on the length of water section and the ratio of water-oil section length were also considered. The peristaltic pump speed is used instead of flow rate for the discussion, and the results show that for the same cross-fracture angle model, when the water pump speed is unchanged, the length of the water section gradually decreases in the form. of a power function with the increase of the speed of the oil pump. When the oil pump speed is unchanged, as the water pump speed increases, the length of water section increases in the form. of a linear function and the length ratio of wateroil section increases in the form. of the power function. Under different speeds of oil pump and water pump, the influence of fracture crossing angle on the length of water section and the length ratio of water-oil section is different.

Spatial infiltration and redistribution of light crude oil in heterogeneous water-bearing soil layers under different hydrogeological processes.

Two physical models were used to simulate the infiltration and redistribution process of light crude oil after leakage in a heterogeneous soil layer following water level variation and rainfall. Migration fronts and redistribution characteristics of oil during gravity seepage, water level variation, and rainfall were obtained using charge-coupled device (CCD) camera shooting and cyan-magenta-yellow‒black (CMYK)-based gray analysis, which were employed efficiently and at a low cost. Then, the influencing factors and migration mechanisms were examined. Finally, the soil water and oil contents were measured to verify the simulation results. The results are as follows: (1) the geologic lens and fine-coarse interface can intercept oil, resulting in a local highly contaminated area. (2) The crude oil infiltration path and velocity varied greatly with the different soil types and initial water contents. Within a certain range, the higher the initial water content is, the higher the lateral and vertical infiltration speeds. (3) The oil redistribution process was dominated by vertical infiltration under the condition of water level variation or rainfall, but oil-water displacement and the capillary pressure caused some oil to move horizontally near the geologic lens and fine-coarse interface. (4) Water level variation resulted in a synchronous rise or fall of the oil accumulation area, but rainfall caused it to move up. (5) Water level variation and rainfall imposed a certain influence on the periodic accumulation and release of crude oil in heterogeneous soil, especially in the presence of geologic lenses and lithologic interfaces.

Soft Sensor Development for Real-Time Interface Tracking in Multiple Product Pipelines Based on Knowledge and Data

Summary Petroleum products are usually consecutively transported in the same multiple-product pipeline, and the occurrence of mixed oil happens during the process. Accurately tracking the mixed oil interface is essential for the optimal scheduling of oil transportation. However, complicated operating conditions and unavoidable measurement noise pose challenges to methods for locating the interface. The data-driven modeling method is a potential solution, but it may face limitations due to issues of overfitting, especially when the data set is contaminated with noise. To tackle such problems, in this paper, we propose a knowledge-informed Bayesian-Gaussian mixture regression (KIBGMR) model to enable the real-time tracking of the interface. The KIBGMR employs finite Gaussian distribution to learn the multimode characteristics of input data, including the hydrothermal data, measured density of tail oil, and the velocity of interface transportation and output data including the measured density of tail oil and interface transportation velocity. Subsequently, it utilizes the prior knowledge related to the regression coefficient through the Bayesian treatment. Evaluations demonstrate that the R2 index achieved by the proposed model in predicting the interface arrival time is greater than 0.98, even with the contaminated data set. This research can help operators accurately grasp the location of the mixed oil interface, formulate reasonable valve switch operations for better management of the mixed oil section, and provide a reference for the method of knowledge-data hybrid modeling.

Rotary thermal desorption technology for treatment of oil-based drilling cuttings in shale gas industry

Oil-based drilling cuttings are hazardous wastes in shale gas exploitation and need careful treatments to reduce environmental pollution and waste of resources. One of most widely employed waste-treatment technologies is the thermal desorption due to its high oil recovery efficiency. However, it usually suffers low heat exchange efficiency, thus leveraging operation costs and equipment instability. Toward the end of alleviating limitation, this study rationally designs the structure of the heating component under the guidance of the flat wall heat conduction theory, and uses numerical simulation to analyze the heat transfer of the structure. A rotary thermal desorption technology was thus developed and evaluated. The simulation results showed that given a short time of 800 s the temperature difference between device and cuttings became less than 5 K, indicating good heat exchange efficiency. Large inlet radius of device and high inlet velocity of heat transfer oil were critical parameters to maintain high heat transfer rate. Through industrial experiments verification, the 0.14–0.2 % oil content of treated cuttings qualified the environmental standards. The components of the recovered oil were recyclable C9-C23 alkanes, and the dichromate oxidizability of recovered water was less than 500 mg/L limit. Comparing with other technologies, the scores suggested that this technology was a promising candidate for treating oil-based drilling cuttings.

Tilting Pad Journal Bearing Computational Fluid Dynamic Parametric Modeling for New Energy Transition Challenges

Abstract The necessity of increasing the efficiency and reducing the carbon foot-print of machines is pushing centrifugal compressor bearings design to higher and higher peripheral speed and lower oil consumptions especially in the new energy transition fields, resulting in an increase in the bearing temperatures. Therefore, the bearing thermal management starts to play a major role in extending the machine operability and reducing the maintenance frequency. A full three-dimensional (3D) parametric conjugate heat transfer computational fluid dynamic (CFD) model for tilting pad journal bearings (TPJBs) is introduced in this paper to address the temperature aspects of oil-film bearings. The parametric geometry of the model and the automatic mesh update, allow the equilibrium position search to be obtained without adopting any dynamic mesh algorithms. The tilting pad and rotating shaft equilibrium position are automatically calculated with a Newton–Raphson algorithm. The static performance of the TPJB is investigated for different journal diameters, bearing clearance, and operating conditions. The numerical results obtained are compared with experimental data from compressor mechanical running tests to demonstrate the reliability of the model presented. The 3D distributions of the oil pressure, velocity, and temperature given by the CFD model, can be locally optimized to face the new energy transition challenges.

Hybrid lubrication model study of slip ring combination seal under the influence of frictional heat

This paper presents an experimental and theoretical investigation into the factors influencing the sealing performance of combined slip rings. Factoring in the frictional heat from micro convex bodies and convective heat exchange between the slip ring, oil film, and air, we formulate a thermoelastic flow hybrid lubrication model for the combined slip ring seal. This model calculates the distribution of oil film thickness, pressure, temperature, velocity, and viscosity in the sealing zone, drawing on the generalized average Reynolds equation and the transmembrane average energy equation, in conjunction with the heat conduction equation of the slip ring. Utilizing the Archard wear model, we also examine the wear characteristics of the combined slip ring seal, providing insights into seal wear under these conditions. The model enables an analysis of the interplay between parameters and their impact on seal performance. The method proposed accurately predicts friction and leakage in line with experimental data, thereby providing a theoretical foundation for further numerical investigation of seal characteristics.

Experimental investigation of viscous oil–water–sand flow in horizontal pipes: Flow patterns and pressure gradient

Fluid production from unconsolidated reservoirs often leads in sand production, which poses a number of issues. Sand deposition in flowlines can result in significant pressure dips, pipe and facility damage, and obstructions that decrease productivity. More research is needed to understand the movement and deposition of sand in oil–water–sand (O–W–S) fluxes. This article focuses on O–W–S flows in a 6-meter-long horizontal pipe with an inner diameter of 0.0381 m. The study looks at the flow behavior of high viscosity oil–water (O–W), water–sand (W–S), and oil–water–sand (O–W–S) flows. Experiments were carried out at 250 psig pressure in a laboratory flow test facility using various heavy synthetic oils (viscosities ranging from 3500 cP to 7500 cP at 25°C) and tap water. The sand concentration varied from 1% to 10%, with an average sand particle diameter of 145 μm and material density of 2630 kg/m3. Water cuts ranged from 0.0 to 1.0. The experimental results revealed a minor change in pressure gradient between (O–W) and (O–W–S) flows. However, increasing the sand concentration in (O–W–S) flow resulted in higher pressure losses. The reduction factor of pressure gradient indicated that the highest decrease in pressure drop occurred at higher superficial oil velocities. Furthermore, a direct relationship was observed between the reduction factor and the decrease in water cut. The results also showed that the minimum required transportation velocity for sand slurry decreased with increasing superficial oil velocity, while the minimum transportation condition increased with higher sand concentration. The comparison between the expected pressure gradient from Bannwart and McKibben et al. and the actual experimental data demonstrated significant accuracy for the oil viscosities and superficial oil velocities used in the study.

Effect of Particle Concentration and Size on the Time-Averaged Velocity of Oil

Effect of Particle Concentration and Size on the Time-Averaged Velocity of Oil

A one- and three-dimensional coupled model and simulation investigation for the large-scale oil-heating type Mg-based hydrogen storage tank

A large-scale oil-heating type Mg-based hydrogen storage tank is the key device for the high-efficiency and high-safety Mg-based solid hydrogen storage and transportation. However, the complicated heat and mass transfer in the Mg alloy bed and oil tube during the hydrogen desorption process impede the design of high-performance hydrogen storage tanks. In this work, a one- and three-dimensional coupled model considering the impact of oil velocity and temperature on the internal heat and mass transfer was developed to simulate the hydrogen desorption process of large-scale oil-heating type Mg-based hydrogen storage tanks. This model was then solved by the finite element method, and the simulation results agreed well with the experimental data obtained from an Mg-based hydrogen storage tank. Moreover, simulation results indicate that the oil velocity has a considerable impact on the hydrogen desorption performance of the Mg-based hydrogen storage tank, and a recommended oil velocity of 4 m s−1 was identified. In addition, high oil temperature and low hydrogen desorption pressure benefit the hydrogen desorption performance, thus should be determined by the application scenarios. Besides, the complete hydrogen desorption time was barely affected by the initial bed temperature, which is suggested as ≥ 573 K to meet the high rate requirement of hydrogen supply, otherwise as room temperature to reduce energy costs. The model and simulation results presented in this work provided a foundation for the design of high performance large-scale oil-heating type Mg-based hydrogen storage tanks that can be applied practically in the field of hydrogen energy.

Study on dynamical characteristics of cooling fluid in engine piston

The cooling of engine piston is very important, and the fluid vibration characteristics of its internal cooling oil is the key to affect the heat transfer efficiency. In order to effectively ensure that the piston temperature will not be overloaded and avoid the reduction of sealing performance, a two-phase flow model in the piston cooling chamber is established in the paper. The flow field and heat transfer characteristics of the cooling oil are simulated by finite element method using FLUENT. In terms of model selection, VOF multiphase flow calculation and SST k-ω model are selected as turbulence model. The setting of boundary conditions combines the piston stroke characteristics of the hydraulic cylinder, so as to obtain accurate inlet parameters, and obtain the oil liquid phase proportion distribution, oil velocity field and the change law of convective heat transfer coefficient under different piston positions. The results show that the instantaneous ratio of cooling oil is closely related to the speed, and increasing the oil speed is an important means to improve the heat transfer performance. The multiphase flow model has high reliability, and there is no obvious difference between the average convective heat transfer coefficient obtained by the near-wall model method and the wall function method.

Characteristics of Surface Wave on the Unstable Interface in Gas Jet Forming

The surface accuracy and quality of the mirror blank determine the performance of the optical mirror after coating; therefore, it is crucial to seek a simple and effective method for mirror blank processing. The gas jet forming provides a new idea, which employs a gas jet to impinge on a liquid pool, forms a specific curved surface and solidifies it. However, due to the interface instability that occurred with a specific range of jet velocity, periodical fluctuations appear on the interface and affect the forming of the mirror blank. In this study, the amplitude and transfer period of surface waves in the air gas/dimethyl silicone oil system are taken as the research objects. After conducting orthogonal experiments, this study uses a high-speed camera to record the generation of the surface wave and the fluctuation of the gas–liquid interface during its transfer. Subsequently, this study analyses the influences of jet velocity and viscosity of dimethyl silicone oil on the amplitude and transfer period of the surface wave. In the following experiments, multiple groups of parameters were selected in the range of jet velocity of 11~13 m/s and dimethyl silicone oil viscosity of 500~2000 Pa·s. This study measures the interface morphology with different parameters using the method of image recognition. Finally, using the measured data, this study establishes the calculation model of surface wave amplitude and transfer period, realizing the study of the characteristics of surface waves on the unstable interface. This research can be used to enhance the forming accuracy of the gas jet-forming method.

Visual Comparative Analysis for the Oil-air Two-Phase Flow of An Oil-Jet Lubricated Roller-Sliding Bearing

To discuss the lubrication characteristics of roller-sliding bearing under oil-injected lubrication, the CFD method was introduced into the fluid-structure interaction model to realize the transient simulation of oil-air two-phase flow (OATPF). The volume of fluid (VOF) method is applied to capture the oil-air interface. A sliding mesh is established between the inner flow field and outer flow field. Moreover, the two design schemes of roller-sliding bearing are compared. A reasonable design scheme is obtained. The bearing rotation speed, oil velocity, oil viscosity, oil ratio, and oil temperature have a significant impact on the lubrication performance of the roller-sliding bearing. The results show that the oil distribution inside the bearing is uneven. The lowest oil volume fraction exists in the basin, which is near the upstream of the nozzle, and gradually increases from the inner raceway to outer raceway. The oil storing rate increases with the increase of oil viscosity. A novel method of oil volume prediction is proposed in a deep manner. It also provides some reference for the design of roller-sliding bearing and other bearings.

Research on Wear Particle Online Monitoring Using Machine Vision for Rotating Machinery

A high-precision wear particle monitoring instrument based on numerical simulation, machine vision, multi-target tracking algorithm, and microfluidic technology is designed and developed in this paper. The instrument not only performs the traditional particle number and size detection, but also proposes a particle density detection model based on motion velocity. Firstly, an on-line visual microfluidic chip for oil particles motion was specially designed. Then a mathematical model relationship between particles velocity and particles diameter, particles density, oil viscosity, oil density was established by force analysis and solving the equation, which was used to explain the working principle of the instrument. Meanwhile, a multi-target tracking algorithm incorporating the characteristics of wear particles based on YOLOv5-Deepsort was custom-developed to detect the number, size, and motion characteristics of particles under the optical field of view of the image sensor. Secondly, the oil flow field distribution and the four factors affecting the particle motion characteristics in the self-developed chamber, particle size, particle material, particle radial position, and oil velocity were analyzed by using the finite element analysis in COMSOL. Finally, a pin-disk wear experimental validation results demonstrated this approach has excellent suitability to monitor the number, size, and density of wear particles with diameters above 20μm and densities above 2000 kg/m3 simultaneously. This portable oil particle monitoring instrument provides technical support for condition monitoring, fault diagnosis, and intelligent maintenance of rotating mechanical equipment.