Outer Fluid Research Articles

Modeling and analysis of fluid-solid coupling heat transfer and fluid flow in transonic nozzle

Solid rocket motors (SRMs) are the power units of modern aerospace transportation, and it is of great significance to predict their flow and heat transfer characteristics by numerical simulation. This numerical study is based on a self-developed code framework MHT (Multi-X Heat Transfer, where X represents the region, scale, physical field, and other aspects) and presents an effective method of analyzing fluid–solid coupling heat transfer problem in an axisymmetric supersonic nozzle. For the nozzle wall heat conduction and nozzle-in fluid flow there are two kinds of solution methods, the detached (solved separately in solid and fluid region and them coupling at the interface) and the whole field method (solve the conduction and convection simultaneously). The whole field method is more efficient but few scholars use it to solve the nozzle coupled problem. This paper introduces the numerical details of the whole field solution method, and provides a new idea for the coupling solution of the nozzle. In addition, a mixed grid system is proposed around the interface region of fluid and solid, in which the quadrilateral structured mesh is used at the fluid side, and the triangular unstructured mesh is used for the outer fluid region and the whole solid region to ensure the accuracy of the 1st-oder normal derivatives calculation. The self-developed code is validated by comparison with well-known commercial soft-ware. Transient results of temperature and velocity are presented for the instants of 1st 20 and 40 s of a practical nozzle.

Simultaneous Optimization of Exergy and Economy and Environment (3E) for a Multistage Nested LNG Power Generation System

The study introduces an innovative three-stage nested power generation system that enables the cascading utilization of LNG cold energy. It makes the most of wasted energy by using ship jacket cooling water (JCW) and exhaust gas (EG) as heat sources, a trans-critical carbon dioxide cycle as internal circulation, and utilizing the pressure exergy of LNG. We choose two azeotrope mixing fluids that match the requirements and create four cases for the outer and middle cycle working fluids in the three-stage nested system. To discover the ideal system performance from the perspectives of exergy (E), economy (E), and environment (E), four cases were subjected to multi-objective optimization using the multi-objective particle swarm optimization technique (MOPSO). Finally, the optimal solution was found by applying the TOPSIS decision-making method. Through comparative analysis, the optimal system is selected among the four optimization results. R170 (22.66%) and R1150 (77.34%) are used as the outer circulating working medium, while R170 (90.86%) and R1270 (9.14%) are utilized as the inter-cycle working fluid. The net output work is 575.75 kW, the optimal exergy efficiency is 46.09%, the optimal electricity production cost is $0.04009 per kWh, the carbon dioxide emissions can be reduced by 36,910 tons, and the payback period is 2.548 years. After optimization, a more energy-efficient and environmentally friendly power generation system is obtained.

High-throughput generation of monodisperse double emulsions via controllable symmetric splitting in Y-shaped microchannels

To achieve high-throughput generation of monodisperse double emulsions via controllable symmetric splitting, the splitting dynamics of double emulsions in Y-shaped microchannels are systematically investigated by the combination of experimental study and numerical simulation. Four distinct breakup flow patterns of double emulsions splitting are initially identified, namely non-breakup, once uneven breakup, twice uneven breakup and twice even breakup, and the underlying hydrodynamic mechanisms of each flow pattern are further elucidated through the flow field structures and pressure distributions. The results show that the upstream pressure created by the flow obstruction of continuous phase governs the stable and symmetric splitting of double emulsions in Y-shaped microchannels. Effects of the flowrates of continuous phase, the outer and inner diameters of double emulsions, the physical properties of all the inner, middle and outer fluids as well as the angle of Y-shaped microchannel on the flow pattern transition laws are systematically clarified, and the corresponding universal flow pattern diagrams for predicting the critical boundary for the transition of flow patterns are established. Based on controllable symmetric splitting of double emulsions, three-level splitting microfluidic networks are rationally designed to achieve high-throughput generation of monodisperse double emulsions as well as monodisperse microcapsules via template synthesis. The results in this study not only advance the deep understanding of the breakup dynamics of double emulsions in Y-shaped microchannels, but also offer valuable guidance for the rational design of microfluidic devices for mass production of monodisperse double emulsions, thus providing a significant contribution to the fields of micro-chemical engineering and droplet microfluidics.

Double emulsion generation in shear-thinning fluids under electric field effects

Double emulsions are encapsulated microstructures with medical, food, and cosmetics applications. Precise control over their parameters, such as volume, thickness, and size distribution, is crucial. This study numerically investigates, for the first time, the generation of double emulsions in a shear-thinning outer fluid under the influence of an external DC electric field. A dual co-flowing microfluidic device is chosen as the flow domain, and the shear-thinning behavior of the outer fluid is approximated by the Carreau–Yasuda rheological model. The governing equations are discretized on structured numerical grids using the VOF-CSF model and the finite volume method. The combined effects of the shear-thinning behavior and electric forces on compound droplet formation parameters, including volume, eccentricity, maximum thickness, and jet length, are studied carefully. Results show that for highly shear-thinning fluids, the application of electric forces can ensure the generation of desired compound droplets, which is not feasible without electric field effects. However, excessive electric forces can disrupt the droplet generation process, especially for moderate to low shear-thinning fluids. These findings provide new insights into the role of external electric fields in double emulsion generation and highlight their potential to optimize the production process.

Micropolar Fluid Flows Past a Porous Shell: A Model for Drug Delivery Using Porous Microspheres

The creeping flow of an incompressible, bounded micropolar fluid past a porous shell is investigated. The porous shell is modeled using a Darcy equation, sandwiched between a pair of transition Brinkman regions. Analytical expressions for the stream function, pressure, and microrotations are given for each region. Streamline patterns are presented for variations in hydraulic resistivity, micropolar constants, porous layer thickness, and Ochoa-Tapia stress jump coefficient. An expression for the dimensionless drag for the unbounded case of the system is presented, and its variation with hydraulic resistivity and porous shell thickness is presented. The unbounded case represents a theoretical model for oral drug delivery using porous microspheres. It was found that optimal circulation between the porous region and the outer fluid occurred for low values of hydraulic resistivity and for a complete porous sphere.

Measurement of pressure gradients near the interface in the viscous fingering instability

The viscous fingering instability, which forms when a less-viscous fluid invades a more-viscous one within a confined geometry, is an iconic system for studying pattern formation. For both miscible and immiscible fluid pairs the growth dynamics change after the initial instability onset and the global structures, typical of late-time growth, are governed by the viscosity ratio. Here we introduce an experimental technique to measure flow throughout the inner and outer fluids. This probes the existence of a new length scale associated with the local pressure gradients around the interface and allows us to compare our results to the predictions of a previously proposed model for late-time finger growth. Published by the American Physical Society 2024

A Digital Twin Development Framework for an Electrical Submersible Pump (ESP)

Premature failure of a sub-system can be critical for an industrial Cyber-Physical System (CPS). A digital twin (DT) assisted predictive maintenance procedure can reduce the risk of costly unplanned maintenance. This study presents a generalized DT development framework for an Electrical Submersible Pump (ESP) that can assist in predictive maintenance. The framework is applied on a single-phase ESP as a proof of concept. The maximum winding temperature of the selected ESP is simulated using a multiphysics simulation tool with transient electromagnetic and transient heat transfer solvers. The simulation parameters were refined using data captured through an ESP free-run experiment. Simulating the total energy loss in the ESP stator and rotor and the transfer of heat from the outer fluid domain facilitates a relationship between the measurable external temperature and the maximum temperature in the stator winding. Following a design of experiments (DOE) approach, a series of simulations were run to establish a statistical model for the winding temperature in terms of the fluid temperature, the time duration a particular temperature was persistent, and the initial maximum stator winding temperature. As the instantaneous maximum stator winding temperature is related to the remaining useful lifetime, it was shown using a case study that the proposed framework can prognosticate the ESP failure, assisting effective decision-making for predictive maintenance of a CPS.

A New Calculation Model for Equivalent Circulating Density Considering Interface Effect between Various Fluids during Cementing Process

Summary Equivalent circulating density (ECD) is an essential parameter in the construction of oil and gas wells, which can be used to control the downhole pressure and prevent serious incidents such as well leakage or blowouts. Different engineering tasks will lead to changes in the ECD calculation model; the classical pipe flow theory can be used to calculate the ECD of circulating drilling fluid, but it is not suitable for the cementing displacement because it does not consider the interface effect between various fluids. In this paper, a new ECD calculation model has been developed that accounts for the changes in fluid interface morphology between displacing fluid and displaced fluid during the cementing process. Moreover, a simulation of the effects of borehole radius, casing eccentricity, displaced fluid density, and flow rate on the ECD were analyzed and quantified by a numerical approach to solve the fluid dynamics equilibrium equations that describe the flow in the eccentric annuli based on the semi-implicit method for pressure-linked equations (SIMPLE) algorithm. The results show that the calculated ECD predicted by the proposed model is larger than the traditional model with the reduction in the borehole radius, and the maximum deviation at the inlet position can reach 0.03 g·cm−3. Variation in the length of the interface transition zone is the main reason for the deviation in ECD prediction accuracy. In the case of constant casing outer diameter, fluid rheology, and displaced fluid density, the ECD decreases with increasing borehole radius. Meanwhile, it increases with higher displaced fluid density, eccentricity, and annular velocity. It is also shown that the length of the mixing zone can reach up to 40% of the pipe length under the conditions of eccentricity and displacement described in the paper. The proposed model predicts the ECD in the annulus by considering the influence of different engineering parameters on the movement of displacement interface, which can effectively ensure the safety of the cementing operation.

Creeping thermocapillary motion of a Newtonian droplet suspended in a viscoelastic fluid

In this work we consider theoretically the problem of a Newtonian droplet moving in an otherwise quiescent infinite viscoelastic fluid under the influence of an externally applied temperature gradient. The outer fluid is modelled by the Oldroyd-B equation, and the problem is solved for small Weissenberg and Capillary numbers in terms of a double perturbation expansion. We assume microgravity conditions and neglect the convective transport of energy and momentum. We derive expressions for the droplet migration speed and its shape in terms of the properties of both fluids. In the absence of shape deformation, the droplet speed decreases monotonically for sufficiently viscous inner fluids, while for fluids with a smaller inner-to-outer viscosity ratio, the droplet speed first increases and then decreases as a function of the Weissenberg number. For small but finite values of the Capillary number, the droplet speed behaves monotonically as a function of the applied temperature gradient for a fixed ratio of the Capillary and Weissenberg numbers. We demonstrate that this behaviour is related to the polymeric stresses deforming the droplet in the direction of its migration, while the associated changes in its speed are Newtonian in nature, being related to a change in the droplet’s hydrodynamic resistance and its internal temperature distribution. When compared to the results of numerical simulations, our theory exhibits a good predictive power for sufficiently small values of the Capillary and Weissenberg numbers.

Computational Modeling of Walking Beam Type Reheat Furnace for the Prediction of Slab Heating and Scale Formation

Abstract Computational modeling using the high-viscosity laminar flow approach was applied to study the effect of slab crossing time on slab heating and scale growth. Simulation of an existing industrial walking beam reheating furnace with four zones, outer refractory body, skid, slab, and fluid zone is considered. The fuel used was a mixture of coke oven and blast furnace gas. Preheated air is supplied co-axially with the fuel mixture. The combustion simulation is performed using the constrained equilibrium mixture fraction model. From the results, it has been observed that with an increase in slab residence time, the slab temperature and scale growth increase across the slab. For the system considered, with a fuel mass flowrate of 70,000 kg/h, 150–180 min of slab crossing time is appropriate to obtain desired slab temperature at the discharge end. The overall equivalence ratio is taken as Φ = 1 (fuel/air ratio is the same as stoichiometric ratio). The maximum slab scale thickness is evaluated as 2.4 mm at the discharged end for 180 min of slab crossing time.

Numerical study of the steady core-annular flow in a focusing geometry in the presence of soluble surfactants

The steady state core annular flow of two immiscible fluids in the presence of soluble surfactants is investigated numerically in an axisymmetric tubular or flow focusing geometry. The two immiscible fluids form an interface onto which surfactants can be adsorbed/desorbed from the annular fluid where they are dissolved. The finite element method is employed to discretize the governing equations using the spine method to create the computational mesh, follow the shape of the interface and the axisymmetric wall and capture the flow domain. An unknown pressure distribution is imposed along the interface that quantifies the pressure discontinuity, while allowing the bulk pressure to remain continuous in each phase. GMRES is employed to accommodate the nearly singular nature of the jacobian matrix. The bulk surfactant concentration varies only inside a thin boundary layer of thickness δ∼Pe−1, which justifies omission of the advection-diffusion equation in the annulus bulk. Simulations reveal that the onset of Marangoni stresses tends to decelerate the velocity at the interface which is seen to translate towards the wall/axis of symmetry when the more viscous fluid is the inner/outer fluid, respectively. Finally, simulations in flow-focusing nozzles capture the development of spatially growing instabilities in the downstream region of the interface, with wavelength on the order of the nozzle radius, especially when the outer fluid is more viscous or when the surfactant concentration increases. Raising the volumetric flow rate in the annular region suppresses growth of waves due to interfacial friction. Spatial stability analysis verifies downstream growth of waves and recovers the relevant wavelength. Possible repercussions on the onset of jetting instabilities in devices with liquid focusing are discussed.

Conceptual design of narrow annular channel heater with rectangular wire coil for the simulator of solid-fuel thorium molten salt reactor

To heat the simulator core of a solid-fuel thorium molten salt reactor, the narrow annular channel heater with rectangular wire coil separating from the tube wall is proposed. Three-dimensional numerical models are developed, and the simulated result shows that negative axial, radial and tangential velocities in the enhanced narrow annular channel heater are generated compared to the smooth narrow annular channel heater. As the wire width increases and helical pitch decreases, the Nusselt number and friction factor increase. The maximum Nusselt number for enhanced narrow annular channel heater is 5.6 times that for smooth narrow annular channel heater. The overall performance of enhanced narrow annular channel heater is evaluated at a constant pumping power, the value of which is in the range of 1.21–1.85. The best enhanced narrow annular channel heater for the simulator of solid-fuel thorium molten salt reactor is determined based on the overall performance. The maximum outer wall and fluid temperatures of enhanced narrow annular channel heater for the simulator of solid-fuel thorium molten salt reactor are 937.94 K and 931.01 K, which are within the safety limit values of 1143.15 K and 977.15 K, respectively. This design will provide a new method to heat molten salt.

Particle Separation in a Microchannel with a T-Shaped Cross-Section Using Co-Flow of Newtonian and Viscoelastic Fluids.

In this study, we investigated the particle separation phenomenon in a microchannel with a T-shaped cross-section, a unique design detailed in our previous study. Utilizing a co-flow system within this T-shaped microchannel, we examined two types of flow configuration: one where a Newtonian fluid served as the inner fluid and a viscoelastic fluid as the outer fluid (Newtonian/viscoelastic), and another where both the inner and outer fluids were Newtonian fluids (Newtonian/Newtonian). We introduced a mixture of three differently sized particles into the microchannel through the outer fluid and observed that the co-flow of Newtonian/viscoelastic fluids effectively separated particles based on their size compared with Newtonian/Newtonian fluids. In this context, we evaluated and compared the particle separation efficiency, recovery rate, and enrichment factor across both co-flow configurations. The Newtonian/viscoelastic co-flow system demonstrated a superior efficiency and recovery ratio when compared with the Newtonian/Newtonian system. Additionally, we assessed the influence of the flow rate ratio between the inner and outer fluids on particle separation within each co-flow system. Our results indicated that increasing the flow rate ratio enhanced the separation efficiency, particularly in the Newtonian/viscoelastic co-flow configuration. Consequently, this study substantiates the potential of utilizing a Newtonian/viscoelastic co-flow system in a T-shaped straight microchannel for the simultaneous separation of three differently sized particles.

Role of interfacial rheology on fingering instabilities in lifting Hele-Shaw flows.

The lifting Hele-Shaw cell setup is a popular modification of the classic, fixed-gap, radial viscous fingering problem. In the lifting cell configuration, the upper cell plate is lifted such that a more viscous inner fluid is invaded by an inward-moving outer fluid. As the fluid-fluid interface contracts, one observes the rising of distinctive patterns in which penetrating fingers having rounded tips compete among themselves, reaching different lengths. Despite the scholarly and practical relevance of this confined lifting flow problem, the impact of interfacial rheology effects on its pattern-forming dynamics has been overlooked. Authors of recent studies on the traditional injection-induced radial Hele-Shaw flow and its centrifugally driven variant have shown that, if the fluid-fluid interface is structured (i.e., laden with surfactants, particles, proteins, or other surface-active entities), surface rheological stresses start to act, influencing the development of the viscous fingering patterns. In this paper, we investigate how interfacial rheology affects the stability as well as the shape of the emerging fingered structures in lifting Hele-Shaw flows, at linear and early nonlinear dynamic stages. We tackle the problem by utilizing the Boussinesq-Scriven model to describe the interface and by employing a perturbative mode-coupling scheme. Our linear stability results show that interfacial rheology effects destabilize the interface. Furthermore, our second-order findings indicate that interfacial rheology significantly alters intrinsically nonlinear morphological features of the shrinking interface, inducing the formation of narrow sharp-tip penetrating fingers and favoring enhanced competition among them.

Thermocapillary migration of a compound droplet on a substrate

We present a numerical study of the thermal migration of a compound droplet attached to a horizontal substrate. The different constant temperatures are applied to the left and right boundaries of the computational domain. The compound droplet contains one inner core. The problem is solved by using a front-tracking technique associated with the finite difference method. The investigated parameters include the radius ratio (Rio) of the inner droplet and the equivalent radius of the outer droplet (Rio varied in the range of 0.2 to 0.7), the viscosity ratio (μom) of the outer to middle fluids (μom varied in the range of 0.1 to 2.4), and the static contact angle θe (θe varied in the range of 60° to 120°). The results reveal that the inner droplet drives the compound droplet towards the hot region as its radius is sufficiently large (Rio≥ 0.6). The compound droplet moves towards the cold region as the value of Rio is less than 0.6. Increasing the viscosity of the outer fluid (by increasing μom) or θe causes the compound droplet to move towards the hot region. The trajectory of the centroid of the inner droplet is also investigated.

Investigation of 3D-printable chickpea-mealworm protein mixtures and their bolus rheology: A soft-textured and safe-swallowing food for the elderly

Eating and swallowing food are major challenges for the elderly with dysphagia. Three-dimensional (3D) food printing allows the creation of elderly food with nutrition, attractive shapes, and soft texture customizations. This study aimed to investigate the printability of soft-textured food (the mixture of chickpea protein isolate (CPI) with mealworm protein isolate (MPI) gel) by using single-nozzle printing (SNP) and coaxial printing (CoP) techniques. Artificial food boluses were prepared and their rheological properties were determined to understand safe swallowing. In the CoP system, extrusion pressure delivered alginate hydrogel (AH) as an outer fluid to support the structure of fragile food ink, resulting in printability and structural stability. Foods produced using the SNP technique exhibited printing failure. All printed foods exhibited a lower hardness value of ≤5 × 103 N/m2, corresponding to stage 4 of the universal design food (UDF) guideline. After oral food process simulation, the artificial CoP bolus showed significantly higher values of viscoelasticity, yield stress, and viscosity than the SNP and control boluses. This suggests a favorable cohesive bolus form that can prevent pulmonary aspiration during food swallowing. The CoP bolus displayed a denser microstructure due to the binding effect of the alginate molecules with positive electrolytes in the artificial saliva, which agreed with its higher rheological properties. This study successfully transformed unprintable soft food to be printable with an attractive 3D printing food shape using CoP technique as personalized food for the elderly. Additionally, this study provided insight into the relationship between bolus rheology and safe swallowing management.

On-Chip Octanol-Assisted Liposome Assembly for Bioengineering.

Microfluidics is a widely used tool to generate droplets and vesicles of various kinds in a controlled and high-throughput manner. Liposomes are simplistic cellular mimics composed of an aqueous interior surrounded by a lipid bilayer; they are valuable in designing synthetic cells and understanding the fundamentals of biological cells in an in vitro fashion and are important for applied sciences, such as cargo delivery for therapeutic applications. This article describes a detailed working protocol for an on-chip microfluidic technique, octanol-assisted liposome assembly (OLA), to produce monodispersed, micron-sized, biocompatible liposomes. OLA functions similarly to bubble blowing, where an inner aqueous (IA) phase and a surrounding lipid-carrying 1-octanol phase are pinched off by surfactant-containing outer fluid streams. This readily generates double-emulsion droplets with protruding octanol pockets. As the lipid bilayer assembles at the droplet interface, the pocket spontaneously detaches to give rise to a unilamellar liposome that is ready for further manipulation and experimentation. OLA provides several advantages, such as steady liposome generation (>10 Hz), efficient encapsulation of biomaterials, and monodispersed liposome populations, and requires very small sample volumes (~50 µL), which can be crucial when working with precious biologicals. The study includes details on microfabrication, soft-lithography, and surface passivation, which are needed to establish OLA technology in the lab. A proof-of-principle synthetic biology application is also shown by inducing the formation of biomolecular condensates inside the liposomes via transmembrane proton flux. It is anticipated that this accompanying video protocol will facilitate the readers to establish and troubleshoot OLA in their labs.

Modeling droplets with slippery interfaces

Many multiphase fluid systems, such as those involving immiscible polymers or liquid-liquid systems with surfactants, have shown a breakdown of the no-slip condition at the material interface. This results in systems where the tangential velocity of the inner and outer fluid can differ, with the jump in velocity dependent not only on the material properties of the interface but also the stresses applied by the surrounding fluid. In this work a numerical model is presented which is capable of investigating general multiphase fluid systems involving interfacial slip in both two- and three-dimensions. To make the system computationally feasible, a hybrid Navier-Stokes projection method is used, whereby the viscosity, density, and pressure are assumed to be continuous across the interface while the velocity field can experience a jump, which is handled via the Immersed Interface Method. The numerical model is compared to experimental results involving polymer-polymer mixtures and computational results for droplets in extensional flows, showing excellent agreement with both. It is then used to explore the influence of interfacial slip in a number of common multiphase fluid systems, including the shearing of a planar interface, droplet and filament relaxation, and droplets in shear flow, both unbounded and wall-bound.

Analytical calculation method for predicting contact loads and structural strength of metallic gasket of subsea connectors under thermal loads

Identifying the effect of thermal loads that are caused by temperature differences of inner and outer fluids on the structural sealing performance and strength is a long-standing quest in the design of subsea connectors. However, the structural stress and sealing parameters of the gasket under thermal loads are difficult to analyze and calculate using the current theoretical method because the boundary conditions of the gasket’s geometry surface are contact constraints interacted by the gasket and hubs. This paper presents an analytical calculation method (ACM) that evaluates the thermal-structural coupling strength and sealing performance considering such special boundary conditions. The thermal load is converted into an equivalent compression load, that is, a concentrated force, and applied to the contact region of the gasket. Additionally, a thermal-structural coupling finite element model is proposed to verify the ACM and the results show good agreement. Taken together, this work contributes to the design of subsea connectors that more likely take thermal loads into account.

Electrospinning spinneret: A bridge between the visible world and the invisible nanostructures

Electrospinning spinneret: A bridge between the visible world and the invisible nanostructures