Dispersed Plug Flow Research Articles

Dispersed plug flow photocatalytic reactor using TiO2‐coated foams, 2D modeling, and experimental operating mode

Dispersed plug flow photocatalytic reactor using <scp>TiO₂</scp>‐coated foams, <scp>2D</scp> modeling, and experimental operating mode

Solving crystallization/precipitation population balance models in CADET, Part II: Size-based Smoluchowski coagulation and fragmentation equations in batch and continuous modes

A particle size-based Smoluchowski coagulation and fragmentation equation was solved in the free and open source process modeling package CADET. The WFV and MCNP schemes were selected to discretize the internal particle size coordinate. Weights in these schemes were modified to preserve and conserve the zeroth and third moments for size-based equations. Modified propositions and proofs for the scheme are provided. Analytical Jacobians were derived and implemented to reduce the solver’s runtime. A two-dimensional Smoluchowski coagulation and fragmentation equation with axial position as external coordinate was formulated and discretized to support simulations of continuous particulate processes in dispersive plug flow reactors. Five 1D and four 2D test cases were used to validate the implementation and benchmark the solver’s performance. The runtime, L1 error norm, L1 error rate, particle size distribution moments up to sixth order and several scalar metrics were analyzed in detail.

Determining kinetics of fast exothermic reactions using a flow calorimeter

Continuous flow calorimeters are considered an emerging technique due to their ability to reduce safety issues associated with highly exothermic rapid reactions. In this study, a custom-made isoperibolic flow calorimeter was constructed, which uses a pyroelectric IR Sensor for temperature profile recording. The objective of this study is to validate the reactor concept for the determination kinetic parameters. Residence time distribution (RTD) analysis was conducted to assess the mixing performance of the packed-bed reactor employed in the calorimeter. This calorimeter was connected to a custom-made conductivity flow cell (CFC), to measure the in-line conductivity of the outlet stream. An axially dispersed plug flow reactor model (AD-PFR) is required to be able to incorporate the non-ideal behaviour of the flow. The experimental apparatus design and methodology was validated by conducting the hydrolysis of acetic anhydride. The activation energy, EA and the pre-exponential factor, ln(k0) for the hydrolysis of acetic anhydride were found to be 52.05 kJ mol−1 and 12.26 (s−1), respectively, which falls within the range of reported values. The new flow calorimeter proved to be effective, and accurate.

Mixing effects on the gas flow and mass transfer in a vertical single helical ribbon agitated reactor for propylene polymerization

The gas–solid vertical single helical ribbon agitated reactor is widely used in the polypropylene industry. The gas flow and mass transfer determine the heat transfer capacity and product quality. In this work, the pressure drop was measured below and above minimum fluidization velocity (umf). Then, the axial and radial dispersion coefficients (DL and DR) were estimated below umf by measuring the step residence time distribution and the stationary radial tracer profiles, respectively. Pressure analysis show the agitation significantly reduces the bed pressure drop, changing the fixed bed below umf and bubbling bed above umf to an agitated bed with a periodic voidage. The DL was proportional to the gas velocity, with little influences of the stirring speed. The radial tracer profiles show the bed is divided by the inner diameter of the helical ribbon into the peripheral ascending region and the central descending region, without gas exchange between them. Furthermore. the tracer profiles in the descending region are classified into two types. For type I, the DR, calculated by the plug flow model with radial dispersion, is proportional to the gas velocity, with little effects of stirring speed. Type II shows uniform profiles due to the deflection of the gas flow toward the low pressure area at the inner diameter of helical ribbon. The causes of the two types are explained by the relative size of particle circulation and gas flux. These two flow regimes are quantitatively clarified with an empirical correlation of Re and Fr as flow regime transition boundary, namely dispersed plug flow and perfect mixing flow. With lower Re and higher Fr, it changes from dispersed plug flow to perfect mixing flow.

Develop and validate a mathematical model to estimate the removal of indoor VOCs by carbon filters

Adsorption-based air filters, especially carbon-based ones, are usually employed to remove VOCs from indoor air. Conducting tests at ppm level, which is substantially higher than the actual indoor concentration of VOCs, is recommended for reducing the test duration. Consequently, developing a model for estimating the service life of adsorptive filters under actual conditions is imperative.A comprehensive model that considers axially dispersed plug flow for interpellet mass transfer and pore surface diffusion model (PSDM) with variable surface diffusivity for intrapellet mass transfer was used to predict the performance of two filters exposed to three VOCs. First, the results of experiments conducted at concentrations ranging from 9 to 90 ppm in a bench-scale setup were used to compute the Dubinin-Radushkevich (D-R) isotherm parameters, which are concentration-independent. Then, the surface diffusivities at zero loading for various adsorbate-adsorbent systems were determined by fitting the developed model into the results of the experimental data performed at concentrations of 9 ppm or 30 ppm. Finally, the model was validated using experimental data which were conducted at lower concentrations, a higher velocity and on a full-scale setup.The inter-model comparison was carried out by comparing the comprehensive model with four other models to study the importance of various mass transfer steps. Finally, in sensitivity analysis, five dimensionless parameters (Pe, St, Edp, Eds and Dg) were examined to investigate their impact on the filter's efficiency.

Modeling of ternary mixture of VOCs in photocatalytic oxidation reactor for indoor air quality application

Photocatalytic oxidation (PCO) is an innovative method of removing volatile organic compounds (VOCs) from indoor air. PCO technology employs a semiconductor (such as TiO2) and ultraviolet light to decompose VOCs via successive oxidation processes and creates CO2 and H2O as the ultimate products of complete mineralization. The greatest drawback of this technology is, however, the production of hazardous by-products. The possible health risk posed by hazardous by-products inhibits the commercial adoption of PCO-based air purifiers in the indoor environment. Modeling is a powerful tool to address the chemical interaction and mass transfer phenomenon in the PCO reactor. This study presents the modeling of a ternary mixture of VOCs and generated by-products using a proposed degradation reaction pathway. A one-dimensional mathematical model by considering the axially dispersed plug flow and Langmuir-Hinshelwood (L-H) based reaction rate as well as linear source spherical emission model (LSSE) for the irradiation distribution on the media surface were used for modeling of VOCs and by-products. Three VOCs from different chemical groups (aldehyde, ketone, aromatic groups) were chosen as challenge compounds, and a commercial PCO filter (TiO2 coated on silica fiber felts) was considered as a photocatalyst. The model prediction was performed at different levels of concentration (0.1–1 ppm), relative humidity (15–70%), air velocity (0.016–0.1 m/s), and light intensity (7–23W/m2). Among generated by-products, aldehydes were the major by-products of VOCs in the PCO reactor. It was revealed that increasing concentration and irradiation, as well as decreasing relative humidity and velocity, increases by-product generation.

Representing performance of horizontal flow treatment wetlands: The Tanks In Series (TIS) and the Plug Flow with Dispersion (PFD) approaches and their application to design

Horizontal flow wetlands have been designed using the so-called P-k-C* approach, which has been largely embraced by the treatment wetlands literature. P is meant to represent the equivalent number of apparent tanks in series (hydraulic factor), but also incorporates the loss of biodegradability as the wastewater undergoes treatment (kinetic factor). For design purposes, literature proposes fixed values of P. The proposal of this paper is to decouple hydraulics from kinetics and use the traditional concept of N or NTIS (number of tanks in series) as a function of geometric relationships of the wetland to be designed, leaving kinetic elements to be dealt with solely by the first-order removal rate coefficient (k). From the literature, a database with 41 wetlands with data from tracer studies was used, and a novel regression-based equation was derived relating N with the ratio length/depth of horizontal wetlands. This equation can be used at the design stage for estimating N and, hence, the output concentration of the pollutant using the traditional structure of the TIS model, with a possible inclusion of background concentration (C*). The paper presents all relevant equations, including those from the plug-flow with dispersion model (PFD), and it is shown how to convert from one hydraulic model to the other, what is also believed to be a novel approach in the treatment wetland literature. Finally, the area-based removal rate coefficients (kA) proposed by Kadlec and Wallace (2009) for designs of horizontal wetlands treating domestic wastewater based on the P-k-C* approach are converted into kA values for the TIS model in the paper.

Green process of fuel production under porous γ-Al2O3 catalyst: Study of activation and deactivation kinetic for MTD process

One of the methods of industrial dimethyl ether production is the catalytic dehydration of methanol. In this research work, methanol dehydration reactor has been modeled using continuous model and its results have been compared with experimental works and Voronoi pore network model. A 1D heterogeneous dispersed plug flow model was utilized to model an adiabatic fixed-bed reactor for the catalytic dehydration of methanol to dimethyl ether. The mass and heat transfer equations are numerically solved for the reactor. The concentration of the reactant and products and also the temperature varies along the reactor, therefore the effectiveness factor would also change in the reactor. We used the the effectiveness factor that was simulated according to the diffusion and reaction in the catalyst pellet as a Voronoi pore network model. Sensitivity analysis was performed to determine the influence of T, P and weight hourly space velocity on performance of the chemical reactor. Acceptable agreement was reached between the measured and the model data. The results showed that the maximum reaction conversion was obtained about 90 % at WHSV = 10 h−1 and T = 560 K, while the inlet temperature (Tinlet) had a greater effect on methanol conversion. In addition, the effect of water in the feed on methanol conversion was quantitatively studied. Also, the deactivation kinetics of γ-Al2O3 heterogeneous-acidic catalyst in methanol to dimethyl ether dehydration process was studied using integral analysis method. Based on independent deactivation kinetics, a second order was found that accurately fitted the experimental conversion time data. The main reaction activation energies and catalyst deactivation energies were 143.1 and −102.1 kJ/mol, respectively.

Technological assessments on recent developments in fine and coarse particle flotation systems

• Froth flotation of fine and coarse particles is studied, focusing on cell designs. • Generating micro-bubbles, intensive turbulence, and high gas hold-up are advantages of intensified cells. • Scaling up/down procedures for the intensified cells are found unclear. • Positioning the optimum location of discussed cells in flotation circuits is found challenging. After more than a century applying flotation to the mining industry, two completely different strategies have been introduced for processing purposes. One is the classical approach viz. grinding ores to a certain extent (fine particles) and floating them via conventional mechanical and pneumatic cells i.e., Jameson, Imhoflot™ and Reflux™. This strategy continues because mines face declining cut-off grades, complex and poly-mineralized ores, and they are required to achieve an acceptable degree of mineral liberation. The other school of thought deals with coarse particle processes mainly owing to the low energy requirements, that includes SkimAir® flash, fluidized bed and HydroFloat™ cells. There is no study in the literature to comparatively present the recent developments of flotation apparatuses versus the conventional mechanical cells. To cover this knowledge gap in the literature, the present paper endeavors to critically evaluate these concepts from several points of view, including existing technological advancements, water and energy usage, kinetics, and circuit design. A brief introduction of advanced technologies, along with their applications is presented. The data from literature and case studies showed that the Jameson, Imhoflot™ and recently developed Reflux™ flotation cells can be very effective for recovering fine particles owing to their specific hydrodynamic designs, intensive energy dissipation rate and generation of micron-sized bubbles (100–700 µm). Very low (less than a few minutes) mean particle residence time, high gas-hold up (ca. 50–70 %), no agitation and high efficiency of particle-bubble collision were identified as their main advantages compared to traditional mechanical flotation cells. In addition to their common applications in cleaner stage, these cells were used in pre-flotation and scalping (producing final concentrate from the rougher feed) duties. Their main challenges were recognized as relatively unclear procedure on their scale up/down, optimization and simulation. The HydroFloat™ cell was indicated as a promising technology for recovering coarse particle fraction sizes by taking advantage of the fluidized-bed concept with plug-flow dispersion regime, high particle residence time, and limited cell turbulence. We finally concluded that fine particle flotation may remain as the main focus of re-processing tailings dams, while coarse particle treatment should be the focus of this century to reduce total energy consumptions.

Kinetic modeling and reaction mechanism of toluene and by-products in photocatalytic oxidation reactor

Photocatalytic oxidation (PCO) is an innovative and promising technology for removing VOCs from indoor environment. However, partial oxidation of reactants generates by-products that could be more harmful to human health than parent compound. This paper presents the development of a by-products predictive model for the estimation of generated by-products based on the degradation reaction pathway of toluene in PCO. A one-dimensional mathematical model by considering the axially dispersed plug flow and Langmuir-Hinshelwood (L-H)-based reaction rate as well as linear source spherical emission (LSSE) model for the irradiation distribution on the media surface was developed for the prediction of the by-products concentration. Toluene was tested in a continuous flow PCO reactor with a commercial PCO filter under various operating conditions; concentrations (0.05–1 ppm), relative humidities (17–67%), flow rates (10–30 L/min), and irradiance (7–23.5 W/m2). Several by-products from various chemical groups, including aldehyde, ketone, alcohol and light acid, were identified by analytical instruments. Aldehydes were the major by-products of toluene in PCO, in which light aldehydes (acetaldehyde and formaldehyde) had a higher concentration among others. The result of curve fitting using the proposed model showed a high accuracy of the model (with R-squared greater than 0.98) for parameters estimation. Kinetic analysis of toluene indicated that the rate coefficients followed the order of benzaldehyde > propionaldehyde > acetaldehyde > formaldehyde. Benzaldehyde and propionaldehyde had a greater value of the kinetic coefficient in PCO because of higher adsorption tendency towards TiO2. Changes in operating conditions highly affected generation of by-products and the developed model could predict the concentration of toluene and the by-products with acceptable accuracy. The carbon balance analysis at residence time of 0.24 s showed 16.6% of toluene mineralized into carbon dioxide and it increased at longer residence time. The health risk index (HRI) analysis of toluene and its by-products was performed and found out that formaldehyde was the most influential pollutant on HRI due to very low recommended exposure limit and higher generated concentration.

Modeling of CO2 Capture with Water Bubble Column Reactor

The demand for carbon capture is increasing over time due to rising CO2 levels in the atmosphere. Even though fossil emission could be decreased or even eliminated, there is a need to start removing CO2 from the atmosphere. The removed CO2 could be either stored permanently to a reservoir (CCS, Carbon Capture and Storage) or utilized as a raw material in a long-lasting product (CCU, Carbon Capture and Utilization). The capture of CO2 could be done by direct air capture, or capturing CO2 from biogenic sources. Amine absorption is the state-of-the-art method to capture CO2, but it has some drawbacks: toxicity, high heat demand, and sorbent sensitivity towards impurities such as sulfur compounds and degradation in cyclic operation. Another potential solvent for CO2 could be water, which is easily available and safe to use in many applications. The problem with water is the poorer solubility of CO2, compared with amines, which leads to larger required flow rates. This study analyzed the technical feasibility of water absorption in a counterflow bubble column reactor. A dynamic, one-dimensional multiphase model was developed. The gas phase was modeled with plug flow assumption, and the liquid phase was treated as axially dispersed plug flow. CO2 capture efficiency, produced CO2 mass flow rate, and the product gas CO2 content were estimated as a function of inlet gas and liquid flow rate. In addition, the energy consumption per produced CO2-tonne was calculated. The CO2 capture efficiency was improved by increasing the liquid flow rate, while the CO2 content in product gas was decreased. For some of the studied liquid flow rates, an optimum gas flow rate was found to minimize the specific energy consumption. Further research is required to study the integration and dynamical operation of the system in a realistic operation environment.

Kinetic modeling of the photocatalytic degradation of methyl ethyl ketone in air for a continuous-flow reactor

This paper reports the study on kinetic modeling of photocatalytic degradation of methyl ethyl ketone (MEK) using TiO2 coated on silica fiber felts. Two different mathematical models, ideal plug flow model and axially dispersed plug flow model (dispersion model), were used to simulate the performance of the PCO reactor. Six kinetic rate equations on the basis of Langmuir-Hinshelwood (L-H) expression were examined to find the best model that fits the experimental data. Moreover, the light intensity distribution on the photocatalyst surface was simulated using the linear source spherical emission model (LSSE) and validated with the experimental data. The Beer-Lambert model was also applied to demonstrate the diminishment of light intensity in the PCO filter. For model prediction validation, a series of experiments was carried out in a bench-scale continuous flow reactor at different concentrations (0.1–1 ppm), relative humidities (17–67%), flow rates (10–30 L/min), and light intensities (7–23.5 W/m2). In addition, adoption tests with MEK at various concentrations (0.25–1 ppm) and relative humidities (15–50%) were conducted under dark condition. Formaldehyde, acetaldehyde, acetone, and propionaldehyde were identified (through HPLC analysis) as by-products of the MEK PCO reaction. Owing to higher concentrations of formaldehyde and acetaldehyde, aldehyde group was considered as the main by-products. The result of carbon balance indicated that 7.2% of MEK mineralized to CO2 (measured by GC-FID) and around 10.8% of that was converted to by-products (for 18.4% removal efficiency). Evaluation of different kinetic rate expressions revealed that the unimolecular L-H model considering inhibitive effect of water vapor and by-products for adsorption provided the best fit. The dispersion model combined with this rate expression had a higher accuracy at all operating conditions while the plug flow model failed to predict the PCO performance at various intensities and air velocities. Evaluation of mass transfer was also performed, and it was concluded that the mass transfer effect on the PCO process is not dominating step; consequently, the PCO reaction is the rate-limiting process.

Modeling of gas-phase heterogeneous photocatalytic oxidation reactor in the presence of mass transfer limitation and axial dispersion

Mass transfer plays a critical role in the efficiency of photocatalytic oxidation (PCO) technology for air purification applications. There has been limited work on the exploration of mass transfer in the PCO reactor with the non-ideal flow. In this work, the performance of a continuous heterogeneous ultraviolet photocatalytic oxidation (UV-PCO) reactor was investigated and addressed under mass transfer limitation and axial dispersion. First, CFD modeling was used to determine the flow distribution in the reactor at various airflow rates. The residence time distribution (RTD) analysis with a tracer gas (CO2) was carried out for the experimental validation of the simulation model and good agreement between experimental and simulation data was achieved. Further, a quick and straightforward methodology employing an axial dispersion plug flow model was used to study the RTD. The proposed model could predict the residence time distribution of CO2 with high accuracy. Results of the RTD for CO2 in the presence and absence of a PCO filter (silica fiber felts (SFF) modified with TiO2) were almost identical due to the high porosity of the filter. The model was then used for the evaluation of the axial dispersion of methyl ethyl ketone (MEK) at different flow rates. Owing to a low value of the Peclet number (Pe < 100), the flow in the reactor deviated from an ideal plug flow and dispersion could not be ignored. The photocatalysis reaction of MEK by the SFF filter under the mass-transfer-controlled regime was further addressed. A steady-state mass balance equation was implemented for the assessment of the performance of the UV-PCO reactor in the presence of axial dispersion and mass transfer limitation. The mass transfer coefficient was calculated with the use of the developed model and a correlation for the Sherwood number was proposed to relate the mass transfer coefficient to the flow rate and fiber structure. The proposed correlation was assessed and compared with the other empirical formulas available in the literature.

Modeling batch fluidized bed drying of pharmaceutical powder: Influence of hydrodynamic regime and sorption isotherms

A mathematical modeling, based on the two-phase theory of batch fluidized bed drying of type A particles and type B particles pharmaceutical powders, was performed. A perfectly mixed flow bubbling regime and an axially dispersed plug flow turbulent regime with a freeboard section were assumed. The experiments were carried out in a pilot-scale bed and in an industrial scale bed. The experimental sorption isotherms were used to model the falling rate drying period. The influence of the particles hygroscopic properties on the drying rate and on the temperature profile was discussed. The simulated solid moisture content and temperature profiles are in good agreement with the experimental results.

Numerical integration strategies of PFR dynamic models with axial dispersion and variable superficial velocity: the case of CO2 capture by a solid sorbent

In order to integrate mole balances (partial differential equations) of an Axial Dispersion Plug Flow Reactor (ADPFR) model, the overall superficial velocity is usually considered constant, a hypothesis which fits well only null or negligible variations of volumetric flow rate, e.g. feeding flow strongly diluted by inert species. This work proposes a numerical-integration approach (based on the method of lines) for ADPFR dynamic modelling, applied to simulate the CO2 capture in an isothermal-isobaric packed bed, made of purposely synthesized and experimentally characterized CaO-mayenite sorbent particles. This approach proved to be suitable for both constant and variable superficial velocity with respect to time and space. With the latter option, velocity profiles agreed with simulated reactive phenomena, while discrepancies between solutions from the two options became increasingly evident as dilution of inlet CO2 decreased. N2 flow rate and CO2 mole balances obtained from numerical-integrations with variable superficial velocity appeared as the most physicochemically reasonable.

Modeling Residence Time Distribution (RTD) Behavior in a Packed-Bed Electrochemical Reactor (PBER)

This paper focuses on understanding the electrolyte flow characteristics in a typical packed-bed electrochemical reactor using Residence Time Distribution (RTD) studies. RTD behavior was critically analyzed using tracer studies at various flow rates, initially under nonelectrolyzing conditions. Validation of these results using available theoretical models was carried out. Significant disparity in RTD curves under electrolyzing conditions was examined and details are recorded. Finally, a suitable mathematical model (Modified Dispersed Plug Flow Model (MDPFM)) was developed for validating these results under electrolyzing conditions.

Adsorption of vanillic and syringic acids onto a macroporous polymeric resin and recovery with ethanol:water (90:10 %V/V) solution

In this work the adsorption of vanillic (VA) and syringic (SA) acids onto the nonpolar resin SP700 was investigated aiming to collect data to evaluate their separation from a lignin oxidation mixture containing other phenolic compounds. The respective adsorption equilibrium isotherms in aqueous solutions were assessed at three different temperatures 288, 298 and 333 K and experimental results were fitted with Bi-Langmuir isotherm model. Maximum adsorption capacities of 0.486 g g−1dry resin and 0.407 g g−1dry resin were obtained for VA and SA, respectively.Dynamic studies at different temperatures and feed concentrations were performed and a mathematical model comprising the Bi-Langmuir equilibrium isotherm, axial dispersed plug flow, intraparticle mass transfer resistance expressed with linear driving force approximation with no temperature gradients and constant porosity along the bed successfully described the adsorption concentration histories at the outlet of the fixed bed.More than 83% of each phenolic acid was readily eluted within 5 min elution with ethanol:water (90:10 %V/V) solution allowing obtaining a final concentrated solution with 5.8–11.7 g L−1.

Influence of Subflux Turbulence Controller and Ladle Shroud Asymmetric Using on Hydrodynamic Conditions in One Strand Slab Tundish

The tundish plays a key role in the process of continuous steel casting (CSC), as it ensures a stable flow of steel to the mould. Therefore, particular attention is paid to the behavior of liquid steel in the tundish. A wedge-shape tundish with a nominal capacity of 30 tons was tested. The present study has examined different variants of subflux turbulence controller (STC) and ladle shroud (LS) positions relative to one another. For the designed continuous casting variants with the modified tundish pouring zones, numerical simulations of liquid steel behavior were performed. From the computer simulations results, motion, velocity magnitude, and temperature of liquid steel were obtained. Moreover the shares of stagnant volume flow, dispersed plug flow, well-mixed volume flow and transient zone were calculated. It is possible to effectively modify the hydrodynamic conditions by appropriate selection the position of the STC and LS.

Multicycle sorption enhanced steam methane reforming with different sorbent regeneration conditions: Experimental and modelling study

Replacing coal and oil with natural gas reduces greenhouse gas emissions without weakening economic development. Sorption enhanced steam methane reforming (SESMR) is an emerging process for an affordable transition towards cleaner energy systems, as it exploits natural gas coupled with in-situ CO2 capture to produce hydrogen. SESMR is performed on a steam reforming catalyst and a sorbent (cyclically regenerated by calcination) or, alternatively and more efficiently, on bi-functional Combined Sorbent-Catalyst Materials (CSCM). A double fluidized bed (reformer and oxyfuel combustor for calcination) with circulation of particulate material is anticipated for continuous SESMR at commercial scale. In this work, a Ni-CaO-mayenite CSCM was investigated in multicycle experimental tests under mild (pure N2, 850 °C) and severe (pure CO2, 925 °C) regeneration conditions, in thermogravimetric analysis for CO2-capture/regeneration and in an automated packed bed test rig for SESMR/calcination: the evolution of Ni and CaO functionalities as functions of cycle number was highlighted, also with the aid of scanning electron microscopy. Moreover, experimental results obtained with the hybrid material, collected under mild regeneration conditions, were used to simulate both CO2 sorption in TGA and packed bed SESMR multicycle tests: a Particle Grain Model (PGM) and an Axial Dispersion Plug Flow Reactor (ADPFR) model were integrated numerically, respectively. The same parameter values needed to characterize the material behaviour allowed a good fitting of both types of multicycle tests, thus demonstrating the possibility to use CO2-capture TGA data as a predictive tool for the CSCM performance in SESMR, provided that the catalytic activity is preserved.

Continuous Wave Ultrasonic Doppler Modeling for Oil–Gas–Water Three-Phase Flow Velocity Measurement

Oil–gas–water three-phase flow is the most commonly seen fluid in petroleum production and transportation process. Flow velocity measurement of each individual phase is important to estimate the production condition and monitor the operation safety. The continuous wave ultrasonic Doppler (CWUD) technique has a high potential to measure the velocity of multiphase flow in a non-intrusive manner. However, this technique lacks proper measurement models for three-phase flow velocity measurement. In this paper, a one-sided CWUD sensor with 1-MHz center frequency was used for transmitting and receiving the acoustical signal that contains rich flow velocity information of the dispersed phases. By analyzing the momentum balance between different phases and modifying a two-fluid model into three-phase flow, a novel theoretical model to estimate the individual phase superficial flow velocity was established. Experiments were performed in a 50-mm inner diameter pipe, and two typical flow patterns (water dominated dispersed plug flow, oil dominated dispersed plug flow) were generated by adjusting the inlet flow rate of the three phases. By analyzing the ultrasound signal, the flow velocity of dispersed phases can be extracted. After using proposed theoretical model, the phase’s superficial velocities can be calculated. The results show that the mean relative error can achieve within 5%. The proposed theoretical model explains the characteristic and mechanism of ultrasound Doppler frequency shift in three-phase flow, which can be applied in similar flow conditions to obtain acceptable accuracy.