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Slurry flows inTitolo presentazione
pipeline systems
sottotitolo
modelling and management
Gianandrea Vittorio Messa Milano, XX mese 20XX
FluidLab Group
Dept. Civil and Environmental Engineering
www.fluidlab.polimi.it
Politecnico di Milano, Milano, Italy
Seminars organized by the DICA Scientific Commission, V cycle
Why are slurry flows so interesting? 2
Several applications involved
Mining industry
Chemical industry
Food industry
Oil and gas
…and many others
Slurry pipelines Drying/separators
Attractive for academia
Complex system
Many physical mechanisms
Oil sands processing
Challenge is linking scientific research (physical understanding and
modelling) with practical purposes (design and management)
Gianandrea Vittorio Messa, FluidLab Group, DICA
Research approach and milestones 3
2010 2013 2014 2015 2016 2018
Slurry flow modelling years…
Impact erosion years…
Key features of research @ FluidLab group:
Synergy of numerical and experimental
Always a look to the engineering needs
Gianandrea Vittorio Messa, FluidLab Group, DICA
Keynote outline
1 Slurry pipeline flows
2 The impact erosion issue
3 Current and future developments
Gianandrea Vittorio Messa, FluidLab Group, DICA
Keynote outline
1 Slurry pipeline flows
2 The impact erosion issue
3 Current and future developments
Gianandrea Vittorio Messa, FluidLab Group, DICA
The slurry flow team and its partners 4
Stefano me
Dr. Michael Malin
CHAM Limited
London UK
Prof. Vaclav Matousek
Czech Technical University in Prague
Prague CZ
Gianandrea Vittorio Messa, FluidLab Group, DICA
Basic questions 5
What is a slurry pipeline?
A pipeline used to transport granular material
mixed with water
What are the main concerns?
Reduce the energy consumption
Protect the particles against degradation
Protect the pipeline agains E/C
Reduce water consumption?
Solid volume fraction [-] Slurry
What is to be predicted?
Pressure losses
Pressure gradient
Particle distribution
Velocity field
Single-phase
Slurry velocity
Gianandrea Vittorio Messa, FluidLab Group, DICA
How to investigate slurry pipeline flows? 6
Physical modelling
Predominant approach
High economic cost
Technical issues even for simple flows
Size limitations https://sites.ualberta.ca/~turb/facilities.html
"Conceptual" modelling
Effective way for straight pipe flows
Many simplifying assumptions
Sometimes not so easy to implement
Not applicable to other geometries Pecker and Helvaci (2008)
Numerical modelling
Very complex models
Pending issues (particle accumulation)
Many parameters involved Ekambara et al. (2009)
Numerical problems
Potentially applicable to complex geometries and large scale systems
Gianandrea Vittorio Messa, FluidLab Group, DICA
A new predictive model 7
Defining the fundamental assumptions…
What type of model?
Euler-Euler, two-fluid model approach Solid
Liquid phase
Other approaches (e.g. Euler-Lagrange) not Slurry
phase
pratically applicable to dense flows in
complex geometries
What type of slurry flows?
Fully-suspended flow (no particle accumulation)
Fully-suspended flow Flow with a moving bed Flow with a stationary bed
Gianandrea Vittorio Messa, FluidLab Group, DICA
Overview of two-fluid model equations 8
Mass and momentum conservation equations Constitutive equations and closures
t
f f u f f f 2
Tj 2 j j S j TTj 2 j t S j
j kI j f,p
3
t
p pu p p p m f f 2.5
p m f exp
1
1 p 1
p p
p f 1
6 p
M p f M f p Fd Fl Fvm
d 3p
f f u f u f f p f Tf TTf 2
u p u f u p u f
1 dp
Fd Cd f
2 4
f f g M p f f u f t f
24 f up u f dp
Cd max 1 0.15Re0.687
p ,0.44 Re p
m
Re p
p p u p u p p p p Tp TpT
d 3p
Fl Cl f d 3p u f u p u f Fvm Cvm f u f u f u p u p
6
p p g M f p p u p t p
Turbulence modelling Wall boundary conditions for the solid phase
k2 w, p p s p u /p/ u /p/ s p s p ,1 1 s p ,2
t C
f f k
2
f f u f k f f t k
Re w, y
p u /p/ y
t k s p ,1
ln E Re
w, y s p ,1
p
f k t f f f Pk 0.75
m
0.3
p u /p/ d p
dp
s p ,2 0.3105Re 0.25
Re w,d
f f
w,d
f f
l
f f u f f f t
t
f t f f f C1 Pk C2
k
Gianandrea Vittorio Messa, FluidLab Group, DICAA typical pipe flow solution 9
Pressure profile
Flow
y
αp
Chord average
concentration profile
Solution on pipe cross section
Solid volume fraction Velocity of solid phase [m/s] Velocity of liquid phase [m/s]
0.270 0.283 0.295 0.308 0.320 0 0.90 1.80 2.70 3.60 0 0.90 1.80 2.70 3.60
Gianandrea Vittorio Messa, FluidLab Group, DICAMain features of the two-fluid model 10
Modelling of turbulent dispersion1
Friction, mixture viscosity-related parameter2,3
Modelling of wall shear stress due to particles3
Parabolic solution algorithm for straight pipe flows4
Solid volume fraction
0.270 0.283 0.295 0.308 0.320
ACCURATE: good agreement vs experiments
ROBUST: just one tuning, particle shape-related parameter
FAST: 40" for straight pipes, 2-3 days for a valve
NUMERICALLY STABLE: smooth solution, no oscillations
1 Spalding, in Recent Advancements in Numerical Methods in Fluids, Pineridge, 1980. Axial velocity of solid phase [m/s]
2 Messa et al., Powder Technol., 256 (2014), 61-70.
0 0.90 1.80 2.70 3.60
3 Messa and Malavasi, Powder Technol., 270 (2015), 358-367.
4 Patankar and Spalding, Int. J. Mass Transfer, 15 (1972), 1787-1806.
Gianandrea Vittorio Messa, FluidLab Group, DICAApplication to slurry pipeline flows 11
Validated against about 80 pipe experiments1-6
Pressure gradient accuracy within ±10%
Good match of solid volume fraction profiles
Consistent slurry velocity distributions
Cvd=0.11 Cvd=0.21 Cvd=0.31
1 Roco and Shook, Can. J. Chem. Eng. 61 (1983), 494-503
2 Gillies et al., Can. J. Chem. Eng. 82 (2004), 1060-1065
3 Matousek, Exp. Therm. Fluid Sci. 26 (2002), 692-70
4 Shaan et al, Can. J. Chem. Eng. 78 (2000), 717-725
Solid volume fraction
5 Lee at al., Terra et Aqua 99 (2005), 3-10
6 Shaan and Shook, Can. J. Chem. Eng. 78 (2000), 726-730 0.00 0.13 0.25 0.38 0.50
Gianandrea Vittorio Messa, FluidLab Group, DICAApplication to horizontal pipe bends1,2 12
S2 S3
S1 S4
S5
S6
OUTLET
INLET
1 Kaushal et al., Int. J. Multiphase Flow, 52 (2013), 71-91. Solid volume fraction
2 Messa and Malavasi, Eng. Appl. Comput. Fluid Mech., 8(3) (2014), 356-372.
0 0.13 0.25 0.38 0.50
Gianandrea Vittorio Messa, FluidLab Group, DICAApplication to more complex geometries 13
Backward-facing step1…
Solid volume fraction
0 0.08 0.16 0.24 0.32
Fluid velocity magnitude [m/s]
0 1.13 2.25 3.38 4.50
… and flow control valves2
1 Messa and Malavasi, J. Hydrol. Hydromech., 62(3) (2014), 234-240.
2 Messa and Malavasi, PVP2013, Paris, France, 14-18 July 2013.
Gianandrea Vittorio Messa, FluidLab Group, DICAKeynote outline
1 Slurry pipeline flows
2 The impact erosion issue
3 Current and future developments
Gianandrea Vittorio Messa, FluidLab Group, DICAThe impact erosion team and its partners 14
Stefano me Marco Yongbo
Prof. Josè Gilberto Dalfrè Filho
University of Campinas
Campinas, Sao Paulo, Brasil
Prof. Armando Carravetta
Dr. Oreste Fecarotta
Università Federico II di Napoli
Napoli
Gianandrea Vittorio Messa, FluidLab Group, DICABasic questions 15
What is the slurry impact erosion?
The loss of material from hydraulic
components due to the impingement of
solid particles carried by a liquid
Where is impact erosion likely to occur?
Straight pipes and connections
Hydraulic devices (pumps, valves…)
How may research help?
Improve the design of the components
Enhance the management of the system
Develop protective coatings
How does our research develop? Valve needle
Start with the impact erosion in dilute flow
Move on with impact/abrasion erosion in dense flows
Gate valve
Gianandrea Vittorio Messa, FluidLab Group, DICAFirst challenge: the EPICO project 16
EPICO project: "Erosion Prediction In Control Operation"
GOAL: Development of methods for estimating
the useful life of valves subjected to erosive
wear in fields with sand production
Experimental
(two new setups @ LIF)
Numerical
(in-house code)
Gianandrea Vittorio Messa, FluidLab Group, DICATwo experimental facilities @ LIF 17
E-loop DIT
nozzle
specimen
2" to 4" testing line
Up to 28 bar
Up to 160 m3/h
Angle choke valve Gate valve Inconel 718 GRE
Gianandrea Vittorio Messa, FluidLab Group, DICANumerical approach: Eulerian-Lagrangian modelling 18
Fluid simulation Particle tracking Erosion model
coupling
Fluid simulation: solution of the Reynolds-averaged Navier-Stokes equations (RANS)
U 0
U U P U g Re S p
+ turbulence model for Re
Additional source
due to particles
Output:
Fluid velocity magnitude [m/s]
- Mean fluid pressure
- Mean fluid velocity
0 7 14 21 28 35
- Fluid turbulence variables
Gianandrea Vittorio Messa, FluidLab Group, DICANumerical approach: Eulerian-Lagrangian modelling 19
Fluid simulation Particle tracking Erosion model
coupling
Particle tracking: solution of the Lagrangian particle equations of motion
p c f Wpdv
dt
f d p2 Cd w w p f W p g
1
8
du@ p Du@ p * mp
f W p c J 3.0844 ω w
dt Dt pd p ω
Output:
Particle velocity magnitude [m/s]
- Particle trajectories
- Particle-wall impacts characteristics
0 10 20 30 40
Gianandrea Vittorio Messa, FluidLab Group, DICANumerical approach: Eulerian-Lagrangian modelling 20
Fluid simulation Particle tracking Erosion model
coupling
Erosion model: material removal by each particle-wall impingement and sum
Input data:
Impact velocity
Impact angle
Properties of materials
M imp C m p BH vimp f imp
a n
e.g. E/CRC
Impact Output:
Erosion depth [mm]
wear - Mass losses
scar
0 0.25 0.50 0.75
Gianandrea Vittorio Messa, FluidLab Group, DICANumerical modelling 21
In-house tool for erosion prediction Flow
Specifically intended for complex geometries
E-code Multi-component analysis Body
Effect of selective coating
CAD
Cage
Sleeve
Retaining
Volume Surface sleeve
Meshing Meshing
mmeroded
1.0
CFD
E-code 0.8
simulation
0.6
0.4
Erosion 0.2
estimation
0.0
Gianandrea Vittorio Messa, FluidLab Group, DICAResearch strategy1-3 22
Direct impact testing DIT
nozzle
Combine our experiments to literature data
Assess the reliability of the prediction model3
Validate a target-oriented model
E-code
RANS simulation of water flow
specimen
DPM particle tracking
E-code
Fluid velocity magnitude [m/s]
0 7 14 21 28 35
Particle velocity magnitude [m/s]
0 10 20 30 40
1 Messa et al., Int. Conf. on Wear of Materials, Long Beach, US-CA, 2017
2 Gorini et al., Offshore Mediterranean Conference, Ravenna, Italy, 2017
3 Messa and Malavasi, Wear, 370-371 (2017), 59-72.
Gianandrea Vittorio Messa, FluidLab Group, DICAResearch strategy1-4 23
Valve testing and validation
Mass loss history of valve cage
Erosion valve testing in the E-loop 20
Validation of the prediction model 18
Flow 16 E-loop
mmeroded 14
1.0 Body 12
[g]
10
0.8
8
0.6 6
4
0.4 E-code
Cage 2
0.2 Sleeve 0
Retaining 0.00 2.00 4.00 6.00 8.00 10.00
0.0 sleeve [h]
Choke valve
Gate valve
Flow
1 Flow
Messa et al., Int. Conf. on Wear of Materials, Long Beach, US-CA, 2017
2 Gorini et al., Offshore Mediterranean Conference, Ravenna, Italy, 2017
mm/d
3 Malavasi at al., ASME PVP 2018, Prague, CZ, 2018. Under review.
4 Messa at al., AIMETA 2017, Salerno, IT, 2017. 0 1 2 3 4 5
Gianandrea Vittorio Messa, FluidLab Group, DICAResearch strategy1-4 24
Virtual experiments and data analysis
Type of valve
Erosion valve simulation in different conditions
Database collection
Size of valve
Sensitivity analysis
Identification of the most relevant parameters
Engineering failure analysis Useful life-time Valve opening
Flow conditions
Abrasive load
E-code
1 Messa et al., Int. Conf. on Wear of Materials, Long Beach, US-CA, 2017
2 Gorini et al., Offshore Mediterranean Conference, Ravenna, Italy, 2017
3 Malavasi at al., ASME PVP 2018, Prague, CZ, 2018. Under review.
4 Messa at al., AIMETA 2017, Salerno, IT, 2017.
Gianandrea Vittorio Messa, FluidLab Group, DICAKeynote outline
1 Slurry pipeline flows
2 The impact erosion issue
3 Current and future developments
Gianandrea Vittorio Messa, FluidLab Group, DICATowards the modelling of dense slurry erosion 25
Particle-particle interactions become important
Self-induced geometry changes may become important
IDEA: Mixed EE-EL model with self-updating boundary1-4
Computational burden of
Eulerian-Lagrangian
approach grows
exponentially! No practically
feasible for complex flows
EE domain
Interface
EL subdomain
1 Messa et al., ASME Pressure Vessels and Piping Conference, Anaheim, US-CA, 2015.
2 Messa et al., Wear, 398-399 (2018), 127-145.
3 Messa and Malavasi, 9th Int. Conference on Multiphase Flow, Firenze, Italy, 2016.
4 Messa and Malavasi, Wear, 398-399 (2018), 127-145.
Gianandrea Vittorio Messa, FluidLab Group, DICAInvestigation of concrete erosion1-3 26
E-CODE for non-homogeneous materials
Experiments / simulation
Cooperation with UNICAMP, Brazil
E-code Experimental
1 Malavasi et al., XX SBRH, Bento Gonçalves, Brazil, 2013.
2 De Lima Branco et al., XXII SBRH, Florianopolis, Brazil, 2017.
3 Messa et al., J. Hydrol. Hydromech., 66 (2018), 121-128.
Gianandrea Vittorio Messa, FluidLab Group, DICAImpact erosion in devices with moving components 27
E-CODE for rotating bodies
Application to Pumps As Turbines1 and Valves
Cooperation with UNINA
E-code
Stirred tank
Pump used as turbine
Gate valve
1 Fecarotta et al., 3rd Efficient Water Systems Conference, Lefkada, Greece, 2018. Under review.
Gianandrea Vittorio Messa, FluidLab Group, DICATowards a more general view of slurry systems 28
Keyword: sustainability of the process
Accounting for water saving?
Multidisciplinary design and management
Durability Energy
Water
Gianandrea Vittorio Messa, FluidLab Group, DICAThank you for your attention
www.fluidlab.polimi.it
Gianandrea Vittorio Messa
Assistant Professor
FluidLab Group
Dept. Civil and Environmental Engineering
Politecnico di Milano
Piazza Leonardo da Vinci, 32
20133 Milano (Italy)
e-mail: gianandreavittorio.messa@polimi.it
Tel. +39 02 2399 6287
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