A Simple Mathematical Model For Slug Liquid Holdup in Horizontal Pipes
A Simple Mathematical Model For Slug Liquid Holdup in Horizontal Pipes
A Simple Mathematical Model For Slug Liquid Holdup in Horizontal Pipes
KEYWORDS Abstract This paper presents a methodology for calculation of a slug, two-phase flow hold-up in a
Two phase flow; horizontal pipe. The advantage of this method is that the slug unit hold up can be calculated directly
Slug flow; from the solutions of flow field equations with no need to use correlations. An experimental apparatus to
Liquid holdup. measure air–water hold up was setup. The flow pattern and liquid holdup in horizontal and inclined pipes,
from angles 5° to 40°, for air–water two-phase flow, are experimentally observed. The test section, with
an inside diameter of 30 mm and 3 m in length, was made of plexy-glass to permit visual observations
of the flow patterns. The proposed model was tested extensively against experimentally collected data.
Furthermore, other data sources for slug flow in horizontal pipes, for air–water and air–oil systems, were
also used for comparison. The presented methodology was compared against four recently developed
models of a two phase, slug flow holdup in horizontal pipes. Not only does the presented model
demonstrate good agreement, with less than 6.8% error, compared to the experimental data, but also has
less error compared to other models. These results substantiate the general validity of the model.
© 2012 Sharif University of Technology. Production and hosting by Elsevier B.V.
Open access under CC BY-NC-ND license.
1. Introduction a unit cell. Based on this approach, Taitel and Barnea [2] con-
cluded that across the boundary between the liquid slug and
Slug flow can be observed in many two-phase flow engineer- the long gas bubble region, flow appears steady, with mass and
momentum conserved. The unit cell concept bred a number of
ing applications, such as flow in oil and gas pipelines and other
models for calculating slug hydrodynamic parameters [3].
process industries. The formation of the slug regime is transient
The first comprehensive model was developed by Dukler
in nature, passing from stratified to wavy flow and then onto
and Hubbard [4]. Further papers employing the unit cell concept
slug flow. The existence of an interface between the two phases
improved the steady state slug flow model: Nicholson et al. [5];
that will change easily is a challenge for modeling [1]. Initial at-
Kokal and Stanislav [6] and, later, De Henau and Raithby [7] de-
tempts to model slug flow neglect its non-deterministic nature veloped a steady-state two-fluid model for the pressure gradi-
by considering the alternating liquid pistons and gas bubbles in ent and liquid holdup.
an orderly periodic way. They tested their model against a limited number of exper-
The flow is reduced to periodic cells moving downstream imental data. Good agreement was reported for air–water and
composed of a liquid piston trailed by a gas bubble, also named air–oil slug flow in horizontal pipes.
One of the most significant studies in this field was carried
∗ out by Taitel and Barnea published in their second paper [8].
Corresponding author.
E-mail addresses: ferzal.reza@gmail.com (R. Nobakht Hassanlouei),
They employed a consistent method for calculating the pressure
hastifirooz@yahoo.com.au (H. Firouzfar), capepub@cape.iust.ac.ir (N. Kasiri), gradient in steady state slug flow in inclined pipes. For
khanof@iust.ac.ir (M.H. Khanof). calculation of slug holdup, they considered variations of film
Peer review under responsibility of Sharif University of Technology. thickness and, based on this assumption, momentum balance
was developed. Then, the length of liquid film holdup, and the
velocity at the end of the liquid film were the model outputs.
Taitel and Barnea [8] used the holdup to calculate pressure,
while assuming that the film thickness was uniform, and
1026-3098 © 2012 Sharif University of Technology. Production and hosting by Elsevier B.V. Open access under CC BY-NC-ND license.
doi:10.1016/j.scient.2012.05.010
1654 R. Nobakht Hassanlouei et al. / Scientia Iranica, Transactions C: Chemistry and Chemical Engineering 19 (2012) 1653–1660
Figure 2: Variation of liquid holdup by gas flow rate in a horizontal pipe with Figure 5: Variation of liquid holdup by gas flow rate in a pipe with Θ = 30°
D = 0.03 m. and D = 0.03 m.
Figure 3: Variation of liquid holdup by gas flow rate in a pipe with Θ = 10° Figure 6: Variation of liquid holdup by gas flow rate in a pipe with Θ = 40°
and D = 0.03 m. and D = 0.03 m.
Figure 4: Variation of liquid holdup by gas flow rate in a pipe with Θ = 20° Figure 7: Variation of liquid holdup with inclination angle at GF = 20 l/m and
and D = 0.03 m. D = 0.03 m.
liquid slippage increases, and as the gas inertia forces are not increases, because the liquid is naturally pulled to the bottom
enough to overcome it, the gas phase cannot carry over the by gravity. Figure 7 shows this change at 20 l/min gas flow rate.
liquid, resulting in an increase in liquid holdup. The value of In other gas flow rates, the changes of liquid holdup by the
liquid holdup seems to increase when the inclination angle inclination angle are the same.
1656 R. Nobakht Hassanlouei et al. / Scientia Iranica, Transactions C: Chemistry and Chemical Engineering 19 (2012) 1653–1660
The hydraulic diameters (Dhf , DhG ) of the liquid film and gas other air–water and air–oil data sources in horizontal pipes. The
bubbles are [9]: specification of these data sources are recorded in Table 1.
4Af The developed model was compared with Gomez et al. [14],
Dhf = , (17) Leung [25], Abdul-Majeed [16] and Zhang et al. [13] models.
Sf Parameter ranges of these empirical correlations are shown in
4AG Table 2.
DhG = . (18) The Leung [25] model was evaluated based on a wide exper-
(SG + Si )
imental database by Ghajar and Woldesemayat [26]; they sug-
For laminar flow of both phases: gested this correlation is an accurate empirical correlation for
Cf = CG = 16 n = 1. (19) holdup calculations in horizontal and inclined pipes.
For turbulent flow of both phases: The parameter range for which this assessment was carried
out is shown in Table 2. The Zhang model [13] is a mechanistic
Cf = CG = 0.046 m = 0.2. (20)
model for inclined and horizontal pipes, which is valid for gas
The interfacial friction factor suggested by Hanratty and Cohen velocities over 0.1 m/s.
[24] correlation: The accuracy of the models was evaluated by calculating the
fi = 0.0142. (21) percentage error of individual data points (IPE), the Average
The above value can be used for slug flow in inclined pipes too. Percentage Error (APE) and Absolute Average Percentage Error
The film zone flow geometry is shown in Figure 9 and the liquid (AAPE) of each data source, which is defined below [9]. The
holdup in the film zone is defined by one half of the angle that regression coefficient (R2 ) of all data sources is also reported.
subtends the liquid–gas interface, Θ [9]: n
n
2
IPEi |IPEi |
D i=1 i=1
Af = (θ − 0.5 sin 2θ ), (22) APE = , AAPE = , (28)
4 n n
D2 Predicted − Measured
AG = (π − θ + 0.5 sin 2θ ). (23) IPE = × 100. (29)
4 Measured
The wet perimeter of film, gas and interfacial zones (Sf , SG , Si ) The result of this comparison has been shown in Table 3. This
are expressed by: table shows that the theoretical model matches the holdup of
Sf = Dθ , SG = D(π − θ ), Si = D sin θ , (24) 125 data points within an average percent error of 6.72 and
absolute average percent error of 11.14. As demonstrated in
θ − 0.5 sin 2θ Table 3, the error of presented model was the lowest when
Hf = . (25)
π compared to other methods studied.
By contrast, Abdul-Majeed’s [16] model, developed to calcu-
3.2. Computational procedure late slug liquid holdup in horizontal and slightly inclined two-
phase slug flow, has shown scattered results. This empirical
The simple sub model of Taitel and Barnea [8] for horizon- model is not valid for superficial liquid velocities higher than
tal gas–liquid slug flow has been reformulated by Orell [9]. This 2.316 m/s, so outlier data are eliminated for comparison.
model could not predict the slug unit liquid holdup theoreti- Abdul-Majeed [16] and his colleagues did not provide veri-
cally, so the experimental correlation of Andreussi and Bendik- fication results of their model for horizontal pipes. They mixed
sen [10] was used for slug holdup calculations. horizontal data with upward and downward inclined flow data
Also, the slug length is not obtainable from this model. In the (−5 < Θ < 10), then compared and calculated the APE of their
present study, no experimental correlations for film and slug model with horizontal-upward inclined flow and horizontal-
holdups are used, the slug unit liquid holdup being calculated by downward inclined flow data sources.
the equations referred to in the following solution procedure: The error was lower than ±10%, but comparison of Abdul-
1. Following parameters e.g. ρL , ρG , µL , µG , D, USL , USG should Majeed’s [16] model to the experimental data of horizontal
be defined as inputs. pipes shows that this empirical model is not accurate enough
2. Eqs. (1), (2) and (11) constitute the basic equations of the for horizontal pipes.
model. Substituting the required parameters from Eqs. (8) One reason for this problem could be that the empirical cor-
and (12)–(25), result in a set of equations. relation presented by Abdul-Majeed [16] only contained liquid
3. The equations are solved analytically providing the slug flow to gas velocity ratios. Corresponding to literature, the empirical
characteristic variables, Uf , UG , Hf , HS . A computer program correlations which used other significant flow characteristics
was used to solve the equations; (e.g. gas density, liquid density, surface tension, etc.) are more
4. Using the equations below, the average liquid holdup in slug accurate.
unit, HSU , and the average void fraction in the slug unit, ESU , Gomez et al. [14] developed a dimensionless correlation for
were defined: calculating slug liquid holdup in horizontal and upward vertical
lS lf pipes. The dimensionless groups of this correlation are inclina-
HSU = HS + Hf , (26) tion angle and Reynolds number.
l l
The Reynolds number was defined by a mixture velocity
lS lf
ESU = (1 − HS ) + (1 − Hf ) . (27) without considering the slippage of phases, and the effect of the
l l gas phase was ignored for calculation of density and viscosity.
Thus, it is not surprising that the recent model, which considers
4. Results and discussion the slippage of phases and effects of both phases in flow char-
acteristics, provides more accurate results.
The proposed model was tested against the experimental Armand and Massima’s model [25] was considered in the
liquid holdup data of air–water from an available setup and category of K εH correlations by Ghajar and Woldesemayat [26].
1658 R. Nobakht Hassanlouei et al. / Scientia Iranica, Transactions C: Chemistry and Chemical Engineering 19 (2012) 1653–1660
Data source Diameter (m) Gas velocity (m/s) Liquid velocity (m/s) Fluids Data points
Gomez et al. 0–90 7.6, 17.8, 20.3, 5.1 Air–kerosene, freon–water, air–water, nitrogen–diesel, air–oil
Model [14]
Leung [25] 0–90 5.25, 10.22, 2.54, 3.81, 4.55, 7.80, 1.9, 5.08, 1.27 Air–water, air–kerosene, natural gas–water
Abdul-Majeed [16] −10–+9 7.62, 5.10, 17.145, 20.32, 2.58 Air–kerosene, air–light oil, freon–water, air–water, nitrogen–diesel
Table 3: Comparison of slug unit liquid holdup predictions with data sources.
Data source Present model Gomez et al. model [14] Leung [25] Abdul-Majeed [16] Zhang et al. [13]
APE AAPE APE AAPE APE AAPE APE AAPE APE AAPE
Available set up 0.394 1.44 33.69 33.69 26.42 26.42 56.01 56.01 26.53 26.53
Heywood and Richardson [27] 11.62 15.93 29.57 29.57 1.75 3.89 56.27 56.27 38.48 38.48
Abdul-Majeed [16] 14.61 14.61 8.90 8.90 41.67 41.67 12.61 12.61 43.08 43.08
Nicholson et al. [5] 11.49 12.80 34.69 36.56 1.03 15.44 36.14 36.14 38.45 38.45
Kokal and Stanislav [6] 6.24 8.41 24.19 32.30 27.76 27.76 34.67 34.67 36.43 36.43
Total error 6.72 11.14 29.12 30.72 12.46 16.87 44.26 44.26 36.13 36.13
Table 4: Comparison of slug unit liquid holdup predictions with all data sources.
Presented model Gomez et al. model [14] Leung [25] Abdul-Majeed [16] Zhang et al. [13]
References
[1] Ansari, M.R. and Shokri, V. ‘‘Numerical modeling of slug flow initiation in
horizontal channels using a two-fluid model’’, Int. J. Heat Fluid Flow, 32,
pp. 145–155 (2011).
[2] Taitel, Y. and Barnea, D. ‘‘Two-phase slug flow’’, Adv. Heat Transfer, 20,
pp. 43–132 (1990).
[3] Mazza, R.A., Rosa, E.S. and Yoshizawa, C.J. ‘‘Analyses of liquid film models
applied to horizontal and near horizontal gas–liquid slug flows’’, Chem.
Eng. Sci., 65, pp. 3876–3892 (2010).
[4] Dukler, A.E. and Hubbard, M.G. ‘‘A model for gas–liquid slug flow in
horizontal and near horizontal tubes’’, Ind. Eng. Chem. Fundam., 14,
pp. 337–347 (1975).
[5] Nicholson, M.K., Aziz, K. and Gregory, G.A. ‘‘Intermittent two phase flow
in horizontal pipes: predictive models’’, Can. J. Chem. Eng., 56, pp. 653–663
(1978).
[6] Kokal, S.L. and Stanislav, J.F. ‘‘An experimental study of two-phase flow in
slightly inclined pipes-II: liquid holdup and pressure drop’’, Chem. Eng. Sci.,
44, pp. 681–693 (1989).
[7] De Henau, V. and Raithby, G.B. ‘‘A transient two-fluid model for the
simulation of slug flow in pipelines-I, theory’’, Int. J. Multiphase Flow, 21,
pp. 335–349 (1995).
[8] Taitel, Y. and Barnea, D. ‘‘A consistent approach for calculating pressure
Figure 11: Comparison of predicted slug unit liquid holdup and air–water drop in inclined slug flow’’, Chem. Eng. Sci., 45, pp. 1199–1206 (1990).
[9] Orell, A. ‘‘Experimental validation of a simple model for gas–liquid slug
experimental data.
flow in horizontal pipes’’, Chem. Eng. Sci., 60, pp. 1371–1381 (2005).
[10] Andreussi, P. and Bendiksen, K. ‘‘An investigation of void fraction in liquid
slugs for horizontal and inclined gas–liquid pipe flow’’, Int. J. Multiphase
Flow, 15, pp. 937–946 (1989).
[11] Andreussi, P., Minervini, A. and Paglianti, A. ‘‘Mechanistic model of slug
flow in near-horizontal pipes’’, AIChE. J., 39, pp. 1281–1291 (1993).
[12] Al-Safran, E.M., Taitel, Y. and Brill, J.P. ‘‘Prediction of slug length
distribution along a hilly terrain pipeline using slug tracking model’’,
J. Energy Res. Technol., 126, pp. 54–62 (2004).
[13] Zhang, H.Q., Wang, Q., Sarica, C. and Brill, J.P. ‘‘A unified mechanistic model
for slug liquid holdup and transition between slug and dispersed bubble
flows’’, Int. J. Multiphase Flow, 29, pp. 97–107 (2003).
[14] Gomez, L.E., Shohama, O. and Taitel, Y. ‘‘Prediction of slug liquid holdup:
horizontal to upward vertical flow’’, Int. J. Multiphase Flow, 26, pp. 517–521
(2000).
[15] Issa, R.I. and Kempf, M.H.W. ‘‘Simulation of slug flow in horizontal and
nearly horizontal pipes with the two-fluid model’’, Int. J. Multiphase Flow,
29, pp. 69–95 (2003).
[16] Abdul-Majeed, G.H. ‘‘Liquid slug holdup in horizontal and slightly inclined
two-phase slug flow’’, J. Pet. Sci. Eng., 27, pp. 27–32 (2000).
[17] Soleimani, A. and Hanratty, T.J. ‘‘Critical liquid flows for the transition from
Figure 12: Comparison of predicted slug unit liquid holdup and air–oil the pseudo-slug and stratified patterns to slug flow’’, Int. J. Multiphase Flow,
experimental data. 29, pp. 51–67 (2003).
[18] Azzi, A., Friedel, L., Kibboua, R. and Shannak, B. ‘‘Reproductive accuracy of
two-phase flow pressure loss correlations for vertical 90° bends’’, Forsch.
other hand, liquid slug length (ls ) was estimated by the Gregory Ingenieurwesen, 67, pp. 109–116 (2002).
[19] Azzi, A., Alger, U.S.T.H.B. and Friedel, L. ‘‘Two-phase upward flow 90° bend
and Scott [22] correlation. Two critical unknowns for calculat- pressure loss model’’, Forsch. Ingenieurwesen, 69, pp. 120–130 (2005).
ing slug unit liquid holdup (HS , Hf ) are found by solving mo- [20] Balakotaiah, V., Ungar, E., Motil, B.J., Lastochkin, D. and Dao, E.K. ‘‘Modeling
mentum equations. and experimental studies on gas–liquid two-phase flows at normal and
microgravity conditions’’, The University of Houston, Isso Annual Report
So, unlike the Orell model [9], the calculation of slug liquid (2000).
holdup is not dependent on a specific range and is not as [21] Brennen, C.E., Fundamentals of Multiphase Flow, Cambridge University
sophisticated as the Taitel and Barnea [8] model. Press, New York (2005).
[22] Gregory, G.A. and Scott, D.S. ‘‘Correlation of liquid slug velocity and
The experimental work was carried out to gather liquid frequency in horizontal co-current gas liquid slug flow’’, AIChE J., 15,
holdup air–water data in horizontal and inclined pipes. The pro- pp. 933–935 (1969).
posed model was tested extensively against 125 experimental [23] Xin, W., Liejin, G. and Ximin, Z. ‘‘Development of liquid slug length
in gas–liquid slug flow along horizontal pipeline: experiment and
data sets. The average percentage error and absolute average simulation’’, Chinese. J. Chem. Eng., 14, pp. 626–633 (2006).
percentage error were calculated for model comparison. [24] Hanratty, J.T. and Cohen, S.L. ‘‘Effects of waves at a gas–liquid interface on
The results show that the total average percentage error a turbulent air flow’’, J. Fluid Mech., 31, pp. 467–469 (1968).
[25] Leung, L.K.H. ‘‘Two phase flow, thermal hydraulics branch, Chalk river
of the present model was 6.72 and the average absolute laboratories’’, AECL, UNENE Thermal Hydraulic Scours, (2005).
percentage error was 11.14, both of which are lower than other [26] Ghajar, A.J. and Woldesemayat, M.A. ‘‘Comparison of void fraction
empirical and mathematical models. These results substantiate correlations for different flow patterns in horizontal and upward inclined
pipes’’, Int. J. Multiphase Flow, 33, pp. 347–370 (2007).
that the new modified model is independent of various physical [27] Heywood, N.I. and Richardson, J.F. ‘‘Slug flow of air–water mixtures in
properties of flowing fluid, so it has an adequate prediction a horizontal pipe: determination of liquid holdup by X-ray absorption’’,
potential for a broad range of situations for slug liquid holdup Chem. Eng. Sci., 34, pp. 17–30 (1979).
calculations in horizontal pipes.
Hasti Firouzfar began her studies at Arak University, Iran, in 2002, and obtained he established the Computer Aided Process Engineering Research Laboratory
an M.S. degree in Chemical Engineering from Iran University of Science and (CAPE).
Technology (IUST), in 2009. She has worked as a lecturer in Azad University, His research interests include software consultation, training, design,
Iran, and has been teaching assistant for a Modeling and Simulation course at writing and development, process feasibility evaluation, equipment & layout
IUST since 2009. Her research interests include: fluid flow and multiphase flow. design, simulation, optimization & analysis.
She is currently working in the Computer Aided Process Engineering Laboratory
at IUST as a research assistant.
Mohammad Hassan Khanof began his studies at Sharif University of
Technology, Tehran, Iran, in 1975, after which he obtained an M.S. degree
in Chemical and Mechanical Engineering from the University of Southern
Norollah Kasiri began his studies at Glamorgan University, UK, and obtained California, USA, in 1977. He has been lecturer in the Chemical Engineering
M.S. and Ph.D. degrees in Chemical Engineering from Swansea University, UK, Department at Iran University of Science and Technology, since 1989, where
in 1988 and 1993, respectively. Since then, he has been lecturer at the Chemical he also manages the Fluid Flow Laboratory. His research interests include fluid
Engineering Department in Iran University of Science and Technology, where flow and multiphase flow, in which he has published papers.