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Research article
Evaluation of wall slip effects on the flow characteristics of
petroleum coke–water slurry flow along pipelines
Xiaobin Zhang,1,2 Meng Liu,3,4* Kagiso Bikane4 and Yanrong Li1
1
College of Mining Engineering, Taiyuan University of Technology, Taiyuan 030024, China
2
Shanxi Water Conservancy Technical Institute, Yuncheng 044004, China
3
School of Energy and Environment, Southeast University, Nanjing 210096, China
4
Department of Chemical Engineering, Imperial College London, London SW7 2AZ, UK
ABSTRACT: Flow characteristics of petroleum coke–water slurry (PCWS) were investigated in a slurry transportation
facility. True rheological properties, drag reduction, and flow resistances of PCWS under the influence of wall slip were
studied using the Tikhonov regularization method. Results show that the shear viscosity is insensitive to changes in the shear
rate when the solid loading of PCWS is 59.8 wt%. However, the PCWS of 61.1 wt% exhibits typical dilatant fluid properties.
As the shear rate increases, the PCWS of 63.4 wt% initially exhibits shear thinning, and then, the viscosity increases sharply
when the shear rate exceeds 250 s1. In addition, the slurry also displays shear thinning at the shear rates exceeding 600 s1.
Modified friction factor-generalized Reynolds number correlation is established to describe the resistance properties of a
laminar flow of PCWS. When increasing the velocity, the drag reduction produced by the wall slip behavior reduces for
the 59.8 wt% PCWS but increases for the 61.1 wt% PCWS. The drag reduction decreases at the outset followed by an
increase for the 63.4 wt% PCWS. A decrease in the inner diameter of pipeline could enhance the effect of drag reduction
of PCWS flowing in a pipeline. © 2017 Curtin University and John Wiley & Sons, Ltd.
KEYWORDS: petroleum coke–water slurry; wall slip behavior; Tikhonov regularization; drag reduction; generalized
Reynolds number
resistance properties of PCWS flowing in the pipelines. stainless steel pipelines, water cooling system, and a
It is well known that different fluids show different wall slurry tank (1 m3). PCWS was prepared and sealed in
slip characteristics when flowing in pipes, and the wall a slurry tank, and the flow characteristics of PCWS
slip effect is related to many factors, including particle were conducted using different internal diameters (10,
size, test geometry, concentration, and surface 14, 16, and 20 mm) of stainless steel pipelines with
properties [11,16]. Numerical methods have been absolute surface roughness 0.015 mm. The flow rate
developed to investigate the wall slip characteristics of Q and pressure drop ΔP of PCWS flowing in the
slurry flowing in a pipeline [17–21]. The most important pipeline were measured using the electromagnetic flow
and the most widely used numerical method is the meter and a differential pressure sensor, respectively, in
classical Mooney method [17]. However, the classical which the data were recorded online. The slurry was
Mooney method cannot be used in the non-Newtonian pumped through the test section straight pipe (1.8 m)
solid–liquid fluid with a significant immigration of by a 2 m3/h screw pump with a frequency converter
particles. A modified Mooney method was developed to regulate the flow rate. The water cooling system
by Jastrzebski et al. [18] for the generalized Newtonian was installed in the pipeline to control the slurry
fluids, and it built the relationship of slip velocity and temperature. All the experiments were operated at
flow dimension [19]. Tikhonov regularization method 25 ± 1°C. Before each experiment, the slurry was
developed by Yeow et al. [20,21] has been widely used stirred and pumped for more than 0.5 h to allow it to
to analyze the experimental data to calculate the slip homogenize the slurry. In addition, each test was
characteristics of a fluid relating to phase separation, repeated twice to ensure the accuracy of the
i.e. particle immigration and sedimentation, and experimental data.
changes in local solid concentration [11,12,22]. This
method is modified from classical Mooney method,
and the results of slip characterization do not depend Materials
on the assumed rheological constitutive equation and
data extrapolation. Petroleum coke–water slurry was prepared by blending
In this study, the true rheological characteristics, pulverized petroleum coke (obtained from Jinling
drag reduction behavior, and resistance properties of Petro-Chemistry Company, Nanjing, China), tap water,
PCWS flowing in straight pipelines under different and chemical additives (stabilizer and anionic surface
flow conditions (solid loading, velocity, and pipe inner active agents, obtained from Nanjing University) in a
diameter) were investigated using the Tikhonov slurry tank. Weighed tap water was first added into
regularization method. Additionally, the prediction of the tank, and then, the speed of agitator was set to
the friction factor in straight pipeline by applying 100 rpm/min. Subsequently, the petroleum coke
generalized Reynolds number for non-Newtonian particles and a chemical additive were placed into the
fluids was developed. tank. The ratio of additive was kept at 3 wt‰ based
on the mass of petroleum coke for all PCWS. The
mixture was stirred using an agitator at 100 rpm for
EXPERIMENTAL 1 h. Flow behaviors of PCWS were investigated at
three solid loading at 59.8, 61.1, and 63.4 wt%,
Experimental setup respectively. The particle size distribution of petroleum
coke is shown in Fig. 2. Petroleum coke particles
The schematic of the closed-loop pipeline is shown in exhibit a typical bimodal distribution, and more than
Fig. 1. The experiment setup consists of a screw pump, 80% of the particles are less than 200 μm.
8V 8us ðτ w Þ 4 τw 2
¼ þ 3 ∫τ¼0 τ γðτ Þdτ (1) where Reμe is the Reynolds number calculated by the
D D τw
effective viscosity μe which is defined as the ratio of
wall shear stress and apparent shear rate 8Vc/D [28].
where V is the mean velocity, D is pipe internal
diameter, and 8V/D is apparent shear rate; 8usDðτw Þ is the
τw τ 4w
contribution of wall slip behavior; us(τ w) is the wall slip μe ¼ 8V c ¼ τw 2 (3)
velocity and function of wall shear stress τ w; D 4∫τ¼0 τ γðτ Þdτ
4 τw 2
τ 3w ∫τ¼0 τ γðτ Þdτ is ascribed to the shear flow and only
function of local wall shear stress. The Tikhonov
regularization method was applied to solve Eqn (1)
using many sets of data from different internal τ w =μe 8V c =D
M¼ ¼ ¼ 1 us =V (4)
diameters. The solution of the Tikhonov regularization 8V=D 8V=D
method is to discretize the right two terms of Eqn (1) in
the range of wall shear stress and calculate the apparent Therefore, the generalized Reynolds number for non-
shear rate using the data of Q and ΔP under different Newtonian fluids exhibiting wall slip phenomenon is
internal diameter. In addition, the calculation should determined by Eqn (5).
meet the following two conditions: (1) minimum
overall relative error S1 of apparent shear rate between Reμe ρVD
the calculated value and the experimental value and (2) Reg ¼
us ¼
(5)
the sum of the square S2 of the second derivative of the 1V μe 1 uVs
Method for determination of drag reduction overlap, particularly for the 61.1 and 63.4 wt% PCWS.
For the 63.4 wt% PCWS, the larger the diameter of the
During the transportation of PCWS in the pipelines, pipe diameter, the greater the wall stress at the same
drag reduction phenomenon takes place due to the apparent shear rates. The rheological properties of
existence of slip phenomenon near the pipe wall. slurry should be intrinsic features of the slurry, and the
Drag reduction is defined as the ratio of pressure flow behavior curves should be independent of the
drop reduction caused by wall slip behavior and geometry size [14,19]. Yilmazer et al. [30] and Kalyon [31]
pressure drop of PCWS flowing in the pipelines demonstrated that the rheological flow curves for
without wall slip [29]. different pipe diameters exhibited a deviation and did
2τ w
fs ¼ (6)
ρV 2
2τ w
fc ¼ (7)
ρV 2c
2
ΔPc ΔPs fs Vc
DR ¼ ¼1 ¼1
ΔPc fc V
us 2
¼1 1 (8)
V
not overlap at constant apparent shear rate, indicating the center) when the slurry was flowing, resulting in a
effect of the presence of the apparent wall slip. Barnes generally relatively thin layer of water near to the pipe
[32]
also found that the most obvious evidence of the wall and produced the wall slip phenomenon [35–37]. As
presence of wall slip is obtaining different rheological the solid loading of PCWS increases, velocity gradients
properties in different-sized geometries. This suggests increase in the slip layer and the wall slip phenomenon
that there is the wall slip behavior in the PCWS flowing. gets enhanced. Flow behavior curves obtained based on
For the concentrated suspensions, the ‘slip layer’ the assumption that the PCWS flowing in the pipelines
adjacent to the wall is generated by the migration of the does not have wall slip phenomenon deviate from the
solid particles. It will decrease the viscosity of slurry true flow behaviors. The stronger the wall slip is, the
and friction loss and has strong influence on the deviation is more apparent.
rheological properties. In addition, the factors affecting The experimental data were analyzed using a
wall slip include [24,33,34] particle size, concentration of numerical method based on Tikhonov regularization
slurry, dimensions of the measuring geometries, to solve Eqn (1), and the true rheological characteristics
temperature, and shear stress. From Fig. 4, the flow of PCWS are shown in Fig. 5(a). The flow curves of
behavior curves diverged more significantly for PCWS three solid loading PCWS obtained from different
at high solid loading than that for PCWS at low solid diameter overlap closely, suggesting that the effect of
loading, suggesting that the wall slip behavior became wall slip on the flow curves was modified. In addition,
more significant on the PCWS with the higher solid the plot of viscosity and shear rate is also displayed in
loading. The particles in the high shear rate region (near Fig. 5(b). The shear viscosity of PCWS is influenced
the pipe wall) were migrated to low shear rate region (the by solid loading and shear rates. At a PCWS solid
loading of 59.8 wt%, the shear viscosity is insensitive
to the shear rates and has the similar shear properties
as Newtonian fluids. When the solid loading of PCWS
is 61.1 wt%, PCWS becomes a dilatant fluid, and its
shear viscosity increases significantly with shear rates.
PCWS changes from a dilatant fluid to a pseudo-plastic
fluid when the shear rates increase for a solid loading of
63.4 wt%. Galindo-Rosales et al. [38] also found that
some shear thickening non-Newtonian fluids exhibited
complex rheological properties. Slurry first exhibits
shear thinning at low shear rate, followed by shear
thickening when shear rate exceeds a critical value,
and a subsequent shear thinning at high shear rates.
The variation trend of shear viscosity vs. shear rates
for slurry flowing in the pipe is controlled by two
forces: repulsion and hydrodynamic forces [39]. When
the interactions between particles are dominated by
repulsion forces, the forces keep particles as far away
as possible from each other. In addition, the slurry flow
arises in the form of particles moving into adjacent
vacancies, resulting in an extremely high but finite
viscosity of slurry. As the hydrodynamic forces
dominate the interactions, the particles with small
space in the direction of shear are forced into layers.
However, the space between the layers is larger, which
brings about a lower viscosity than the ordered three-
dimensional situation. In a flow of slurry, different
forces control the different shear rate regions. The main
parameters that control the variation trends are particle
size distribution, solid loading, particle shape, and
interaction between particles [40].
The rheological properties of PCWS is very
complicated and controlled by the two forces: repulsion
and hydrodynamic forces in the pipe flow. When the
Figure 5. True rheological of petroleum coke–water slurry solid loading of PCWS is 59.8 wt%, the particle
flowing in pipline. (a) Shear rate vs. shear stress. (b) Shear spacing is large, and the interactions between the
rate vs. true shear viscosity. particles are weak as observed in Fig. 5. Hydrodynamic
© 2017 Curtin University and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. (2017)
DOI: 10.1002/apj
X. ZHANG ET AL. Asia-Pacific Journal of Chemical Engineering
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© 2017 Curtin University and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. (2017)
DOI: 10.1002/apj