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University of Alberta University of Alberta Scaling of Effervescent Atomization and Industrial Two-Phase Flow by Mohammad Azizur Rahman A thesis submitted to the Faculty of Graduate Studies and Research in partial fulfillment of the requirements for the degree of Doctor of Philosophy Department of Mechanical Engineering ©Mohammad Azizur Rahman Spring 2011 Edmonton, Alberta Permission is hereby granted to the University of Alberta Libraries to reproduce single copies of this thesis and to lend or sell such copies for private, scholarly or scientific research purposes only. Where the thesis is converted to, or otherwise made available in digital form, the University of Alberta will advise potential users of the thesis of these terms. The author reserves all other publication and other rights in association with the copyright in the thesis and, except as herein before provided, neither the thesis nor any substantial portion thereof may be printed or otherwise reproduced in any material form whatsoever without the author's prior written permission. 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The author retains copyright L’auteur conserve la propriété du droit d’auteur ownership and moral rights in this et des droits moraux qui protège cette thèse. Ni thesis. Neither the thesis nor la thèse ni des extraits substantiels de celle-ci substantial extracts from it may be ne doivent être imprimés ou autrement printed or otherwise reproduced reproduits sans son autorisation. without the author’s permission. In compliance with the Canadian Conformément à la loi canadienne sur la Privacy Act some supporting forms protection de la vie privée, quelques may have been removed from this formulaires secondaires ont été enlevés de thesis. cette thèse. While these forms may be included Bien que ces formulaires aient inclus dans in the document page count, their la pagination, il n’y aura aucun contenu removal does not represent any loss manquant. of content from the thesis. ABSTRACT The objective of this thesis was to develop a novel understanding of the mechanics of two phase gas-liquid flows and sprays injected through industrial effervescent nozzles. This was done using detailed experimental investigations and scaling for two-phase flows and sprays. This study helps to quantify near-field liquid and gas phase statistics that are challenging and impossible to measure in the reactors due to inaccessibility restrictions. The development of nozzles is generally performed on air-water systems. My plan was to begin with the study of small-scale sprays (air and water) to compare to full scale industrial conditions at pilot operation (air-water) or at commercial operation (steam- bitumen), to determine size scaling relationships. The relationship between the lab scale air-water experiments and real industrial scale steam-bitumen has never been fully examined. Knowledge from this thesis will make the development of future nozzles with much less dependent on trial and error. This thesis was an attempt to establish fundamental scaling relationships for the prediction of two-phase spray behavior that can be applied directly to full scale industrial size nozzles that would be of very significant value to industries and to the scientific community in general. Understanding the performance of two phase nozzles through established scaling laws will aid in optimizing the two phase nozzle flow conditions and will serve as a major tool in nozzle design and development for future generation nozzles for many industrial applications. Acknowledgements I express heartfelt thanks to my supervisors Dr. Brian A. Fleck and Dr. Ted Heidrick for their unique supervision and excellent guidance throughout my PhD thesis work. Their vigorous pursuit of excellence in research, mentorship, advising and every other aspect of their work is truly inspiring. They have always actively encouraged me to broaden my research interests and develop professionalism. I am deeply appreciative for many helpful discussions and all the work they have done on my behalf. I thank my supervisory committee, for the helpful advice and critical feedback. Additionally, I am grateful to Professor André G. McDonald for his productive feedback. The expertise of the machine shop staff, Greg, Berny, Roger, and Tuula, was of great help in the laboratory. I would like to extend my thanks to my colleagues at the University of Alberta and at the Syncrude research facility in Edmonton. Dr. Jennifer McMillan and Dr. Edward Chan have provided me exemplary motivation in my research endeavours. I thank NSERC and Alberta Innovates-Technology Futures for providing financial support. I would like to thank my mother, my late father, my wife, my son, my daughter, and my family for their extraordinary support in my PhD research endeavour. For their commendable encouragement, mental support, inspiration and cooperation, I was able to complete my thesis smoothly and productively. Finally, my greatest thanks go to Almighty Allah for all of His blessings. To my parents and family: To my wife, my daughter, Rodela and my son, Abeer TABLE OF CONTENTS CHAPTER 1 INTRODUCTION................................................................................... 1 1.1. Background................................................................................................................ 2 1.2. Commercial Fluid Coker............................................................................................ 8 1.3. Research Outline........................................................................................................ 8 1.4. Thesis Objectives ..................................................................................................... 10 1.5. Conclusions.............................................................................................................. 10 1.6. Original Contributions in Effervescent Atomization Study..................................... 10 1.7. References................................................................................................................ 12 CHAPTER 2 Literature: Two Phase Flow................................................................. 19 2.1. Introduction.............................................................................................................. 19 2.2. Basic Concepts and Definitions............................................................................... 20 2.3. Dimensionless Numbers in Two-Phase Flows ........................................................ 22 2.4. Advanced Pressure Measurement Techniques......................................................... 24 2.5. Advanced Void Fraction Measurement Techniques................................................ 30 2.6. Advanced Photonics and Image Analysis Techniques ............................................ 34 2.6.1. Taitel and Dukler Flow Maps [87, 103]................................................................ 37 2.6.2. Breber Map [104].................................................................................................. 39 2.6.3. Baker Map [104]................................................................................................... 40 2.7. Bubble Size in Two-Phase, Air-Water Horizontal Flows........................................ 41 2.8. Conclusions.............................................................................................................. 42 2.9. References................................................................................................................ 43 CHAPTER 3 Literature: Two Phase Spray ............................................................... 55 3.1. Introduction.............................................................................................................. 55 3.2. Two-Phase Spray Theory......................................................................................... 56 3.2.1. Stokes Number Effects ......................................................................................... 56 3.2.2. Axial Variation of Jet Half-Width ........................................................................ 57 3.2.3. Droplet Size-Velocity Correlation Factor............................................................. 57 3.2.4. Phase Doppler Particle Anemometer Measurements............................................ 58 3.3. Atomization.............................................................................................................. 59 3.3.1. Mean Drop Diameter ...........................................................................................
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