Two-phase co-current flow simulations using periodic boundary conditions in horizontal, 4, 10 and 90° inclined eccentric annulus, flow prediction using a modified interFoam solver and comparison with experimental results

Abstract

Two-phase oil and gas flow were simulated in an entirely eccentric annulus and compared with experimental data at horizontal, 4, 10, and 90° inclination. The gas-phase was sulphur hexafluoride and the liquid phase a mixture of Exxsol D60 and Marcol 82 for the inclined cases (5–16), and pure Exxsol D60 for the horizontal cases (1–4). The diameter of the outer and inner cylinders was 0.1 and 0.04 m, respectively, for the inclined domains and 0.1 and 0.05 m for the horizontal domain. The cases studied consist of liquid phase fractions between 0.3 and 0.65 and mixture velocities from 1.2 to 4.25 m/s. The mean pressure gradient is within 33% of the expected experimental behavior for all inclined cases. In contrast, the low-velocity horizontal domains exhibit significant deviation, with a drastic over-prediction of the mean pressure gradient by as much as 200–335% for cases 1 and 2. The two remaining horizontal cases (3 and 4) are within 22% of the expected mean pressure gradient. Cases 13–16 are a replication of cases 5–8 at an increased inclination; the mean pressure gradient is within 6.5% of the expected increase due to the increase in hydrostatic pressure. By comparing cases 1–4 to previous published simulations at a lower eccentricity, we found a decrease of the mean pressure gradient by 30–40%, which is in line with existing literature, although for single-phase flows. The simulated and experimental liquid holdup profiles are in good agreement when comparing the fractional data; wave and slug frequencies match to within 0.5 Hz; however, at closer inspection, it is apparent that there is a decrease in the amount of phase-mixing of the simulations compared to the experiments. When increasing the mesh density from 115 k cells/m to 2 million cells/m, the simulations exhibit significantly more phase mixing, but are still unable to produce conventional slugs. In a simplified case, conventional slugs are observed at grid sizing of 1 × 1 × 1 mm, whereas the cells of the 2 million cells/m mesh are roughly 1.5 × 1.5 × 1.5 mm.