Two-phase stratified flow in horizontal pipes: A CFD study to improve prediction of pressure gradient and void fraction

Improved understanding of flow regime effects on design-influencing engineering quantities is of primary importance. This work is focused on the numerical prediction of pressure gradient and void fraction in a horizontal pipe where gas-liquid stratified flow is present in different operating conditions. The problem was modeled with unsteady, multiphase CFD (computational fluid dynamics) simulations. Volume Of Fluid (VOF) method was used as multiphase model. To define the numerical methodology, this study provides details on the influence of discretization grid and turbulence model on the simulation accuracy. It shows that mesh density on pipe cross-section is the most important grid parameter to focus on. Different turbulence models are required depending on the gas velocity and on its turbulence flow regime. Transition SST is able to model all the operating conditions but Realizable k-ε is adopted to further increase the accuracy of the results. A general underestimation of the pressure gradient is reported with an average error of − 6.43 % and − 16.21 % for a liquid superficial velocity of 0.04 m/s and 0.06 m/s respectively. Comparison with two-fluid 1D models shows that CFD simulations are the most accurate tools for predicting the pressure gradient at gas superficial velocities lower than 1.3 m/s. The implementation of a drift flux model shows a good agreement between experimental results and CFD simulations concerning void fraction estimation. CFD results are also used to underline the physical phenomena limiting the performance of 1D models.