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In this work, the modelling of horizontal two-phase flows within the two-fluid Euler–Euler approach is investigated. A modified formulation of the morphology detection functions within the Algebraic Interfacial Area Density (AIAD) model is presented in combination with different models for the drag force acting on a sheared gas–liquid interface. In the case of free surface flows, those closure laws are often based on experimental correlations whose applicability is limited to certain flow regimes. It is investigated here whether the implementation of the modified blending functions in ANSYS CFX avoids this limitation. The influence of the new functions on the prediction of turbulence parameters in free surface flows is also examined quantitatively for the k-ω and k-ε two-equation turbulence models. Transient simulations of the WENKA counter-current stratified two-phase flow experiment were performed for validation. A prediction of the correct flow pattern as observed in the experiment improved dramatically when a turbulence damping term was included in the standard two-equation models. Using the k-ω and a modified k-ε turbulence model with damping terms close to the interface, better agreement with the experimental data was achieved. The morphology detection mechanism of the unified blending functions within the AIAD is seen as an improvement with respect to the detection of sharp interfaces. Satisfactory quantitative agreement is achieved for the modified free surface drag. Furthermore, it is demonstrated that turbulence dampening has to be accounted for in both turbulence models to qualitatively reproduce the mean flow and turbulence quantities from the experiment.

An X-ray microtomography (µCT) system was adapted so that 3D scans of fixed horizontal or vertical test sections can be performed. The mobile µCT system has been applied to measure the local, time-averaged volume fraction distribution of developing annular air-water flow in a horizontal pipe with µm spatial resolution. Based on the volume fraction data the liquid film thickness profile is computed and the accumulation, stripping and renewal of the annular liquid film at a circular orifice is studied. The development length of the annular flow downstream of the orifice is evaluated based on the integral volume fraction and the change of the film thickness profile along the pipe axis. Both parameters give a consistent result, indicating that liquid film renewal can be judged based on integral measurement techniques in this case. Further, the detailed 3D data enables the validation of computational fluid dynamics codes based on phase-averaged variables such as the Euler-Euler approach. Graphic abstract

Two-phase flows are regularly involved in the heat and mass transfer of industrial processes. To ensure the safety and efficiency of such processes, accurate predictions of the flow field and phase distribution by means of Computational Fluid Dynamics (CFD) are required. Direct Numerical Simulations (DNS) of large-scale two-phase flow problems are not feasible due to the computational costs involved. Therefore the Euler-Euler framework is often employed for large-scale simulations which involves macro-scale modelling of the turbulent shear stress and the interphase momentum transfer. As a long term objective, the research activities at Helmholtz-Zentrum Dresden-Rossendorf (HZDR) pursue the development of general models for two-phase flows which are based on first principles and include less empiricism. Part of this effort is focused on the development of an algebraic interfacial area density model (AIAD) which enables the simulation of two-phase flows with general morphologies including bubble, droplet and stratified flow regimes with the two-fluid approach. In this work a short overview of the AIAD model is given and recent developments are presented. The modelling of the interfacial drag in free surface flows is of particular interest and subject to ongoing research. Apart from empirical correlations, which are limited to certain flow regimes, different models for the local calculation of the interfacial drag have been developed. The latter approach is followed in the AIAD model and has recently been subject to modifications which are presented and validated as a part of this study. Furthermore, special attention is paid to the turbulence treatment at the phase boundary of free surface flows. A general damping of the gas-side turbulent fluctuations in the near interface region has been described previously in the literature but has not yet found its way into eddy viscosity turbulence models. In this work, a previously proposed damping source term for the k-ω turbulence model is validated. Model validation is performed by comparing the simulation results to experimental data in case of stratified, countercurrent air-water flow in a closed channel.