Chem. Eng. Technol. 2009, 32, No.

1, 5563

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Zhi-shan Bai1 Hua-lin Wang1 Shan-Tung Tu1

1

Research Article

School of Mechanical and Power Engineering, East China University of Science and Technology, Shanghai, P.R. China.

Study of Air-Liquid Flow Patterns in Hydrocyclone Enhanced by Air Bubbles

In order to improve the oil-water separation efficiency of a hydrocyclone, a new process utilizing air bubbles has been developed to enhance separation performance. Using the two-component phase Doppler particle analyzer (PDPA) technique, the velocities of two phases, air and liquid, and air bubble diameter were measured in a hydrocyclone. The air-liquid mixing pump can produce 15 to 60 lm-diameter air bubbles in water. There is an optimum air-liquid ratio for oil-water separation of a hydrocyclone enhanced by air bubbles. An air core occurs in the hydrocyclone when the air-liquid ratio is more than 1 %. The velocities of air bubbles have a similar flow pattern to the water phase. The axial and tangential velocity differences of the air bubbles at different air-liquid ratio are greater near the wall and near the core of the hydrocyclone. The measured results show that the size distribution of the air bubbles produced by the air-liquid mixing pump is beneficial to the process where air bubbles capture oil droplets in the hydrocyclone. These studies are helpful to understand the separation mechanism of a hydrocyclone enhanced by air bubbles.
Keywords: Air bubble enhancement, Hydrocyclone, Oil-water separation, Phase Doppler particle analyzer (PDPA) Received: October 08, 2008; revised: October 17, 2008; accepted: October 20, 2008 DOI: 10.1002/ceat.200800518

Introduction

Hydrocyclones have been used for industrial purposes for more than 100 years. With considerable efforts in research and development, hydrocyclones are now widely used in various industries to separate two components of different densities with the aid of the strong centrifugal force created by the swirling flow. The flow inside a hydrocyclone is a complicated three-dimensional swirling flow. The study of the flow pattern in a hydrocyclone is very important for the optimum design and evaluation of its separation performance. Since the separation mechanisms are associated with the velocity field, its exact determination is crucial for the understanding of the separation process [13]. Many studies have been conducted to understand the internal flow pattern of a hydrocyclone. The velocity profiles of hydrocyclones were first measured by Kelsall [4], who used a stroboscope with a rotating microscope objective

Correspondence: Prof. H. Wang (fbaizs@yahoo.com.cn), Key Lab of Safety Science of Pressurized Systems, Ministry of Education, School of Mechanical and Power Engineering, East China University of Science and Technology, Shanghai, 200237, P.R. China.

lens to determine the velocities of aluminum flakes that seeded the flow in a transparent test section. Then Ohashi and Maeda [5] employed photographic techniques, which flashed at precisely-controlled time intervals to determine the velocity of the seed particle. More recently, a number of authors used laser Doppler velocimetry (LDV) to determine the tangential and axial velocities in hydrocyclones [69]. With the development of science and technology, mathematical models based on computational fluid dynamics (CFD) are highly desirable. The first successful work in predicting the fluid flow in hydrocyclones was achieved by Pericleous and Rhodes [10]; using the PHOENICS computer code for the solution of the partial differential equations, including the simple Prandtl mixing length model and the axisymmetry assumptions, the authors reported the velocity predictions in a 200-mm hydrocyclone. Later, Hsieh and Rajamani [11] numerically solved the turbulent momentum equations to obtain the velocities and compared them with the laser Doppler velocimetry measurements in a 75-mm hydrocyclone. In recent years, some works on the simulation of hydrocyclones using the incompressible NavierStokes equations, supplemented by a suitable turbulence model, have proven to be appropriate for modeling the flow in a hydrocyclone [1216]. In order to improve the oil-water separation performance, we enhanced the separation efficiency of conventionally con-

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structed hydrocyclones by using air bubbles. However, up to today, no measured data is available for an air-liquid twophase flow field in a hydrocyclone. The purpose of the present work is to obtain detailed knowledge of the air-liquid twophase flow characteristics in a hydrocyclone using the phase Doppler particle analyzer (PDPA) technique which is necessary to understand the separation mechanism of the hydrocyclone enhanced by air bubbles.

7 8 3 1 4 6 5 7 8 9

2
2.1

Experimental Setup and Procedure

Hydrocyclone
2 7

A 35 mm-diameter hydrocyclone with two symmetrical, rectangular inlets (5 mm 10 mm) was used for the laser Doppler measurements. The dimensions of the hydrocyclones used in the experimental work are shown in Tab. 1.
Table 1. Dimensions of the hydrocyclone used in the experimental work.
Do/D 0.07 Du/D 0.23 Ls/D 1.00 L/D 7.37 Lu/D 9.71 h 6

Figure 2. Diagram of oil-water separation using hydrocyclones enhanced by air bubbles: 1 Water pot; 2 Wastewater pot; 3 Oil pot; 4 Air flowmeter; 5 Air-liquid separation pot; 6 Airliquid mixing pump; 7 Liquid flowmeter; 8 Pressure gauge; 9 Hydrocyclone.

2.2

Air-Liquid Mixing

As shown in Fig. 1, air and liquid are mixed by the air-liquid mixing pump technology from Japanese NIKUNI Company. The maximum air-liquid ratio of the pump is about 1:9. Air enters the pump through the air inlet and is mixed and broken up in the pump. The rejected air volume is controlled by a valve.
Water with air Air inlet

Water inlet

cyclone, the detailed process of which is shown in Fig. 3. Gas moves faster than oil due to their differences in density and can lead to interaction between oil and air [1720]. The interaction between air bubbles and oil droplets can be summarized as an entrapment of the air bubbles by a single or flocculated structure of oil droplets. So the oil can be removed more easily and rapidly with the air bubbles than without in the hydrocyclone. Larger diameter air bubbles were removed from the water in the air-liquid separation pot because they can cause deterioration of the separation performance. In order to acquire air-liquid two-phase flow characteristics in the hydrocyclone, water was the working fluid. Water (20 C) with small air bubbles was fed into the hydrocyclone under controlled flow conditions by a set of valves. The fluid was pumped from a 1.5-m3 water pot by means of an air-liquid mixing pump. Feed pressure and flow rates were monitored with accurate manometers and a flowmeter. Hollow glass microspheres were added to the water to generate tracer particles, which can provide sufficient water phase flow seeding. Air bubbles can reflect light well and, therefore, no additional seeding was needed.

Air bubbles

Figure 1. Air-liquid mixing.

2.4

PDPA System and Measurement Procedure

2.3

Flow Configuration

The flow diagram of oil-water separation using a hydrocyclone enhanced by air bubbles is illustrated in Fig. 2. Oil enters the pump by atmospheric pressure and is mixed with water in the pump. The pump generates small air bubbles and provides high probability for oil/bubble interaction. Water, oil, and air bubbles are fed into the hydrocyclone together. Oil droplets collide with bubbles and were carried by bubbles in the hydro-

A two-component phase Doppler particle analyzer (PDPA) was adapted for measuring. The base unit included a SpectraPhysics Stabilite 2017 ion laser operating in multiline mode and a fiber drive from Aerometrics. A Bragg cell inside the fiber drive split the laser beam in the 0 and 1 orders, which were then separated by two prisms into the different wavelengths, thus providing two blue (488.0 nm) and two green (514.5 nm) laser beams. The laser beams were transmitted by monomode polarization preserving glass fibers to the PDPA probe. The original transmitting/receiving lens was substituted by dedicated backscatter receiving optics. This setup allows si-

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Figure 3. Oil/bubble attachment [18].

multaneous two-component velocity measurements in the backscatter mode. Light collected by the transmitting/receiving lens was focused by an achromatic lens onto the end of a multimode fiber optics. The collected light was separated into the individual wavelengths by a Dantec color separator and then transmitted to two Dantec photomultipliers. The PDPA signals were then processed by two Dantec 57N20 BSA enhanced units, operating in synchronous mode. Fig. 4 shows a block diagram of the PDPA system. Because the surfaces of the test section were cylindrical and conical in shape, the pair of laser beams bend asymmetrically when they cross the inside and outside surfaces. This bending took place in all three dimensions because of the three-dimensional shape of the test model. The asymmetrical bending of the laser beams at the inside and outside surfaces of the test section affected the probe volume position, the separation angle of the beams, and the direction of the measured velocity. In order to overcome the asymmetrical bending phenomena, a 5 mm-diameter orifice vertical to the hydrocyclone axial was opened in the position of the laser beams entrance and was then stopped up with optical glass. This is shown in Fig. 5. The optical ports can avoid the asymmetrical bending phenomena because of lower refraction ratio and plane surface. The laser route is illustrated in Fig. 6.
Transmitting lens Lase

1 2

In order to study the effect of optical ports on the flow inside the hydrocyclone, the computational fluid dynamics method was used to simulate the flow fields inside the hydrocyclone with optical ports. In this work, the fluid flow is modelled as turbulent, described by the Reynolds stress model (RSM). The simulated results show that the optical ports have little influence on the internal flow of axial half planes without optical ports inside the hydrocyclone. During the measurements, the probe was moved by using a highly accurate three-component (xyz) traverse system controlled by a computer. Velocity data were measured for the ten axial half planes without optical ports from inlet to exit as defined in Fig. 7. For a given axial coordinate, the first measurement point was placed near the wall of the cyclone and the last point was chosen in proximity of the core. The first axial step was equal to 20 mm from the top of the hydrocyclone. The other axial step was equal to 30 mm and radial steps of 0.5 mm were applied. Finally, in all the experimental work, a sample of typically 1000 Doppler bursts was taken for each measurement. The experimental device, including testing model and system, are shown in Fig. 8.

Orifice

Figure 5. Model of testing.

Receiving lens

Laser

Laser

Model

Bragg cell

Computer

Processo

Without optical port

With optical port

Figure 4. Schematic of the PDPA system.

Figure 6. The laser route.

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Z1 20 30

Z2 30

Z3 30

Z4 30

Z5 30

Z6 30

Z7 30

Z8 30

Z9 30

Z10

Figure 7. The dispose of testing plane.

Hydrocyclone

Optical port

air-liquid ratio will cause performance deterioration. This is caused by the following: A certain air bubble number in liquid is advisable to reduce the viscosity of the liquid and to raise the collision probability of oil with water. It will make the removal of oil more easily. For a high air-liquid ratio, the air bubbles can also reduce the viscosity of the liquid and raise the collision probability of oil with water, but excessive air bubbles disturb the flow field in the hydrocyclone and decreases the separation efficiency. The air-liquid ratio of 1 % can provide a better separation of oil from water. The experimental results show that air bubbles that occur in water can improve the deoiling efficiency of hydrocyclones.

4
(a) Model of testing (b) Testing system

Results and Discussion

Size Distribution of Air Bubbles

Figure 8. Photograph of the experimental system.

4.1

Separation Performance of the Hydrocyclone Enhanced by Air Bubbles

The Reynolds number of the inlet flow in the hydrocyclone is described as follows: Re qDv l (1)

where v 4Q i pD2

In order to acquire the high oil-water separation performance using the hydrocyclone enhanced by air bubbles, the size distribution of air bubbles in water is an important factor. According to the appropriate literature [17 19], the oil droplets in oily wastewater are normally stabilized as an oil-in-water emulsion, having a median droplet diameter usually in the range of 350 lm. A range of air bubbles is beneficial because the smaller bubbles can capture the smaller oil droplets and the larger ones, the larger droplets [2628]. The distribution of air bubble diameter inside the hydrocyclone is plotted in Fig. 10 under the condition of the inlet flow rate of

In the hydrocyclone, the air-liquid ratio could be defined as follows: Qq Qg Ql (2)

92 88 84
E/%

The flow diagram of oil-water separation using the hydrocyclone enhanced by air bubbles is illustrated in Fig. 2. The influence of air-liquid ratio, Qq1), on separation efficiency, E, is illustrated in Fig. 9. When the air-liquid ratio is less than 1 %, an increase in the air-liquid ratio will improve the efficiency of oil removal. The efficiency reaches a maximum when the airliquid ratio is close to 1 %, beyond which further increases in

80 76 72 0.0

0.5

1.0

1.5
Qq

2.0

2.5

3.0

3.5

1) List of symbols at the end of the paper.

Figure 9. Separation efficiency (E) vs. air-liquid ratio (Qq) (Oil concentration 100 mg/L; inlet Reynolds number 15000).

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1.50 m3/h. It indicates that the diameter of air bubbles increase from the wall towards the center. The size distributions remain similar at different axial heights in the body of the hydrocyclone. The diameter change diminishes at radial distance with the increase of axial height. At an axial height of 260 mm, there is no diameter change at any of the radial distances. This result is in agreement with previous theoretical studies on size distribution [4].

4.2 Velocity of Water

For the inlet flow rate of 1.50 m3/h, the axial velocity profiles at different radial distances and at different axial heights in the hydrocyclone are integrated and presented in Fig. 12a). The axial velocity is downward, i.e., negative, close to the hydrocyclone wall and upward towards the center. It can be observed from the figure that a peak positive axial velocity is immediately below the bottom of the vortex finder and a minimum value of positive axial velocity is at a vertical distance of 170 mm from the top of the hydrocyclone. The figure also indicates that at an axial height (Z) of 200 mm, there is no positive vertical velocity at all the radial distances, indicating no further classification of water in this region. With increasing axial distance, the positive values of axial velocity decreases till it reaches zero at some axial distance. At an axial height of

Figure 10. Size distribution of air bubbles.

1.50 m3/h and Qq = 1.0 %. It can be seen that the air-liquid mixing pump can produce 1560 lm-diameter air bubbles in water. The size distribution of air bubbles produced by the airliquid mixing pump is beneficial to the process where air bubbles capture oil droplets in the hydrocyclone. Fig. 11 shows the distribution profiles of air bubble size in the hydrocyclone when Qq = 1.0 %; the inlet flow rate at

r/mm

r/mm 0 5 10 15 20 -30 0 30 60 90

r/mm 0 5 10 15 20 -30 0
60 0 30

0 5 10 15 20

30
90

60
120

90 120
Z/mm 150

120 150
180 210 240 270 300

150 Z/mm 180 210 240 270 300 330 360

Figure 11. Granularity distribution of air bubbles.

Z/mm

180 210 240 270 300

5m/s

330
20m

330 360

360

(a) Axial velocity

(b) Tangential velocity

Figure 12. Velocity distribution of water.

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200 mm, there is no positive axial velocity at any radial distances, indicating no further classification in this region. The distributions of axial velocity indicate that the main separation parts are the cylinder and the upside of the cone. The geometry of the cylinder and cone angle is key to the design of a hydrocyclone. The measured results of tangential velocity at different vertical heights are plotted in Fig. 12b) under the condition of inlet flow rate at 1.50 m3/h. It can be observed from the figure that the tangential velocity increased from the hydrocyclone wall towards the center, reached a maximum value, and then rapidly decreased. The profiles of tangential velocity remain similar at different axial heights in the body of the hydrocyclone. Maximum values of tangential velocities are observed in the cylindrical portion. It can also be noted that the maximum values of tangential velocity decrease with decrease in axial height.

The tangential velocities at different Qq are shown in Fig. 14. It can be seen from the figure that Qq affects tangential velocity only in the core of the hydrocyclone; there is little change in other regions. The axial velocity increases in the core region with the increase in Qq. It can be seen from Fig. 13 and Fig. 14 that the air core occurs in the hydrocyclone when the air-liquid ratio is more than 1 %. There is an optimum air-liquid ratio for oil-water separation of a hydrocyclone enhanced by air bubbles. At the same inlet flow rates, an increase in air-liquid ratio will improve the separation efficiency under the condition of the air-liquid ratio being less than the optimum split ratio, beyond which further increase in the air-liquid ratio will decrease the separation performance. This is because at higher air-liquid ratio, an air core occurs in the hydrocyclone, large numbers of air bubbles will arouse turbulence fluctuation and then make it possible for finer oil droplets to move into the underflow, thus reducing the separation efficiency.

4.3 The Effects of Air-Liquid Ratio on Velocity of Water 4.4 Velocity of Air Bubbles
For an inlet flow rate of 1.50 m3/h, the axial velocities at different Qq are shown in Fig. 13. It can be seen from the figure that the axial velocity increases in the core region with the increase of Qq. This is because the air content is higher in the core than other regions due to centrifugal force. It is beneficial to remove oil droplet bypass overflow. The change rule of axial velocity is not uniform with the increase in Qq in other regions. The axial velocity distributions of air bubbles at different Qq are shown in Fig. 15. It can be seen that the axial velocity distributions of air bubbles have a similar trend to the water phase. The tangential velocity distributions of air bubbles at different Qq are shown in Fig. 16. It can also be noted that the maximum values of tangential velocity decrease with decrease

1.2 0.8 0.4

-1

1.2

Qq=0.5% Qq=1.0%
-1

0.8 0.4 uZ/m.s 0.0 -0.4 -0.8 -1.2

Qq=0.5% Qq=1.0% Qq=2.0%

Qq=2.0%

uZ/m.s

0.0 -0.4 -0.8 -1.2 0 2 4 6 8 10 12 14 16 18 20 r/mm

8 r/mm

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1.0 0.5 0.0
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1.0 0.5 0.0 uZ/m.s -0.5 -1.0 -1.5 -2.0

Qq=0.5% Qq=1.0% Qq=2.0%

Qq=2.0%

uZ/m.s

-0.5 -1.0 -1.5

-2.5 0 2 4 6 r/mm 8 10 12 14

4 r/mm

10

Z5

Z7

Figure 13. Axial velocity distribution of water at different Qq.

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-1

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61

Qq=0.5% Qq=1.0% Qq=2.0%

-1

-7 -6 -5 u/m.s -4 -3 -2 -1

Qq=0.5% Qq=1.0% Qq=2.0%

-5 -4 -3 -2 -1 0 2 4 6 8

u/m.s

10 12 14 16 18 20 r/mm

0 0 2 4 6 8 r/mm 10 12 14 16

Z1
-8 -7 -6 -5
-1

Z3
-12

Qq=0.5% Qq=1.0% Qq=2.0%

u/m.s
-1

-11 -10 -9 -8 -7 -6 -5 -4 -3

Qq=0.5% Qq=1.0% Qq=2.0%

u/m.s

-4 -3 -2 -1 0 0 2 4 6 r/mm 8 10 12

4 r/mm

10

Z5
Figure 14. Tangential velocity distribution of water at different Qq.
1.2 0.8 0.4
-1

Z7

1.2

Qq=0.5% Qq=1.0% Qq=2.0%

-1

0.8 0.4 uZ/m.s 0.0 -0.4 -0.8

Qq=0.5% Qq=1.0% Qq=2.0%

uZ/m.s

0.0 -0.4 -0.8 -1.2 0 2 4 6 8 10 12 14 16 18 20 r/mm

-1.2

8 r/mm

10

12

14

16

Z1
1.0 0.5 0.0
-1

Z3
1.0

Qq=0.5% Qq=1.0%
uZ/m.s
-1

0.5 0.0 -0.5 -1.0 -1.5 -2.0

Qq=0.5% Qq=1.0% Qq=2.0%

-0.5 -1.0 -1.5 -2.0 -2.5 0 2 4 r/mm 6

Qq=2.0%

uZ/m.s

10

-2.5

4 r/mm

10

Z5

Z7

Figure 15. Axial velocity distribution of air bubbles.

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-8

Qq=0.5% Qq=1.0%
u/m.s

-7 -6
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Qq=0.5% Qq=1.0% Qq=2.0%

u/m.s

-5 -4 -3 -2 -1 0 2 4 6 8

Qq=2.0%

-5 -4 -3 -2

10 12 14 16 18 20 r/mm

8 r/mm

10

12

14

16

Z1
-9 -8 -7 -6
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Z3
-11

Qq=0.5% Qq=1.0% Qq=2.0%

-1

-10 -9 -8 u/m.s -7 -6 -5 -4 -3

Qq=0.5% Qq=1.0% Qq=2.0%

-5 -4 -3 -2 -1 0 0 2 4 6 r/mm 8

u/m.s

10

12

14

4 r/mm

10

Z5
Figure 16. Tangential velocity distribution of air bubbles.

Z7

in axial height. The magnitude of the tangential velocity value increases at the same radial distance with the increase in Qq. The tangential velocity distributions of air bubbles have a similar trend to the water phase. The axial and tangential velocity differences at different Qq are greater near the wall and near the core of the hydrocyclone. The velocity differences are greater near the core because the velocity and velocity gradients at the core region are greater and then arouse the turbulence fluctuation. The collision between wall and fluid make the velocity fluctuations strengthen near the wall.

Conclusions

numbers of air bubbles will reduce the separation efficiency. The size distribution of air bubbles produced by air-liquid mixing pump is beneficial to the process that air bubbles capture oil droplets in the hydrocyclone. The velocities of air bubbles have a similar flow pattern to the water phase. The axial and tangential velocity differences of air bubbles at different air-liquid ratios are greater near the wall and near the core of the hydrocyclone. This work is helpful to understand the separation mechanism of a hydrocyclone enhanced by air bubbles. However, in order to achieve an optimal design, further studies are considered in two directions: (1) The oil-water-air three-phase velocities in hydrocyclones should be examined; (2) the interactions of air bubbles and oil droplets should be studied.

By using a two-component phase Doppler particle analyzer (PDPA) technique, the velocities of two phases, air and liquid, were measured in a hydrocyclone enhanced by air bubbles. The results are summarized as follows: In order to overcome the influence of shape on laser beams, optical ports were set up in the hydrocyclone and the asymmetrical bending phenomena were resolved. Under the condition of the inlet flow rate of 1.50 m3/h and Qq = 1.0 %, the air-liquid mixing pump can produce 15 to 60 lm-diameter air bubbles in water. There is an optimum air-liquid ratio for oil-water separation of a hydrocyclone enhanced by air bubbles. At higher air-liquid ratios, large

Symbols used
D Do Du E L Ls Lu Qg Qi [mm] [mm] [mm] [%] [mm] [mm] [mm] [m3/h] [mm] hydrocyclone diameter overflow orifice diameter underflow orifice diameter separation efficiency length of cone length of swirl chamber length of tail pipe air and liquid flow rate inlet flow rate

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Ql Qq Re uz uh m Z

[m3/h] [] [] [m/s] [m/s] [m/s] [mm]

liquid flow rate air-liquid ratio Reynolds number axial velocity tangential velocity hydrocyclone characteristic velocity axial height from top wall

Greek symbols q h [kg/m3] [] density of liquid cone angle

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