1. Introduction
Two-phase flow appears in a wide variety of applications in the chemical and petrochemical industries, energy industries like nuclear or concentrated solar power, civil engineering and so on. Different liquid and vapor flow patterns are found in the applications, which denote different topologies or configurations of the liquid and vapor distribution inside the pipe, channel or vessel containing the two-phase flow [
1]. Notice that each flow pattern corresponds also to a characteristic distribution of the interfaces between the fluid phases. Each flow pattern depends on a set of conditions such as: pressure, superficial velocities of the liquid and vapor phases, temperature of each phase, heat flux through the walls, and geometry [
2]. One of the more important flow regimes found in the applications is annular flow, which is characterized by a thin liquid film flowing adjacent to the walls of the pipe while a gas flow that usually transport entrained drops flows through the central part of the pipe. Usually, waves of different kinds are formed at the interface of this liquid film with the vapor or steam [
3,
4,
5]. In addition, in many engineering applications the determination of the liquid fraction in two- and three-phase systems such as some fluidized beds is very important [
6,
7,
8].
The main goal of this paper is to study the different types of conductance probes analytically and to compare these analytical results with numerical results and experiments of different authors to apply them to two-phase flow tomography and hold-up applications. The advantage of developing analytical models in 3D is that they allow a good design of the conductance probe selecting the most convenient size of the electrodes, distance between them, and type such as ring or plate. However, the developed models must be checked experimentally to ensure their ability to performs good experimental predictions. Once their prediction capability has been checked, they can be used to compare different conductance probes with different geometries and characteristics.
The main advantage of the flush-mounted conductance probes is that the two-phase flow, assuming perfect device manufacturing, is not perturbed by the probe. This issue is important for the analysis of annular two-phase flows, especially when the film thickness is very thin. In this case, the sensor design should not perturb the waves produced at the film surface, since a small disturbance would introduce appreciable percent errors in the experimental measurements. There exist different types of conductance probes that have been designed for different applications in the past: the first one is the ring electrode probe formed by two ring shape electrodes, which are mounted along the circumference of the pipe perpendicular to the flow direction; this type of electrode has been studied by Fossa [
8], and Tsochatzidis et al. [
7]. There exist also four-ring electrode probes that have been used by Lina and Yingwei [
9] to measure the water fraction in oil-water annular two-phase flow where the oil circulates through the core region of the pipe and the water flows close to the wall forming an annulus. Coney [
10] measured the thickness of a rapidly varying wavy film by using a probe consisting in two parallel rectangular electrodes of length
, being 2
a the distance between the electrodes. These electrodes are surface mounted in the pipe to not perturb the flow and are parallel to the flow direction. Also, Coney developed the three electrode probes segmenting the receiving electrode in two parts and measuring the ratio of the intensities flowing from the emitter electrode to the two receiver electrodes; this design has the advantage of compensating for changes in conductivity due to temperature. Recently Lee et al. [
11] used the three-electrode probe, based on the ratio of the currents, to measure the film thickness under temperature-varying conditions because of the ratio of intensities is independent of the fluid conductivity changes with the temperature. In addition, Fossa [
8] also performed measurements with two plate electrodes of 3mm diameter, flush mounted with a separation of 9 mm in the pipe axial direction. Finally, Ko et al. [
12] and Lee et al. [
13] designed recently improved electrical conductance sensors to perform void fraction measurements. Normally a high frequency alternating current (AC) is applied to the emitter electrode to avoid high gradients of ions and redox electrochemical reactions in the electrodes, which will degrade them.
The main novelty of this paper is that we have developed analytical expressions for the absolute and the relative conductance of two-plate conductance probes when the two sensors are mounted parallel to the flow direction or orthogonal to the flow direction in a 3D geometry with the goal of improving the results given by the Coney expression [
10]. In addition, we computed the electric potential distribution generated by the two-plate electrode sensors in the film annulus. Moreover, other goal of the paper is to validate the new analytical expressions with experimental data and numerical calculations from different authors to know their limitations and potential range of applications.
There exist also numerical methods for sensor design by solving numerically the generalized Laplace equation using the finite element method (FEM) as shown by Lee et al. [
13], and Ko et al. [
12]. These authors use the commercial program COMSOL Multiphysics to perform numerical calculations.
The paper has been organized as follows, first in
Section 2.1, we deduce the expression for the electric potential and the relative conductance for ring conductance probes. In
Section 2.2 we deduce the expressions for the electric potential and the relative conductance for two-plate conductance probes in two cases when the plate electrodes are located in the direction of the flow and when they are mounted orthogonal to the flow along the inner circumferential direction of the pipe. In
Section 3.1 we perform the comparison of the expressions deduced in this paper for two-plate conductance probes with the experiments of Fossa [
8], using two-plate electrodes along the flow direction. In
Section 3.2 we perform a comparison of the variations of the relative conductance with the fraction of liquid (hold-up) for homogeneous bubbly flow with the experimental results of Fossa [
8], and we discuss the influence of the effective-conductivity calculation on the results. In addition, in
Section 3.3 we compare the results obtained using the expression deduced in this paper with the experimental results obtained by Coney [
10] for the relative conductance, when changing the liquid fraction and using electrodes of different lengths that are parallel to the flow direction. Additionally, also in this section, we compare the results obtained with Coney formulas for two electrode probes of infinite electrode length with the results of our analytical expression when the length of the electrodes becomes large. In addition, in
Section 3.4 we compare the experimental results obtained by Ko et al. [
12] and Lee et al. [
13] using static experiments in annular flow 4. Finally, in
Section 4 we discuss the main results and findings of this paper.
4. Discussion of Results, their Interpretation and Implications, Future Trends, and Final Conclusions
In this paper we have deduced the analytical expressions for the relative conductance and the potential difference for two plate-electrode conductance probes in two configurations: the first one is when the electrodes are flush mounted in the flow direction i.e., along the z direction of the pipe axis as displayed in
Figure 3, and the second one is when the electrodes are flush mounted along the circumferential direction of the pipe as displayed in
Figure 2a,b. All these expressions are fully 3D and have been deduced solving the 3D Laplace equation with a proper boundary condition, as shown in the
Appendix B and
Appendix C, assuming that the current density is constant over each electrode and that the frequency is high enough to neglect capacitive effects. Also, we have assumed an average potential over each electrode, that have been obtained using Equation (7), so the potential difference between the electrodes has been calculated as the difference between the averaged electric potential over each separate electrode. Previously Coney [
10] obtained a very well-known expression for a conductance probe consisting in two flush-mounted parallel electrodes of unequal widths and infinite length and separated by an insulator. The expression deduced by Coney was checked experimentally by many authors such as Fossa [
8], Tsochatzidis et al. [
7], and Coney himself [
10]. Because Coney used parallel finite length electrodes flush-mounted inside a pipe, his experimental results approach the value deduced by himself for the relative conductance in terms of the liquid fraction but never attains the analytical results. We have checked this in this paper, because the analytical expression is fully 3D as a result of the analytical Equation (19) obtained in this paper, that the relative conductance in terms of the liquid fraction exactly matches the experimental results obtained by Coney with smaller electrodes as displayed in
Figure 7. In addition, we have found that Equation (19) for the relative conductance between two plate parallel electrodes approach the result of the expression obtained by Coney as the electrode lengths becomes large, as can be observed in
Figure 9. Also, it is deduced using the new expression, as displayed in
Figure 8, that when the height of the electrodes becomes smaller the relative conductance attains faster the saturation value and the slope of the curve increases. This means that the measurements are more sensitive to small variations of liquid thickness. However, the liquid film thicknesses we can measure are smaller.
In addition, Fossa performed a set of experiments with two-plate electrodes, with the electrodes located along the flow direction, and at 12 mm distance between the electrode centers. For this case Fossa measured the relative conductance for different liquid fractions and obtained the results displayed at
Figure 4 (blue x), with electrodes that had a circular shape. We have made the calculations with square electrodes of the same area using Equation (25), and the results are represented by the green inverted triangles that agree with the experimental data for liquid fractions below 0.1, and show a very small difference above 0.1. Then we performed the calculations assuming that the electrodes have the same area than the circular electrodes and were centered at the same point as displayed in
Figure 4b, but the upper and lower sides of each electrode crossed through the circular electrode point that formed a 45° angle with the x-axis; in this case the experimental results matched exactly the analytical ones obtained with Equation (25). The total number of modes used to perform the calculations was
, and the solution is obtained in a few seconds with a PC, having programmed the equation in MATLAB. Therefore, we conclude that the shape of the electrodes (circular, square or rectangle) can have some influence on the results but this influence is small if the area and the location of the electrode centers are the same and the relation of the length to the height of the electrode dimensions are within the following limits (
).
Another question to be discussed is the influence of the number of modes in the results, and what are the optimal values of
and
. To answer this question at
Table 1 we compare the results obtained for the relative conductance of the case displayed as the upper curve of
Figure 8, using
, and
, with the same case performed using
, and
. The difference in the number of terms contributing to the result in the numerator and the denominator of Equation (19) for both cases is 980. It is observed that the influence of adding these extra terms on the results is always smaller than 0.0012.
We have seen that diminishing the length of the electrodes in the Coney experiments, as displayed in
Figure 8, increases the relative conductance
versus delta, for a fixed distance
between the electrodes. In
Figure 8 the distance between the electrodes was fixed at 2 mm, and the electrode length varied from the smaller one (2.88 mm) for the upper curve “
versus delta”, to the largest one of the lower curve. So, it is concluded that when the length of the electrodes or their guard electrode lengths diminishes, then the relative conductance increases faster especially for lower values of delta. This means that the two-plate detector attains faster the saturation for smaller electrode sizes in the axial direction. What happens when we maintain fixed the length of the electrodes and we increase the distance between the electrodes? The response to this question is displayed in
Figure 12. We have performed the calculation of the relative conductance for two parallel electrodes with
, a pipe diameter of
, and
. Then we changed the distance
between the electrodes, and performed the following cases
. The results for the relative conductance are displayed in
Figure 12. The results of this figure tell us that diminishing the distance between the electrodes for fixed values of their sizes increases the slope of the curve
versus delta. The quantitative effect on the slope is small and, therefore, the effect on the saturation is small.
In addition, to the previous comparisons with two plate electrodes, we performed a comparison with the sensor designs of Ko et al. [
12], and Lee et al. [
13], that consisted in two plate electrodes orthogonal to the flow, and spanning 2.54 radians each electrode and with different separation at both sides 0.7 radians, and 0.5 radians, respectively. The sensor designs of both authors were very similar, the only difference being the internal radius, which was slightly different. These designs were performed to obtain a response as close as possible to the linear conductance response, where the linear response was set to
, being
the conductance for a void fraction
, and
the conductance when the pipe was full of liquid. The conductance for a void fraction
was achieved by these authors inserting small rods of an acrylic non-conducting material, and then they measured the conductance ratio for different radius of the acrylic inner cylinder. Then they obtained the results displayed in
Figure 11a,b for the annular flow, which are slightly above (6%) the linear behavior, denoted as Begovich–Watson, as can be observed in
Figure 11b. The results obtained using Equation (19), deduced in this paper are slightly below (1%) the linear behavior curve, and are also displayed in
Figure 11a,b. At this point, it is convenient to remark that the electrical signals of a sensor based on the electric-impedance between two electrodes depends not only on the fraction of liquid or the void fraction in the sensor region but in addition of the liquid distribution inside the pipe which in turn depends on the flow regime (bubbly, slug, annular…) that we have in that region as will be discussed below.
The next issue to be discussed is the measurement of the liquid fraction (
) and the void fraction (
from measurements of the relative conductance performed with flush-mounted two-ring electrode probes in two-phase flow homogeneous mixtures. In this case assuming a homogeneous two-phase mixture as for instance homogeneous bubbly flow, one obtains as deduced in
Appendix C, Equation (A40), which shows that the ratio of the conductance of the two-phase mixture to the conductance of the pipe full of water is equal to the ratio of the conductivities of the mixture and the water
.
is the effective conductivity of the two-phase mixture, which depends not only on the void fraction but also on the two-phase distribution. For homogeneous bubbly flow distribution, as in the experiments performed by Fossa [
8], the best prediction of the relative conductance in term of the liquid fraction is obtained using the Maxwell formula. However, Yang and Kim [
22] measured the relative resistance
, using different types of conductance probes, for type II probes, which are two-electrode probes formed by two electrodes A, and B spanning less than pi radians of each electrode, with a radius of 6 cm and a height of 6 cm. Moreover, the frequency used in their experiments was 100 kHz so the capacitive part of the impedance was small and we can write
. In the experiments of Yang and Kim [
22], the air–water mixture was not homogeneous as in Fossa experiments, as it is deduced observing the figures of the void distribution of their paper [
22]. The results obtained by Yang and Kim with probe II for the relative resistance are displayed in
Figure 13 of this paper. It is observed in this case that the best prediction of the experimental data is obtained with the self-consistent EMT theory, in this approach of the effective medium theory, one assumes that the bubbles are embedded in an effective medium with conductivity
, which is the same for all the bubbles as explained in
Section 3.2. These results are different from those obtained with the Fossa experiments where the Maxwell formula gives the best predictions. We must consider that for the case displayed in
Figure 13, the bubbly flow is not homogeneous, contrary to the case displayed in
Figure 5, where it is homogeneous. Therefore, for Yang and Kim experiments the self-consisting EMT theory gives the best predictions for the non-homogeneous bubbly flow that the non-consistent EMT (Maxwell equation). This result is coherent because of the Maxwell equation for the mixture conductivity is based on the hypothesis of homogeneity.
To finish we conclude that the formulas obtained in this paper for the two electrode conductance probes in cylindrical geometry predict the relative conductance very well in terms of the liquid fraction for different set of experiments and different sizes and geometries of the sensors, and the results can be obtained in a few seconds using modes.
We have seen that when using the sensors for holdup applications to predict the average void fraction in a region, the results depend not only on the void fraction but also on the two-phase distribution. Therefore, in the simple case of bubbly flow as in Fossa experiments, which uses a homogeneous flow, the experimental results show that the Maxwell equation is the best suited to predict the void fraction. However, for bubbly but not homogeneous flow, the self-consistent EMT equation is that which most approaches the experimental data obtained by Yang and Kim [
22]. Future research directions could study the influence of wall peak and core peak void fraction distribution for bubbly flow on the conductance or resistance ratios. Also, an interesting question that is now becoming relevant is if we can get the liquid fraction from relative conductance measurements using conductance probes for slug and churn turbulent flows i.e., for low water holdup structures. This question has been addressed recently by Wang et al. [
21,
23] and Yang et al. [
24]. These authors arrive from the experimental data, by a fitting procedure, to the result that this relation is given for this type of flow by:
For more general flow Yang et al. [
24] propose a general expression that it is a weighting average of Maxwell expression for bubbly flow and the Wang et al. [
21] equation for slug flow and they write:
where, according to these authors,
is the weight of the high-water holdup structures, and
is the weight of the low water holdup structures. These authors determine these weights experimentally counting the number of sampling points
of signals of high-water holdup structures, and the number of sampling points of signals
of low water holdup structures. Then
, and
.
, is the total number of sampling points.