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Table of Contents

FATHOM 9 SLURRY MODEL.......................................................................................... 2


Volume and Mass Fractions..................................................................................... 2
Mixture properties................................................................................................... 2
Critical velocity........................................................................................................ 3
Fathom Output........................................................................................................ 4
Fluid Head............................................................................................................... 5
Appendix A (WPT-RPT-175)........................................................................................... 9
APPENDIX B.................................................................................. AFT Correspondence
10

FATHOM 9 SLURRY MODEL


Nomenclature
Symbols
d
diameter, ft
d50 mass-median particle diameter, ft
D
pipe diameter (inside), ft
g
gravitational accelewration, 32.174 ft/s2
i
hydraulic gradient, ft of water head/ft of pipe
im
value of i for flow of mixture in terms of water density (value of i for flow of
mixture)
iw
value of i for equal volume flow of water
jm
head gradient in terms of slurry density (Im*Eater density/Slurry density)
Re* shear reynolds number
S
specific gravity
V
velocity, ft/s
V* shear velocity, ft/s
V50 Mixture median velocity (mixture velocity at which 50% of the solids are
suspended), ft/s
w
particle associated velocity, ft/s
x
wight fraction of solids

volume fraction of solids

density, lb/ft3

dynamic viscosity, lbm-ft/s

pipe roughness, ft

slope of the pipe measured from horizontal, deg


subscripts
l
liquid (carrier) f fluid in Wilson
m
mixture
s
solid, settling (velocity)
t
terminal
w
wall friction

Volume and Mass Fractions


x
=
s
x +(1x )
l

x=

+(1 )

(1)

(2)

l
s

Mixture properties
m= s+ (1 ) l

(3)

S i=

i
w

i = s, l, m

(4)

m=(1+2.5 ) l

0.01

m=(1+2.5 +10.05 2) l

0.01< 0.20

m=(1+2.5 +10.05 2+ 0.00273 e16.6 ) l

0.20< 1

(5)

Critical velocity

V =

( sl ) g d 50
6 l

l V d 50
l

Vt

2.80
+
=
1.2
V 3 (1+0.08 ) 1+3 10 4 3.2

V s=0.9V t +2.7

l =

( s l ) g l
2

1 /3

l V m D
l

9.35
f l = 1.142 log +
D l f l

)]

Shear velocity
[Eqn. 2.61 of Wilson]

(1)

Shear Reynolds number


[Eqn. 2.63 of Wilson]

(2)

Terminal velocity of particle


[Eqn. 2.64 of Wilson]

(3)

Settling velocity
[Pg. 134 of Wilson (2nd Edition)]
[EQn. 4-51 of Abulnaga]

(4)

Eqn. 2.63 of Wilson

(5)

Darcy friction factor


[Crane 6?]

(6)

Darcy friction factor


[Crane 6?]

(7)

or

f l=

0.25

[ (
log

5.74
+ 0.9
3.7 D l

)]

V 50=V s

60 d 50
8
cosh
fl
D

f
1 d Pwl
i l= l V 2m
V
2 gD
gl L
m

( imi l )0=0.22(S mS l)

Vm
V 50

( )

( imi l )=( im il )0 cos ( )

d Pwm
f
=g l i m m m V 2m
dL
2 gD

Eqn 2.9 of Fathom SSL Manual


(4-52 of Abulnaga)

(8)

Hydraulic gradient liquid only flow


Eqn 2.16 of Fathom SSL Manual

(10)

Hydraulic gradient mixture flow


Eqn 2.6 of Fathom SSL Manual
(horizontal pipe)

(12)

Eqn 2.25 of Fathom SSL Manual


(=0, horizontal pipe)

(13
)

Definition

(9)

Fathom Output
dP gr=m g ( z oz i ) sin ( )

dPw =f

V
L
m m
D
2

(100)

f does not match any of the friction factors


fm, fl, or fw

(101)

dPfr for vertically down flow does not


agree with this equation.

V 2m
dP K =K m
2

(102)

dPtotal=dPfr +dP K + dPgr

i m=

(103)

dPw
1

L
g l

(104)

V
i mi l=0.22 m
V 50

( )

( Sm S l )cos ( )

Matches horizontal and sloped pipes but


not vertical pipes.

2
1
L V
f l l m
l gL D
2

( )

il=

Eqns. 2.6 and 2.25 of SSL Manual

(105)

(106)

Calculate the critical velocity at 50% (mixture velocity at which 50% of the solids
are suspended) [Wilson, Eqn. 6.11

V 50=3.93 d

0.35
50

( S s1 )

0.45

l
w

()

0.25

( )

Fluid Head
f
V
i m= l V 2m+ 0.22(S mS l) m
2 gD
V 50

( )

i m=Sm 1+

fl
V 2m
2 gD

()

(for horizontal pipes)

()
(for vertical pipes)

fx V 2
p+ gz+ =Constant( p0 + z 0 )
D 2
dp
f
dz
=g
V 2+
dx
2 gD
dx

i=

dp 1

f
dz
=
V 2+
dx ref g ref 2 gD
dx

dz/dx = 1 for flow vertically upward

1.
2.
3.
4.
5.

Assume a velocity
Calculate Rel, fl
Calculate il (Eqn. 17)
Calculate im (Eqn. 16)
Calculate dPfr (Eqn. 14)

()

Questions and AFT Answers


We are in the process of verifying Fathom 9 for use in modeling waste transfer
operations in Hanford Tank Farms. So far we have been able to satisfactorily verify
the flow of Newtonian fluids but are having diffuculty in verifying the flow of slurries.
Our specific questions and comments are listed below.
1. Critical Velocity
The equation for calculating the critical velocity, V 50, (Equation 4 in Detailed
Slurry Calculation Method) uses a parameter designated as w50 and described
as particle associated velocity. Neither the Fathom theory section nor the
referenced source document (Wilson) provide an equation to calculate this
parameter. How is this parameter calculated in Fathom 9?
The equation for w was not included in the third edition of Wilson, but it was
in the second edition on page 134. This equation is

w=0.9 v t + 2.7

( s f ) g
f2

1/ 3

Where vt is the terminal velocity of the d50 particle. This is calculated based
on the equations (and notes) presented starting on page 44 of Wilsons book
using the particle shape factor or Vo/Vs term entered in System Properties.
The V50 value is then calculated as described in equation 4 as you
referenced.
2. Vertical Pipe Model
The pressure gradient for vertical pipes calculated by Fathom 9 is not
consistent with the equations given in the theory section (Equations 2 and 3
in Vertical Pipe Theory for Slurry Flow). It appears that the Pressure gradient
calculated by Fathom 9 includes only the friction component and has the
units ft of water/ft of pipe length, i.e.,

i m=

fw 2
dp 1
=Sm
V
dz w g
2 gD m

In contrast, Equations 3 and 4 in the theory section include also the gravity
head. Please clarify which equation is used by Fathom 9.
In the theory presented in Wilson, the i term is always the frictional
gradient in terms of head, and does not include any effects of elevation
change (i.e. these correlations were developed for horizontal pipes).
However, when Wilson discusses vertical pipes, with an obvious elevation
difference, then the equations are in terms of dP which now does include
gravitational effects and are also in pressure.

The equations shown in Vertical Pipe Theory for Slurry Flow are in terms of
total pressure drop that includes both gravity and frictional loss. The I m
reported on the slurry tab is only the frictional part to be consistent with the
definition by Wilson. The dP reported will include both.
Note that internally in Fathom we do all calculations in terms of pressure so
any head gradients (like i) are determined from the actual dP values.
Attached is the Fathom 7.0 Slurry Module Users Guide. This is a little easier to
read than the help files. The derivations for sloped pipes start on page 31. For
vertical pipes, theta = 90 deg, second term in eq. 2.29 on page 33 drops out.
When rearranged, this is consistent with Willsons eq. 8.9. There are also
comments in Wilsons book which discuss particle size and their effect on wall
friction.

3. Slurry Friction Factorl


The theory section is silent about the the way slurry friction factors are
calculated. Are they independently calculated or are simply the equivalent
friction factors matching the calculated pressure gradients?
Wilsons methods are based on the effects of solids. It uses the friction factor
to get the clear water head loss as a basis from which the effect of the solids
is applied. We report an equivalent friction factor, but this is not strictly part
of the Wilson method.
4. Vertical Upflow versus Vertical Downflow
In our model we have noted that the presure gradient due to friction in a
downflow pipe is different than that in an upflow pipe. This is despite the fact
that both pipes are identical in size, flow, and fluid properties. Is this
intentional, and if so, what are the theoretical differences downflow and
upflow pipes with respect to handling of the friction pressure drop?
We have not been able to reproduce this. Attached is a model with pipes at
various angles with fixed flows at the inlet. The I m and Jm values for the
vertical upward and downward pipes are the same. Note, these values are
just frictional losses and do not include the effects of gravity.
The dP that is reported in on the Slurry tab is the total static dP in the pipe
which does account for gravity. You can add the pipe output parameter Pipe
Loss Static Friction Total (to be shown on the Pipes tab) to see just the
pressure loss due to friction.
5. Pressure gradient in Horizontal Pipes
The equation describing the pressure gradient in horizontal pipes (Equation 3
in Detailed Slurry Calculation Method) has the units ft of mixture/ft of pipe

length. In contrast, as discussed in item 2 above, the pressure in vertical


pipes has the units of ft of water/ft of pipe length. If this is not intentional,
how should the differences in units be reconciled.
The equations describing horizontal pipes in Detailed Slurry Calculation
Method are in terms of i which has units of ft-water/ft-pipe. Note that the j
term, more commonly used for pumps, is based on the mixture density and
has units of ft-mixture/ft-pipe.
The vertical pipe discussion is all in terms of pressure (really delta pressure)
and has pressure units. This can be converted to i by dividing by water
density and g
6. Pressure Gradient in Inclined Pipes
The equation for pressure gradient in inclined pipes (Equation 1 in Sloped
Pipe Theory for Slurry Flow) has a term designated by (0). The source
document (Wilson) does not provide any information on this parameter other
than a statement that for homogenous flow it is zero. Please provide the
basis for calculating the pressure gradient in inclined pipes.
Wilson discusses i(0) on page 183 of his book and describes it as the extra
head gradient due to the solids in a horizontal pipe (i.e. i m if at theta = 0)
(see eq. 6.4 on page 130). This is the head loss of the solids in a horizontal
pipe, which is then modified to account for the angle. This should not be
confused with the im terms Wilson uses for horizontal pipes. Fathom uses eq.
6.4 for this term.
7. Sloped Pipe Theory for Slurry Flow
We would like to know the limitations of the SSL slurry model with respect to:
Solid particle size (minimum and maximum)
Liquid phase (density, viscosity)
Mixture ratio (mass or volume based)
Sloped pipe theory is not well defined by Wilson. It is clear from Figure 8.2
that there are only data points for slopes ranging from -20 degrees to +40
degrees. There is also some discussion on page 178 regarding particle size
with the largest size mentioned being 2mm. He does say that, for volumetric
concentrations of 15-30%, the minimum mixture velocity should be 4-5 times
the settling velocity of the largest particle (bottom of page 178)

December 15, 2015/Tahsin Dogan

Dear Dylan,
Thank you for your support for answering our questions regarding the Fathom 9
Slurry Model.
After going through the material you have provided we are still unable to reconcile
our results. We are working with a simple slurry model and using the SSL module of
Fathom 9. A copy of the Fathom input file and an Excel spreadsheet detailing our
calculations are attached for your information. There are two main issues:
1. The critical velocity (V50) calculated using Equation 2.5 (1.71 ft/s) is not in
agreement with the result obtained from Fathom (4.99 ft/s)
2. The head gradient (im) for vertical pipes (0.165 ft/ft of pipe) is not matching the
Fathom result (0.241 ft/ft of pipe)
We will appreciate your support to help us resolve these questions.
Thank you,
Tahsin Dogan

APPENDIX A (WPT-RPT-175)
Critical velocity is defined as the point where a moving bed of particles begins to
deposit on the bottom of
a straight horizontal pipe during slurry-transport operations. The design objective is
to ensure that the slurry velocity is above this critical velocity so that the risk of
pipe plugging is not likely.

Section 3.1

1.85C

0.1536
c

0.3564

(1C c )

( ) (
D
d

0.378

l D gd ( S1)
l

0.098

0.3

V cr = gd (S1)
d
D
l
l
Cc
S

particle diameter, m
pipe diameter, m
carrier liquid density, kg/m3
carrier liquid viscosity, Pa s
coarse particle volume fraction (i.e., particles exceeding 74 m)
ratio of the solid density to carrier liquid density
hendered settling factor (0.95 recommended)

For particle sizes under 74 m

V cr =9

D l
l

0.11

( ) (

g l (S1)
l

0.37

e
( 17 1)
1+2.5 +10.05 2+1.3 (0.735)
m=2.0

Section A.7

DP=

fL
V 2
2D

0.193

f =10
with

c=1.47[1+0.146 exp (2.9 105 He ) ]


Hedstrom number

He=

D2 o
2

yield stress

APPENDIX B AFT CORRESPONDENCE

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