Computational Fluid Dynamics Simulation of Oil-Water Batch Transport in a Pumpless Virtual Flow Loop

Batch transportation of oil and water is a new transportation method in oil and gas gathering and transportation pipelines. Its corrosion inhibition effect has been preliminarily verified in a horizontal pipe experiment. However, achieving overall visualization in traditional loops is difficult, resulting in limited flow pattern classification and analysis of influencing factors. Combining the advantages of the traditional flow loop and the wheel flow loop, we introduce in this paper a round-head straight pipe loop and analyze the influence of key factors on the evolution of the flow pattern of the oil-water interface and the dimensionless length of the oil-water film (eLoeLw) on the pipe wall through computational fluid dynamics (CFD) numerical simulation. The results show that the batch transportation of oil and water using the round-head straight pipe loop is more in line with the flow characteristics of oil and water two-phase flow in gathering pipelines. Three distinct three-layered flow patterns were identified, which are Flow Pattern I (oil-in-water in the upper layer, annular flow in the middle layer, and oil as the annular phase, water as the core phase, and oil-in-water in the lower layer, abbreviated as DW/O-AN-DW/O), Flow Pattern II (oil phase in the upper layer, annular flow in the middle layer, water as the annular phase, oil as the core phase, and oil in the lower layer, abbreviated as O-AN-O), and Flow Pattern III (oil phase in the upper layer, water-in-oil dispersion flow in the middle layer, and oil in the lower layer, abbreviated as O-DO/W-O). Additionally, parametric analysis reveals that the velocity of the rigid body () has the greatest influence on the coverage rate of the oil film on the pipe wall, followed by the viscosity of crude oil. The density of crude oil has the least influence. The round-head straight pipe loop model offers an accurate simulation of the process of oil and water batch transportation in actual production pipelines. Therefore, the corrosion mitigation efficiency increases with the increase in oil viscosity when the viscosity of the oil lies within the range of 0.01–1 Pa·s. This increase is due to the formation of a more stable oil film on the pipe wall at higher viscosities. When the speed of the rigid body ranges from 0.5 to 1 m/s, due to the small fluid velocity, the erosion effect on the oil film on the pipe wall is relatively small, and the corrosion mitigation efficiency remains stable within a wide range. Copyright © 2023 Society of Petroleum Engineers.