Non-newtonian flow and applied rheology : engineering applications

This book bridges the gap between the theoretical work of the rheologist, and the practical needs of those who have to design and operate the systems in which these materials are handled or processed. It is an established and important reference for senior level mechanical engineers, chemical and process engineers, as well as any engineer or scientist who needs to study or work with these fluids, including pharmaceutical engineers, mineral processing engineers, medical researchers, water and civil engineers. This new edition covers a considerably broader range of topics than its predecessor, including computational fluid dynamics modelling techniques, liquid/solid flows and applications to areas such as food processing, among others.

Author Notes

Raj has over 20 years of experience in chemical engineering; his specialism is fluid flow and heat transfer. He won the RPG Life Science Professor M M Sharma medal & the Chemcon distinguished speaker award in 2013. He is a fellow of the Indian National Science Academy, and is an editorial board member of 2 Elsevier journals. He has written 7 books and has contributed over 300 papers to both journals and contributed books.

Preface to the Second Edition	p. xi
Preface to the First Edition	p. xiii
Acknowledgements (First Edition)	p. xv
1 Non-Newtonian fluid behaviour	p. 1
1.1 Introduction	p. 1
1.2 Classification of fluid behaviour	p. 1
1.2.1 Definition of a Newtonian fluid	p. 1
1.2.2 Non-Newtonian fluid behaviour	p. 5
1.3 Time-independent fluid behaviour	p. 6
1.3.1 Shear-thinning or pseudoplastic fluids	p. 6
1.3.2 Viscoplastic fluid behaviour	p. 12
1.3.3 Shear-thickening or dilatant fluid behaviour	p. 14
1.4 Time-dependent fluid behaviour	p. 18
1.4.1 Thixotropy	p. 18
1.4.2 Rheopexy or negative thixotropy	p. 20
1.5 Visco-elastic fluid behaviour	p. 24
1.6 Dimensional considerations for visco-elastic fluids	p. 34
1.7 Influence of micro-structure on rheological behaviour	p. 37
Further Reading	p. 52
References	p. 53
Nomenclature	p. 54
2 Rheometry for non-Newtonian fluids	p. 56
2.1 Introduction	p. 56
2.2 Capillary viscometers	p. 56
2.2.1 Analysis of data and treatment of results	p. 56
2.2.2 Sources of errors	p. 63
2.3 Rotational viscometers	p. 75
2.3.1 The concentric cylinder geometry	p. 76
2.3.2 The wide gap rotational viscometer: determination of the flow curve for a non-Newtonian fluid	p. 79
2.3.3 The cone-and-plate geometry	p. 83
2.3.4 The parallel plate geometry	p. 86
2.3.5 Moisture loss prevention: the vapour hood	p. 89
2.4 The controlled-stress rheometer	p. 89
2.5 Yield stress measurements	p. 91
2.6 Normal stress measurements	p. 96
2.7 Oscillatory shear measurements	p. 97
2.8 Extensional flow measurements	p. 101
2.8.1 Lubricated planar stagnation die flows	p. 101
2.8.2 Filament-stretching techniques	p. 102
2.9 On-line viscometry	p. 102
Further reading	p. 106
References	p. 106
Nomenclature	p. 108
3 Flow in pipes and in conduits of non-circular cross-sections	p. 110
3.1 Introduction	p. 110
3.2 Laminar flow in circular tubes	p. 111
3.2.1 Power-law fluids	p. 112
3.2.2 Bingham plastic and yield-pseudoplastic fluids	p. 115
3.2.3 Average kinetic energy of fluid	p. 123
3.2.4 Generalized approach for laminar flow of time-independent fluids	p. 124
3.2.5 Generalized Reynolds number for the flow of time-independent fluids	p. 126
3.3 Criteria for transition from laminar to turbulent flow	p. 131
3.4 Friction factors for transitional and turbulent conditions	p. 137
3.4.1 Power-law fluids	p. 137
3.4.2 Viscoplastic fluids	p. 142
3.4.3 Bowen's general scale-up method	p. 145
3.4.4 Effect of pipe roughness	p. 151
3.4.5 Velocity profiles in turbulent flow of power-law fluids	p. 152
3.5 Laminar flow between two infinite parallel plates	p. 159
3.6 Laminar flow in a concentric annulus	p. 163
3.6.1 Power-law fluids	p. 165
3.6.2 Bingham plastic fluids	p. 166
3.6.3 Herschel-Bulkley fluids	p. 172
3.7 Laminar flow of inelastic fluids in non-circular ducts	p. 177
3.8 Miscellaneous frictional losses	p. 185
3.8.1 Sudden enlargement	p. 186
3.8.2 Entrance effects for flow in tubes	p. 187
3.8.3 Minor losses in fittings	p. 191
3.8.4 Flow measurement	p. 191
3.9 Selection of pumps	p. 194
3.9.1 Positive-displacement pumps	p. 194
3.9.2 Centrifugal pumps	p. 195
3.9.3 Screw pumps	p. 199
Further reading	p. 201
References	p. 201
Nomenclature	p. 204
4 Flow of multi-phase mixtures in pipes	p. 206
4.1 Introduction	p. 206
4.2 Two phase gas and non-Newtonian liquid flow	p. 207
4.2.1 Introduction	p. 207
4.2.2 Flow patterns	p. 208
4.2.3 Prediction of flow patterns	p. 209
4.2.4 Holdup	p. 212
4.2.5 Frictional pressure drop	p. 220
4.2.6 Practical applications and optimum gas flow rate for maximum power saving	p. 233
4.2.7 Two phase flow of drag reducing polymers	p. 237
4.3 Two phase liquid-solid flow (hydraulic transport)	p. 238
4.3.1 Pressure drop in slurry pipe lines	p. 239
4.3.2 RTD and slip velocity	p. 243
Further reading	p. 245
References	p. 245
Nomenclature	p. 247
5 Particulate systems	p. 249
5.1 Introduction	p. 249
5.2 Drag force on a sphere	p. 250
5.2.1 Drag on a sphere in a power-law fluid	p. 251
5.2.2 Drag on a sphere in viscoplastic fluids	p. 258
5.2.3 Drag in visco-elastic fluids	p. 261
5.2.4 Terminal falling velocities	p. 262
5.2.5 Effect of container boundaries	p. 270
5.2.6 Hindered settling	p. 272
5.3 Flow over a cylinder	p. 273
5.4 Effect of particle shape on terminal falling velocity and drag force	p. 274
5.5 Motion of bubbles and drops	p. 282
5.6 Flow of a liquid through beds of particles	p. 286
5.7 Flow through packed beds of particles (porous media)	p. 287
5.7.1 Porous media	p. 287
5.7.2 Prediction of pressure gradient for flow through packed beds	p. 289
5.7.3 Wall effects	p. 298
5.7.4 Effect of particle shape	p. 299
5.7.5 Dispersion in packed beds	p. 300
5.7.6 Mass transfer in packed beds	p. 302
5.7.7 Visco-elastic and surface effects in packed beds	p. 303
5.8 Liquid-solid fluidization	p. 305
5.8.1 Effect of liquid velocity on pressure gradient	p. 305
5.8.2 Minimum fluidizing velocity	p. 307
5.8.3 Bed expansion characteristics	p. 308
5.8.4 Effect of particle shape	p. 309
5.8.5 Dispersion in fluidized beds	p. 310
5.8.6 Liquid-solid mass transfer in fluidized beds	p. 310
Further reading	p. 311
References	p. 311
Nomenclature	p. 314
6 Heat transfer characteristics of non-Newtonian fluids in pipes	p. 316
6.1 Introduction	p. 316
6.2 Thermo-physical properties	p. 316
6.3 Laminar flow in circular tubes	p. 319
6.4 Fully developed heat transfer to power-law fluids in laminar flow	p. 320
6.5 Isothermal tube wall	p. 322
6.5.1 Theoretical analysis	p. 322
6.5.2 Experimental results and correlations	p. 327
6.6 Constant heat flux at tube wall	p. 331
6.6.1 Theoretical treatments	p. 331
6.6.2 Experimental results and correlations	p. 332
6.7 Effect of temperature-dependent physical properties on heat transfer	p. 335
6.8 Effect of viscous energy dissipation	p. 337
6.9 Heat transfer in transitional and turbulent flow in pipes	p. 338
Further reading	p. 339
References	p. 339
Nomenclature	p. 341
7 Momentum, heat and mass transfer in boundary layers	p. 343
7.1 Introduction	p. 343
7.2 Integral momentum equation	p. 345
7.3 Laminar boundary layer flow of power-law liquids over a plate	p. 347
7.3.1 Shear stress and frictional drag on the plane immersed surface	p. 349
7.4 Laminar boundary layer flow of Bingham plastic fluids over a plate	p. 351
7.4.1 Shear stress and drag force on an immersed plate	p. 352
7.5 Transition criterion and turbulent boundary layer flow	p. 356
7.5.1 Transition criterion	p. 356
7.5.2 Turbulent boundary layer flow	p. 356
7.6 Heat transfer in boundary layers	p. 357
7.6.1 Heat transfer in laminar flow of a power-law fluid over an isothermal plane surface	p. 359
7.7 Mass transfer in laminar boundary layer flow of power-law fluids	p. 365
7.8 Boundary layers for visco-elastic fluids	p. 367
7.9 Practical correlations for heat and mass transfer	p. 367
7.9.1 Spheres	p. 368
7.9.2 Cylinders in cross-flow	p. 368
7.10 Heat and mass transfer by free convection	p. 371
7.10.1 Vertical plates	p. 371
7.10.2 Isothermal spheres	p. 372
7.10.3 Horizontal cylinders	p. 372
Further reading	p. 373
References	p. 374
Nomenclature	p. 374
8 Liquid mixing	p. 376
8.1 Introduction	p. 376
8.1.1 Single phase liquid mixing	p. 376
8.1.2 Mixing of immiscible liquids	p. 376
8.1.3 Gas-liquid dispersion and mixing	p. 377
8.1.4 Liquid-solid mixing	p. 377
8.1.5 Gas-liquid-solid mixing	p. 377
8.1.6 Solid-solid mixing	p. 377
8.1.7 Miscellaneous mixing applications	p. 378
8.2 Liquid mixing	p. 379
8.2.1 Mixing mechanisms	p. 379
8.2.2 Scale-up of stirred vessels	p. 382
8.2.3 Power consumption in stirred vessels	p. 384
8.2.4 Flow patterns in stirred tanks	p. 402
8.2.5 Rate and time of mixing	p. 410
8.3 Gas-liquid mixing	p. 419
8.3.1 Power consumption	p. 421
8.3.2 Bubble size and hold-up	p. 422
8.3.3 Mass transfer coefficient	p. 423
8.4 Heat transfer	p. 424
8.4.1 Helical cooling coils	p. 424
8.4.2 Jacketed vessels	p. 428
8.5 Mixing equipment and its selection	p. 431
8.5.1 Mechanical agitation	p. 432
8.5.2 Rolling operations	p. 442
8.5.3 Portable mixers	p. 443
8.6 Mixing in continuous systems	p. 444
8.6.1 Extruders	p. 444
8.6.2 Static mixers	p. 445
Further reading	p. 456
References	p. 456
Nomenclature	p. 459
Further exercises	p. 462
Index	p. 501

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Table of Contents