轴向涡流分离器内分散相油滴的破碎机制研究

doi:10.11949/0438-1157.20251272

化工学报

• •

轴向涡流分离器内分散相油滴的破碎机制研究

陈家庆¹^,⁴(), 王春尧¹^,³, 傅剑峰², 姬宜朋¹^,³(), 李贵旺⁵, 张蕾¹^,³, 阚滨滨², 司政⁶, 张超¹^,³

^1.北京石油化工学院机械工程学院，北京 102617
^2.中海石油（中国）有限公司湛江分公司，广东湛江 524057
^3.深水油气管线关键技术与装备北京市重点实验室，北京 102617
^4.北方工业大学机械与材料工程学院，北京 100144
^5.中海石油（中国）有限公司天津分公司，天津 300450
^6.中化化肥控股有限公司，北京 100031

收稿日期:2025-11-17 修回日期:2025-12-29 出版日期:2026-02-02
通讯作者: 姬宜朋
作者简介:陈家庆（1970-），男，博士研究生，教授，jiaging@ncut.edu.cn
基金资助:
国家自然科学基金面上项目(52274059)

Study on the breakup mechanism of dispersed phase oil droplets in axial vortex separator

Jiaqing CHEN¹^,⁴(), Chunyao WANG¹^,³, Jianfeng FU², Yipeng JI¹^,³(), Guiwang LI⁵, Lei ZHANG¹^,³, Binbin KAN², Zheng SI⁶, Chao ZHANG¹^,³

^1.School of Mechanical Engineering, Beijing Institute of Petrochemical Technology, Beijing 102617, China
^2.China National Offshore Oil Corporation Limited (China) Zhanjiang Branch, Zhanjiang 524057, Guangdong，China
^3.Beijing Key Laboratory of Key Technologies and Equipment for Deepwater Oil and Gas Pipelines, Beijing 102617, China
^4.School of Mechanical and Materials Engineering, North China University of Technology, Beijing 100144, China
^5.China National Offshore Oil Corporation Limited (China) Tianjin Branch, Tianjin 300450, China
^6.Sinofert Holdings Limited, Beijing 100031, China

Received:2025-11-17 Revised:2025-12-29 Online:2026-02-02
Contact: Yipeng JI

摘要/Abstract

摘要：

动态旋流分离技术广泛应用于油田采出水处理，明确强旋流场内油滴破碎机制，对低剪切起旋元件结构优化设计及工艺参数确定具有重要意义。借助高速摄像机和Image J软件，观测含油污水中油滴在轴向涡流分离器内变形和破碎过程；耦合实验与计算流体动力学（CFD）软件模拟结果，分析不同湍动能耗散率下油滴破碎临界粒径d_cri，修正强旋流场中Hinze公式常数C，修正后公式决定系数R²为0.82。在此基础上计算油滴破碎时临界Weber数We_cri与毛细管数Ca_cri，探究叶栅入口、迎水面和背水面三处油滴形态和破碎规律与所受应力分量的关系。结果表明，We_cri和Ca_cri随油滴粒径增加而增加；剪切应力分量τ_rθ、τ_θz使油滴发生不规则变形并破碎，拉伸应力分量τ_θθ、τ_rr使油滴变形为均匀线形并破碎。

关键词: 油滴破碎, 剪切应力, 轴向涡流分离器, 强旋流流场, 计算流体力学, 湍动, 两相流

Abstract:

Dynamic hydrocyclone technology is widely applied in the field of produced water treatment in oilfields. Clarifying the breakup mechanism of dispersed oil droplets in the strong oil-water swirl field is of great significance for optimizing the structure of low-shear swirler and determining the operational process parameter boundaries. In this study, with the help of a high-speed camera and Image J graphic processing software, the deformation and breakup process of dispersed oil droplets in oily wastewater within a Axial Vortex Separator were observed and analyzed. Meanwhile, the computational fluid dynamics (CFD) software was employed to calculate the flow field parameters at the locations where oil droplet deformation and breakup occur. Combining the experimental and simulation results, the critical diameter d_cri of droplet breakup were analyzed under different turbulent kinetic energy dissipation rate conditions, the calculation constant C in the Hinze equation during the formation of the strong swirling flow field was modified. After modification, the coefficient of determination R^² of the calculation formula reached 0.82. And the critical Weber number and Capillary number during oil droplet breakup were calculated. Furthermore the corresponding relationships between the deformation and breakup laws of oil droplets and the stress components were investigated at three locations—namely the cascade inlet, cascade pressure surface, and cascade suction surface. The results show that, both the critical Weber number and capillary number during oil droplet breakup increase with the increase in oil droplet diameter, with the average critical Weber number being 12.67, which is consistent with Hinze's research results. Under the action of the shear stress components τ_rθ and τ_θz, oil droplets undergo irregular deformation followed by multiple breakup into several sub-droplets with different diameters. Under the action of the tensile stress components τ_θθ and τ_rr, oil droplets deform into a uniform linear shape and undergo binary breakup. The research results can provide a theoretical basis for the design of low-shear swirler and the improvement of the separation performance of Axial Vortex Separator.

Key words: drop breakage, shear stress, axial vortex separator, swirling intensity, CFD, turbulence, two-phase flow

中图分类号:

TQ 051.8

陈家庆, 王春尧, 傅剑峰, 姬宜朋, 李贵旺, 张蕾, 阚滨滨, 司政, 张超. 轴向涡流分离器内分散相油滴的破碎机制研究[J]. 化工学报, DOI: 10.11949/0438-1157.20251272.

Jiaqing CHEN, Chunyao WANG, Jianfeng FU, Yipeng JI, Guiwang LI, Lei ZHANG, Binbin KAN, Zheng SI, Chao ZHANG. Study on the breakup mechanism of dispersed phase oil droplets in axial vortex separator[J]. CIESC Journal, DOI: 10.11949/0438-1157.20251272.

图/表 15

图1 轴向涡流分离器结构示意图

Fig.1 Schematic diagram of the Axial Vortex Separator structure

表1 轴向涡流分离器主要结构尺寸

Table 1 The main structural dimensions of the Axial Vortex Separator

起旋叶栅直径D₁/mm	叶片长度e/mm	叶栅高度H/mm	过渡段圆锥长度L₀/mm	分离机筒直径D₂/mm	分离机筒长度L₁/mm
25.00	50.00	6.00	13.00	22.00	190.00

图2 实验工艺流程图

Fig.2 Experimental process flow chart

图3 轴向涡流分离器的网格示意图

Fig.3 Schematic diagram of the Axial Vortex Separator mesh

图4 网格独立性验证

Fig.4 Grid independence verification

表2 油滴尺寸范围和破碎观测次数

Table 2 Droplet size range and number of fragmentation observations

油滴尺寸范围/mm	[0.60-0.90)	[0.90-1.20)	[1.20-1.50]
破碎次数	22	27	38

图5 油滴在叶栅中的破碎情况

Fig. 5 The breakup of oil droplets in the swirler

图6 不同湍动能耗散率下dcri与实际值的对比

Fig. 6 Comparison of dcri and actual values under different turbulent kinetic energy dissipation rates

图7 油滴临界破碎直径拟合曲线

Fig. 7 Fitted Curve of Critical Breakup Diameter of Oil Droplets

图8 湍流微尺度分布

Fig. 8 Turbulent microscale distribution

表3 不同油滴破碎Weber数和毛细管数对比

Table 3 Comparison of We and Ca number for oil droplets of different sizes

序号	粒径/mm	湍动能耗散率/m²/s³	临界Weber数	水力旋流器Weber数	毛细管数
1	0.75	270.08	11.18	0.42	0.94
2	0.94	223.85	12.73	0.23	1.08
3	1.02	179.43	12.31	1.27	1.06
4	1.39	134.04	14.47	0.65	1.24
平均值			12.67	0.64	1.08

图9 剪切应力张量的模分布

Fig. 9 Distribution of the shear stress tensor magnitude

图10 油滴A破碎情况及剪切应力分量对比

Fig.10 Comparison of oil droplet A broken situation and shear stress components

图11 油滴B破碎情况及剪切应力分量对比

Fig.11 Comparison of oil droplet B broken situation and shear stress components

图12 油滴C破碎情况及剪切应力分量对比

Fig.12 Comparison of oil droplet C broken situation and shear stress components

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轴向涡流分离器内分散相油滴的破碎机制研究

Study on the breakup mechanism of dispersed phase oil droplets in axial vortex separator

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