Reducing Carbon Footprint in Petrochemical Plants by Analysis of Entropy Generation for Flow in Sudden Pipe Contraction

A very important method of reducing carbon emissions is to make sure industrial plants are operated at optimal energy efficiency. The oil and petrochemical industries spend large amounts of energy in the transportation of petroleum and its various products that have high viscosities. A critical component in these plants is abrupt pipe contraction. Large amounts of energy are lost in pipe contractions. In this paper we investigate the energy losses in pipe contraction using the local entropy generation method after solving the detailed flow field around an abrupt pipe contraction. We have applied the method at various Reynolds numbers covering laminar and turbulent flow regimes. Furthermore, we have used an integral entropy analysis and found excellent agreement between the differential and integral entropy methods when the computational grid is well refined. The differential analysis was able to predict the local entropy generation and find where the large losses are located and therefore be able to minimize these losses effectively. Based on the detailed entropy generation field, it is recommended to use rounded contraction in order to reduce the losses. By introducing rounded contractions in laminar flow, the losses have been reduced by 22%. In the case of the turbulent flow regime, the losses were reduced by 96% by introducing a rounding radius to diameter ratio r/D2 of 10%. The turbulent flow results for the case of pipe entrance, which is a special case of abrupt contraction (D2/D1 goes to zero) agree very well with the present results. This work addresses a large range of D2/D1 for laminar and turbulent flows. It is recommended that companies involved in designing petrochemical plants and installations take these findings into consideration to reduce carbon emissions. These recommendations also extend to the design of equipment and piping systems for the food industry and micro-device flows.