Development of a mixer-viscometer for studying rheological behavior of settling and non-settling slurries

Slurry transport has become a subject of interest in several industries, including oil and gas. The importance of slurry/solid transport in the oil and gas industry is evident in areas of cuttings transport, sand transport and, lately, hydrates. There is therefore a great need to develop instrumentation capable of characterizing fluids with high solid content. Presence of solids in fluids makes the rheological characterization of these systems difficult. This is because available rheometers are designed with a narrow gap and cannot prevent solids from settling. The main aim of this paper is to present a step-by-step procedure of converting torque and shaft speed into viscosity information by applying the Couette analogy, equivalent diameter and inverse line concepts. The use of traditional impeller geometries such as cone and plate may be challenging due to their narrow gap and inability to prevent settling. Therefore, the use of non-conventional impeller geometry is imperative when dealing with settling slurries and suspensions. The most challenging task using complex geometry impeller is data interpretation especially when dealing with complex rheology fluids. In this work, an autoclave is transformed into a mixer-type viscometer by modifying its mixing, cooling and data acquisition systems. Mathematical models relating the measured torque to shear stress and the measured shaft speed to shear rate were developed and expressed in terms of the equivalent diameter. The shear rate and shear stress constants were expressed in terms of equivalent diameter and measureable parameters such as impeller speed and torque. The mixer-type viscometer was calibrated using four Newtonian and four Power-Law fluids to determine the rheological constants (equivalent diameter, shear rate and shear stress constants). The concept of inverse line was used to identify the laminar flow regime. The calibrated instrument was used to characterize two Power-Law fluids. This procedure can be extended to any rheological model. Methods developed in this work can be used to characterize fluids with high solid content. This is particularly important when dealing with complex rheology slurries such as those encountered in food processing, oil and gas and pharmaceuticals.