The formation of heavy crude oil in water (O/W) emulsion by a low energy laminar controlled flow has been investigated. The emulsion was prepared in an eccentric cylinder mixer. Its geometry allows the existence of chaotic flows that are able to mix well highly viscous fluids. This new mixer design is used to produce high internal phase ratio emulsions for three oils: castor oil and two heavy crude oils of different initial viscosity (Zuata and Athabasca crude oils). The influence of the stirring conditions, geometrical parameters, and water volume fraction on the rheological properties of the resulting O/W emulsion is studied.

An active inline mixer suitable for flows at low Reynolds number and high Péclet number is studied. An alternated oscillatory forcing protocol is imposed by three rotating circular arc-walls in a straight channel. In the two-dimensional case, simple phenomenological arguments are used to estimate heuristically the mixing efficiency with two nondimensional control parameters: the Strouhal number based on the bulk flow velocity and the strength of the cross flow relative to the transport flow. The validity and limitations of the proposed mixing conditions are explained by the transport mechanisms in the mixer. The beneficial role of the elliptic flow regions for stretching and folding the passive scalar interfaces is highlighted as well as a correlation between good mixing ability and the chaotic advection of tracers in the mixing zone.

Estimating singular pressure losses for multi-stage obstacles in pressurized hydraulic ducts is a challenging task. An experimental study was conducted in a closed-loop hydrodynamic tunnel to characterize the pressure losses of a system consisting of a porous fibrous foam placed in front of a bar rack. The pressure losses of different foam–rack configurations were measured over a range of inlet velocities in order to highlight the mutual influence of their characteristics on the flow. The interdependence between the two stages has been evidenced by both the experimental results and additional numerical simulations using RANS (Reynolds-Averaged Navier–Stokes Equations) simulations with a k-$\omega$ SST turbulent closure model. The pressure losses were first modeled using two approaches based on the assumption of either independence or full dependence between the stages. The respective advantages and limitations of these approaches led to an improved analytical formula that considers the transition of the flow from the porous foam to the bar rack. By taking into account an empirical transition factor, the proposed model improves the head loss prediction for all tested configurations, with an average relative error between the formula and experimental results less than that of the two simpler approaches. This study improves our understanding of global pressure losses in multi-stage systems that include a porous foam or other filtering or clogging media in front of bar racks.