Drag Reduction
Drag Reduction
net/publication/235625460
Drag Reducing Agents in Multiphase Flow Pipelines: Recent Trends and Future
Needs
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            Mattheus F A Goosen
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                                         B. A. Jubran
               Department of Aerospace Engineering, Ryerson University,
                              Toronto, Ontario, Canada
                                        Y. H. Zurigat
                           University of Jordan, Amman, Jordan
                                      M. F. A. Goosen
        School of Science and Technology, University of Turabo, Puerto Rico
Abstract: In this paper, recent work on drag reducing agents in single and multiphase
flow pipelines is reviewed. Focus is placed on theories of drag reduction, the influence
of drag reduction agent types, and hydrodynamic and heat transfer characteristics of
flows in the presence of drag reducing additives. Questions are raised, shortcomings
are assessed, and future research needs are outlined.
Keywords: drag reducing agents, heat transfer, multiphase flow, flow conditioner
INTRODUCTION
Drag reduction in pipe flow using polymeric drag reduction agents (DRAs)
is a problem of great practical engineering interest because DRAs reduce
pumping power and increase piping system capacity. DRAs have been used
in several engineering systems, such as district heating and cooling, oil pro-
duction and transportation pipelines, and others. Its first commercial use was
in the 1.2 m diameter Trans-Alaskan Pipeline in 1979, where a 50% drag
reduction was achieved, thereby increasing the capacity of the pipeline from
1.45 to 2.1 MBPD (Burger et al., 1982). This resulted in eliminating the
need for installing two pumping stations, which were planned to achieve the
                                               1403
1404                                                         B. A. Jubran et al.
mentioned increase in capacity. Since that time, the DRAs have been used
in many petroleum product pipeline installations, such as the Iraq-Turkey oil
pipeline and Oseberg Field in the North Sea (Berge and Solvik, 1996). Thus,
the use of DRAs has the following advantages:
Drag reducing agents (DRAs) are applied in pipelines with turbulent flow,
hence, they are not effective in laminar flows. The reduction is achieved by the
interaction between the polymer molecules and the turbulence components
of the flow. Polymers tend to stretch in the flow and absorb the energy in the
streak, which in turn stops the burst that produces the turbulence in the core
and results in a reduction in turbulence (Lester, 1985; Mizunuma et al., 1996).
Drag Reducing Agents in Multiphase Flow Pipelines                           1405
Figure 3. Cost comparison of conventional gel-type DRA with new generation type
DRA.
1406                                                          B. A. Jubran et al.
Drag reducing agents (DRAs) are high molecular weight, long chain poly-
mers, such as polymethacrylate (PMMA), polyethyleneoxide (PEO), and
polyisobutylene (PIB). DRA polymers commonly used are x-olefin polymers
and copolymers of very high molecular weight. A new generation of drag
reduction agents is now available commercially. In general, the new DRA
is characterized by high polymer content. The active component is still a
polyalphaolefin polymer with a fast dissolution rate and a slow degradation
rate. Moreover, they are characterized by low viscosity and are much easier
to handle. Berge and Solvik (1996) reported field results in crude oil and mul-
tiphase flows using the new generation DRA, which is an emulsified powder
product with a polymer content of 20–25%, as compared to conventional
gel-type product with polymer content of 5–8%. They reported that the new
DRA tends to be four times more effective than the conventional gel-type
DRA, with cost savings of 25%. Table 2 summarizes drag reducing additives
and their properties, while Table 3 lists the drag reduction and heat transfer
behavior as reported by Kostic (1994).
       Table 1. Theories of drag reduction phenomena
Theory Description
       Shear thinning           Originally it was speculated that near-wall-layer, by virtue of shear-thinning, may have extremely lower friction coefficient than pure
                                  solvent. Later this theory was discounted since it was proved that shear-thinning friction is somewhat lower, but not nearly that of
                                  drag-reduction friction.
       Visco-elasticity and     This may well be the most unfortunate theory. Drag-reducing polymer solutions are viscoelastic and show the normal-stress differences,
         normal-stresses          but for concentrations extremely high by drag-reduction standards. Very dilute solutions do not exhibit any measurable elasticity, nor
                                  change of viscosity from pure solvent, still they are very strong drag reducers. Also, viscoelastic, cross-linked polyacrylic acid
                                  (Carbopol) solutions do not show any drag-reduction, except for shear-thinning effect. It may well be that viscoelasticity does not play
                                  any major role in drag reduction, but is merely an accompanying property of some drag-reduction fluids. It is known that both
1407
                                  viscoelastic and non-elastic fluids may produce drag-reduction.
       Molecular “stretching”   Greatly extended linear macromolecules in shear direction interfere with turbulence, providing a stiffening effect, thus reducing friction
                                  drag. Others postulate that molecular entanglements are responsible for interfering with and enlarging the sublayer eddies. Some have
                                  argued that macromolecules’ elastic properties and continuous deformation, like a “yo-yo” effect, are responsible for damping small
                                  turbulent eddies, storing and recovering otherwise dissipated turbulent energy. However, for extremely dilute solutions it seems
                                  unlikely that such a hypothesis could be valid.
       Decreased turbulence     Some researchers suggest that polymer additives interfere with the production of turbulence, and that the reduction phenomena are not
         production               due to turbulence dissipation, but are driven by reduced generation of turbulence. Since the two have to be in balance, their roles may
                                  be easily mistaken.
                                                                                                                                                             (continued)
       Table 1. (Continued)
Theory Description
       Decreased turbulence       Turbulence energy dissipation via finest eddies is greatly reduced (suppressed) by additives interference, to an extent equal to the
         dissipation                 drag-reduction, while larger eddies and large-scale flow instability are present (still turbulent flow), but with different and more
                                     favorable structure.
       Vortex stretching          It is postulated that resistance to vortex stretching reduces the mixing and energy losses. It is further shown that dilute polymer solutions
                                     may have thousands of times higher extensional viscosity than the steady-state viscosity, which may have a strong influence on
                                     drag-reduction mechanism, believed to play a major role in a region just outside the laminar sublayer (5 < y + < 50).
       Non-isotropic properties   Since viscosity is shear-rate dependent and the shear-rate is directional, the solution structure becomes anisotropic; hence viscosity
         and turbulence              (including dynamic and higher-order stress coefficients) has to be anisotropic: for shear thinning fluids, it is lower in the flow
                                     direction and higher in cross-flow directions, thus suppressing considerably the cross-flow fluctuating velocity components (especially
1408
                                     small-scale eddy fluctuations).
       Laminarization of          Turbulence is the “wasteful” dissipation of fluid energy via the finest turbulent eddies, thus it directly increases friction drag. Therefore,
         turbulent flow              drag reduction is a direct measure of partial flow laminarization. By definition, turbulence implies random fluctuations and energy
                                     dissipation, otherwise flow instability will have some orderly secondary (and unsteady) flow patterns.
       Unanswered questions:
         • Does viscoelasticity have any direct relation with turbulent drag reduction?
         • Is influence of wall crucial since polymers may profoundly modify jets and free turbulence?
         • What is the influence on drag reduction of internal and external boundary layers and how can concepts be unified?
         • Why is “Onset” of drag reduction present with some but not all drag-reducing fluids?
         • Why do additives produce the maximum friction and heat-transfer reduction asymptotes, but cannot fully laminarize flow (Ultimate Drag Reduction)?
         • Why is the asymptotic heat-transfer reduction stronger and occurs for higher polymer concentration than friction drag?
       Table 2. Drag reducing additives and their properties
       High-polymers                         Macromolecules—high-molecular weight (106 or higher), linear structure, with maximum extensivity, excellent solubility.
         —Polyethylene oxide (the best)
         —Polyisobutylene (oil-soluble)
         —Polyacrylamide
         —Carboxymethylcellulose
       Soap and surfactant aggregates        Low-molecular-weight alkali-metal and ammonium soap molecules form aggregates or “micelles” in long-chains.
       Fibers                                Asbestos fibers are extremely long (hair-like). Nylon fibers are shorter (length-to-diameter ratio about 50). Wood pulp
         —Asbeston                             suspensions in water reduce turbulent friction. Drag reduction is less in fiber-gas suspensions.
1409
         —Nylon
         —Wood pulp
       Solid-liquid particles                Pneumatic systems have higher flow rates when dust-laden than with clean air only. Suspension of thoria in water show drag
         —Thoria                               reduction. Even droplets in gases reduce friction.
         —Sand and dust particles
         —Droplets in gases
       Other natural sources                 Natural gums (like guar), algae, and bacteria usually produce copious, high-molecular-weight polysaccharide.
       Principal properties of drag-reducing additives
         • Extended length and/or sufficient mass (inertia) to interfere and suppress turbulent fluctuations, particularly transverse ones.
         • Rigidity and/or elasticity to suppress and absorb turbulent fluctuations.
       Table 3. Known friction and heat-transfer behavior of drag reducing fluids
Characteristic phenomena
       Friction factor            High friction drag reduction for very small concentrations gives a friction reduction of 40%, which, with increase of polymer
                                    concentration, reaches the limiting asymptotic value up to 80%.
       Heat transfer              Stronger heat-transfer reduction than friction drag reduction; over 90% of corresponding Newtonian values for the limiting asymptotic
                                    case. Generally, this phenomenon is not useful, as in crude-oil pipelines. In contrast, heat transfer is increased in boiling and in
                                    laminar flow through non-circular ducts.
       Entrance lengths           Much longer than the corresponding Newtonian values, on the order of 100 and 500 hydraulic diameters for hydrodynamic and thermal
                                    entrance lengths, respectively.
       Transition to turbulence   Smoother transition from laminar to turbulent flow, as opposed to abrupt transition of Newtonian fluids. Also, higher transitional
1410
                                    Reynolds number values (much higher than 2000, often 5000 or higher). In some cases the “onset” of drag-reduction is encountered.
       Mean velocity profiles     Flatter velocity profiles (in central region) than the solvent alone. That is quite the opposite from the influence of pipe roughness on the
                                    profile.
       Turbulence structure       Fluctuating v  velocity component is reduced, while axial component u is less affected; though some results are conflicting. Spacing
                                    between large-scale slow-streaks is more than doubled, and time between the “bursts” (fluid lumps) ejected from the wall region is
                                    increased ten-fold.
       Other                      Cavitation is of a different character and is often greatly reduced. Extensional flows through porous media (an application in
                                    enhanced-oil-recovery) and jet flows have different characteristics than in pure solvent. Several other behaviors of more-concentrated
                                    polymer solutions, such as die-swell, Weissenberg rod-climbing effect, tubeless siphon, inverse secondary flow, etc. are markedly
                                    different from Newtonian flows.
Drag Reducing Agents in Multiphase Flow Pipelines                          1411
Figure 4. (a) Type A “fan” for collapsed conformation of B1120, in 0.3 N NaCL
(b) type B “ladder for extended conformation of B1120, in 0.0003 N NaCl.
Drag Reducing Agents in Multiphase Flow Pipelines                          1413
                                                                                                                       Concentration
         Drag reducing agents              Properties                    Applications                  Fluids             (ppm)                Effectiveness               References
       CDR polymer (water         Injection concentration, wt%    Horizontal-oil pipeline,       Oil, single phase     5, 10, 20       6–23%                           Burger et al. (1980)
        soluble polymers)            10%; solvent flash point,      (field tests), diameter
                                     PM, 60◦ C; density, g/cm3      48-in
                                     0.814, K = 230 Pa.s
       CDR polymers               Injection concentration, wt%    Horizontal-oil pipeline,       Oil, single phase     10, 20%         14–23%                          Wahl et al. (1982)
                                     10%; solvent flash point,      (field tests), diameter 8,
                                     PM, 60◦ C; density, g/cm3      12, and 48-in
                                     0.814, K = 230 Pa.s
       Modified CDR               Injection concentration, wt%    Horizontal-oil pipeline,       Oil, single phase     5, 2%           23–46%                          Wahl et al. (1982)
                                     10%; solvent flash point,      (field tests), diameter 8,
                                     PM, 60◦ C; density, 0.814,     12, and 48-in
                                     K = 280 Pa.s
1414
       Guargum (GM),                                              Horizontal water pipeline,     Water, single phase   250–1500 ppm    17% for CMC, 37% for            Reddy (1986)
         Xanthangum (XM),                                           diameter 1-in, Re =                                                  GM, 40% for XM, 33%
         Polyacrylamide (PAM),                                      20,000 to 60,000                                                     for PAM, and 28% for AF
         Carboxymethylcellulose
         (CMC), and asbestos
         fiber (AF)
       Oil soluble DRA                                            Horizontal 10-cm               Multiphase, oil/gas   20 and 50 ppm   82% for slug flow and 47%       Kang and Jepson
                                                                    diameter pipeline                                                    for annular flow; slug          (2000)
                                                                                                                                         frequency decreased
                                                                                                                                         significantly with addition
                                                                                                                                         of DRA
       GEM                        (Detergent)                     Horizontal 2.5–10 cm           Single crude oil      10–500 ppm      10% (2.5 and 5 cm dia.),        Mansour and Aswad
                                                                    diameter pipelines                                                   35% (7.5 cm dia.) and          (1989)
                                                                                                                                         50% (10 cm dia.)
       New generation DRA         Emulsified powder with a        Horizontal 14-in dia,          Single crude oil,     10–100 ppm      70%, new generation DRA;        Berge and Solvik
                                   polymer content of               9.5 miles, 28 in dia,          multiphase flow                       50%, conventional DRA           (1996)
                                   20–25%                           75 miles
Drag Reducing Agents in Multiphase Flow Pipelines                           1415
                                          Drag                 Pipe
             Flow regime              effectiveness         inclination                      Flow conditions                           Reference
       Full pipe flow (100% oil)     42%                 Horizontal pipe   DRA: 10 ppm, superficial liquid: velocity 0.25 m/s      Kang et al. (1998)
       Stratified flow               More than 40%       Horizontal pipe   DRA: 10 ppm, superficial liquid: velocity 0.03          Kang et al. (1998)
                                                                             m/s, gas velocities 4–7 m/s
1417
                                     67–81%              Horizontal pipe   DRA: 75 ppm, superficial liquid: velocity 0.03          Kang et al. (1998)
                                                                             and 0.11 m/s 7 m/s
                                     90%                 Vertical pipe     Superficial liquid velocity: 0.5 m/s, superficial gas   Kang et al. (1999)
                                                                             velocity less than 4 m/s
       Slug flow                     50%                 Vertical pipe     Superficial liquid velocity: all velocities;            Kang et al. (1999)
                                                                             superficial gas velocity more than 4 m/s
1418                                                         B. A. Jubran et al.
used previously (2001). However, they found that compared with the large
diameter pipe, a larger concentration of polymer is required in the smaller
diameter pipe to achieve the maximum drag reduction (10 ppm in 9.53 cm
pipe and 30 ppm in 2.54 cm pipe). Differences in the resulting flow pattern
were also observed. At the large diameter pipe the resulting flow pattern was
stratified with smooth interface while at the smaller diameter pipe the pattern
was characterized by stratified-annular.
     The study of Soleimani et al. (2002) investigated the effect of DRAs on
the transition form stratified to slug flow in a horizontal 2.54 cm pipe. It was
found that at gas superficial velocities greater than 4 m/s the DRAs delay
the transition to slug flow; i.e., transition occurs at larger liquid holdup. As
DRAs are added into a stratified flow, a higher thickness of the liquid layer
is required to initiate the slugging. In view of these findings, the addition
of DRAs to multiphase flow has potential in flow conditioning. In general,
limited work has been done on the role of DRAs as a flow conditioner and
more comprehensive work is needed.
     Dass et al. (2000) reported a model to predict the components of pressure
drop in slug flow in a horizontal pipe. The aim of their work was to shed
light on the contributions of the frictional and acceleration components to
total pressure drop in horizontal slug flow in the presence of drag reducing
agents. The predicted and experimental results showed good agreement. The
DRA was active in reducing both components of the pressure drop. It was
found that the acceleration component was dominant and contributed more
than 80% of the total pressure. This increased significantly as the superficial
gas velocity was increased. Both components of the pressure were reduced
by 67% and 78% at DRA of 20 and 50 ppm, respectively. However, drag
reduction was decreased as the superficial gas velocity was increased. It is
interesting to note in their study that the drag reduction obtained was mainly
in the acceleration component, indicating that the DRA was effective in the
mixing zone of the slug flow. Fan and Hanratty (1993) developed a model to
predict the pressure drop across a stable slug flow. They treated the slug as a
hydraulic jump and assumed that the pressure change takes place at the rear
of the slug, where the change could be positive or negative.
     Dukler and Hubbard (1975) developed a model to predict the frictional
and acceleration components of total slug pressure drop in an air-water sys-
tem. The model assumed that the two phases within the slug body were
homogeneously mixed with negligible slip. The frictional component of the
pressure was predicted using an equation similar to that used in a single phase
flow after modifying the density of the mixture and the friction factor. The
acceleration contribution was found by assuming a stabilized slug flow body
that is receiving and losing mass at equal rates. The acceleration pressure drop
was then calculated from the force required to accelerate the liquid to slug
velocity. Vlachos and Karabelas (1999) investigated shear stress circumfer-
ence in stratified flow. They used the momentum equations for both phases
to predict the liquid holdup, axial pressure gradient, and average liquid to
Drag Reducing Agents in Multiphase Flow Pipelines                          1419
wall shear stress, for the wavy stratified and stratified/atomization gas/liquid
flow in a horizontal pipe.
Drag reduction and heat transfer phenomena associated with drag reducing
fluids are far from being well understood. Certain applications for the uti-
lization of drag reduction agents necessitate a closer look at the heat transfer
process as well as the hydrodynamics process involved. However, it is inter-
esting to note that in the case of using drag reduction in crude oil pipelines,
the effect of these agents on the heat transfer process can be useful in keep-
ing the loss of heat to the atmosphere to a minimum, while keeping the oil
flowing at a lower pumping power. Moreover, in certain cases it brings down
the cost of thermal insulation of the pipelines.
     Matthys et al. (1987) reported local and heat transfer measurements in
circular tubes for suspensions of betonite and for a combination of betonite
and polyacrylamide in water for both laminar and turbulent flow. It was found
that a viscosity model based on rheological measurements could represent the
results with a Newtonian relationship. It was also found that combining clay
and polymer in a fluid produced viscoelastic solutions that were very sen-
sitive to mechanical degradation. The local heat transfer results were well
correlated using the Colburn and Reynolds analogies, regardless of the con-
centration of bentonite. Yoo et al. (1993) investigated experimentally the heat
transfer characteristics of drag reducing polymer solutions in the thermal en-
trance region of circular tube flows. The tests were conducted in two stainless
steel tubes with length to diameter ratios of 710 and 1100. The fluids used
were aqueous poly-acrylamide solutions of Separan AP-273 with a concen-
tration range of 300 to 1000 wppm. The main finding of this investigation
was that the order of magnitude of the thermal entrance length of the maxi-
mum drag reducing polymer solutions was much higher than that of turbulent
Newtonian fluids in tube flows.
     Gasljevic and Matthys (1994) reported local heat transfer results and
friction in the entry region of a circular pipe in the presence of a drag re-
duction surfactant. Two entrance arrangements were used: a cone contraction
and a wire mesh plug fitted to flatten the velocity profile. The main findings
of this work were the restructuring of the fluid itself due to high local en-
ergy dissipation in the inlet region, and the stronger coupling between the
hydrodynamic and thermal field development in the case of surfactant so-
lutions than in the case of polymer solutions. The Reynolds analogy and
the direct relation between the friction and heat transfer coefficients were
not valid for drag reducing fluids; i.e., the Reynolds and Colburn analogies
were not valid for this type of flow. The reasoning behind this is still not
clear and further research is needed (Matthys, 1991; Matthys and Sabersky,
1987).
1420                                                           B. A. Jubran et al.
     Toh and Ghajar (1988) and Matthys (1991) observed that the thermal
entrance and hydrodynamic lengths for drag reducing solutions were more
than that observed for Newtonian fluid flow with values of more than 20 and
100 diameters, respectively.
     Matthys (1991) carried out a comprehensive survey on the most impor-
tant results and the current research needs of heat transfer, drag reduction,
and fluid characterization for turbulent flow of polymer solutions in pipes.
He investigated the problem of the reduction in convective heat transfer in
the presence of a drag reducing agent. It was pointed out that the reduction
produced by the addition of the agent was upset by the greater reduction pro-
duced in the convection heat transfer. He attributed the lack of investigations
on heat transfer of polymer solutions to the complexity of viscoelastic flows.
This required a more demanding experimental set up to accurately record the
data. Matthys (1991) indicated the availability of macroscopic and correla-
tion work for purely viscous non-Newtonian fluids, but not for viscoelastic
non-Newtonian fluids that cover flows with drag reduction agents.
     Gasljevic and Matthys (1991) investigated the thermal and hydrodynamic
characteristics of drag-reducing surfactant solutions in the entry region of the
pipe, as well as after fittings. In addition, they provided an excellent literature
review on the subject. It was reported that for surfactant solutions the friction
coefficient and the Nusselt number were varying at the same rate beyond 300
diameters. Heat transfer downstream of an elbow tended to increase over that
obtained for fully developed flow, but it did not degrade the fluid.
     Gasljevic et al. (1993) conducted a comprehensive experimental investi-
gation on the performance of various types of heat exchangers in the presence
of drag reducing surfactants in the working fluid. The working fluid used was
a solution of 2300 ppm of Ethoquad T/13 and 2000 ppm of NaSal in deionized
water. Pressure and heat transfer measurements were taken at an operating
temperature in the range of 312–319 K and fluid velocities of 0.2–3 m/s.
They compared their results with those obtained when tap water was used as
the working fluid and concluded that the thermal and hydrodynamic charac-
teristics are very much dependent on the geometry and flow conditions in the
heat exchanger. It was also noted that a significant drag reduction could be
achieved in heat exchangers with little penalty in the heat transfer process.
     Gasljevic and Matthys (1993, 1991) reported an investigation to explore
the use of surfactant drag reducing additives to reduce the pumping power
in hydronic heating and cooling systems. Various issues were investigated,
namely the matching of the additives with system characteristics, drag reduc-
tion in fittings and valves, and the heat transfer process in the presence of
reduction agents. It was concluded that the use of drag reducing agents in
heating and cooling systems can be implemented at a small cost and would
lead to significant energy savings.
     Kostic (1994) carried out a critical review on turbulent drag, heat transfer
reduction phenomena, and laminar heat transfer enhancement in non-circular
duct flow of non-Newtonian fluids. The review outlined peculiar behaviors
Drag Reducing Agents in Multiphase Flow Pipelines                          1421
CONCLUDING REMARKS
This paper has highlighted research conducted on drag reduction in single and
multiphase flows with particular reference to the oil industry. It has examined
work related to theories of drag reduction, the influence of drag reduction
types, and hydrodynamic and heat transfer characteristics of the flows in the
presence of a drag reducing agent. Moreover, it has raised questions and
shortcomings that need answers, as well as pin-pointing potential areas that
need further research.
      Drag reduction phenomena and theories related to multiphase flow are
still far from being well understood. More work is needed in the areas of
shear degradation, and the effect of wax content, water cut, and pipe incli-
nation on the performance of drag reduction in smooth and perforated pipes
with emphases on oil wells. Most of the work carried out on the performance
of horizontal wells consider only the friction component of the total pressure
without taking into consideration the acceleration component. Limited work
has been done on the role of drag reducing agents as a flow conditioner, espe-
cially for large pipe inclinations with a high water cut. Further fundamental,
experimental, and analytical investigations are needed to better understand
the heat and hydrodynamic processes associated with drag reduction in sin-
gle and multiphase flows, since the Reynolds and Colburn analogies are not
valid for drag reducing fluids.
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Drag Reducing Agents in Multiphase Flow Pipelines                           1423