Reducing Gas Accumulation in Horizontal Diffusers Under Two-Phase Flow Using Upstream Cross-Flow Steps

In gas–liquid two-phase flows, diverging channels such as diffusers often develop low-pressure separation zones where gas can accumulate, hindering pressure recovery and reducing system performance. This issue is particularly critical in centrifugal pumps, where it leads to efficiency losses. Unlike pumps, diffusers without rotating components allow for more precise experimental studies. This research investigates a passive control method using upstream cross-flow steps to reduce gas accumulation in a horizontal diverging channel. Thin metallic sheets with toothed geometries of 2 mm, 5 mm, and 8 mm heights were installed upstream to interact with the flow. These features aim to enhance turbulence, break up larger gas pockets, and promote vertical bubble dispersion, all while minimizing additional flow separation. The diffuser was intentionally designed with an expanding angle to encourage flow separation and gas accumulation. The experiments covered various two-phase flow conditions (liquid Reynolds number 59,530–78,330; gas Reynolds number 3–9.25), and high-speed imaging captured detailed phase interactions. The results show that the steps significantly reduce gas accumulation, especially at higher water flow rates. These findings support the development of more accurate computational models and offer insights for optimizing centrifugal pump designs by minimizing gas buildup in separated flow regions.