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Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834 A 0 F d P D A K F Y C f 1 i a t a t s v f M p i f i u i f h R Contents lists available at ScienceDirect Journal of Non-Newtonian Fluid Mechanics journal homepage: www.elsevier.com/locate/jnnfm low instabilities in fluid displacement through enlarged regions in annular ucts .R. Varges, E.C. Rodrigues, L.C. Moraes, P.R. de Souza Mendes, M.F. Naccache ∗ epartment of Mechanical Engineering, Pontifícia Universidade Católica do Rio de Janeiro, Rua Marquês de São Vicente 225, Rio de Janeiro, RJ 22453-900, Brazil R T I C L E I N F O eywords: low displacement ield stress fluids omputational fluid dynamics low instabilities A B S T R A C T This work presents numerical results of flow displacement and the instabilities that appear when a viscoplastic fluid is displaced by a Newtonian one in a vertical annular duct with an enlarged region. Hydrodynamic instabilities in displacement flows may be due to viscosity and density differences, inertia effects and geometry irregularities like eccentricity and variable cross sections. If one of the fluids is non-Newtonian, the situation can be more challenging due to the dependence of the rheology on the flow kinematics. The geometry analyzed is found in the well cementation process in the oil industry, where the drilling fluid (viscoplastic behavior) is displaced by a spacer fluid (Newtonian). The drilling fluid wash out must be perfect in order to guarantee the success of the cementation operation, thus preventing the collapse of the oil well. Situations with excessive wellbore enlargement can occur, hampering the removal of the drilling fluid and the establishment of a perfect zonal isolation. The numerical solution of the problem is obtained using the finite volume technique to solve the governing conservation equations of mass and momentum. The volume of fluid method is employed to deal with the multiphase problem. The aim of this study is to look at how the governing parameters affect the flow displacement pattern and efficiency inside the enlarged region, with the goal to optimize the displacement process. The results focus on real case scenario for unstable situations, and present new findings that helps understanding the role of viscous, inertia and buoyancy effects. . Introduction The displacement flow of a fluid by another has been widely studied n the literature due to its relevance to several natural phenomena nd industrial processes. Depending on the flow and fluid parame- ers, hydrodynamic instabilities may appear. When a fluid displaces more viscous one, viscous fingering occurs, a phenomenon called he Saffman–Taylor instability. Density differences may also play a ignificant role in the onset of instabilities, either for horizontal or ertical displacements. The complexity increases when non-Newtonian luids are present, due to viscosity dependence on the flow kinematics. oreover, elasticity and thixotropy can affect the flow displacement attern. Besides fluid properties, flow rate and geometry can play an mportant role, often leading to instabilities that can improve or impair low displacement. Depending on the application, the hydrodynamic nstabilities can be desirable or not, but in any case it is essential to nderstand which parameters are responsible for them, and how they nfluence their development. Displacement flows through abruptly varying cross sections are ound in several industrial and natural processes, such as flows through ∗ Corresponding author. E-mail address: naccache@puc-rio.br (M.F. Naccache). URL: http://greo.mec.puc-rio.br (M.F. Naccache). porous media, blood flow circulation, extrusion, and cementation of oil wells. The analysis presented here focus on the last one, in cir- cumstances where an enlarged region is present. In this and other situations, the fluids can present a non-Newtonian behavior, which can lead to some special features that result in a more complex analysis. For example, when a viscoplastic fluid is displaced, it will remain stagnant in the regions where the stress do not surpass the yield stress, resulting in a non-effective displacement and changing significantly the pressure drop throughout the flow. The most probable outcome will be a non perfect final product or process. These issues are critical in the oil industry, not only during cementing and drilling operations but also in the displacement through reservoirs during production [1–5]. In several other areas, flow displacement problems appear in flows during extrusion processes. Another example of application, in the area of biomedicine, is studied by Roberts et al. [6], who analyzed the process of using flow of a viscoplastic aqueous foam to deliver surfactant to a varicose vein, and showed that increasing the yield stress leads to a more effective blood displacement inside the veins. vailable online 25 May 2022 377-0257/© 2022 Elsevier B.V. All rights reserved. ttps://doi.org/10.1016/j.jnnfm.2022.104834 eceived 29 October 2021; Received in revised form 17 March 2022; Accepted 17 May 2022 http://www.elsevier.com/locate/jnnfm http://www.elsevier.com/locate/jnnfm mailto:naccache@puc-rio.br http://greo.mec.puc-rio.br https://doi.org/10.1016/j.jnnfm.2022.104834 https://doi.org/10.1016/j.jnnfm.2022.104834 http://crossmark.crossref.org/dialog/?doi=10.1016/j.jnnfm.2022.104834&domain=pdf Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834P.R. Varges et al. Fig. 1. Schematic of the abrupt annular expansion–contraction geometry. The effects of flow rate and fluid rheology through regular and irreg- ular geometries have been analyzed for single fluids both numerically and experimentally [7–15]. These researchers studied the role of flow rate and yield stress in the appearance and development of unyielded regions that directly affect the flow pattern and pressure drop. They observed the presence of unyielded stagnant zones near corner regions and/or unyielded plug zones close to the center of the duct. Regarding the displacement of one fluid by another, not only the fluids rheology, flow rate and geometry are relevant, but also and more importantly the viscosity and density differences. Flow displacement in annular spaces has been analyzed in the literature focusing mainly on cementing operations of oil wells [15–23], where it has been examined the effects of viscosity and density ratios, flow rate and annulus eccen- tricity on the displacement efficiency. Geometry irregularities are also addressed, due to its importance for the oil industry. The cementing operation in a vertical washout section of a well (annular duct with an expansion followed by a contraction) has also been analyzed [1–3]. The flow of miscible viscoplastic fluids in eccentric annuli was analyzed numerically and experimentally by Deawwanich et al. [20]. Flow images showed the effects of eccentricity, cylinder rotation and rheology on the displacement. Etrati et al. [2] presented a numerical study of the displacement of a Bingham fluid (modeling the drilling fluid) by a Newtonian one (the spacer fluid) to investigate the effect of the washout length, flow rate, density difference and viscosity ratio 2 on the displacement efficiency. The results are limited to positive density differences (heavier fluid displacing a lighter one) and higher Reynolds numbers (but still within the laminar range), showing that density differences play a major role in the process, with larger density differences improving displacement efficiency. The authors also ob- served unstable situations as the Reynolds number increases, but they verified that the instabilities may improve or impair the displacement. Some unyielded fluid is left behind, which is very damaging in the case studied. Naccache et al. [1] also performed a numerical study, using different combinations of pairs of fluids. The results showed the transition from viscous-dominated (low Re), where a fore–aft symmetry is observed inside the washout zone, to inertia-dominated(higher Re) regimes, where the symmetry breaks and the interface between fluids is displaced to the wall near the contraction zone. Flow rate, rheology and geometry effects on the displacement efficiency were investigated. Espinoza et al. [3] presented experimental and numerical results in a concentric annuli washout zone in a low scale geometry. All the cases analyzed resulted in stable situations, and it is observed that increasing the Reynolds number, washout depth and length, the displacement improves. However, the viscosity ratio did not seem to be relevant. Renteria et al. [24] conducted experiments and 2D numerical sim- ulations to study eccentricity and inclination effects on displacement flows of yield stress materials in near-horizontal irregular annuli. It was observed a poor displacement efficiency when considering fluids with high yield stresses flowing in eccentric annuli at 0 or 80◦. Moreover, it was noticed that when the displacement in the annulus is already poor, enlarged regions worsen the displacement efficiency. On the other hand, when the regular annulus presents high displacement effi- ciency, the enlarged region may improved the displacement. Skadsem et al. [25] also investigated experimentally and numerically the effects of eccentricity and inclination in an irregular annulus characterized by an enlarged region. The variation in axial flow velocity across the cross-section of the annulus was observed to be the most prominent consequence of eccentricity. The difference in flow velocity caused an elongated interface in the regular part of the annulus, as well as a poor displacement in the horizontal annulus enlargement. Furthermore, they observed that as inclination decreases, the displacement efficiency increases within concentric and eccentric annuli and within the regular part of the annulus in front of the enlarged region. Another experimental study of interest was performed by Akbari and Taghavi [26], who analyzed the process of placement of a heavy fluid to remove a lighter fluid in an inclined closed-ended pipe. This process simulates a method used for plug and abandonment opera- tions of oil wells. The two fluids were miscible and Newtonian, with different densities. The results showed instabilities and mixing in the front interface. It was shown that density and viscosity differences increase the placement efficiency. Instabilities in flow displacement were also observed by Tehrani et al. [27]. The authors analyzed the flow through upward inclined annular eccentric cylinders, and showed the channeling of the displacing fluid in the wide side of the geom- etry, worsening the displacement process. Density difference (denser displacing fluid) promotes azimuthal flow of the denser fluid towards the narrow side, which, depending on the flow rate (or on the ratio between the buoyancy to Reynolds number), may lead to instabilities that improve the displacement. Fig. 2. Volume fraction for 𝑡∗ = 1, 𝐷∗ = 1.5, 𝑑′∗ = 0.5, 𝑙∗ = 0.5, 𝐿∗ = 6.4, 𝑅𝑒 = 3.92, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.72, 𝑛 = 0.78, 𝛥𝜌∗ = 0, and 𝐺𝑎 = 0. Flow from the left (bottom) to right (top). (a) Mesh 1 with 295,554 nodes; (b) Mesh 2 with 348,824 nodes; (c) Mesh 3 with 401,112 nodes. Fluid 2 is represented by black color and fluid 1 by gray color. Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834P.R. Varges et al. Fig. 3. Velocity profile at the center of the enlarged region for 𝑡∗ = 1, 𝐷∗ = 1.5, 𝑑′∗ = 0.5, 𝑙∗ = 0.5, 𝐿∗ = 6.4, 𝑅𝑒 = 3.92, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.72, 𝑛 = 0.78, 𝛥𝜌∗ = 0, and 𝐺𝑎 = 0 for the meshes with 295,554, 348,824, and 401,112 nodes. Renteria et al. [28] and Sarmadi et al. [29] explored borehole irregularities in primary cementing, specially in horizontal wells in- volving yield stress materials. The first [28] focus on displacement flows in eccentric and elliptic geometries, while Sarmadi et al. [29] focus on circular geometries with enlargements of different depths and wavelengths. It was observed that borehole irregularities can reduce the displacement efficiency. Additionally, Jung and Frigaard [30] recently investigated common cementing practices in horizontal wells to im- prove the displacement efficiency. Excess of cement volume, centralizer usage and staged cementing operations were numerically evaluated and fully discussed. Truzzolillo and Cipelletti [31] presented a review of the general mechanisms driving hydrodynamic instabilities in miscible fluids, ad- dressing the differences between miscible and immiscible interfaces. Atmakis and Kenig [32] presented numerical results of the Kelvin– Helmholtz (KH) instability in a 2D model geometry of two liquid layers, using the Volume of Fluid method (VoF) and level-set methods. The authors observed the stabilization effect of the surface tension over the unstable finger-like structures. Lee and Kim [33] studied numerically the Kelvin–Helmholtz instability of multi-component fluids using a phase-field model, investigating the effects of surface tension, density ratio, and magnitude of velocity difference. It was shown that increasing the surface tension or the density ratio reduces the growth of the KH instability. It was also observed that as the initial horizontal velocity difference gets larger, the interface rolls up more. Furthermore, Dihn et al. [34] observed that the presence of viscosity slows the rate at which the interface grows. In the present work, we extend the work of Espinoza et al. [3], using real data of cementing operations for the geometry of the enlarged 3 Table 1 Mesh sizes, displacement efficiency 𝜙 and its difference with the most refined mesh result 𝜖. Mesh Number of nodes 𝜙 % 𝜖 % Mesh 1 295,554 85.80 1.27 Mesh 2 348,824 85.22 0.59 Mesh 3 401,112 84.72 0 zone, fluids rheology and flow rates. It is worth mentioning that the experimental and numerical results presented in [3] are all related to stable situations and lower flow rates than the real cases. Therefore, the present work aims to contribute to a better understanding of the role of viscosity and density differences, geometry and inertia in the upward flow displacement through expansion–contraction flows, and how these parameters affect the displacement efficiency. Although the main motivation of this study is to investigate the displacement flow to optimize washout cementing operations in the oil industry, the results can be used to avoid/induce instabilities to increase the displacement efficiency of other similar processes, since all results are analyzed via dimensionless parameters. We present numerical results of a Newtonian fluid displacing a yield stress material modeled by a regularized Herschel–Bulkley viscosity function. The effects of some rheological, flow and geometric parameters on flow pattern/volume fraction distribution and displacement efficiency are presented and dis- cussed. Understanding the role of the governing parameters in the onset and development of the hydrodynamic instabilities should provide means to the optimization of the flow displacement process. 2. Modeling Scheme of the flow geometry is presented in Fig. 1. The tube is positioned vertically, and the upstream and downstream length and diameter of the outer tube are equal to 𝑙 and 𝑑, respectively. The diameter of the inner tube is 𝑑′, and the length and diameter of the enlarged region are 𝐿 and 𝐷, respectively. Initially all the annular space is filled with fluid 1. At the beginning of the simulation, fluid 2 enters the tube from the bottom. Fluids are considered incompressible, fluid 2 is Newtonian and fluid 1 is a yield stress material. Flow is isothermal and axisymmetric, since only cases of concentric inner and outer tubes are investigated. The fluids are immiscible, and the volume of fluid (VoF) method is used to track the interface between the fluids [35]. This method calculates the volume fraction of each phase 𝑗, 𝛼𝑗 = ∀𝑗∕∀ (𝑗 = 1, 2, . . . , n), where 𝑛 is the number of phases and ∀𝑗 is the volume occupied by phase𝑗 in the cell control volume ∀. In the problem analyzed, 𝑛 = 2 so that the volume fractions are obtained solving the mass conservation equation for one phase plus a restriction equation, Eqs. (1), (2), respectively given by: 𝜕𝛼1 𝜕𝑡 + 𝐯 ⋅ ▽𝛼1 = 0 (1) 𝛼 + 𝛼 = 1 (2) 1 2 Fig. 4. Volume fraction at 𝑡∗ = 1 for 𝐿∗ = 6.4, 𝐷∗ = 1.5, 𝛥𝜌∗ = 0, 𝐺𝑎 = 0, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78 and: (a) 𝑅𝑒 = 0.04; (b) 𝑅𝑒 = 3.88; (c) 𝑅𝑒 = 93.1. Fluid 2 is represented by black color and fluid 1 by gray color. Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834P.R. Varges et al. 𝜂 w z a c a b 𝛷 t ▽ 𝜌 I a g a c c h v 2 l 𝐷 𝜏 d Fig. 5. Displacement efficiency through time for 𝐿∗ = 6.4, 𝐷∗ = 1.5, 𝛥𝜌∗ = 0, 𝐺𝑎 = 0, ∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78 and: (a) 𝑅𝑒 = 0.04; (b) 𝑅𝑒 = 3.88; (c) 𝑅𝑒 = 93.1. here v is the velocity vector. The volume fraction is equal to one or ero when a control volume is entirely filled with one of the phases, nd it is equal to a value between one and zero if the control volume ontains both fluids. The velocity and pressure at each control volume re equal for both phases, while the properties are given by the average etween the properties (𝛷) of each fluid: = 𝛼1𝛷1 + (1 − 𝛼1)𝛷2 (3) The mass and momentum conservation equations, and the constitu- ive equation are given by: ⋅ 𝐯 = 0 (4) [ 𝜕𝐯 𝜕𝑡 + (𝐯 ⋅ ▽)𝐯 ] = −▽𝑝 +▽ ⋅ 𝝉 + 𝜌𝐠 + 𝐅𝐬 (5) 𝝉 = 2𝜂(�̇�)𝐃 (6) In the above equations, 𝜌 is the density, 𝑝 is the pressure, 𝐠 is the gravity vector, 𝐃 ≡ 1∕2 [ ▽𝐯 +▽𝐯𝑇 ] is the rate-of-strain tensor, �̇� ≡ √ 2tr𝐃2 is the magnitude of 𝐃, and 𝐅𝑠 = 𝜎𝛿1▽𝛼1 is the surface force per unit volume [36], where 𝜎 is the interfacial tension between the two fluids and 𝛿1 is the curvature of the interface of fluid 1, defined as the divergence of the unit normal vector. 𝝉 is the deviatoric stress tensor, given by the Generalized Newtonian Fluid constitutive equation (Eq. (6)). The displacing fluid, fluid 2, is Newtonian, so the viscosity is constant and equal to 𝜇2. The displaced fluid (fluid 1) is a yield stress material, modeled by a regularized Herschel–Bulkley equation [37], given by: ⎧ ⎪ ⎨ ⎪ ⎩ 𝜂(�̇�) = 𝜏𝑦 �̇� + 𝑘�̇�𝑛−1, if �̇� > �̇�cr 𝜂(�̇�) = 𝜏𝑦 �̇�cr [ 2 − �̇� �̇�cr ] + 𝑘�̇�𝑛−1cr [ (2 − 𝑛) + (𝑛 − 1) �̇� �̇�cr ] , otherwise. (7) n the above equation, 𝜏𝑦, 𝑘 and 𝑛 are the yield stress, consistency index nd power-law index of fluid 1. �̇�cr is the regularization parameter, iven by the small rate-of-strain below which the viscosity is equal to constant high value ≈ 500𝜂𝑐 . Therefore, �̇�cr ≈ 𝜏𝑦 500𝜂𝑐 , where 𝜂𝑐 is a haracteristic viscosity. In the present work 𝜂 = 𝜂(�̇� ), where �̇� is a 4 𝑐 𝑐 𝑐 𝑙 haracteristic shear rate defined as �̇�𝑐 = 𝑉 ∕𝐷ℎ, 𝐷ℎ = 𝐷 − 𝑑′ being the ydraulic diameter of the central (enlarged) tube, and 𝑉 is the mean elocity at this enlarged region. The initial and boundary conditions are: • At the instant of time t = 0, the tube is filled with fluid 1 (𝛼1 = 1 and 𝛼2 = 0), and the velocity vector is zero (𝐯 = 𝟎). • At the tube entrance, the Newtonian fluid (fluid 2) is injected with a developed (parabolic) flow profile (𝐯 = 𝑢𝐞𝑥), with an average velocity 𝑣𝑖𝑛. • At the outlet, the flow is assumed fully developed. • At the walls, no slip and impermeability conditions are applied, so that both axial and radial velocity components are equal to zero. .1. Scaling The flow under analysis is scaled based on the following dimension- ess variables. ∗ = 𝐷 𝐷ℎ 𝑑′∗ = 𝑑′ 𝐷ℎ 𝑑∗ = 𝑑 𝐷ℎ 𝑙∗ = 𝑙 𝐷ℎ 𝐿∗ = 𝐿 𝐷ℎ 𝑡∗ = 𝑡 𝑡𝑐 ∗ 𝑦 = 𝜏𝑦𝐷ℎ 𝜇2𝑉 𝛥𝜌∗ = 𝜌2 − 𝜌1 𝜌2 𝜂∗ = 𝜇2 𝜂𝑐 𝜎∗ = 𝜎 𝜇2𝑉 (8) The dimensionless time 𝑡∗ is obtained using the characteristic time (𝑡𝑐) that represents the instant of time when exactly one domain volume of fluid 2 has crossed the inlet boundary. Besides the dimensionless geometric quantities (𝐷∗, 𝑑′∗, 𝑑∗, 𝑙∗, 𝐿∗), the dimensionless time 𝑡∗, the dimensionless yield stress 𝜏∗𝑦 , the dimensionless density difference 𝛥𝜌∗, the viscosity ratio 𝜂∗, and the dimensionless interfacial tension 𝜎∗, some relevant dimensionless parameters can be defined to address the balance among inertia, viscous and buoyancy forces. Then, the Reynolds and the Galilei numbers are respectively defined as: 𝑅𝑒 = 𝜌2𝑉 𝐷ℎ 𝜇2 (9) 𝐺𝑎 = (𝜌2 − 𝜌1)𝑔𝐷2 ℎ 𝜇2𝑉 (10) To evaluate quantitatively the flow displacement we define the isplacement efficiency 𝜙 as 𝜙 = ∀2 ∀𝑇 (11) where ∀2 is the volume occupied by the displacing fluid (fluid 2) at an instant of time and ∀𝑇 is the total volume of the geometry. 3. Numerical solution The conservation equations of mass and momentum are solved using Fluent software (Ansys Inc.). The finite volume method is used to discretize the conservation equations, and the volume of fluid method was employed to deal with the multiphase flow. The pressure–based solver is used for the transient model, and the PISO algorithm is employed to couple the pressure–velocity equations. The mass conser- vation equation is discretized with the power law method, and the upwind discretization method is employed for the momentum equation [19]. A validation of the numerical procedure with experimental results was performed in a previous work [3], using different geometries and parameters. The results are presented in the Supplementary Material (Fig. S1), where we also show comparisons of 2D and 3D simulations (Fig. S2). In all simulations analyzed in the present work, the flow is assumed to be axisymmetric, so only 2D (𝑟 − 𝑥) situations were investigated. A structured non-uniform mesh was generated using the open source Gmsh software. Mesh tests were performed for a base case, whose values of the governing parameters are 𝐷∗ = 1.5, 𝑑′∗ = 0.5, ∗ ∗ ∗ ∗ ∗ = 0.5, 𝐿 = 6.4, 𝑅𝑒 = 3.92, 𝛥𝜌 = 0, 𝜂 = 0.08, 𝜏𝑦 = 12.7, 𝑛 = 0.78. Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834P.R. Varges et al. Fig. 6. Volume fraction at 𝑡∗ = 1 for 𝑅𝑒 = 1, 𝜂∗ = 0.02, 𝜏∗𝑦 = 47.7, 𝑛 = 0.78, 𝐷∗ = 1.5, 𝐿∗ = 6.4, and : (a) 𝛥𝜌∗ = −0.67 and 𝐺𝑎 = −2.4 × 105, (b) 𝛥𝜌∗ = −0.01 and 𝐺𝑎 = −3.5 × 103 (c) 𝛥𝜌∗ = 0 (isodense) and 𝐺𝑎 = 0, (d) 𝛥𝜌∗ = 0.13 and 𝐺𝑎 = 4.7 × 104. Fluid 2 is represented by black color and fluid 1 by gray color. Fig. 7. Displacement efficiency through time for 𝑅𝑒 = 1, 𝜂∗ = 0.02, 𝜏∗𝑦 = 47.7, 𝑛 = 0.78, 𝐷∗ = 1.5, 𝐿∗ = 6.4, and : (a) 𝛥𝜌∗ = −0.67 and 𝐺𝑎 = −2.4 × 105, (b) 𝛥𝜌∗ = −0.01 and 𝐺𝑎 = −3.5 × 103 (c) 𝛥𝜌∗ = 0 (isodense) and 𝐺𝑎 = 0, (d) 𝛥𝜌∗ = 0.13 and 𝐺𝑎 = 4.7 × 104. Three different meshes were analyzed and the results were compared. Table 1 presents the meshes used and the displacement efficiency for each case. The difference between the displacement efficiency at a given mesh (𝜙𝑖) and the one obtained with the finest Mesh 3 (𝜙𝑀3), defined as 𝜖 = (𝜙𝑖 − 𝜙𝑀3)∕𝜙𝑀3, is also presented. All meshes are slightly concentrated close to the walls, to the entrance and to the cross section transition regions, as it can be seen in detail in Fig. S3 of the Supplementary Material. Fig. 2 shows the volume fraction field and Fig. 3 shows the velocity profile at the center of the eroded region for the three different meshes. Considering the differences obtained and the simulation time, the mesh with 348,824 nodes was chosen for this geometry. For this case, the minimum face area normalized by the area of the eroded zone, equal to 𝐿(𝐷 − 𝑑), is equal to 5.6 × 10−5, and the maximum is 2.8 × 10−3. Mesh tests were not performed for the geometries with different 𝐿∗. Instead, we kept the average size of the face areas at the same order of magnitude, for all geometries analyzed. The time step used in all simulations was adaptive, keeping the numerical Courant number 𝐶𝑜 = (𝛥𝑡∕𝛥𝑥)𝑣 less than 1, where 𝛥𝑡 and 5 𝛥𝑥 are the time step and the local longitudinal cell size, and 𝑣 is the local velocity. In all cases, the time step wasaround 10−3 to 10−2 s throughout the simulation. The convergence criteria used at each time step was to consider the scaled residual [37] for the mass and momentum equations below 10−5. It is worth mentioning that the simulations are very time consuming. A regular case pumping one total volume of fluid 2 (𝑡∗ = 1) with the mesh chosen, took around 96 h running in a PC with Intel core i7 processor (3.4 GHz, 16 GB) with only 4 physical cores. 4. Results and discussion The results of flow displacement were obtained for different com- binations of flow parameters, fluids rheology and geometry. We focus the study at the enlarged region, and analyze snapshots of the flow displacement and results of the displacement efficiency through time, to study the influence of the parameters on the stability and efficiency of the flow displacement. Instabilities are expected to occur due to buoyancy effects (when upper fluid is heavier than lower one), adverse viscosity ratios (less viscous fluid displacing a more viscous one) and inertia effects (above a critical Reynolds number). We begin showing the results of an iso-dense base case. Then, we discuss the buoyancy effects, including a density difference 𝛥𝜌∗. We continue investigating the influence of Reynolds number 𝑅𝑒, viscosity ratio 𝜂∗, enlarged region length 𝐿∗, and finally interfacial tension 𝜎∗. In all cases, the dimensionless diameter of the enlarged region is kept equal to 𝐷∗ = 1.5. The inner tube, and entrance and exit tube dimensionless diameters 𝑑′∗ = 0.5 and 𝑑∗ = 0.6 were also held fixed. The entrance and exit tubes length were kept equal to 𝑙∗ = 5(𝑑∗−𝑑′∗) = 0.46, chosen to avoid any disturbances inside the enlarged region due to entrance and exit boundaries, while minimizing the computational domain. Moreover, all the results were obtained with interfacial tension equal to zero (𝐅𝐬 = 𝟎, Eq. (5)), except in the last subsection, when the effect of interfacial tension is analyzed. The results were explored for a range of parameters variation, which were based in real case scenario of cementing operations representing a spacer fluid displacing the drilling mud. The dimensionless density difference ranges from −0.7 to 0.13, Reynolds number ranges from 0.04 to 100, the viscosity ratio varied from 0.0008 to 0.08. The dimensionless enlarged region length range was 1 to 14 and the dimensionless interfacial tension varies up to 0.2. It is worth mentioning that all cases are in the laminar regime for both fluids and in all regions (entrance and exit tubes and enlarged region). 4.1. Effect of density difference We first present a result of an iso-dense base case (𝛥𝜌∗ = 0 and 𝐺𝑎 = 0), using the rheology of fluids employed in real cementing Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834P.R. Varges et al. Fig. 8. Volume fraction at 𝑡∗ = 1 for 𝐿∗ = 6.4, 𝐷∗ = 1.5, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, and: (a) 𝑅𝑒 = 0.04, (b) 𝑅𝑒 = 3.88, and (c) 𝑅𝑒 = 93.1. Fluid 2 is represented by black color and fluid 1 by gray color. Fig. 9. Displacement efficiency through time for 𝐿∗ = 6.4, 𝐷∗ = 1.5, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, and: (a) 𝑅𝑒 = 0.04, (b) 𝑅𝑒 = 3.88, and (c) 𝑅𝑒 = 93.1. The blue square points refer to 𝑅𝑒 = 3.88 at 𝑡∗ = 2 and 3. operations of the oil well industry. For these cases, the enlargement length is 𝐿∗ = 6.4. Fluid 1 represents the drilling fluid, modeled as a yield stress material with the viscosity given by the regularized HB equation (7), with 𝜏∗𝑦 = 47.7 and 𝑛 = 0.78, and the displacing fluid (fluid 2) is Newtonian, representing the spacer fluid that flows prior to the cement paste. The viscosity ratio is kept equal to 𝜂∗ = 0.02. The results of the volume fraction field for three different Reynolds numbers at 𝑡∗ = 1 are depicted in Fig. 4, while the displacement efficiency evolution is shown in Fig. 5. Both figures show a very efficient displacement in all three cases. However, the evolution of the displacement is different among them. In the first two cases, the Reynolds number is low and so viscous forces dominate over inertia. As a result, and due to the low viscosity ratio, the flow develops with a large finger of fluid 2, which occupies almost all the enlarged region in the end, but no instabilities are verified. It can be observed that only a small layer of the displaced fluid remains close to the enlarged region walls and close to the entrance and exit corners. In these regions, the stress does not overcome the yield stress, and fluid 1 remains static. Moreover, the displacement is almost fore–aft symmetric for this range of 𝑅𝑒, with a slight deviation at the entrance due to viscous effects. Comparing both low 𝑅𝑒 cases, we can also observe that as 𝑅𝑒 increases, the level of stress increases and the layer of fluid close to the walls is slightly 6 reduced. As Reynolds increases further (Fig. 4c) the inertia effect can be noted. First, the symmetry is reduced, and the entrance corner is filled with the displacing fluid, while an amount of fluid 1 remains close to the exit corner. Moreover, we can observe small spots of the displaced fluid all over the enlarged region. This is in fact a result of the evolution of the flow displacement. Despite the fact that the dis- placement efficiency is quite similar for all cases, the flow displacement evolution is completely different. This is shown in Figs. S4 and S5 of the Supplementary Material. When inertia plays a role, the flow destabilize, and recirculating vortices appear and develops throughout the enlarged region, as fluid 2 flows. The unstable flow promotes mixing between fluids and results in an efficient displacement, although some very small spots of the displaced fluid seem to remain in the middle of the enlarged region. It is worth mentioning that the presence of fluid 1, mixed with fluid 2 throughout the domain or close to the walls, can impair the cementing operation so that both situations should be avoided. Fig. 5 also shows that the displacement efficiency increases linearly with time, and reaches an asymptote before 𝑡∗ = 1 for the stable flows, meaning that the remaining fluid close to the walls and corners will remain static, even for larger values of pumped volume. For the higher 𝑅𝑒 case, this plateau is not reached because of the instabilities that promote fluids mixing. Density difference plays a significant role on the onset of instability. When fluid 2 is lighter than fluid 1 the density difference is negative and a destabilizing mechanism occur. Fig. 6 shows the volume fraction for the same geometry of the previous cases, for 𝑅𝑒 = 1, 𝜂∗ = 0.02, 𝜏∗𝑦 = 47.7, 𝑛 = 0.78, and (a) 𝛥𝜌∗ = −0.67 (𝐺𝑎 = −2.4 × 105), (b) 𝛥𝜌∗ = −0.01 (𝐺𝑎 = −3.5 × 103), (c) 𝛥𝜌∗ = 0 (𝐺𝑎 = 0), and (d) 𝛥𝜌∗ = 0.13 (𝐺𝑎 = 4.7 × 104). All cases have low viscosity ratio and low 𝑅𝑒, so inertia is negligible. Moreover, except for the iso-dense case, 𝐺𝑎 is high in modulus, which indicates that buoyancy forces dominates over viscous ones. Figs. 6a and b show the cases where the displaced fluid is heavier than the displacing one. These cases show a completely different pattern from the iso-dense cases showed above. The displacement is highly unstable and its efficiency is very poor, which can also be observed in Fig. 7. In both cases, buoyancy forces are responsible for the onset of instabilities, since inertia is negligible. The heavier fluid 1 tends to remain at the lower region of the enlarged zone. As fluid 2 enters the enlarged zone, it generates a recirculation of fluid 1, which on the other hand carries pieces of fluid 2 throughout the enlarged zone. The same snapshots are shown in color at the Supplementary Material (Fig. S6). For the highest density difference (𝛥𝜌∗ = −0.67), we note a three layer pattern: at the lower zone of the enlarged region, close to the entrance, fluid 1 remains almost static, at the upper zone, close to the exit, a layer of fluid2 (lighter) forms, and between then there is a recirculation zone filled mostly with fluid 1. This can be better observed with the aid of the velocity magnitude field, shown in the Supplementary Material (Fig. S7). As the density difference decreases (𝛥𝜌∗ = −0.01) the mixing region dominates all over the enlarged zone, but the velocities are lower because the driving force Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834P.R. Varges et al. Fig. 10. Time evolution of the volume fraction field for 𝑅𝑒 = 3.88, 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, and: (a) 𝑡∗ = 0.05; (b) 𝑡∗ = 0.10; (c) 𝑡∗ = 0.15; (d) 𝑡∗ = 0.2; (e) 𝑡∗ = 0.25; (f) 𝑡∗ = 0.5; (g) 𝑡∗ = 0.75; (h) 𝑡∗ = 1. Fluid 2 is represented by black color and fluid 1 by gray color. Fig. 11. Volume fraction for: 𝑅𝑒 = 3.88, 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, 𝑡∗ = 1, and: (a) 𝑡∗ = 2 and (b) 𝑡∗ = 3. Fluid 2 is represented by black color and fluid 1 by gray color. Fig. 12. (a) Velocity intensity and (b) strain rate fields at 𝑡∗ = 1 for: 𝑅𝑒 = 3.88, 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, and 𝑡∗ = 1. of the instabilities is lower. Fig. 6c shows the iso-dense case, which is very similar to the ones shown in Fig. 4a and b, with an efficient and stable displacement, and a thinner stagnant layer of the displaced fluid near the walls and corners due to the level of stress, lower than the 7 yield stress. When the density difference is inverted, Fig. 6d, the stable regime continues and fluid removal is nearly perfect, with an almost negligible layer remaining adjacent to the walls. For this case, the final efficiency is equal to 99.56%, as it can be observed in Fig. 7. Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834P.R. Varges et al. Fig. 13. (a) Velocity profile at the entrance of the enlarged region (𝑥∗ = 2𝑙∗ = 1.5) at 𝑡∗ = 1 for: 𝑅𝑒 = 3.88, 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78. From now on we present the effects of the other parameters to better evaluate the role of the destabilizing mechanisms on the flow displacement process. 4.2. Effect of Reynolds numbers Fig. 8 shows the volume fraction after one pumped volume of fluid 2 at 𝑡∗ = 1, for 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78 and: (a) 𝑅𝑒 = 0.04, (b) 𝑅𝑒 = 3.88, and (c) 𝑅𝑒 = 93.1, while the displacement efficiency is depicted in Fig. 9. In addition, it also shows the efficiency for 𝑅𝑒 = 3.88 and 𝑡∗ = 2 and 3 (blue squares). The large value of 𝐺𝑎 indicates that buoyancy forces dominate over viscous ones. For the lowest 𝑅𝑒, inertia is negligible and instabilities are only due to buoyancy. It can be seen that the vortices are larger than the ones shown in Fig. 6b, where the dimensionless yield stress is higher. Therefore, viscous effects tend to dampen the instabilities generated by buoyancy forces. As 𝑅𝑒 increases, 𝑅𝑒 = 3.88, inertia begins to slightly affect, viscous dampening decreases and a small increase in the displacement efficiency is observed. For the highest value of 𝑅𝑒, instabilities are also observed, but the displacement is different due to increased mixing between fluid, similar to what happened with the iso-dense case (Fig. 4c). Inertia seems to overcome buoyancy, viscous and yield stress effects, and promotes mixing between fluids so that the displacing fluid removes fluid 1 more efficiently. Fig. 10 shows the evolution in time of the volume fraction field for the unstable case shown in Fig. 8b: 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, 8 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78 and 𝑅𝑒 = 3.88. Focusing the analysis in the enlarged region, it is noted that the instability of the interface begins as fluid 2 enters the enlarged region, with a pattern similar to the one seen by Lee and Kim [33]. This interface evolves with time and remains unstable. At the final time 𝑡∗ = 1, it is noted that a periodic pattern of the interface is formed throughout the enlarged region. Patches of fluid 1 (gray color) remain attached to the walls and fluid 2 (black color) flows around them in a wavy path, establishing an unfavorable displacement scenario. To evaluate the effect of pumped volume, we analyzed the same case, but increasing the pumped volume, up to three times the total volume of the tube (𝑡∗ = 3), as depicted in Fig. 11. For 𝑡∗ = 2 it is noted that near the wall at the exit of the enlarged region, fluid 2 become more concentrated due to buoyancy forces, which induces fluid 1 to flow downstream, slightly increasing fluids mixing. This effect continues as time evolves. Regarding the displacement efficiency, there is an asymptotic improvement as time increases, due to the increased mixing: it varies from 51.6% for 𝑡∗ = 1 to 58.9% for 𝑡∗ = 2 and 62.8% for 𝑡∗ = 3, as can be seen in Fig. 9. The velocity and rate-of-strain intensity fields at 𝑡∗ = 1 for this same case are shown in Fig. 12. It is clear that the regions occupied by fluid 1 are regions of almost zero strain rate (unyielded regions) and velocity, indicating that fluid 1 remains stagnant. Looking at regions occupied by fluid 2, there is a finger-type formation at the enlarged region entrance. The velocity pattern of this finger repeats periodically. Fig. 13 shows the velocity profile at the entrance of the enlarged region (at 𝑥∗ = 2𝑙∗ = 1.5). It can be observed a parabolic shape for the velocity profile though fluid 2 finger, close to the inner tube, with a maximum deviated to the upper part of this finger. Moreover, the velocities magnitude at the enlarged zone are very small, showing that the fluid (mostly fluid 1 at this region) is almost stagnant. Accordingly, we observe higher strain rates at the entrance of the enlarged region and at the boundaries of the finger region. 4.3. Effect of viscosity ratio Fig. 14 shows the volume fraction field at 𝑡∗ = 1 for 𝑅𝑒 = 3.88, 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝜏∗𝑦 = 12.7, and three viscosity ratios: (a) 𝜂∗ = 0.0008, (b) 𝜂∗ = 0.008, (c) 𝜂∗ = 0.08. It is important to observe that in these cases, since the viscosity ratio varies, 𝑅𝑒 and 𝐺𝑎, which were defined using fluid 2 properties, can give different insights when we define them using the viscosity of fluid 1. So, if we look at these quantities using the characteristic viscosity of fluid 1 instead of 𝜇2, 𝑅𝑒∗ = 𝑅𝑒.𝜂∗ and 𝐺𝑎∗ = 𝐺𝑎.𝜂∗. Therefore, 𝑅𝑒∗ = 3.1 × 10−3, 0.031 and 0.31, for cases (a), (b) and (c), respectively, and inertia effects are low. At the same way, 𝐺𝑎∗ is equal to −1.3,−1.6 and −76.4, while 𝐺𝑎 = −1630,−196 and −955.4 for cases (a), (b) and (c), respectively. For the lowest two viscosity ratios, the displacements are stable with a large finger flowing through the enlarged region. Again, we observe unyielded regions close to the walls and to the corners, where the shear Fig. 14. Volume fraction at 𝑡∗ = 1 for 𝑅𝑒 = 3.88, 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝜏∗𝑦 = 12.7, and: (a) 𝜂∗ = 0.0008, (b) 𝜂∗ = 0.008, (c) 𝜂∗ = 0.08. Fluid 2 is represented by black color and fluid 1 by gray color. Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834P.R. Varges et al. Fig. 15. Displacement efficiency through time for 𝑅𝑒 = 3.88, 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝜏∗𝑦 = 12.7, and: (a) 𝜂∗ = 0.0008, (b) 𝜂∗ = 0.008, (c) 𝜂∗ = 0.08. Fig. 16. Volume fraction at 𝑡∗ = 1 for 𝑅𝑒 = 3.88, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, and : (a) 𝐿∗ = 1.8, (b) 𝐿∗ = 6.4, (c) 𝐿∗ = 13.7. Fluid 2 is represented by black color and fluid 1 by gray color. Fig. 17. Displacement efficiency through time for 𝑅𝑒 = 3.88, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955, and : (a) 𝐿∗ = 1.8, (b) 𝐿∗ = 6.4, (c) 𝐿∗ = 13.7. 9 stress does not overcome the yield stress. It is interesting to observe that the shape of the finger is slightly different between cases (a) and (b). Inertia effects seems to be negligible in both fluids in all three cases.However, 𝐺𝑎∗ reveals that viscous forces in fluid 1 seem to balance buoyancy for the first two cases, while for the case of 𝜂∗ = 0.08, buoyancy forces are much stronger than viscous forces for fluid 1, destabilizing the flow and reducing the displacement efficiency. The resulting displacement efficiency through time is displayed in Fig. 15, which shows the decrease of the efficiency as the viscosity ratio in- creases. When instabilities are not present, the displacement efficiency is very close for both cases, despite the fact of a 10 times increase in the viscosity ratio. However, the onset of instabilities, generated by buoyancy forces, causes a steep decrease in the displacement efficiency. 4.4. Effect of geometry To analyze the effect of geometry on flow instabilities and displace- ment efficiency, we present the volume fraction results for different values of the dimensionless length 𝐿∗. Fig. 16 shows the volume fraction field at 𝑡∗ = 1 for 𝑅𝑒 = 3.88, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, and: (a) 𝐿∗ = 1.8, (b) 𝐿∗ = 6.4, (c) 𝐿∗ = 13.7. All cases are unstable flows due to buoyancy effects, with similar patterns and periodicity, with a mild loose in periodicity as 𝐿∗ gets larger, probably due to a slight increase in mixing between fluids. Therefore, the enlargement length does not affect flow stability, but since mixing increases, the displacement efficiency improves, as it can be seen in Fig. 17. Journal of Non-Newtonian Fluid Mechanics 305 (2022) 104834P.R. Varges et al. Fig. 18. Volume fraction at 𝑡∗ = 1 for 𝑅𝑒 = 3.88, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, 𝐷∗ = 1.5, 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, and: (a) 𝜎∗ = 0, (b) 𝜎∗ = 0.07, and (c) 𝜎∗ = 0.21. Fluid 2 is represented by black color and fluid 1 by gray color. 4.5. Effect of interfacial tension Fig. 18 shows the effect of interfacial tension on flow stability. The results are shown after one pumped volume of fluid 2, 𝑡∗ = 1, for 𝑅𝑒 = 3.88, 𝜂∗ = 0.08, 𝜏∗𝑦 = 12.7, 𝑛 = 0.78, 𝐿∗ = 6.4, 𝛥𝜌∗ = −0.01, 𝐺𝑎 = −955.4, and 𝜎∗ = 0, 0.07, and 0.21. It is seen that the interfacial tension tends to suppress the undulations and stabilize the flow, as expected. This is more evident as flow develops upwards, and is stronger as interfacial tension increases. 5. Conclusions We analyzed numerically the displacement flow of a yield stress material by a Newtonian one, through an enlarged region of vertical annular tubes. This situation is usually found in cementing operations of oil wells, where the drilling fluid (yield stress fluid) is pushed by a spacer fluid (Newtonian) and this by the cement paste (also yield stress fluid). The problem was solved using the finite volume technique and the volume of fluid method to track the interface between phases. The scaling showed that the flow can be described by several dimen- sionless geometrical, flow and rheological parameters. Flow patterns through the enlarged region, and the displacement efficiency were obtained to investigate the role of the aforementioned parameters. The results were obtained for typical properties, flow rates and geometries of the oil industry, and mainly for situations where the displaced fluid is heavier than the displacing one, representing the dis- placement of the drilling fluid by the spacer fluid. Within this range of parameters, instabilities, which are mostly caused by buoyancy forces, have the greatest impact on the displacement process efficiency. In all cases analyzed, the displacing fluid enters the enlarged region with a finger-type configuration, and develops in different ways, depending on the role of the buoyancy, inertia and viscous forces. When viscous effects dominate, the finger-type configuration contin- ues, and portions of the displaced fluid remain close to the walls, due to yield stress effects. Flow patterns show that inertia and buoyancy forces destabilize the flow, while viscous and interfacial forces tend to damp these instabilities. The instabilities lead to a decrease on the displacement efficiency. On the other hand, the dimensionless length and inertia increase mixing, which in the end can be beneficial for the displacement efficiency, although one has to have in mind that any remaining displaced fluid can lead to contamination issues that may impair the operation. This is important to point out, since there can be situations where the displacement efficiency is high, but portions of the displaced fluid remain mixed within the displacing fluid inside the domain. It is worth recalling that any remaining fluid needs to be washed later by the cement paste. Looking further for this stage of the cementing operation, the wash out of the remaining fluid by the cement paste will be easier when the remaining portions of the displaced (drilling, yield stress) fluid are among the displacing one (spacer fluid) than when the yield stress fluid remains close to the walls, because stress levels are higher away from the walls. Therefore, comparing two cases presenting highly efficient displacement, one obtained for higher 10 Reynolds number and another for lower Reynolds number, it would probably be more interesting to work with highly inertia flows than highly viscous ones. The results obtained show interesting and important features of the displacement of a yield stress material by a Newtonian one. The development of unstable interfaces may lead to undesirable situations that can result in an unpredictable and/or ineffective displacement processes. 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http://refhub.elsevier.com/S0377-0257(22)00074-X/sb34 http://refhub.elsevier.com/S0377-0257(22)00074-X/sb34 http://refhub.elsevier.com/S0377-0257(22)00074-X/sb34 http://refhub.elsevier.com/S0377-0257(22)00074-X/sb34 http://refhub.elsevier.com/S0377-0257(22)00074-X/sb34 http://refhub.elsevier.com/S0377-0257(22)00074-X/sb35 http://refhub.elsevier.com/S0377-0257(22)00074-X/sb35 http://refhub.elsevier.com/S0377-0257(22)00074-X/sb35 http://refhub.elsevier.com/S0377-0257(22)00074-X/sb36 http://refhub.elsevier.com/S0377-0257(22)00074-X/sb37 Flow instabilities in fluid displacement through enlarged regions in annular ducts Introduction Modeling Scaling Numerical solution Results and discussion Effect of density difference Effect of Reynolds numbers Effect of viscosity ratio Effect of geometry Effect of interfacial tension Conclusions Declaration of competing interest Acknowledgments Appendix A. Supplementary data References