Suspensions of finite-size solid particles in a turbulent pipe flow are found in many industrial and technical flows. Due to the ample parameter space consisting of particle size, concentration, density and Reynolds number, a complete picture of the particle–fluid interaction is still lacking. Pressure drop predictions are often made using viscosity models only considering the bulk solid volume fraction. For the case of turbulent pipe flow laden with neutrally buoyant spherical particles, we investigate the pressure drop and overall drag (friction factor), fluid velocity and particle distribution in the pipe. We use a combination of experimental (MRV) and numerical (DNS) techniques and a continuum flow model. We find that the particle size and the bulk flow rate influence the mean fluid velocity, velocity fluctuations and the particle distribution in the pipe for low flow rates. However, the effects of the added solid particles diminish as the flow rate increases. We created a master curve for drag change compared to single-phase flow for the particle-laden cases. This curve can be used to achieve more accurate friction factor predictions than the traditional modified viscosity approach that does not account for particle size.

We report experimental observations of turbulent flow with spherical particles in a square duct. Three particle sizes, namely 2H/d_p=40, 16 and 9 (2H being the duct full height and d_p being the particle diameter), are investigated. The particles are nearly neutrally buoyant with a density ratio of 1.0035 and 1.01 with respect to the suspending fluid. Refractive index matched-particle image velocimetry (RIM-PIV) is used for fluid velocity measurement even at the highest particle volume fraction (20%) and particle tracking velocimetry (PTV) for the particle velocity statistics for the flows seeded with particles of the two largest sizes, whereas only pressure measurements are reported for the smallest particles. Settling effects are seen at the lowest bulk Reynolds number Re_2H ≈ 000, whereas, at the highest Re_2H ≈, particles are in almost full suspension. The friction factor of the suspensions is found to be significantly larger than that of single-phase duct flow at the lower Re_2H investigated; however, the difference decreases when increasing the flow rate and the total drag approaches the values of the single-phase flow at the higher Reynolds number considered, Re_2H=27 000. The pressure drop is found to decrease with the particle diameter for volume fractions lower than φ=10% for nearly all Re_2H investigated. However, at the highest volume fraction φ=10%, we report a peculiar non-monotonic behaviour: the pressure drop first decreases and then increases with increasing particle size. The decrease of the turbulent drag with particle size at the lowest volume fractions is related to an attenuation of the turbulence. The drag increase for the two largest particle sizes at φ=10%, however, occurs despite this large reduction of the turbulent stresses, and it is therefore due to significant particle-induced stresses. At the lowest Reynolds number, the particles reside mostly in the bottom half of the duct, where the mean velocity significantly decreases; the flow is similar to that in a moving porous bed near the bottom wall and to turbulent duct flow with low particle concentration near the top wall.