Flow in annular geometries, i.e., flow through the gap between two cylindrical pipes, occurs in many different engineering professions, such as petroleum engineering, chemical engineering, mechanical engineering, food engineering, etc. Analysis of the flow characteristics through annular geometries is more challenging when compared with circular pipes, not only due to the uneven stress distribution on the walls but also due to secondary flows and tangential velocity components, especially when the inner pipe is rotated. In this paper, a mathematical model for predicting flow characteristics of Newtonian fluids in concentric horizontal annulus with drill pipe rotation is proposed. A numerical solution including pipe rotation is developed for calculating frictional pressure loss in concentric annuli for laminar and turbulent regimes. Navier-Stokes equations for turbulent conditions are numerically solved using the finite differences technique to obtain velocity profiles and frictional pressure losses. To verify the proposed model, estimated frictional pressure losses are compared with experimental data which were available in the literature and gathered at Middle East Technical University, Petroleum & Natural Gas Engineering Flow Loop (METU-PETE Flow Loop) as well as Computational Fluid Dynamics (CFD) software. The proposed model predicts frictional pressure losses with an error less than ± 10% in most cases, more accurately than the CFD software models depending on the flow conditions. Also, pipe rotation effects on frictional pressure loss and tangential velocity is investigated using CFD simulations for concentric and fully eccentric annulus. It has been observed that pipe rotation has no noticeable effects on frictional pressure loss for concentric annuli, but it significantly increases frictional pressure losses in an eccentric annulus, especially at low flow rates. For concentric annulus, pipe rotation improves the tangential velocity component, which does not depend on axial velocity. It is also noticed that, as the pipe rotation and axial velocity are increased, tangential velocity drastically increases for an eccentric annulus. The proposed model and the critical analysis conducted on velocity components and stress distributions make it possible to understand the concept of hydro transport and hole cleaning in field applications.

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