Dissertation submitted in fulfilment of the requirements for the Masters Degree in Technology: Chemical Engineering in the Department of Chemical Engineering of Cape Peninsula University ofTechnology, 2005 / The emulsion used for this study is a new thermodynamically unstable multi-component waterin- oil (w/o) explosive type with an internal phase ratio of approximately 94%, i.e. far beyond the close packing limit of spherical droplets of 74%. Economic considerations and the ongoing need for continuous drilling, loading and blasting in the mining industry, has made long-distance pipeline transportation of these emulsion explosive systems a viable economic option. Presently, rheological characterization of emulsion explosives is well documented (Bampfield & Cooper, 1988, Utracki, 1980). However, very little or none has been done for this system, pertaining to the use of rheometry for prediction of pumping characteristics of these systems in long-distance pipeline transport. This Master's dissertation is devoted to develop rheological methods of testing, characterization and correlation in order to develop a basis for predicting the pumping characteristics of highly concentrated w/o emulsion explosives from rheometry. The literature and theory pertinent to the pipeline flow of high internal phase ratio emulsion explosives are presented, as well as the fundamentals of both concentric cylinder rheometry and pipe viscometry. The most relevant is the work of Bampfield and Cooper (1988), Utracki (1980) and Pal (1990). Two experimental test facilities were used for data collection. Pipeline experiments were done using an experimental test facility at African Explosives Limited (AEL), and rheometry was conducted at the Rheology Laboratory of the Cape Peninsula University of Technology Flow Process Research Centre. The AEL experimental test facility consisted of a four-stage Orbit progressive cavity pump, two fluid reservoirs, (a mixing tank and a discharge reservoir), five 45m HOPE (high density polyethylene) pipes of internal diameters of 35.9 mm, 48.1 mm, 55.9 mm, 65.9 mm and 77.6 mm pipes. The test work was done over a wide range of laminar flow rates ranging from 3 kg.min-I to 53 kg.min-I . Rheometry was done using a PaarPhysica MCR300 rheometer, and only standard rotational tests (i.e. flow curve) at 30 °c in controlled rate mode were done. Rheological characterisation was done using three rheological models, i.e. the Herschel-Bulkley, the Power Law and the Simplified Cross models. The coefficients obtained from these models were then used to predict pumping characteristics. The performances of these models were then evaluated by comparing the pipeline flow prediction to the actual pipeline data obtained from pipeline test experiments. It was found that the flow behaviour depicted by this explosive emulsion system was strongly non-Newtonian, and was characterized by two distinct regions of deformation behaviour, a lower Newtonian region of deformation behaviour in the shear rate region lower than 0.001 S-I and a strong shear thinning region in the shear rate range greater than 0.001 S-l. For all the models used for this study, it was evident that rheometry predicts the pumping characteristics of this high internal phase ratio emulsion reasonably well, irrespective of the choice of the model used for the predictions. It was also seen that the major difference between these models was in the lower shear rate domain. However, the Simplified Cross model was preferred over the other two models, since its parameter (the zero shear viscosity denoted by 110) can in general be correlated to the structure of the emulsion systems (i.e. mean droplet size, bulk modulus, etc.). Thus, structural changes induced by shearing (either inside the pump or when flowing inside a pipe) can be detected from changes in the value of the 110. The above statement implies that Tlo can be used as a quality control measure. Different pumping speeds were found to cause different degrees of shear-induced structural changes which were manifested by two opposing processes. These two opposing processes were the simultaneous coalescence and flocculation of droplets encountered at low rates of shear, and the simultaneous refinement and deflocculation of droplets encountered at high rates of shear. These two droplet phenomena were associated with a decrease or an increase in viscous effects, leading to both lower and higher viscous stresses and pumping pressures during pump start-up respectively.