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We consider the steady, gravity-driven flow of a thin film of viscous fluid down a helically wound shallow channel of arbitrary cross-sectional shape with arbitrary torsion and curvature. This extends our previous work [D. J. Arnold et al., "Thin-film flow in helically-wound rectangular channels of arbitrary torsion and curvature," J. Fluid Mech. 764, 76-94 (2015)] on channels of rectangular cross section. The Navier-Stokes equations are expressed in a novel, non-orthogonal coordinate system fitted to the channel bottom. By assuming that the channel depth is small compared to its width and that the fluid depth in the vertical direction is also small compared to its typical horizontal extent, we are able to solve for the velocity components and pressure analytically. Using these results, a differential equation for the free surface shape is obtained, which must in general be solved numerically. Motivated by the aim of understanding flows in static spiral particle separators used in mineral processing, we investigate the effect of cross-sectional shape on the secondary flow in the channel cross section. We show that the competition between gravity and inertia in non-rectangular channels is qualitatively similar to that in rectangular channels, but that the cross-sectional shape has a strong influence on the breakup of the secondary flow into multiple clockwise-rotating cells. This may be triggered by small changes to the channel geometry, such as one or more bumps in the channel bottom that are small relative to the fluid depth. In contrast to the secondary flow which is quite sensitive to small bumps in the channel bottom, the free-surface profile is relatively insensitive to these. The sensitivity of the flow to the channel geometry may have important implications for the design of efficient spiral particle separators. [ABSTRACT FROM AUTHOR]

Laminar gravity-driven thin-film flow down a helically wound channel of rectangular cross-section with small torsion in which the fluid depth is small is considered. Neglecting the entrance and exit regions we obtain the steady-state solution that is independent of position along the axis of the channel, so that the flow, which comprises a primary flow in the direction of the axis of the channel and a secondary flow in the cross-sectional plane, depends only on position in the two-dimensional cross-section of the channel. A thin-film approximation yields explicit expressions for the fluid velocity and pressure in terms of the free-surface shape, the latter satisfying a nonlinear ordinary differential equation that has a simple exact solution in the special case of a channel of rectangular cross-section. The predictions of the thin-film model are shown to be in good agreement with much more computationally intensive solutions of the small-helix-torsion Navier-Stokes equations. The present work has particular relevance to spiral particle separators used in the mineral-processing industry. The validity of an assumption commonly used in modelling flow in spiral separators, namely, that the flow in the outer region of the separator cross-section is described by a free vortex, is shown to depend on the problem parameters. [ABSTRACT FROM AUTHOR]