Numerical analysis of a steady-state and transient performance using a tube-in-tube heat exchanger unit for cryogenic process simulator

Large scale Helium Refrigerators and Liquefiers (HRLs) are essential technologies in particle physics experiments and the nuclear energy sector. Most HRLs employ a modified version of the Collin's cycle, which involves a room temperature compressor, several counter-flow heat exchangers (HXs), expanders, and a J-T valve to produce liquid helium. The performance of HRLs is mainly governed by the efficacy of HXs and requires accurate process modeling and simulation. Although various platforms for process modeling and simulation of HXs are available, both commercial and open source, significant customization is required to use them in the cryogenic domain. Moreover, the transient simulation of a HX in two-phase has always been a concern. Therefore, there is a need to develop a numerical model of a HX to meet the requirements of the cryogenic domain specially in two-phase region. In present study, a HX is being modeled on the open source platform Python (R). The developed numerical model is based on the distributed parameter approach to capture the impact of the variable fluid properties as well as their impact on the heat transfer coefficient. The model allows user to choose a suitable heat transfer correlation as per the requirement in different regime of the phases across the length of HX. The developed model may be suitable to simulate the HXs used as LN2 precooling, HXs of helium plant operating in mixed mode, and JT heat exchangers where fluids undergoes phase changes along the flow length. The created models are initially tested against their design data, and results are then acquired under nonstandard operating conditions. The outcomes are validated with experimental data from the ITER-India cryogenic Laboratory (IICL) after being first verified using the commercial process simulator Aspen HYSYS (R).