A Simulation Tool for Coil-Wound Heat

Exchanger in LNG Process

Speaker: Duan Zhongdi

Shanghai Jiao Tong University, China

Outlines

Background

CWHE Model and Algorithm

Simulation Tool
Conclusions

Background
Coil-Wound Heat Exchanger(CWHE)main cryogenic HE in LNG process
Advantages

Compact structure
Large operation range
Multi-stream flow
Large-scale oriented

Background
The performance of CWHE is critically important
2

1
CWHE represents 20%~30% of
the investment costs and about
25% of the total exergy lost.

Main Component

The liquid production rate is

sensitive to the effectiveness
of CWHE.

Outlet of

CWHE 4

Liquid
6

Gas

Storage
Condition

mLiquid 1 x5 m
S

Background
Existed models for CWHE heat exchanger
Effect considered by model

Effects

Effect not considered by model

LPM

DPM
Zones

Elements

SEM

Single-phase flow
Two-phase flow
Change in fluid properties
Multiple streams
Flow maldistribution
Tube arrangement
Pressure drop coupling effects

Need to be considered for high-effectiveness CWHE design!

Approach

Flow maldistribution

Tube arrangement

Pressure drop effects

Layer evolution model

Description method
based on graph theory

Specific decoupling
algorithms

Simulation tool

CWHE Model
Layer evolution model
Model characteristic
1.CV is divided layer-by-layer
Shell-side fluid

Model can evaluate the thermal

hydraulic performance of each layer

2.Fluid is simplified to one-dimensional
flow
Tube-side fluid is axial flow along tube
Tube-side
fluid

Shell-side fluid is downward flow

One layer of CWHE

3.The fluid vapor and liquid are in

thermal equilibrium

CWHE Model
Governing equations

Tube-side fluid
Mass equation

Fluid #2

0
tu

Momentum equation

tu

Shell-side fluid
Mass equation

0
su

Momentum equation

u
u

Fluid #1

Energy conservation
N

G
hh

G
hh

t
,
i t
,,
i
n
i
i

t
,
o
u
t
,
i

ss
,
o
u
t s
,
i
n

l
n

CWHE Model
Tube arrangement description method
LNG to storage tank
26

27

30 31
28 29

24

25

16

17

20 21
18 19
22 23

18

14

14

19
21

22

23

15
16

4
8 9

13

20

13

0 when No.j is not connected to No.i

mi , j
1 when No.j is connected to No.i

11

12

15

12

10

17

24

10 11

25
28

29
30

31

26

1
1
2

0
0
0
0

0
0
0
0

0
0
0
0
0
0

0
0 0
0 0 0
0 0 0
0
0 0

= 0
0
0
0
0
0

0
0
0
0

0
0
0
0
0
0

27 28 29 30 31 32

0
0 0
0
0 0
0 1 0
0 1 0
0
0 1
0
0 1

0
0
0
0

0
0
0
0
0
0

0
0
0
0

0
0
0
0
0
0

0
0
0
0

1
0 1
0 2
0 3
0 4

0
0
0
0
0
0

0
0
0
0
0
0

27

Feed
gas

1
0

Arbitrary tube arrangement

The directed graph

The adjacent matrix

27
28
29
30
31
32

CWHE Model
Heat transfer path creation

Starts from one join point or split point, and

ends at the next join point or split point

LNG to storage tank

26

27

30 31
28 29

24

Inlet 0

17

15
20 21
18 19
22 23

4
6

Feed
gas

14

13

3
7

8 9

10 11

1
0

Inlet 1

Inlet 2

25

16

12

According to the broad first search algorithm

0->6->3
0->7->3
3->12
12->18->15
12->19->15
15->24
24->28->26
24->29->26

1->8->4
1->9->4

2->10->5
2->11->5
5->13
13->20->16
13->21->16
5->14
14->22->17
14->23->17
17->25
25->30->27
25->31->27

CWHE Model
Pressure drop path creation
According to the depth first search algorithm
Starts from one split point, and ends at the
refrigerant outlet point

Inlet 0

LNG to storage tank

26

27

30 31
28 29

24

Inlet 1

25

16
17

15
18 19
12

20 21
22 23

4
6

Feed
gas

14

13

8 9

10 11

1
0

Inlet 2

0->6->3->12->18->15->24->28->26
0->7->3->12->18->15->24->28->26
3->12->18->15->24->28->26
12->18->15->24->28->26
12->19->15->24->28->26
15->24->28->26
24->28->26
24->29->26
1->8->4
1->9->4
2->10->5->13->20->16
2->11->5->13->20->16
5->13->20->16
5->14->22->17->25->30->27
13->20->16
13->21->16
14->22->17->25->30->27
14->23->17->25->30->27
17->25->30->27
25->30->27
25->31->27

Algorithm
Heat transfer and pressure drop alternative iteration algorithm
Heat transfer module
Start

Initial parameter and tube

arrangement information

Current HTpath No.[i]

Creation of
calculation path

i=i+1

j=j+1

Current tube No.[j]

PDPath No.i=1Tube No.j=0

CV No.k=1
Current PDpath No.[i]

Current tube No.[j]

k=k+1

Current CV No.[k]

Current CV No.[k]

Heat transfer calculation

of CV

Pressure drop calculation

of CV

k>Total
amount of
CV

Pressure drop
calculation module

No

Yes
j>Total amount
of Tube

No

Pressure drop module

No

Yes
No

j>Total amount
of Tube

No

No

Yes
i>Total
Amount of
HTPath

No

Yes
i>Total
Amount of
HTPath

k>Total
amount of
CV

Convergence
criterion module

i=i+1

j=j+1

k=k+1

Heat transfer
calculation module

end

Initial parameter and tube

arrangement information

HTPath No.i=1Tube No.j=0

CV No.k=1

Initial parameter
setting

Convergence
criterion module

Pressure drop module

Algorithm
Mass flow rate distribution principle

The value of S (equivalent flow resistance) and p are updated

The distribution of refrigerant mass flow rate is adjusted
The inlet and outlet refrigerant pressure of each control volume are updated,
The pressure drops of each path group become identical within a given tolerance.

Pressure drop of each path

p S1G12 p S 2G22

... p S n G n2

Mass flow rate of each path

G1 : G2 : : Gn

S1

1
S2

::

Sn

Normalization of mass flow rate

G1' : G2' : : Gn'

1 / S1
n

1 /
i 1

Si

1/ S 2
n

1 /
i 1

Si

::

1/ S n
n

1 /
i 1

Si

Simulation tool
Framework of Simulation tool
Third-party software
ExcelModeFrontier...

3D/2D interactive
graphic interface
CWHE geometry

OPenGL and object-oriented

languages Mixed programming

Flow arrangement

Results shown as table

Simulation
package

Tube-side and shellside working fluid and

refrigerant inlet status

General results

Results shown as chart

Results shown as 3D
colored graph

Input module

Output module

Calculation of mixture
refrigerant thermal
properties

Decoupling the equations

of heat transfer and
pressure drop

Heat transfer and flow

model for tube-side fluid

Heat transfer and flow

model for shell-side fluid

A general flow description

method based on graph theory

Simulation module

Simulation tool
Main interface of Simulation tool
Main menu and toolbar
Tree Menu of input
and output Dialogs

Simulation tool
Three-bundle Type

Double-bundle Type

Single-bundle Type

Simulation tool
Three-dimensional graphics aided design

Set helix angle to 3

Set helix angle to 1.1

Simulation tool
Results in coordinate chart
Show the temperature, pressure, enthalpy and quality variation along the tube

Simulation tool
Results in 3D colored graph

Setting dialog
Select
parameter

Select stream

Conclusions
1. A layer evolution model is built, which could take the flow
maldistribution effect and the tube arrangement effect into
account .

2. A directed graph and corresponding adjacent matrix is

introduced to describe arbitrary tube.

3. Specific algorithms are designed to consider the pressure drop

effects on heat transfer and tube-side mass flow rate distribution.

4. A general framework of the simulation tool is established and a

friendly GUI with OpenGL display technique is developed.

5. This simulation tool can be applied to study the above-mentioned

effects on CWHE performance and guide for CWHE