Role of heat exchangers in helium liquefaction cycles: Simulation studies using Collins cycle

Energy efficiency of large-scale helium liquefiers generally employed in fusion reactors and accelerators is determined by the performance of their constituting components. Simulation with Aspen HYSYS (R) V7.0, a commercial process simulator, helps to understand the effects of heat exchanger parameters on the performance of a helium liquefier. Effective UA (product of overall heat transfer coefficient U, heat transfer surface area A and deterioration factor F) has been taken as an independent parameter, which takes into account all thermal irreversibilities and configuration effects. Nondimensionalization of parameters makes the results applicable to plants of any capacity. Rate of liquefaction is found to increase linearly with the effectiveness of heat exchangers. Performance of those heat exchangers that determine the inlet temperatures to expanders have more influence on the liquid production. Variation of sizes of heat exchangers does not affect the optimum rate of flow through expanders. Increasing UA improves the rate of liquid production: however, the improvement saturates at limiting UA. Maximum benefit in liquefaction is obtained when the available heat transfer surface area is distributed in such a way that the effectiveness remains equal for all heat exchangers. Conclusions from this study may be utilized in analyzing and designing large helium plants. (C) 2011 Elsevier B.V. All rights reserved.