A design model for spiral wound heat exchangers which accounts for property variation, longitudinal heat conduction, and heat-in-leak

Spiral Wound Heat Exchangers (SWHEs) can be a good and reliable choice for serving as the main heat exchanger in the cryogenic gas liquefaction cycles using throttling process such as the Linde-Hampson cycle. In this application, a high-pressure hot gas stream has to be cooled down via transferring heat to a low pressure cold gas in a high-effectiveness heat exchanger. Present research has been organized to develop a design model, which is able to find the optimum SWHE configuration for gas liquefaction cycles. The model has to be capable of considering the important physical phenomena in the cryogenic temperature ranges, including variation of fluid properties with temperature, longitudinal heat conduction (LHC) through separating walls, and heat-in-leak. Therefore, a combined analytical-numerical design model has been developed in the present study. The design model is essentially composed of two stand-alone modules, i.e. an analytical sizing module and a numerical performance evaluation module. To develop the design model, first, the geometrical characteristics of SWHE are studied and primary geometrical parameters are recognized. Then, the analytical sizing module is developed which is able to determine the optimum values of primary geometrical parameters of SWHE minimizing the heat transfer surface area based on the input design requirements. Afterwards, a 1D finite difference numerical module is presented in which important physical phenomena can be considered in the evaluation of the thermo-hydraulic performance of all types of counter flow or parallel flow heat exchangers as well as SWHEs. Finally, the two modules are combined to construct a design model. Two examples in which the low pressure superheated vapor helium is intended to cool down the high pressure supercritical helium flowing inside the tubes are also provided to demonstrate the applicability of the proposed combined model, and also, to elucidate its sensitivity to the input constraints. It was concluded that while variations of fluid properties and the external heat fluxes due to the radiation and convection have significant influence on the performance of cryogenic SWHE, the LHC is of minor importance and can be neglected. Moreover, decreasing the shell-side allowable pressure drop from 10 kPa to 2 kPa, causes the heat exchanger length and its outside diameter to increase by 79 % and 48 %, respectively.