Conceptual design and exergy analysis of an integrated structure of natural gas liquefaction and production of liquid fuels from natural gas using Fischer-Tropsch synthesis

In this paper, utilizing absorption refrigeration system as an alternative to compression refrigeration system of MFC refrigeration cycle in an integrated superstructure with the main aim of reduction in required energy is investigated. High-energy consumption in such units is reduced because of the removal of a stage of the compression system, while the possibility of using waste energy through employing of absorption refrigeration system can be provided. A superstructure including cogeneration of heating, cooling and power for LNG production and liquid fuels using Fischer-Tropsch synthesis are investigated. Exergy analysis shows that the greatest amount of exergy destruction of equipment is related to the compressors by 28.99% and the lowest exergy destruction is related to the gas turbine by 0.17%. Integrated structure has overall thermal efficiency of 90% and specific power of 0.1988 kW h/(kg LNG)⁻¹.     

A closed-cycle 1 K refrigeration cryostat

A 1 K closed-cycle cryostat has been developed to provide continuous cooling to a photon detector below 2 K. A two-stage 4 K pulse tube cryocooler is used to liquefy evacuated vapor from a 1 K pumping port to form a closed-cycle refrigeration loop. A 1 K instrumentation chamber, attached to the 1 K cooling station, is designed to operate with helium inside and provide more uniform cooling. The design of the cryostat has no direct mechanical contact between the pulse tube cryocooler heat exchangers and the 1 K cooling station resulting in almost no vibration transfer to instrumentation chamber. The cryostat can reach a no-load temperature of 1.62 K and provide 250 mW cooling power at 1.84 K.     

Analysis and optimisation of a mixed fluid cascade (MFC) process

A mixed fluid cascade (MFC) process that comprises three refrigeration cycles has great capacity for large-scale LNG production, which consumes a great amount of energy. Therefore, any performance enhancement of the liquefaction process will significantly reduce the energy consumption. The MFC process is simulated and analysed by use of proprietary software, Aspen HYSYS. The effect of feed gas pressure, LNG storage pressure, water-cooler outlet temperature, different pre-cooling regimes, liquefaction, and sub-cooling refrigerant composition on MFC performance are investigated and presented. The characteristics of its excellent numerical calculation ability and the user-friendly interface of MATLAB™ and powerful thermo-physical property package of Aspen HYSYS are combined. A genetic algorithm is then invoked to optimise the MFC process globally. After optimisation, the unit power consumption can be reduced to 4.655 kW h/kmol, or 4.366 kW h/kmol on condition that the compressor adiabatic efficiency is 80%, or 85%, respectively. Additionally, to improve the process further, with regards its thermodynamic efficiency, configuration optimisation is conducted for the MFC process and several configurations are established. By analysing heat transfer and thermodynamic performances, the configuration entailing a pre-cooling cycle with three pressure levels, liquefaction, and a sub-cooling cycle with one pressure level is identified as the most efficient and thus optimal: its unit power consumption is 4.205 kW h/kmol. Additionally, the mechanism responsible for the weak performance of the suggested liquefaction cycle configuration lies in the unbalanced distribution of cold energy in the liquefaction temperature range.     

Magnetic refrigerator for hydrogen liquefaction

This paper reviews the status of magnetic refrigeration system for hydrogen liquefaction. There is no doubt that hydrogen is one of most important energy sources in the near future. In particular, liquid hydrogen can be utilized for infrastructure construction consisting of storage and transportation. When we compare the consuming energy of hydrogen liquefaction with high pressurized hydrogen gas, FOM must be larger than 0.57 for hydrogen liquefaction. Thus, we need to develop a highly efficient liquefaction method. Magnetic refrigeration using the magneto-caloric effect has potential to realize not only the higher liquefaction efficiency >50%, but also to be environmentally friendly and cost effective. Our hydrogen magnetic refrigeration system consists of Carnot cycle for liquefaction stage and AMR (active magnetic regenerator) cycle for precooling stages. For the Carnot cycle, we develop the high efficient system with >80% liquefaction efficiency by using the heat pipe. For the AMR cycle, we studied two kinds of displacer systems, which transferred the working fluid. We confirmed the AMR effect with the cooling temperature span of 12 K for 1.8 T of the magnetic field and 6 s of the cycle. By using the simulation, we estimate the efficiency of the hydrogen liquefaction plant for 10 kg/day. A FOM of 0.47 is obtained for operation temperature between 20 K and 77 K including LN₂ work input.     

Thermodynamic study of a combined double-way solid–gas thermochemical sorption refrigeration cycle

A combined double-way thermochemical sorption refrigeration thermodynamic cycle was proposed and tested. Both adsorption refrigeration and resorption refrigeration processes were combined in order to improve the system performance. Two different consolidated composite materials were used as the reactive sorbents and ammonia was used as the refrigerant. Experimental results showed that a system operating with such proposed cycle can have two useful cold productions during one cycle at the expense of only one heat input at high temperature. The average specific cooling power (SCP) during the adsorption refrigeration phase was 301 W kg^?1. Analysis of the experimental data showed that the driving equilibrium drop during the resorption process was much lower than that during the adsorption process, when the cold production temperature was similar. The proposed combined double-way sorption cycle has a larger cooling capacity per unit of heat input and the maximum theoretical coefficient of performance (COP) is 1.24 when MnCl₂ and BaCl₂ are used as the reactive sorbents.     

Operating characteristics of a single-stage Stirling cryocooler capable of providing 700 W cooling power at 77 K

High cooling capacity Stirling cryocooler generally has hundreds to thousands watts of cooling power at liquid nitrogen temperature. It is promising in boil-off gas (BOG) recondensation and high temperature superconducting (HTS) applications. A high cooling capacity Stirling cryocooler driven by a crank-rod mechanism was developed and studied systematically. The pressure and frequency characteristics of the cryocooler, the heat rejection from the ambient heat exchanger, and the cooling performance are studied under different charging pressure. Energy conversion and distribution in the cryocooler are analyzed theoretically. With an electric input power of 10.9 kW and a rotating speed of 1450 r/min of the motor, a cooling power of 700 W at 77 K and a relative Carnot efficiency of 18.2% of the cryocooler have been achieved in the present study, and the corresponding pressure ratio in the compression space reaches 2.46.     

Design and experimental investigation of a cryogenic system for environmental test applications

This paper is concerned with the design, development and performance testing of a cryogenic system for use in high cooling power instruments for ground-based environmental testing. The system provides a powerful tool for a combined environmental test that consists of high pressure and cryogenic temperatures. Typical cryogenic conditions are liquid hydrogen (LH2) and liquid oxygen (LO2), which are used in many fields. The cooling energy of liquid nitrogen (LN2) and liquid helium (LHe) is transferred to the specimen by a closed loop of helium cycle. In order to minimize the consumption of the LHe, the optimal design of heat recovery exchangers has been used in the system. The behavior of the system is discussed based on experimental data of temperature and pressure. The results show that the temperature range from room temperature to LN2 temperature can be achieved by using LN2, the pressurization process is stable and the high test pressure is maintained. Lower temperatures, below 77 K, can also be obtained with LHe cooling, the typical cooling time is 40 min from 90 K to 22 K. Stable temperatures of 22 K at the inlet of the specimen have been observed, and the system in this work can deliver to the load a cooling power of several hundred watts at a pressure of 0.58 MPa.     

Performance characteristics of an irreversible regenerative magnetic Brayton refrigeration cycle using Gd0.74Tb0.26 as the working substance

The cycle model of an irreversible regenerative magnetic Brayton refrigerator using Gd_0.74Tb_0.26 as the working substance is established. Based on the experimental characteristics of iso-field heat capacities of the material Gd_0.74Tb_0.26 at 0 T and 2 T, the corresponding iso-field entropies are calculated and the thermodynamic performance of an irreversible regenerative magnetic Brayton refrigeration cycle is investigated. The effects of the irreversibilities in the two adiabatic processes and non-perfect regenerative process of the magnetic Brayton refrigeration cycle on the cooling quantity, the heat quantity released to the hot reservoir, the net cooling quantity and the coefficient of performance are discussed in detail. Some significant results are obtained.     

Cryogenic design and test results of 30-m flexible hybrid energy transfer line with liquid hydrogen and superconducting MgB2 cable

In this paper we present the development of a new hybrid energy transfer line with 30 m length. The line is essentially a flexible 30 m hydrogen cryostat that has three sections with different types of thermal insulation in each section: simple vacuum superinsulation, vacuum superinsulation with liquid nitrogen precooling and active evaporating cryostatting (AEC) system. We performed thermo-hydraulic tests of the cryostat to compare three thermo-insulating methods. The tests were made at temperatures from 20 to 26 K, hydrogen flow from 70 to 450 g/s and pressure from 0.25 to 0.5 MPa. It was found that AEC thermal insulation was the most effective in reducing heat transfer from room temperature to liquid hydrogen in ∼10 m section of the cryostat, indicating that it can be used for long superconducting power cables. High voltage current leads were developed as well. The current leads and superconducting MgB₂ cable passed high voltage DC test up to 50 kV DC. Critical current of the cable at ∼21 K was 3500 A. It means that the 30 m hybrid energy system developed is able to deliver ∼50–60 MW of chemical power and ∼50–75 MW of electrical power, i.e. up to ∼135 MW in total.     

Experimental investigation and optimization of small-scale helium liquefaction with multi-cryocoolers

Small-scale helium liquefiers using regenerative cryocoolers with cooling power up to 1.5 W at 4.2 K could be used to re-liquefy evaporated helium gas of small- and medium-sized cryogenic devices such as MEG and PPMS. A serial–parallel-path helium liquefier with a liquefaction rate of 83 Litres per day (L/d) using five 4 K G-M cryocoolers is developed, and has been applied to the Wuhan National High Magnetic Field Center (WHMFC) in China. Different from parallel-path helium liquefier, the helium gas is effectively, stepwise precooled by heat exchangers on multi-cold flanges, and thus the additional purifier and precooling coil heat exchangers on the thinner part of the cold head cylinder containing the 2nd stage displacer could be removed to simplify the construction. Through theoretical calculation and conclusive analysis, an optimum configuration is proposed and makes a reference to the design of serial–parallel-path helium liquefier with multi-cryocoolers.     

Design and prototyping of a large capacity high frequency pulse tube

This document describes the design and the prototyping performed at CEA/SBT in partnership with AIR LIQUIDE of a high frequency large cooling power pulse tube. Driven at 58 Hz by a 7.5 kW flexure bearing pressure wave generator, this system provides a net heat lift of 210 W at 65 K. The phase shift is obtained by an inertance and a buffer volume. This type of cryogenic cooler can be used for on site gas liquefaction or drilling site and for high temperature superconductivity power device cooling (transmission lines, large generators, fault current limiters).In this paper, we focus on two essential points, the regenerator and the flow straightener. The regenerator is a key component for good performance of the pulse tube cooler. It must have a large thermal inertia, a low dead volume, a good heat transfer gas/matrix and at the same time, small pressure drop. In the present case and unlike typical moderate cooling power pulse tubes, the regenerator is very compact. However, the resulting conductive losses remain negligible compared to the cooling power targeted. The goal of the flow straightener is to avoid as much as possible any jet stream effect and to guarantee the uniformity of the velocity field at both ends of the pulse tube. Indeed multi-dimensional flow effects can significantly impact the performances of the machine.     

Novel compact sorption generators for car air conditioning

A prototype compact generator using the activated carbon–ammonia pair based on the plate heat exchanger concept has been designed and built at Warwick University. The novel generator has low thermal mass and good heat transfer. The heat exchanger uses nickel-brazed shims and spacers to create adsorbent layers only 4 mm thick between pairs of liquid flow channels of very low thermal mass. The prototype sorption generator manufactured was evaluated under EU car air conditioning test conditions.The prototype sorption generator is described and its experimental performance reported. While driven with waste heat from the engine coolant water (at 90 °C), a pair of the current prototype generators (loaded with about 1 kg of activated carbon) operating out of phase has produced an average cooling power 1.6 kW with about 2 kW peaks. The typical average COP obtained is 0.22.     

Condensation stage of a pulse tube pre-cooled dilution refrigerator

In our article, experiments with a pulse tube (PTR) pre-cooled dilution refrigerator (DR) are presented, where an upgraded ³He condensation stage has been tested. The DR had a ³He flow rate of up to 1.1 mmol/s. The ³He gas entering the refrigerator was first pre-cooled to a temperature of ～50 K at the first stage of the PTR. In the next cooling step, the ³He was run through a recently installed heat exchanger, which was attached to the regenerator of the second stage of the pulse tube cryocooler; at the outlet of this heat exchanger the temperature of the ³He was as low as ～4 K. Due to the non-ideality of the helium gas, the second regenerator of a two stage PTR has excess cooling power which can be made use of without affecting the base temperature of this stage, and it is this effect which was put to work, here. Finally, the ³He was further cooled in a heat exchanger, mounted at the second stage of the PTR, before it entered the dilution unit of the cryostat.The installation of a heat exchanger at the regenerator of the second stage of the PTR is especially important for the construction of DRs with high refrigeration capacities; in addition, it allows for a plain design of the subsequent Joule–Thomson (JT) stage, and herewith facilitates considerably the construction of “dry” DRs. The condensation rate of the ^3,4He mash prior to an experiment was increased. The pressure during condensation could be kept near 1 bar, and thus a compressor was no longer necessary with the modified apparatus.     

Dry dilution refrigerator with 4He-1 K-loop

In this article we summarize experimental work on cryogen-free ³He/⁴He dilution refrigerators which, in addition to the dilution refrigeration circuit, are equipped with a ⁴He-1 K-stage. This type of DR becomes worth considering when high cooling capacities are needed at T ∼ 1 K to cool cold amplifiers and heat sink cables. In our application, the motivation for the construction of this type of cryostat was to do experiments on superconducting quantum circuits for quantum information technology and quantum simulations. In other work, DRs with 1 K-stage were proposed for astro-physical cryostats. For neutron scattering research, a top-loading cryogen-free DR with 1 K-stage was built which was equipped with a standard commercial dilution refrigeration insert.Cooling powers of up to 100 mW have been reached with our 1 K-stage, but higher refrigeration powers were achieved with more powerful pulse tube cryocoolers and higher ⁴He circulation rates in the 1 K-loop. Several different versions of a 1 K-loop have been tested in combination with a dilution refrigeration circuit.The lowest temperature of our DR was 4.3 mK.     

40 K single-stage coaxial pulse tube cryocoolers

Several 40 K single-stage coaxial high frequency pulse tube cryocoolers (PTCs) have been developed to provide reliable and low-noise cooling for GaAs/AlGaAs Quantum-Well infrared photodetectors (QWIPs). The inertance tubes together with the gas reservoir become the only phase shifter to guarantee the required long-term stability. The mixed regenerator consisting of three segments has been developed to enhance the overall regenerator performance. At present, the cooler prototype has achieved a no-load temperature of 29.7 K and can typically provide 860 mW cooling at 40 K with 200 W electric input power rejecting at 300 K. The performance characteristics such as the temperature stability and ambient temperature adaptability are also presented.     

Failure analysis of heat exchanger tubes

Primary waste heat exchanger tubes of material ASTM A213 grade T11 failed after operation of only three and a half months. The heat exchanger was of the bayonet type with boiler water inside the tubes and secondary reformer outlet process gas at the shell side. The heat exchanger environment was rich in hydrogen, carbon monoxide and nitrogen. The temperature of the process gases was 960 °C and the heat exchanger was producing steam at a temperature of 306 °C and a pressure of 1500 psig. The failed, used and new heat exchanger tubes were subjected to stereo/optical microscopy, chemical analysis and hardness testing. The cause of the failure was thoroughly investigated using optical/scanning electron microscope equipped with energy dispersive spectrometer. The study revealed that the material was exposed to thermal cycling and excessive local heating. The same was also confirmed by simulated experimentation. These conditions lead to thermal fatigue of the material with consequent failure.     

Ultra-low-vibration pulse-tube cryocooler system – cooling capacity and vibration

This report describes the development of low-vibration cooling systems with pulse-tube (PT) cryocoolers. Generally, PT cryocoolers have the advantage of lower vibrations in comparison to those of GM cryocoolers. However, cooling systems for the cryogenic laser interferometer observatory (CLIO), which is a gravitational wave detector, require an operational vibration that is sufficiently lower than that of a commercial PT cryocooler. The required specification for the vibration amplitude in cold stages is less than ±1 μm. Therefore, during the development of low-vibration cooling systems for the CLIO, we introduced advanced countermeasures for commercial PT cryocoolers. The cooling performance and the vibration amplitude were evaluated. The results revealed that 4 K and 80 K PT cooling systems with a vibration amplitude of less than ±1 μm and cooling performance of 4.5 K and 70 K at heat loads of 0.5 W and 50 W, respectively, were developed successfully.     

Characterization of a thermoelectric/Joule–Thomson hybrid microcooler

Micromachined Joule–Thomson (JT) coolers are attractive for cooling small electronic devices. However, microcoolers operated with pure gases, such as nitrogen gas require high pressures of about 9 MPa to achieve reasonable cooling powers. Such high pressures severely add complexity to the development of compressors. To overcome this disadvantage, we combined a JT microcooler with a thermoelectric (TE) pre-cooler to deliver an equivalent cooling power with a lower pressure or, alternatively, a higher cooling power when operating with the same pressure. This hybrid microcooler was operated with nitrogen gas as the working fluid at a low pressure of 0.6 MPa. The cooling power of the microcooler at 101 K operating with a fixed high pressure of 8.8 MPa increased from 21 to 60 mW when the precooling temperature was reduced by the thermoelectric cooler from 295 to 250 K. These tests were simulated using a dynamic numerical model and the accuracy of the model was verified through the comparison between experimental and simulation results. Based on the model, we found the high pressure of the microcooler can be reduced from 8.8 to 5.5 MPa by lowering the precooling temperature from 295 to 250 K. Moreover, the effect of TE cooler position on the performance of the hybrid microcooler was evaluated through simulation analysis.     

Absorption and desorption of gaseous toluene by an absorbent microcapsules column

Heavy solvents absorption appears to be very attractive in recovering of volatile organic compounds (VOCs) from industrial tail gas. Their high viscosities make good dispersion required but difficult to reduce mass transfer resistance. Microencapsulation techniques provide a candidate solution. In this paper, vapor pressures for toluene + poly(dimethylsiloxane) (PDMS) mixtures were measured at temperature ranging from 273.2 K to 343.2 K. Polyacrylonitrile (PAN) hollow microspheres, prepared by orifice dispersion plus solvent extraction method, was used to immobilize PDMS. The capacity was adjusted from 2.3 g to 9.3 g PDMS/g PAN by addition of cyclohexane in PDMS during solvent impregnation. The breakthrough curves of column packed with PDMS/PAN microcapsules were determined, indicating shapes close to ideality, high absorption efficiencies and considerable absorption capacities before breakthrough. The influence of operational temperature, concentration of feed and gas feed flow rate on the absorption process were investigated as well. A mathematical model, suitable for dilute gas absorption process, was used to simulate the breakthrough curves. This model has proved to be useful to fit curves and analyze the absorption kinetics of PDMS/PAN microcapsules column. After absorption, the column can be regenerated completely by gas stripping. Enrichment of toluene was founded by increasing desorption temperature. Through absorption and desorption by turns, the stability of PDMS/PAN microcapsules column was verified.     

Theoretical and experimental investigations on the cooling capacity distributions at the stages in the thermally-coupled two-stage Stirling-type pulse tube cryocooler without external precooling

The two-stage Stirling-type pulse tube cryocooler (SPTC) has advantages in simultaneously providing the cooling powers at two different temperatures, and the capacity in distributing these cooling capacities between the stages is significant to its practical applications. In this paper, a theoretical model of the thermally-coupled two-stage SPTC without external precooling is established based on the electric circuit analogy with considering real gas effects, and the simulations of both the cooling performances and PV power distribution between stages are conducted. The results indicate that the PV power is inversely proportional to the acoustic impedance of each stage, and the cooling capacity distribution is determined by the cold finger cooling efficiency and the PV power into each stage together. The design methods of the cold fingers to achieve both the desired PV power and the cooling capacity distribution between the stages are summarized. The two-stage SPTC is developed and tested based on the above theoretical investigations, and the experimental results show that it can simultaneously achieve 0.69 W at 30 K and 3.1 W at 85 K with an electric input power of 330 W and a reject temperature of 300 K. The consistency between the simulated and the experimental results is observed and the theoretical investigations are experimentally verified.