Steady-state thermodynamic simulation and structural design of the dephlegmator used in mixed-refrigerant Joule-Thomson refrigerators

Dephlegmators can be used to reduce the energy consumption and simplify the layout of the mixed-refrigerant Joule-Thomson (MRJT) cycle. Heat-exchange characteristics and refrigeration design are currently based on highly simplified assumptions. Synthesis methods to efficiently solve all design issues of dephlegmators in MRJT cycle are insufficient. No suitable separation module is available for the simultaneous heat and mass transfer processes in Aspen Plus because the module should be programmed and incorporated into Aspen Plus as a user-defined unit. In this paper, a systematic steady-state method was proposed for the detailed design of dephlegmators for gas mixture separation, considering the simulation and heat exchanger design simultaneously. The material balance, vapor-liquid equilibrium, mole fraction summation and heat balance (MESH) model was programmed in FORTRAN language. Good agreements and the feasibility of the MESH model were found. Deviations between the simulation results and patent data were all within 5%. The errors in the predicted temperatures of vapor and liquid products were less than 2% and 10%, respectively. Fine applicability and low energy consumption of the dephlegmator were addressed. The mole fraction of n-butane in the liquid phase had high recovery ratio of 90%. The dephlegmator decreased more than 30% of energy consumption compared with the traditional distillation tower under similar separation effects. In the structural design process, the dephlegmator was divided into certain segments by baffle plates on the basis of segmented calculation. The heat transfer coefficient, heat transfer area, pressure drop, and structural parameters of the dephlegmator were evaluated. A clear and comprehensive three-dimensional dephlegmator model was shown.