Design of efficient hydrogen liquefaction process integrated with ORC system

doi:10.11949/0438-1157.20241353

Abstract

Abstract:

In response to the issues of high energy consumption and unused high-temperature waste heat from compressor units in conventional hydrogen liquefaction systems, an efficient process coupled with organic Rankine cycle (ORC) is proposed based on the Claude hydrogen liquefaction system with liquid nitrogen precooling. The steady-state cases are simulated and the energy analysis and exergy analysis are conducted in Aspen Hysys. The results indicate that the proposed process can achieve a liquid hydrogen yield of 5 t/d. Compared with the conventional system without ORC, the net power consumption is significantly reduced from 1803.97 kW to 1701.39 kW, the specific energy consumption is 8.17 kWh/kg, and the exergy efficiency is 42.14%.

Key words: hydrogen, liquefaction, catalysis, organic Rankine cycle, specific energy consumption, exergy efficiency

摘要：

针对常规氢液化流程存在的高能耗和压缩机组高温余热未利用的问题，基于液氮预冷的Claude氢液化系统提出一种耦合有机朗肯循环的高效流程，利用Aspen Hysys进行稳态模拟并开展能量分析和㶲分析。结果表明，该流程可以实现5 t/d的液氢产率，相比无ORC的常规系统，净功耗从1803.97 kW显著降低至1701.39 kW，比能耗为8.17 kWh/kg，㶲效率为42.14%。

关键词: 氢, 液化, 催化, 有机朗肯循环, 比能耗, ?效率

CLC Number:

TK 123

Qiuying LI, Yihuai HUA, Hao CHENG, Hanwei ZHANG, Wenrui LIU, Haochuan BAI, Kai WANG, Limin QIU. Design of efficient hydrogen liquefaction process integrated with ORC system[J]. CIESC Journal, 2025, 76(7): 3651-3658.

李秋英, 花亦怀, 程昊, 张涵玮, 刘文睿, 白昊川, 王凯, 邱利民. 集成ORC系统的高效氢液化流程设计研究[J]. 化工学报, 2025, 76(7): 3651-3658.

Figures/Tables 9

Fig.1 The detailed flow chart of the proposed process

Table 1 The exergy efficiency calculation formulas of the main components in the processes

设备	㶲效率公式	公式
压缩机	$η c = E o u t E i n = q m e o u t q m e i n + W c$	(5)
膨胀机	$η e = E o u t E i n = q m e o u t + W e q m e i n$	(6)
泵	$η p = E o u t E i n = q m e o u t q m e i n + W p$	(7)
换热器	$η H X = E o u t E i n = ∑ j = 1 N q m, j e o u t, j ∑ j = 1 N q m, j e i n, j$	(8)
节流阀	$η v = E o u t E i n = q m e o u t q m e i n$	(9)

Table 1 The exergy efficiency calculation formulas of the main components in the processes

设备	㶲效率公式	公式
压缩机	$η c = E o u t E i n = q m e o u t q m e i n + W c$	(5)
膨胀机	$η e = E o u t E i n = q m e o u t + W e q m e i n$	(6)
泵	$η p = E o u t E i n = q m e o u t q m e i n + W p$	(7)
换热器	$η H X = E o u t E i n = ∑ j = 1 N q m, j e o u t, j ∑ j = 1 N q m, j e i n, j$	(8)
节流阀	$η v = E o u t E i n = q m e o u t q m e i n$	(9)

Table 2 Flow parameters for process simulation

系统	流股	温度/K	压力/kPa	质量流量/(kg/s)	系统	流股	温度/K	压力/kPa	质量流量/(kg/s)
原料氢液化系统	H0	300	2100	0.069	氢Claude制冷循环系统	F19	79.31	800	0.580
	H1	170	2100	0.069		F20	96.98	800	0.580
	H2	80	2100	0.069		F21	198.1	800	0.580
	H3	65	2100	0.069		F22	50	1800	0.598
	H4	50	2100	0.069		F23	40	1800	0.598
	H5	40	2100	0.069		F24	30	1800	0.598
	H6	30	2100	0.069		F25	24.58	300	0.598
	H7	26	2100	0.069		F26	24.58	300	0.598
	H8	21.15	130	0.069		F27	28	300	0.598
	H9	21.15	130	0.011		F28	48	300	0.598
	H10	21.15	130	0.058		F29	63	300	0.598
氢Claude制冷循环系统	F1	198	300	0.598		F30	78	300	0.598
	F2	276.8	800	0.598		F31	100	300	0.598
	F3	253.2	800	0.598		N1	78.06	110	5.580
	F4	226.3	800	1.178		N2	78.09	200	5.580
	F5	297.7	1800	1.178		N3	83.65	200	5.580
	F6	253.2	1800	1.178		N4	78.06	110	0.732
	F7	170	1800	1.178		N5	78.09	200	0.732
	F8	80	1800	1.178		N6	83.65	200	6.312
	F9	65	1800	1.178		N7	190.2	200	6.312
	F10	65	1800	0.598		R1	187.2	300	1.976
	F11	65	1800	0.580	ORC系统	R2	187.6	1000	1.976
	F12	60.98	1500	0.580		R3	187.6	1000	1.559
	F13	37.51	1500	0.580		R4	187.6	1000	0.418
	F14	34.67	1200	0.580		R5	226.3	1000	0.418
	F15	30	800	0.580		R6	226.3	1000	1.559
	F16	32.02	800	0.580		R7	226.3	1000	1.976
	F17	55.04	800	0.580		R8	190.2	300	1.976
	F18	59.93	800	0.580

Table 3 The operating parameters of compressor， pump and expander

设备	流量/(kg/s)	入口温度/ K	出口温度/ K	入口压力/ kPa	出口压力/ kPa	输入功率/ kW
C1	0.598	198	276.8	300	800	657.5
C2	1.178	226.3	297.7	800	1800	1195
P1	5.580	78.06	78.09	110	200	0.696
P2	0.732	78.06	78.09	110	200	0.091
P3	1.976	187.2	187.6	300	1000	2.833
E1	0.58	65	60.98	1800	1500	-21.85
E2	0.58	37.51	34.67	1500	1200	-10.61
E3	0.58	34.67	30	1200	800	-16.77
E4	1.976	226.3	190.2	1000	300	-105.5

Fig.2 Energy consumption analysis of the process

Fig.3 The exergy efficiency of each component in the process

Fig.4 The variation of SEC with evaporation pressure under different condensation pressures in ORC system

Fig.5 The variation of SEC with pump efficiency under different expander efficiencies in ORC system

Table 4 Comparison of hydrogen liquefaction systems

参数	本研究	Leuna ^[25-26]	中科富海^[27]
流程	液氮预冷的Claude氢液化系统+ORC系统	液氮预冷的Claude氢液化系统	液氮预冷的双压Claude氢液化系统
产量/(t/d)	5	5	5
原料氢压力/kPa	2100	2400	2500
原料氢温度/K	300	<313	310
液氢压力/kPa	130	130	150
液氢温度/K	21.15	21	21.5
压缩机效率/%	85	65~70	—
膨胀机效率/%	85	85	—
换热器级数	7	8	8
比能耗/(kWh/kg)	7.93~8.22	11.9	11
㶲效率/%	42.14	23.6	26.2

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