Development of a Universal Tube-Side Heat Transfer Correlation for Upward Hydrocarbon Condensation in LNG Spiral Wound Heat Exchangers

To accurately predict tube-side heat transfer coefficients of spiral wound heat exchangers (SWHEs) in liquefied natural gas (LNG) production facilities, this study conducted a numerical investigation on the heat transfer behaviors of upward hydrocarbon condensation in helical coils. An integrated experimental-numerical methodology was implemented. The numerical framework was validated against experimental data with deviations within ±15%. Subsequently, it was used to generate a comprehensive database of 455 points, covering six pure and mixed refrigerants across a wide range of parameters. Using these simulated data, 57 heat transfer correlations were assessed, covering seven distinct categories: equivalent Reynolds number-based, liquid-phase multiplier-based, shear-based, mixed convection-based, flow pattern-based, and general-type. The top five correlations were then identified, which are capable of predicting almost 80% of the data points with an error within ±30%. To further improve the prediction accuracy and expand the applicable range, a universally improved liquid-only multiplier-based correlation was developed by considering the comprehensive effects of major operational and structural parameters. Together with the modified Silver approach, it is able to reliably predict 91.58% of the data points with an error within ±30%. For a total of 867 data points (455 from new numerical simulations, 296 from new experimental studies, as well as 116 from experimental data reported in previous literature), the mean absolute relative deviation (MARD) is 13.29%. Its robustness was further verified against 130 independent R134a experimental data points with a MARD of 13.63%. This work is expected to provide constructive guidance for the design of SWHEs within large-scale LNG facilities.