Cryogenics Applied Technology Development

Dana Arenius, Rao Ganni

Engineering Division

Cryogenic Systems Department

Technology Town MeetingFeb 9, 2012

This work is supported by the United States Department of Energy (DOE) contract #DE-AC05-060R-23177

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Presentation Outline

• Technology Development Sources• Focus Goals and Status• Funding Sources• Technology Outreach• Status of Current Collaborations• Summary

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Sources for Technology Development

• DOE Laboratory Community– Cryogenics Operational Workshops

(attended by Industry and physics research labs world wide)

– JLab operational experience and needs– Other DOE laboratory cryogenic collaborations to retain and

develop cryogenic engineering technology and personnel

• Cryogenic Engineering Conferences

• Accelerator Division SRF advancements

• Insight of where industrial developments ended

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Development Focus Goals

• Establishing the use of Jlab’s Ganni Cycle by the end user and industry for existing and new plants

• Reducing utilities used by helium refrigerator plants in terms of electric power, cooling water, and LN2

• Improved helium plant reliability with less maintenance • Conservation of helium (reduced helium gas loss) and the

means of recycling helium for use (i.e. recovery purifiers)• Warm helium compressor efficiency improvement coupled

with reduced capital equipment cost via a standard compressor skid design model

• Development and retention of qualified engineers and designers in support of cryogenic technology in the DOE community

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General Focus Status

• Ganni Cycle implementation in a number of plants• Floating Pressure Technology use for existing plants• Improved LN2 pre-cooling technology developed • JLab’s SNS 2K system design is demonstrating low

helium operational gas loss technology, ~$10K per year, ½ plant size of Jlab

• Standard helium compressor design model in place • Combined He plant/cryomodule design optimization

approach, (MSU funded CM 2K heat exchanger configuration test, further power reduction over current 12 GeV design)

Process Cycle Technology Use So Far

Existing Plant Conversions (Partial Ganni Cycle i.e. Floating Pressure )• Jefferson Lab...all six refrigerators, 2K/4K, 200 to 4.6 kW • Brookhaven RHIC ….Central Helium Liquefier• Spallation Neutron Source (SNS)…CHL, 2.3 kW @ 2.1K• Michigan State University….Cyclotron Test Facility• NASA Johnson Space Center, Environmental Test Chamber A, twin 3.5 kW 20K

refrigerators

New Facilities (Full Implementation of Ganni Cycle) • Jefferson Lab 12 GeV Upgrade, 4.6 kW @ 2.1K • Jefferson Lab’s 4kW End Station Refrigerator (ESR-2)• NASA JSC Houston, James Webb Telescope Test Facility, 12.5 kW @ 20K• MSU FRIB

Other Possible FacilitiesProject X, BNL Upgrade, FEL programs

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Funding Sources

• NASA, JSC• MSU FRIB Project• Future MSU FRIB Operations• SNS Operations• JLab Accelerator Division• JLab Engineering Division

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Technology Outreach

• Optimal Helium Refrigeration Course Instruction– Once a year, at CEC conference or Cryogenic Operations

Workshop, industry and laboratory attended

• Advanced engineering degree thesis work assigned to each technology collaboration

• Participation of collaborators at JLab– currently have two MSU engineers (controls and

mechanical) working with cryogenics group for one year– Past engineers from SNS and MSU

• Publications and talks

NASA-JSC/JLab Collaboration

James Webb TelescopeSpace TelescopeReplaces Hubble~1 million miles out

Telescope Mockup at the National Mall, D.C.

NASA Funded-JSC/JLab Cryogenic Collaboration

• Help NASA engineers modify Current Environmental Space Simulation Chamber cryogenic system to JLab’s Floating Pressure Technology

• Help develop specification of additional new 20K, 12.5 KW refrigerator using the Ganni Helium Process Cycle

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NASA Design Goals

• Both the existing (using Floating Pressure) and new machine (using the Ganni Cycle) to have constant high efficiency with wide range of load

• The utilities used by the cycle to vary directly with the refrigeration load required

• Improve existing Helium plant temperature stability

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Benefits of the NASA Collaboration

• Eliminated much of the compressor engineering/design effort for Jlab 12 GeV

• First full implementation of the Ganni Cycle in a new refrigeration plant

• Served to help industry develop the understanding of implementing the Ganni Cycle

• Demonstrated the improvement of temperature stability in a pure refrigerator (10x over previous industrial design at NASA)

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NASA 20K Refrigerator

Helium Compressors 12.5 kW, 20K Cold Box

Startup: Summer 2012

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NASA Test Results and Plan

141 10 100

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11K11K (est)20K20K (est)40K40K (est)60K60K (est)80K - 1 Turbine80K - 1 Turbine (est)80K - 2 Turbine80K - 2 Turbine (est)100K - 1 Turbine100K - 1 Turbine (est)100K - 2 Turbine

Shield Load [kW]

Inve

rse

Coeffi

cien

t of

Per

form

ance

[W/W

]

Shield Return Temperature

Recognition of “Third Dimension” with Ganni Cycle (Wide Operating Temperature Domain)

Other Possible Dom

ains O

ther Possible Domains

Standard Helium Compressor Design

NASA/JSC Funded• Utilizes lessons learned from previous designs and

performance• Next generation compressor skid assembly design

– Initially supports NASA James Webb Telescope Testing – JLab 12 GeV warm helium compressors– MSU FRIB compressors – “Best value” design approach as evaluated by industry

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Notable Compressor Design Features

• Bulk Oil Separation Vessel– Vessel diameters reduced 50%– Vertical to horizontal design with specialized flow distributor– Oil coalescer filter eliminated– Large vessel flanges eliminated

• Gas after cooler oil removal system added• Cooling oil flow adjusted with temperature• Oil hold capacity requirement by 75%• Vibration isolation for I/C and heat exchangers• Easy access to all the components requiring maintenance

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Standard Model Visual Comparison

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Existing JLab CHL Compressors New CHL 12 GeV Compressors

~2/3 of Original CHL Power and LN2 Needed

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Helium Gas Recovery

• Recover helium gas rather than use once through flow • Helium gas costs are increasing 15% per year• Growing demand for helium gas recovery and

purification equipment among end users• Linde collaboration to develop standard helium

purification recovery unit• Design completed and first article built for use in

JLab’s 6 GeV accelerator

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Linde Funded Purifier Development

Masters Thesis Project: Mat Wright (JLab) JLab Advisor: Rao Ganni (JLab)

Industry Funded R+D Collaboration• Linde Model 1600 “standard” refrigerator (Funded by Linde)

– Normally 100-200KW electric utility use– Standard for laboratory DOE / University Investigations and Experimentation– Efficiency/Capacity of refrigeration and liquefaction improvement– JLab focused on the refrigerator heat exchanger design

Model 1600 Refrigerator Internal Heat Exchangers

Linde Fin-Coil Heat Exchanger• 3 Series of the Model 1600 Studied (1610/1620/1630)

• 2 configurations per series (1 or 2 compressors)

• 3 New Exchanger study options per configuration

• Capacity & Efficiency comparisons

Masters Thesis: Errol Yuksek (Jlab)Jlab Advisor: Rao Ganni (Jlab)

Linde Test Results

Tested Results by Linde was…

25-30% increase capacity with same compressors

Increased Capacity ( %) PLUS efficiency (% of Carnot)

M1600 Summary

2-Comp 1-Comp 2-Comp 1-Comp 2-Comp 1-CompMod-1 Liq. Acc. [g/s] 3.10 2.23 0.00 0.00 0.00 0.00 Ref. Load [W] 2 2 236 158 980 870 LN2 Usage [g/s] 12.01 8.48 8.64 5.05 6.59 5.41 Make-up [g/s] 2.49 1.84 0.00 0.00 0.00 0.00 Input Power [kW] 182.76 111.42 186.85 113.90 177.47 115.80 Carnot Load [kW] 17.60 13.10 14.91 10.41 19.19 16.86 Useful Exergy [%] 8.52 10.21 7.31 8.40 10.07 13.33 Load Increase [%] 26.53 5.69 17.41 3.95 15.98 8.75 Efficiency Increase [%] 19.50 2.20 10.26 -0.71 14.17 3.82Mod-2 Liq. Acc. [g/s] 3.25 2.29 0.00 0.00 0.00 0.00 Ref. Load [W] 2 2 227 148 985 845 LN2 Usage [g/s] 12.26 8.55 8.40 4.88 6.64 5.32 Make-up [g/s] 2.60 1.89 0.00 0.00 0.00 0.00 Input Power [kW] 182.76 111.42 186.85 113.90 175.16 115.73 Carnot Load [kW] 18.36 13.43 14.38 9.74 19.40 16.53 Useful Exergy [%] 8.86 10.45 7.07 7.88 10.30 13.10 Load Increase [%] 32.65 8.53 12.94 -2.63 16.57 5.63 Efficiency Increase [%] 24.26 4.60 6.64 -6.86 16.78 2.02

1610 1630 1620

Summary• A JLab patented helium refrigerator process (Ganni Cycle) is being used more and

more for other US applications

• JLab project and outside collaborations is used to retain and develop both engineering staff and needed laboratory technology

• The cycle has demonstrated positive effects for repair, maintenance, operation, and capital equipment cost for JLab and other laboratory cryogenic plants

• A standard model has been developed for warm helium screw compressors to reduce cost and improve efficiency for the Physics research user community. Compressors have been built for NASA and 12 GeV

• To support the growing need for helium gas conservation, a standard purification system has been developed and is being built to support 6 GeV and later 12 GeV operations, now available through industry to other DOE laboratories

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