CHL and Hall D - Jefferson Lab

Report
Cryogenics
Applied Technology Development
Dana Arenius, Rao Ganni
Engineering Division
Cryogenic Systems Department
Technology Town Meeting
Feb 9, 2012
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This work is supported by the United States Department of Energy (DOE) contract #DE-AC05-060R-23177
Presentation Outline
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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
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community
General Focus Status
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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)
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Process Cycle Technology Use So Far
Existing Plant Conversions (Partial Ganni Cycle i.e. Floating Pressure )
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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
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(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 Facilities
Project X, BNL Upgrade, FEL programs
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
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NASA-JSC/JLab Collaboration
James Webb Telescope
Space Telescope
Replaces 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
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
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Recognition of “Third Dimension” with Ganni Cycle
(Wide Operating Temperature Domain)
Shield Return Temperature
11K
11K (est)
20K
20K (est)
40K
40K (est)
60K
60K (est)
80K - 1 Turbine
80K - 1 Turbine (est)
80K - 2 Turbine
80K - 2 Turbine (est)
100K - 1 Turbine
100K - 1 Turbine (est)
100K - 2 Turbine
100K - 2 Turbine (est)
Inverse Coefficient of Performance [W/W]
100
10
1
10
Shield Load [kW]
100
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Standard Helium Compressor Design
NASA/JSC Funded
• Utilizes lessons learned from previous designs and
performance
• Next generation compressor skid assembly design
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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
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)
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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
Increased Capacity ( %) PLUS efficiency (% of Carnot)
Tested Results by
Linde was…
M1600 Summary
25-30% increase
capacity with
same
compressors
Mod-1
Liq. Acc. [g/s]
Ref. Load [W]
LN2 Usage [g/s]
Make-up [g/s]
Input Power [kW]
Carnot Load [kW]
Useful Exergy [%]
Load Increase [%]
Efficiency Increase [%]
Mod-2
Liq. Acc. [g/s]
Ref. Load [W]
LN2 Usage [g/s]
Make-up [g/s]
Input Power [kW]
Carnot Load [kW]
Useful Exergy [%]
Load Increase [%]
Efficiency Increase [%]
1610
2-Comp 1-Comp
1630
2-Comp 1-Comp
1620
2-Comp 1-Comp
3.10
2
12.01
2.49
182.76
17.60
8.52
26.53
19.50
2.23
2
8.48
1.84
111.42
13.10
10.21
5.69
2.20
0.00
236
8.64
0.00
186.85
14.91
7.31
17.41
10.26
0.00
158
5.05
0.00
113.90
10.41
8.40
3.95
-0.71
0.00
980
6.59
0.00
177.47
19.19
10.07
15.98
14.17
0.00
870
5.41
0.00
115.80
16.86
13.33
8.75
3.82
3.25
2
12.26
2.60
182.76
18.36
8.86
32.65
24.26
2.29
2
8.55
1.89
111.42
13.43
10.45
8.53
4.60
0.00
227
8.40
0.00
186.85
14.38
7.07
12.94
6.64
0.00
148
4.88
0.00
113.90
9.74
7.88
-2.63
-6.86
0.00
985
6.64
0.00
175.16
19.40
10.30
16.57
16.78
0.00
845
5.32
0.00
115.73
16.53
13.10
5.63
2.02
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
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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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