2K CRYO SYSTEM FOR SMALL LOADS In the Order of 100W

VenkataRao Ganni Data from P. Knudsen (M. S. Thesis) Jefferson Lab

2K Cryo System for small loads Carnot Refrigeration Cycle

Coefficient of Performance COP:

COP

QLOW Useful Refrigeration = Work Input WNET

QLOW QHIGH QLOW

T1 T2 T1

2K Cryo System for small loads

160 140 120 100 80 60 40 20 0 1 10 100 1000

COP INV

1 = COP

Pcarnot (W / W)

Load Temperature (K)

Clausius (In)equality (the 2nd Law of Thermodynamics)

QL TL

QH TH

300W 300K

4W 4K

2W 2K

quality or availability

2K Cryo System for small loads Fixed parameters: Load temperature for helium II T ~ ln(p), so T ~ isothermal input power

2K Cryo System for small loads

Case-1

Case-2

2K Cryo System for small loads

Case-3

Case-4

2K Cryo System for small loads

Case-5

2K Cryo System for small loads

Direct (warm) vacuum pumping (with no refrigeration recovery) typical for small 2 K helium refrigerators Referring to configuration C1: Ideal COPINV ~700 W/W Real COPINV ~6500 W/W

What if a small HX is introduced as shown in configuration C1-A)? For HX-1 w/ 2 NTUs: Ideal COPINV ~480 W/W Real COPINV ~4500 W/W i.e., a COPINV reduction by ~30% as compared to no HX

2K Cryo System for small loads The improvement offered by the HX tapers-out quickly. For HX-1 w/ 6 NTUs, the COPINV has decreased an additional ~5% from the 2 NTU performance (i.e., 30 to 35%)

2K Cryo System for small loads

Case-5

2K Cryo System for small loads

2K Cryo System for small loads

2K Cryo System for small loads

Three process configurations were studied: C2-A, C2-A-p & C2-B The following parameters were identified as key independent variables, and were varied as follows: Flow ratio (high to low pressure stream mass flow rate): 40 to 100% Total HX size (i.e., length): 20 to 45 NTUs NTUs > 45 considered impractical due to high sub-atmospheric stream p) Supply pressure to cold box: 6 to 18 atm 4.5K plant injection location

2K Cryo System for small loads

C2-A Would need an additional purifier in the 4.5K plant C2-A-p Uses LN2 to pre-cool the HP stream; re-injecting 80K helium back into 4.5K plant at a lower pressure (i.e., it is throttled) This is a practical consequence of the difficulty in matching the 2K CBX HP to the 4.5K CBX HP streams Purification can be easily integrated into this 2K CBX configuration C2-B HP flow is recycled through HX-2 to take advantage of both the real fluid specific heat difference between HP and sub-atmospheric pressure streams; as well as, the increase in fluid temperature after being throttled through JT-1 The cold injection from JT-1 and the 4.5K plant injection are switched, depending on which is colder Would need an additional purifier in the 4.5K plant (or configuration C2-B-p could be used)

2K Cryo System for small loads

2K Cryo System for small loads

HX cooling curves for the particular case of configuration C2-A with 40 NTUs and a 12 atm. supply pressure to the CBX at the minimum real COPINV As is well known, these figures clearly show the non-linear effect of the helium specific heat below 20K

2K Cryo System for small loads

HX-2 cooling curve (below) highlights the purpose for studying configuration C2-B HP stream heat capacity is less than the sub-atmospheric stream heat capacity (until the temperature reaches lambda)

2K Cryo System for small loads The table below summarizes the optimum performance results of the three configurations studied, as well as, direct vacuum pumping and using cold compressors
Configuration C1 C1-A C2-A C2-A-p C2-B Ideal COPINV [W/W] 693 478 (a) 447 (b) 250 271 254 (c) N/A Real COPINV [W/W] 6500 4490 (a) 4200 (b) 1780 1720 1800 (d) 900 Notes No HX. (a) HX-1 = 2 NTUs; (b) HX-1 = 6 NTUs Total HX NTUs = 40; Supply Pressure = 12 atm.; Flow Ratio = 78% Total HX NTUs = 40; Supply Pressure = 12 atm.; Flow Ratio = 77% Total HX NTUs = 40; Supply Pressure = 12 atm. (c) Flow Ratio = 78%; (d) Flow Ratio = 79%

Cold Compressor System

Possible using Floating Pressure Cycle with well matched cold box and compressor system.

2K Cryo System for small loads Input power distribution of C2-A-p at optimum real COPINV ( 77%, ph,1 = 12 atm) for Ntutot = 40
hl

2K Cryo System for small loads

2K Cryo System for small loads

Case-5 (C2-A-p)

2K Cryo System for small loads

Compression System Main Components

2K Cryo System for small loads 2K Cold Box Main Components -Heat exchangers

2K Cryo System for small loads

Helium Vacuum Pumping System (for ~ 5 g/s)

2K Cryo System for small loads

KINNEY VACUUM PUMP
8
y = 0.344x

6
5 4 3 2 1 0 0 5 10 15 20 25

FLOW [g/s]

Psuction [Torr]

2K Cryo System for small loads

Helium Screw Compressor Skid

2K Cryo System for small loads

4.5 K Cold Box

2K Cryo System for small loads

10 Torr pressure on the low pressure side of the heat exchangers

Stanford University 300W, 1.8 K Helium Liquefier (1969)

2K Cryo System for small loads Cryo Systems Cost Comparison

2-K Load Specific 4.5-K Liquefier Cost Specific Compr. Sys. Cost Specific 2-K Liquefier Cost Specific Vacuum Sys. Cost 4.5-K Mass Flow 2-K Mass Flow 4.5-K Liquefier System Other. 4K Equipment (Dewar, tanks etc.) 2-K Liquefier System Vaccum Pumping System Other. 2K Equipment Controls Engineering Installation Commisioning Total Capital 120 [W] 300 150 75 25 [K$/(g/s)] [K$/(g/s)] [K$/(g/s)] [K$/(g/s)]

Case-1 Case-2 Case-3 Case -4 Case-5 8.0 6.0 8.0 6.0 1.5 [g/s] 8.0 6.0 8.0 6.0 6.0 [g/s] 0 150 0 200 25 25 10 19 12 441 0 150 45 150 25 50 10 19 12 461 2400 150 60 200 25 50 58 128 48 3119 1800 150 45 150 25 75 58 128 48 2479 675 200 450 275 50 100 96 160 72 [K$] [K$] [K$] [K$] [K$] [K$] [K$] [K$] [K$]

2078 [K$]

2K Cryo System for small loads 2-K Systems Operating Cost Comparison

Cost of Electricity Cost of Ln2 4.5-K Helium Unit Cost

0.05 [$/kW-h] 0.25 [$/gal] 3.00 [$/l] Case-1 Case-2 Case-3 Case -4 Case-5

COPINV Operating Power Electric Power Cost Ln2_Cost Monthly Utility Cost Yearly Utility Cost 530 6360 398 4770

4.8 576 29 10 29 343

3.1 372 19 8 19 231

2.2 [kW/W] 264 [kW] 13 [$/Hr] 2 [$/Hr] 11 [K$/3 mo.] 133 [K$/yr]

2K Cryo System for small loads Other Infra Structure & Utilitiy Systems Required
Input Power to Cryo Systems x 1.5 Input Power to RF Systems x 4 Input Power to controls & Other Total Electric Input Power for transformer sizing Ln2 Use Ln2 Dewar (5000 Liters) Power (1MW) Cooling Water (1MW) LCW (GPM?) Instrument Air Vacuum Systems KW KW KW KW GPM K$ K$ K$ K$ K$ K$ 500 120 80 700 15

2K Cryo System for small loads Summary

Carnot Power at 4.5K Carnot Power at 2.1K Electric Power Cost Q_Ref_Load W/W W/W $/kW W 70 145 0.05 120 @4.5K 8 105 1 46 875 3500 120 @ 2.1K 6 290 2 127 2417 9667 800 @ 4.5K 12 467 2 204 583 2333 1623 806 3222 504 250 1000 12GeV 4600 @2.1K 18 3706 4600 @4.5K 28 1150

Carnot_Eff Input Electric Power Capital Cost Operating Cost/year Actual Electric Power Ratio Actual Thermal Power Ratio

% kW M$ K$ W/W W/W

Are we sure 2.1 K is the correct Temperature choice for this application?