Cryogenics FacilityCryogenics Facility and Cryocomponentand Cryocomponent

Development at RRCATDevelopment at RRCAT

P K Kush, RRCAT

• Cryogenics Facility– Production of Liquid Helium and Liquid q q

Nitrogen to meet the requirements of RRCAT

• Research & DevelopmentD l t f C l C– Development of Cryocoolers, Cryopumps

– Development of Reciprocating Type Expansion Engine and Cross Counter FlowExpansion Engine and Cross Counter Flow Heat Exchangers

Liquid Helium Plant : Make M/s Linde

Model : TCF 20

Installed capacity : 40 Lit/ hr

Annual Consumption touched 70,000 liters

A) Liquid Nitrogen Plant : Make M/s LindeModel : Linit 50

Installed capacity : 40 Lit/ hr

B) Liquid Nitrogen Plant : Make M/s PhilipsInstalled capacity : 20 Lit/ hr

Annual Consumption touches 60,000 liters

Liquid Nitrogen Production at Cryogenics Section

70,000

80,000

30 000

40,000

50,000

60,000

Prod

uced

, Lite

rs

0

10,000

20,000

30,000

2000 2001 2002 2003 2004 2005 2006 2007

Liqu

id

YEAR

Liquid Helium Production at Cryogenics Section

60,000

70,000

80,000

Lite

rs

20,000

30,000

40,000

50,000

Liqu

id P

rodu

ctio

n, L

0

10,000

2000 2001 2002 2003 2004 2005 2006 2007

YEAR

4.2 K Cryogenic Test Station

To meet the requirement Testing facility was developed with

For LHC 2000 magnets tested at 4.2 K in a duration of about 3 years

magnet testing Capacity of 100 Magnets/ month

Power Converter3V-1200 Amp

Sextupole Corrector

Magnet (MCS): 1142 Nos

Decapole- Octupole Corrector

Magnet (MCDO): 636 Nos

RESEARCH & DEVELOPMENT:RESEARCH & DEVELOPMENT: Cryocoolers and Cryogenic Expansion Engine

D l t f C l– Development of Cryocoolers

– 30 K Cryocoolers

– 10 K Cryocoolers

– Cryopump with pumping speed of 1,200 liters/sec f ifor air

– Development of Reciprocating Type Expansion Engine and Cross Counter Flow Heat Exchangersand Cross Counter Flow Heat Exchangers

• Cryocoolers like domestic refrigerator require only electricity to produce low temperature. The Cryocoolers developed at RRCAT are based on Gifford McMahon Cycle. They produce 30K in a single-stage system and 10K in a two-stage system. The entire cryocooler is made of indigenously available components.

• The Cryocooler consist of two parts, an expander module and a compressor module.p p

• The Cryocooler uses Helium gas as working fluid.fluid.

Development of CryocoolersDevelopment of Cryocoolers

30 K Cryocooler 10 K Cryocooler

30 K Cryocooler Characteristics

Cooling Power V/s Speed

7

8

50 K

5

6

er, W

50 K

40 K

3

4

Coo

ling

Pow

e

1

230 K

040 50 60 70 80 90 100 110 120 130 140

Motor Shaft Rotation per Minute

300

Cool down Characteristics

250

200

e, K

150

mpe

ratu

r

50

100Te 60 rpm

120 rpm

0

50

29.2 K22.1 K

0 5 10 15 20 25 30 35 40 45 50

Time, min

3D Design Model Prod ct Photograph3D Design Model Product Photograph

30 K CCR supplied to user Labs30 K CCR supplied to user Labs.

05 Numbers of 30 K systems are supplied to different labs

+ One Compressor Module matched with Cimported unit and supplied to BARC, Mumbai,

Year 2002.

(1)(1) One 30 K Cryocooler supplied during first half of year 2004 (Laser Physics Applications Division, RRCAT), It is being used for study of “Temperature Dependent Transient Ph t d ti it & Ph t l i f O i S i d t ”Photoconductivity & Photoluminescence of Organic Semiconductors”

Sample Holder

(2) Another 30 K Cryocooler was supplied to Semiconductor Laser Section, RRCAT during year 2004. It is being used to study “Temperature Dependent Electrical Transport measurements

a) Hall Mobility, Carrier Concentration, Resistivityb) Study of J – V and e – V characteristics at low TemperatureOn semiconductors thin films and optoelectronic structures like lasers,

detectors – Regularly grown using MOVPE system at RRCAT

(3) Another 30 K Cryocooler was supplied to Laser Physics Applications Division , RRCAT. It is being used to study pp , g y“Temperature Dependent Carrier Dynamics measurements by Ultra Fast Pump Probe Spectroscopy”

(4) One 30 K Cryocooler is coupled to a specrofluorometer(4) One 30 K Cryocooler is coupled to a specrofluorometer of Jobin-Vyon (Model no- Fluoromax-3) suitable for experiments in Temperature range of 40 to 300K. This is b i d i Ph t l i t t BARCbeing used in a Photoluminescence setup at BARC Spectroscopy Lab RRCAT Indore.

(5) Another 30 K Cryocooler was supplied to Materials, Advanced Accelerator Science & Cryogenics Div. , RRCAT. On this y g ,Cryocooler a cryogen free ac-susceptometer working over a wide temperature range (30-400K) is developed. Which amongst other things is capable of precision measurements of g g p pphase transition phenomenon in magnetic materials and superconductors.

10K Cryocooler10K CryocoolerLowest Temperature – 10 K

S i i 0Temperature Stability - ± 0.5 deg

260

280

300

320

Cooldown Characteristics of Two Stage Cryocooler

140

160

180

200

220

240

ratu

re, K

3.5

4

4.5

5

20

40

60

80

100

120

9 K Second Stage

41 K First Stage Temperature

Tem

per

1.5

2

2.5

3

Coo

ling

Pow

er, W

0

20

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255

9 K Second Stage T t

Time After Startup, Min

0

0.5

1

5 10 15 20 25 30

Temperature, K

Cryopump Using Our 10K G-M CryocoolerC yopu p Us g Ou 0 G C yocoo e

• Ultimate Vacuum: 4 x 10E-8 mbar

• Pumping Speed

– Nitrogen: 1200 Liter/sec

– Argon: 900 Liter/sec

• Max. Throughput: 2 mbar. Liter/sec

• Impulsive gas load (Cross over) Tolerance: 60 mbar-Liter

• Gas Capacity for Nitrogen: 300 Std. liters

Compressor Modules Developed at RRCATCompressor Modules Developed at RRCAT

Problems Related with Helium Compressor:

• Helium gas compressors of suitable size are not available in open market.

• High heat of compression for Helium Gas• Suitable Lubricating Oil for clean operation• On line Oil removal system for ultra clean high

pressure Helium gaspressure Helium gas

All the above problems solved by modifying Commercially available Air-y g yConditioner Compressor for helium gas. Completed more than 3,000 hours of operation.

Development of Cryogenic Expansion Engine

Main Components of a Helium Liquefier• Expansion Devices• Heat Exchangers • Main Process Compressor• Process Control Components (Gas pressure Regulators, Metering Valve,

NRV, Relief valve, Solenoid valves, Temperature Sensors, Pressure Transducers, controllers etc).

• Integral Purifierg• Thermal Insulation system (Cold Box) • Thermally Insulated Transfer Lines• Main Dewar (To collect Liquid)

Helium Liquefier Schematic

High Density Finned Tube Heat Exchangers

Heat Transfer area / Volume (m2/ m3) 700

H t T f C ff ti (T b Sid /Sh ll

H ig h P re s s u re

Heat Transfer Coeff ratio (Tube Side/Shell Side) 3.5, 4.9

H ig h P re s s u reH o t G a s S tre a m

L o w P re s s u reC o ld S tre a m

Heat Exchanger –I [Temperature range: 306 - 90 K]

Tube Side Pressure Drop (HP) 8.2 psi 9.0 psi

Design Values (Theoretical)

Experimentally Observed values

(HP) p p

Shell Side Pressure Drop (LP) 0.82 psi 1.10 psi

Effectiveness 97.00% 95.60%

Heat Exchanger –II [Temperature range: 306 - 200 K]Design Values (Theoretical)

Experimentally Observed values

Tube Side Pressure Drop i iTube Side Pressure Drop (HP) 7.2 psi 7.6 psi

Shell Side Pressure Drop (LP) 0.080 psi 0.10 psi(LP)Effectiveness 96.00% 95.30%

Cryogenic Expansion Engine• Expansion Engine:

A Critical part in Claude cycle based cryogenic refrigerators and liquefiersrefrigerators and liquefiers

• Types of Expansion EnginesReciprocating TypeTurbine Type

• Reciprocating Type Expansion EngineHi h E i R ti• High Expansion Ratio

• Low Flow Rate• Constant Efficiency Over Wide Range of Operating Conditions.• Less Sensitive to Contamination and Power Fluctuation Problems• Control of Speed/Flow Rate is Easier

Expansion Engine Developed at RRCATp g p

Cylinder and pistonCrank and connecting rodCrank and connecting rodValve for pressurization and depressurization at cryogenic temperatureCam and rocker armFlywheelFlywheelBraking and speed control mechanism

- Alternator with external resistor

Performance of 1st EngineP P 0 7 b P• Psupply – Ph = 0.7 bar ⇒ Pr. Drop in valve and heat exchangerP P 1 2 b• PL – Pexit = 1.2 bar

• Rounding of corners ⇒ Finite time of valve closing and

iopening

P-V Diagram at 250K P-V Diagram at 150K

Present Performance Status

1st Engine 2nd EngineCylinder bore 75 mm 50 mmStroke 50 mm 50 mmInlet Pressure 225 psi 225 psiExit Pressure 20 psi 20 psi

Exit temperature 40 1 K 14 2 KExit temperature 40.1 K 14.2 K

Efficiency 45% 74.8%

Speed 80 r/min 80 r/min

Refrigeration Produced 103 W 68.6 W

R f i ti 160 W 69 W

At 80 rpm should perform as follows

Refrigeration 160 W 69 WEfficiency 75% 75%

Main Process compressor:Main Process compressor:

Make: Sulzer India, Four Stage, air cooled, oil g , ,Lubricated, Reciprocating type

(Suitably modified for using it with above expansion engine)(Suitably modified for using it with above expansion engine)

Oil Removal System: Designed, Processed and i i d bcommissioned by us.

(Fabricated by local fabricator)

Test SetupTest Setup

Following works are still to be done t l t H li Li fito complete Helium Liquefier

• Improve Efficiency of the Expansion Engines

• Development of Integral Purifier.

• Automatic process control for cool down, unattended operation and shut down.

Future Plans

“Development of Superconducting cavities and Associated Technologies for High Energy AcceleratorsAssociated Technologies for High Energy Accelerators

& their Applications”

Infrastructure has to be set up and develop the necessary technologies needed for successful production of superconducting cavities required for various accelerator programs in DAEvarious accelerator programs in DAE.

Future Plans for Enhancement of C i F ili RRCATCryogenics Facility at RRCAT

• Development of Saturated bath type vertical Test• Development of Saturated bath type vertical Test Cryostats: 4.5 K – 2 K(For Sensor calibrations, RRR measurements etc.) D l t f S t t d b th t ti l C t t• Development of Saturated bath type vertical Cryostats for testing SCRF Cavities: 4.5 K – 2 K

• Development of Horizontal Test stand for testing/ Characterizing SCRF Cavities at temperatures below 2K.

• Development of Cryomodules Augmentation of present facility of liquid Helium and LiquidAugmentation of present facility of liquid Helium and Liquid

Nitrogen production to Approx. 200 lit/hr Liq Helium Production/ with 5,000 – 10,000 Lit storage capacity and Approx 400 lit/hr of Liquid NitrogenApprox. 400 lit/hr of Liquid Nitrogen.