Cryogenics Facility and Cryocomponent Development at RRCAT

P K Kush, RRCAT

 Cryogenics Facility
Production of Liquid Helium and Liquid q q Nitrogen to meet the requirements of RRCAT

Research & Development

D Development of Cryocoolers, C l t fC l Cryopumps Development of Reciprocating Type Expansion Engine and Cross Counter Flow Heat Exchangers

Liquid Helium Plant : Make M/s Linde Model Installed capacity : TCF 20 : 40 Lit/ hr

Annual Consumption touched 70,000 liters

A) Liquid Nitrogen Plant Model Installed capacity B) Liquid Nitrogen Plant Installed capacity

: Make M/s Linde : Linit 50 : 40 Lit/ hr : Make M/s Philips : 20 Lit/ hr

Annual Consumption touches 60,000 liters

Liquid Nitrogen Production at Cryogenics Section

80,000 70,000 Liquid Produced, Liters 60,000 50,000 40,000 30,000 30 000 20,000 10,000 0 2000 2001 2002 2003 YEAR 2004 2005 2006 2007

Liquid Helium Production at Cryogenics Section

80,000 70,000 Liquid Production, Liters L 60,000 50,000 40,000 30,000 20,000 10,000 0 2000 2001 2002 2003 YEAR 2004 2005 2006 2007

4.2 K Cryogenic Test Station

For LHC 2000 magnets tested at 4.2 K in a duration of about 3 years To meet the requirement Testing facility was developed with magnet testing Capacity of 100 Magnets/ month

Power Converter 3V-1200 Amp

Decapole- Octupole Corrector Magnet (MCDO): 636 Nos

Sextupole Corrector Magnet (MCS): 1142 Nos

RESEARCH & DEVELOPMENT:

Cryocoolers and Cryogenic Expansion Engine

Development of C D l t f Cryocoolers l 30 K Cryocoolers 10 K Cryocoolers Cryopump with pumping speed of 1,200 liters/sec for i f air

Development of Reciprocating Type Expansion Engine and 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 p p expander module and a compressor module. The Cryocooler uses Helium gas as working fluid.

Development of Cryocoolers

30 K Cryocooler

10 K Cryocooler

30 K Cryocooler Characteristics
Cooling Power V/s Speed
8 7 50 K 6

Cooling Powe W er,

5 40 K 4

3 30 K 2

0 40 50 60 70 80 90 100 110 120 130 140

M otor Shaft Rotation per M inute

Cool down Characteristics

300

250

T e m p e ra t u r e , K

200

150

100
120 rpm

60 rpm

50
29.2 K 22.1 K

0 0 5 10 15 20 25 Time, min 30 35 40

45

50

3D Design Model

Product Photograph Prod ct

30 K CCR supplied to user Labs. Labs

05 Numbers of 30 K systems are supplied to different labs + One Compressor Module matched with imported unit and supplied to BARC, Mumbai, C Year 2002.

(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 Photoconductivity & Photoluminescence of Organic Semiconductors Ph t d ti it Ph t l i fO i S i d t

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, Resistivity b) Study of J V and e V characteristics at low Temperature On 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 pp g y Applications Division , RRCAT. It is being used to study Temperature Dependent Carrier Dynamics measurements by Ultra Fast Pump Probe Spectroscopy

(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 being b i used i a Photoluminescence setup at BARC d in Ph t l i t t Spectroscopy Lab RRCAT Indore.

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

10K Cryocooler
Lowest Temperature Temperature S i i Stability 10 K 0 deg 0.5

Cooldown Characteristics of Two Stage Cryocooler

320 300 280 260 240 220 200
4.5 5

180 Temper rature, K 160 140 120 100 80 60 40 20 0 0 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255
0.5 C o o l in g P o w e r , W 3 4

3.5

2.5

41 K First Stage Tem perature 9 K Second Stage T t

1.5

Tim e After Startup, Min

0 5 10 15 Temperature, K 20 25 30

C yopu p Using Our 0 G-M Cryocooler Cryopump Us g Ou 10K 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 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 gas

All the above problems solved by y g y modifying Commercially available AirConditioner 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). g Integral Purifier 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) Heat T H t Transfer Coeff ratio (Tube Side/Shell f C ff ti (T b Sid /Sh ll Side) 700 3.5, 4.9

H ig h P r e s s u r e H o t G a s S tr e a m

L o w P re s s u re C o ld S tr e a m

Heat Exchanger I [Temperature range: 306 - 90 K] Design Values Experimentally (Theoretical) Observed values Tube Side Pressure Drop 8.2 psi p 9.0 psi p (HP) Shell Side Pressure Drop 0.82 psi 1.10 psi (LP) Effectiveness 97.00% 95.60%

Heat Exchanger II [Temperature range: 306 - 200 K] Design Values Experimentally (Theoretical) Observed values Tube Side Pressure Drop (HP) Shell Side Pressure Drop (LP) Effectiveness i 7.2 psi 0.080 psi 96.00% 7.6 psi i 0.10 psi 95.30%

Cryogenic Expansion Engine Expansion Engine:

A Critical part in Claude cycle based cryogenic refrigerators and liquefiers

Types of Expansion Engines

Reciprocating Type Turbine Type

Reciprocating Type Expansion Engine

High E Hi h Expansion Ratio i R ti 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 RRCAT p g p

Cylinder and piston Crank and connecting rod Valve for pressurization and depressurization at cryogenic temperature Cam and rocker arm Flywheel Braking and speed control mechanism - Alternator with external resistor

Performance of 1st Engine

Psupply Ph = 0 7 bar P 0.7 b Pr. Drop in valve and heat exchanger PL Pexit = 1 2 bar 1.2 b Rounding of corners Finite time of valve closing and opening i

P-V Diagram at 250K

P-V Diagram at 150K

Present Performance Status

1st Engine 75 mm 50 mm 225 psi 20 psi 40.1 40 1 K 45% 80 r/min 103 W 2nd Engine 50 mm 50 mm 225 psi 20 psi 14.2 14 2 K 74.8% 80 r/min 68.6 W

Cylinder bore Stroke Inlet Pressure Exit Pressure Exit temperature Efficiency Speed Refrigeration Produced

At 80 rpm should perform as follows Refrigeration R fi ti Efficiency 160 W 75% 69 W 75%

Main Process compressor:

Make: Sulzer India, Four Stage, air cooled, oil g , , Lubricated, Reciprocating type
Designed, Processed and commissioned by us. i i db (Fabricated by local fabricator)

(Suitably modified for using it with above expansion engine)

Oil Removal System:

Test Setup

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

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 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 DAE DAE.

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

Development of Saturated bath type vertical Test Cryostats: 4.5 K 2 K (For Sensor calibrations, RRR measurements etc.) D Development of S t t d b th type vertical Cryostats l t f Saturated bath t ti l C t t 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 Liquid Nitrogen production to Approx. 200 lit/hr Liq Helium Production/ with 5,000 10,000 Lit storage capacity and Approx. Approx 400 lit/hr of Liquid Nitrogen Nitrogen.