Large-capacity Helium refrigeration :from state-of-the-art

towards FCC reference solutions

Francois Millet – March 2015

Large-capacity helium refrigeration – FCC week 20152

Contents

Introduction

FCC requirements & constraints

From the state-of-the-art towards FCC Refrigeration scheme & components Cooling capacity Cooling architecture

Conclusion

Large-capacity helium refrigeration – FCC week 2015

Introduction

Main FCC cryogenic challenges : - towards 1 MW @ 4.5 K (> 200 MW of electrical power consumption)

- mainly dynamic heat loads at 40-60 K (Synchrotron radiation)

- Large-scale superfluid helium refrigeration down to 1,6 K (*) (*) see presentation “Study of a magnetic refrigeration stage”

0

200

400

600

800

1000

1200

1940 1960 1980 2000 2020 2040 2060 2080

kW @

4.5

K

Year

HistoryHL-LHCFCC

OMEGA, BEBCISR Low-Beta

ALEPH, DELPHI,LEP Low-Beta

LEP2

LHCATLAS, CMS

?

Toda

y

FCC-hh

FCC-ee

0

20

40

60

80

100

120

1980 2000 2020 2040 2060 2080

kW @

1.8

K

Year

HistoryHL-LHCFCC

FCC-hh (1.9 K)

?Toda

y

Test areas

LHC

FCC-ee

=> Study & Developments of Larger Refrigeratorswith high reliability and efficiency

(50-100 kW @ 4.5 K range including 5-10 kW @ 1.8 K)

Large-capacity helium refrigeration – FCC week 2015

Analysis of FCC requirements & constraints

Review of the State-Of-the-Art

Identification of present process and component limits

Development of new technologies or architectures in collaboration with CERN & major cryoplant industries

=> Definition of FCC reference solutions

CEA study roadmap

Study & Developments of Larger Refrigerators(40-100 kW @ 4.5 K range including 5-10 kW @ 1.8 K)

Large-capacity helium refrigeration – FCC week 20155

Contents

Introduction

FCC requirements & constraints

From the state-of-the-art towards FCC Refrigeration scheme & components Cooling capacity Cooling architecture

Conclusion

Large-capacity helium refrigeration – FCC week 2015

FCC-hh cryogenic layout

A B

C

D

E

FGH

I

J

K

LA B

C

D

E

FGH

I

J

K

L

Cryoplant L Arc+DS [km] L distribution [km]

2 x 4 = 8 2 x 4.7 = 9.4

8.4 8.4

Cryoplant L Arc+DS [km] L distribution [km]

4 4.7

4.4 5.1

4 4

4.4 6.5

10 cryoplants6 technical sites

20 cryoplants10 technical sites

No cryoplant redundancy at Point A and GNo distribution in ESS

L. Tavian / CERN

=> 12 sectors to be cooled with different lengths and heat loads

Large-capacity helium refrigeration – FCC week 2015

Rough FCC-hh heat loads estimate

7

L. Tavian / CERN

+ cooling for HTS current leads from 40 K to 300 K

Temperature level

LHC [W/m] FCC-hh [W/m]

50-75 K 4.5-20 K 1.9 K 40-60 K 1.9 K

Static heat

inleaks

CM supporting system 1.5 0.10 2.0 0.13

Radiative insulation 0.11 0.13

Thermal shield 2.7 3.1

Feedthrough & vac. barrier 0.2 0.1 0.2 0.1

Distribution 3.2 0.1 0.02 4 0.1

Total static 7.6 0.1 0.3 9.3 0.46

Dynamic heat loads

Synchrotron radiation 0.33 e 57 (88) 0.2

Image current 0.36 2.7 (2.9)

Resistive heating 0.1 0.3 (0.4)

Beam-gas scattering 0.05 0.45

Total dynamic 0.7 0.15 64 (95) 0.95 (1.05)

Total 7.6 0.8 0.45 73 (104) 1.4 (1.5)

(): Value in brackets for 80-km FCC-hh

Large-capacity helium refrigeration – FCC week 2015

FCC-hh main heat loads

SC Magnets & RF cavities at 1.9 K

Beam screens at 40-60 K

Thermal Shield at 40-60 K

HTS Current leads between 40-300 K

FCC–hh cooling requirements

1.8 K bath

300 K to 4.5 K refrigeration

SC Magnets + Cavities

HTS Current Leads

40 K

60 K

300 K

4.5 K 42 K

Assumptions : w/o over-capacity margin / integral CC & CC efficiency = 70%

Beam Screen

1 MW eq @ 4.5 K (> 200 MW of Elec. Power)

Thermal Shield

10 cryoplants 20 cryoplants40 2146 247 36 4

Cryoplant kW eq @ 4.5 K 99 51

beam screenthermal shield

HTS current leads

1,8 K magnets + RF cavitieskW eq @ 4.5K

Large-capacity helium refrigeration – FCC week 20159

Contents

Introduction

FCC requirements & constraints

From the state-of-the-art towards FCC Refrigeration scheme & components Cooling capacity Cooling architecture

Conclusion

Large-capacity helium refrigeration – FCC week 2015

Conventional refrigeration scheme

Warm Compression System

Compressor

Gas cooling

Oil removal

Cold Box

Heat exchangers Turbines

Valves

Two phase vessel

Liquid helium supply

Principle scheme of a simple refrigerator

ORS

U.Wagner/ CERN

Large-capacity helium refrigeration – FCC week 2015

Refrigeration technology – Main components

Warm Compressor System Cold Box

Linde / Air Liquide

Large-capacity helium refrigeration – FCC week 2015

Present large-scale He refrigerators & Liquefiers

U.Wagner/ CERN

F.Andrieux / ALAT

LHC 4.5 K Refrigerators 18 kWeq @4.5K

Qatar Helium Recovery Unit 20 tons/day - 24 kWeq @4.5K

Under construction

ITER He Plant3x25 kWeq @4.5K

3 modules in //+

ITER 80 K Loop2x20 kWeq @4.5K

2 modules in //

Large-capacity helium refrigeration – FCC week 2015

FCC cryoplant cooling capacity

He plant cooling capacity for FCC ?Larger cryoplants (up to factor 4)or modules in // (2 to 4 modules)

Large-capacity helium refrigeration – FCC week 2015

LHC architecture

One 18kW eq @ 4.5 K Refrigerator per sector to provide all cooling capacity for one LHC sector

C: 4.5 K; 3.0 bar

B: 3.5 K; 15 mbar

D: 20 K; 1.3 bar

F: 75 K; 18.0 bar

E: 50 K; 18.5 bar

Warm recovery

WarmCompressorStation

4.5 KRefrigerator

ColdBox

1.8 KRefrigerationUnit

WarmCompressorStation

ColdCompressorBox

Interconnection Box

U.Wagner/ CERN

SC Magnets

HTS Current Leads

Beam Screen

Thermal Shield

Large-capacity helium refrigeration – FCC week 2015

ITER architecture

E.Monneret/ITER

One He plant for ITER heat loads < 80 KSC magnets, HTS current leads, cryopumps

One 80 K loop for ITER heat loads > 80 KThermal shields, precooling of He plant

Large-capacity helium refrigeration – FCC week 2015

FCC-hh cryoplant architecture

Cryoplant architecture for FCC ?

LHC-like design = One cryoplant per sector for all cooling needs of the FCC machine• SC magnets & RF cavities, HTS current leads, beam screens, thermal shields

ITER-like design = Two cryoplants (4.5K & 40K) per sector for separated cooling needs of the FCC machine• 4.5K plant for SC magnets & RF cavities• 40K plant for beam screens, thermal shields , HTS current leads, He plant

precooling (see TU-Dresden presentation)

Low number of plants & interfacesLimited efficiency optimisation

Possible efficiency optimisationLarge number of plants & interfaces

Large-capacity helium refrigeration – FCC week 201517

Contents

Introduction

FCC requirements & constraints

From the state-of-the-art towards FCC Refrigeration scheme & components Cooling capacity Cooling architecture

Conclusion

Large-capacity helium refrigeration – FCC week 2015

Conclusion

Large helium refrigeration capacity required for FCC Towards 1 MW eq.@ 4.5K for FCC-hh / 100 km @ 1.8 K

Mainly dynamic heat loads around 50 K ~50% of total kW eq @ 4.5 K heat loads

On-going works to define reference solutions for FCC based on : FCC cryogenic requirements and constraints, Review of the State-Of-The-Art and present limitations, Study of new architectures and technologies with industries and partners (*).

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(*) CEA study with strong interaction with CERN and TU-Dresden as well as major cryoplant industries

Large-capacity helium refrigeration – FCC week 2015

Thanks you for your attention

Any question ?

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