ESR2 Process Cycle Design ESR2 Preliminary Design Review June 19, 2019

Presentation Outline BACKGROUND EXISTING EQUIPMENT AND CAPACITY MODIFIED CAPACITY PROCESS CYCLES CONSIDERED FINAL DESIGN CYCLE SUMMARY

Background ESR1 Complex: 3 x Warm Compressors 1.5 kW Cold Box Valve Box - Experimental Hall Distribution Cans - CHL ESR TL Bayonet(s) - GHe Supply from CHL - Existing LHe Dewar Proposed ESR2 Complex: 4 x Warm Compressors 4.0 kW Cold Box CBX Distribution Recovery System GHe Storage Tank(s) LN Storage LHe Dewar CHL ESR TL ESR2 ESR1

ASST-A Cryogenic System History: Originally procured in 1992 by SSCL Magnet Testing Lab for Magnet String Test Preliminary concept of Floating pressure process (Ganni Cycle) Developed and successfully used for the variable capacity operation to recover after the magnet string quench test Never been used after SSCL cancellation Majority of the components already present at JLab

Existing Equipment and Capacity Features Compressor System (Sullair) 2 x 186 kW (250 hp) 1st stage 2 x 522 kW (700 hp) 2nd stage Four turbo-expanders Eleven heat exchangers Grouped into six brazed aluminium cores Two 80 K beds, One 20 K bed LN Consumption: 125 gph (Design, Max. Liquefaction) 70 gph (Design, ½ Capacity R+L) 4.0 kW 4.5 K cold box Capacity (tested) 4.5 K Refrigeration: 2.0 kW AND 4.5 K Liquefaction: 20 g/s OR 4.5 K Refrigeration: 4.0 kW 4.5 K Liquefaction: 37 g/s (Design)

ESR2 Future Loads 12 GeV Loads: Expected 12 GeV Era Cryogenic Loads (Cumulative) Fall 2017 – Present (Up to FY 2019)1 4.5 K Refrigeration: 0.8 kW 4.5 K Liquefaction (Lead Cooling): 7.54 g/s (0.75 kW Equivalent 4.5 K Refrigeration) 15 K Target: 1.0 kW (0.35 kW Equivalent 4.5 K Refrigeration) Total: 1.90 kW @ 4.5 K _____________________________________________________________________________________ Expected (?) Loads (2020)1 4.5 K Refrigeration: 0.80 kW 15 K Target: 2.0 kW (0.70 kW Equivalent 4.5 K Refrigeration) Total: 2.25 kW @ 4.5 K Expected MOELLER Load (2023-2026)1 4.5 K Refrigeration: 0.48 kW 4.5 K Liquefaction (Lead Cooling): 4.94 g/s (0.50 kW Equivalent 4.5 K Refrigeration) 15 K Target: 6.00 kW (2.0 kW Equivalent 4.5 K Refrigeration) Total: 3.0 kW @ 4.5 K 1Per ESR 2 Distribution System and Support for Moeller Experiment (D. Kashy, Dated 12 September, 2018)

Process Cycles Considered 15K Target load broken down into 5kW for MOELLER and 1kW for other experiments Turbine and HX parameters from previous testing of cold box Developed process model for seven supply points for the 15K load and 4 return points

Process Cycles Considered Initial modeling showed that return to point (2) required higher CHL support flow due to return conditions being warmer than injection point Return conditions set to point (1) on either LP or MP

Comparison of Various Target Supply and Return Conditions   "35K" LP "35K" MP MOELLER Supply Hall C supply CHL support flow (g/s) Cost for 2 years Available DP MOELLER (Atm) Available DP Hall C (Atm) T2 outlet w/ new moller transferline T2 outlet $1,170,000 1.52 15K HP $1,190,000 14.9 $1,160,000 13.5 T3 inlet HP $1,250,000 1.5 $1,230,000 2 $1,750,000 $1,570,000 13.2 $1,770,000 $1,590,000 T4 inlet HP $1,780,000 $1,620,000 5 $2,140,000 $1,920,000 4 $2,060,000 $1,930,000 $2,070,000 $1,950,000 T3 outlet , 4 Atm 3 2.9 $1,810,000 1.1 $1,960,000 CHL 8 $2,400,000 1.9 $2,310,000 1.43 T3 outlet , 5 Atm 8.5 $2,460,000 3.9 9 $2,430,000 2.43 $2,380,000 $2,280,000 1.4 T4 outlet 12 $2,780,000 1.33 4K direct from ESR 14.5 Discuss how lower temperature levels require more CHL support flow and are more costly. Taking HP flow requires more support flow than flow after turbine Supply Point Temperature (K) Pressure (atm) MOELLER flow (g/s) T2 outlet (green) 13 2.5-3.5 127 15K HP (blue) 14 16 122 T3 inlet HP (red) 12 84 T3 outlet , 4 Atm 8 4-5 71 T4 inlet HP (orange) 60 T4 outlet 6 53 4K direct from ESR 4.5 4 47

Final Design Cycle MOELLER supplied from T3 inlet HP (red), other halls supplied from 15K HP (blue) All return goes to (1) MP dP of ~13 atm for the halls and MOELLER -No modifications to transfer line required Only 1 first stage compressor required ~5 g/s CHL support flow

T-S Diagram of Design Cycle

Summary Design of the upcoming ESR2 plant based off of existing cold box and compressors and upcoming loads from MOELLER experiment Modelled ESR2 cold box to find the best way of supplying target flow for MOELLER and halls After discussions with Physics, chose how to supply target flow without modifying existing Hall transfer lines Will use the values for this mode in sizing other piping for the plant Other presentations will discuss what modifications need to be made to run in this configuration

Questions?