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

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

3. 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

4. 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

5. 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)

6. 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: kW
4.5 K Liquefaction (Lead Cooling): g/s (0.75 kW Equivalent 4.5 K Refrigeration)
15 K Target: kW (0.35 kW Equivalent 4.5 K Refrigeration)
Total: K
_____________________________________________________________________________________
Expected (?) Loads (2020)1
4.5 K Refrigeration: kW
15 K Target: kW (0.70 kW Equivalent 4.5 K Refrigeration)
Total: K
Expected MOELLER Load ( )1
4.5 K Refrigeration: kW
4.5 K Liquefaction (Lead Cooling): g/s (0.50 kW Equivalent 4.5 K Refrigeration)
15 K Target: kW (2.0 kW Equivalent 4.5 K Refrigeration)
Total: K
1Per ESR 2 Distribution System and Support for Moeller Experiment (D. Kashy, Dated 12 September, 2018)

7. 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

8. 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

9. 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
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

10. 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

11. T-S Diagram of Design Cycle

12. 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

13. Questions?