ESR 2 Process Cycle Design ESR 2 Preliminary

ESR 2 Process Cycle Design ESR 2 Preliminary Design Review June 19, 2019

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

Background ESR 1 Complex: 3 x Warm Compressors 1. 5 k. W Cold Box Valve Box - Experimental Hall Distribution Cans - CHL ESR TL Bayonet(s) - GHe Supply from CHL - Existing LHe Dewar SR CH L E TL ESR 2 ESR 1 Proposed ESR 2 Complex: 4 x Warm Compressors 4. 0 k. W Cold Box CBX Distribution Recovery System GHe Storage Tank(s) LN Storage LHe Dewar

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 k. W (250 hp) 1 st stage 2 x 522 k. W (700 hp) 2 nd stage § Four turbo-expanders § Eleven heat exchangers Grouped into six brazed aluminium cores § Two 80 K beds, One 20 K bed § 4. 0 k. W 4. 5 K cold box Capacity (tested) 4. 5 K Refrigeration: 2. 0 k. W AND 4. 5 K Liquefaction: 20 g/s OR 4. 5 K Refrigeration: 4. 0 k. W OR 4. 5 K Liquefaction: 37 g/s (Design) § LN Consumption: 125 gph (Design, Max. Liquefaction) 70 gph (Design, ½ Capacity R+L)

ESR 2 Future Loads 12 Ge. V Loads: Expected 12 Ge. V Era Cryogenic Loads (Cumulative) Fall 2017 – Present (Up to FY 2019)1 4. 5 K Refrigeration: 4. 5 K Liquefaction (Lead Cooling): 15 K Target: 0. 8 k. W 7. 54 g/s (0. 75 k. W Equivalent 4. 5 K Refrigeration) 1. 0 k. W (0. 35 k. W Equivalent 4. 5 K Refrigeration) Total: 1. 90 k. W @ 4. 5 K ___________________________________________ Expected (? ) Loads (2020)1 4. 5 K Refrigeration: 4. 5 K Liquefaction (Lead Cooling): 15 K Target: 0. 80 k. W 7. 54 g/s (0. 75 k. W Equivalent 4. 5 K Refrigeration) 2. 0 k. W (0. 70 k. W Equivalent 4. 5 K Refrigeration) Total: 2. 25 k. W @ 4. 5 K ___________________________________________ Expected MOELLER Load (2023 -2026)1 4. 5 K Refrigeration: 4. 5 K Liquefaction (Lead Cooling): 15 K Target: 0. 48 k. W 4. 94 g/s (0. 50 k. W Equivalent 4. 5 K Refrigeration) 6. 00 k. W (2. 0 k. W Equivalent 4. 5 K Refrigeration) Total: 3. 0 k. W @ 4. 5 K 1 Per ESR 2 Distribution System and Support for Moeller Experiment (D. Kashy, Dated 12 September, 2018)

Process Cycles Considered • 15 K Target load broken down into 5 k. W for MOELLER and 1 k. W for other experiments • Turbine and HX parameters from previous testing of cold box • Developed process model for seven supply points for the 15 K 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 Return "35 K" LP "35 K" MP MOELLER Supply Hall C supply CHL support flow (g/s) Cost for 2 years Available DP CHL support Available DP MOELLER (Atm) Hall C (Atm) flow (g/s) Cost for 2 years MOELLER (Atm) Hall C (Atm) T 2 outlet w/ new moller transferline T 2 outlet 0 $1, 170, 000 1. 52 T 2 outlet w/ new moller transferline 15 K HP 0 $1, 190, 000 1. 52 14. 9 0 $1, 160, 000 T 2 outlet w/ new moller transferline T 3 inlet HP 0 $1, 250, 000 1. 5 14. 9 0 15 K HP 2 $1, 750, 000 14. 9 2 15 K HP T 3 inlet HP 2 $1, 770, 000 14. 9 15 K HP T 4 inlet HP 2 $1, 780, 000 14. 9 T 3 inlet HP 15 K HP 5 $2, 140, 000 14. 9 T 3 inlet HP 4 $2, 060, 000 14. 9 1. 52 13. 5 $1, 230, 000 1. 5 13. 5 $1, 570, 000 13. 2 2 $1, 590, 000 13. 2 2 $1, 620, 000 13. 2 14. 9 5 $1, 920, 000 13. 2 14. 9 4 $1, 930, 000 13. 2 T 3 inlet HP T 4 inlet HP 4 $2, 070, 000 14. 9 4 $1, 950, 000 13. 2 T 3 outlet , 4 Atm 15 K HP 3 $1, 930, 000 2. 9 14. 9 3 $1, 810, 000 1. 1 13. 2 T 3 outlet , 4 Atm T 3 inlet HP 3 $1, 960, 000 2. 9 14. 9 3 $1, 780, 000 1. 1 13. 2 T 3 outlet , 4 Atm CHL 8 $2, 400, 000 2. 9 1. 9 8 $2, 310, 000 1. 43 1. 9 T 3 outlet , 5 Atm CHL 8. 5 $2, 460, 000 3. 9 1. 9 9 $2, 430, 000 2. 43 1. 9 T 3 outlet , 4 Atm T 4 inlet HP 8 $2, 380, 000 2. 9 14. 9 8 $2, 280, 000 1. 4 13. 2 12 $2, 780, 000 1. 33 2. 9 T 4 outlet 4 K direct from ESR Supply Point T 2 outlet (green) 15 K HP (blue) T 3 inlet HP (red) T 3 outlet , 4 Atm T 4 inlet HP (orange) T 4 outlet 4 K direct from ESR Temperature (K) 13 14 12 8 8 6 4. 5 Pressure (atm) 2. 5 -3. 5 16 16 4 -5 4 14. 5 MOELLER flow (g/s) 127 122 84 71 60 53 47

Final Design Cycle Return "35 K" LP "35 K" MP MOELLER Supply Hall C supply CHL support flow (g/s) Cost for 2 years Available DP CHL support Available DP MOELLER (Atm) Hall C (Atm) flow (g/s) Cost for 2 years MOELLER (Atm) Hall C (Atm) T 2 outlet w/ new moller transferline T 2 outlet 0 $1, 170, 000 1. 52 T 2 outlet w/ new moller transferline 15 K HP 0 $1, 190, 000 1. 52 14. 9 0 $1, 160, 000 T 2 outlet w/ new moller transferline T 3 inlet HP 0 $1, 250, 000 1. 5 14. 9 0 15 K HP 2 $1, 750, 000 14. 9 2 15 K HP T 3 inlet HP 2 $1, 770, 000 14. 9 15 K HP T 4 inlet HP 2 $1, 780, 000 14. 9 T 3 inlet HP 15 K HP 5 $2, 140, 000 14. 9 T 3 inlet HP 4 $2, 060, 000 14. 9 1. 52 13. 5 $1, 230, 000 1. 5 13. 5 $1, 570, 000 13. 2 2 $1, 590, 000 13. 2 2 $1, 620, 000 13. 2 14. 9 5 $1, 920, 000 13. 2 14. 9 4 $1, 930, 000 13. 2 T 3 inlet HP T 4 inlet HP 4 $2, 070, 000 14. 9 4 $1, 950, 000 13. 2 T 3 outlet , 4 Atm 15 K HP 3 $1, 930, 000 2. 9 14. 9 3 $1, 810, 000 1. 1 13. 2 T 3 outlet , 4 Atm T 3 inlet HP 3 $1, 960, 000 2. 9 14. 9 3 $1, 780, 000 1. 1 13. 2 T 3 outlet , 4 Atm CHL 8 $2, 400, 000 2. 9 1. 9 8 $2, 310, 000 1. 43 1. 9 T 3 outlet , 5 Atm CHL 8. 5 $2, 460, 000 3. 9 1. 9 9 $2, 430, 000 2. 43 1. 9 T 3 outlet , 4 Atm T 4 inlet HP 8 $2, 380, 000 2. 9 14. 9 8 $2, 280, 000 1. 4 13. 2 12 $2, 780, 000 1. 33 2. 9 T 4 outlet 4 K direct from ESR Supply Point T 2 outlet (green) 15 K HP (blue) T 3 inlet HP (red) T 3 outlet , 4 Atm T 4 inlet HP (orange) T 4 outlet 4 K direct from ESR Temperature (K) 13 14 12 8 8 6 4. 5 Pressure (atm) 2. 5 -3. 5 16 16 4 -5 4 14. 5 MOELLER flow (g/s) 127 122 84 71 60 53 47 • MOELLER supply from T 3 HP inlet, Hall supply from 15 K HP • Both return to MP header • Chosen for lower MOELLER supply flow while minimizing electrical costs and CHL support flow and having 13 atm d. P

T-S Diagram of Design Cycle

Summary • Design of the upcoming ESR 2 plant based off of existing cold box and compressors and upcoming loads from MOELLER experiment • Modelled ESR 2 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?