©2003 Qi3 Ltd 23.10.03Superconductivity UK Cryogenic Refrigeration Costs and Prospects K Nathan...

23.10.03 Superconductivity UK ©2003 Qi3 Ltd

Cryogenic RefrigerationCosts and Prospects

K Nathan HillManaging Director, [email protected]


Contents

• The cryogenic challenge• Where are the manufacturers coming from?• Cryocooler development targets• Who’s active in the area?• Concluding remarks


The cryogenic challenge

U.S. Patent Office; “Apparatus and Method for Detecting Cancer in

Tissue”; Raymond Damadian 1974A modern MRI magnet, 2003



• October 6 2003: A respected physicist has been awarded a Nobel Prize for his continuing research into one of the most important breakthroughs in medical science.

• Sir Peter Mansfield —the first Nottingham academic to receive such an accolade — has been awarded the 2003 Nobel Prize in Medicine for his work in the application of magnetic resonance imaging (MRI) to medical diagnosis - a breakthrough now recognized to be comparable with the discovery of x-rays.

• The award has been bestowed upon Sir Peter jointly with US researcher Professor Paul Lauterbur, also an international leader in the field of MRI.

• Many thousands of superconducting MRI systems are installed around the world



• Cryocoolers are in multiple use• MRI shield cooling• Gas liquefaction• Device cooling• Semiconductor applications• Research cryostats

• So why not in HTS?



• Funding for cooler development has come from• Particle physics• Astronomy and space science• IR device cooling for defence applications• Scientific research• Detector cooling for industrial analysis

• Only one of these is pursued for truly commercial purposes (and it’s hardly a vast market)



• Factors affecting cooling requirements• Operating temperature• Electric current dissipation (DC/AC)• Leaks from the outside world• Geometrical proportions

• Applications vary hugely, thus leading to requirement for many cooler types

• Several immature technologies are available• Not enough demand “right now” for any

single application• Stalemate


Patents

Cryogenic Cooling System patents filed in the U.S.

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File

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Cryogenic Cooling System Patents

Cryocooler


Cryocooler development targets

• Cryogenic systems providing 100-1000 Watts of cooling power at 65-80K are required if devices utilizing high-temperature superconductors (HTS) are to become a part of the national electric power delivery and utilisation system

Now Required20% Carnot efficiency for 80K cooler

>30% Carnot

$100-150/Watt <$25/Watt

High reliability (present systems depend heavily on redundancy)

Operating availability >99.8% by 2007



• Primary targets

Goals Objectives OutcomesIncreased efficiency (present nominal 20%)

>30% Carnot by 2005 Reduced operating expenses and market viability

Lower capital cost (present nominal $100/Watt)

<$25/Watt by 2007 with cryogenic components costing <10% of the system

Reduced capital cost and market viability

High reliability (present systems depend heavily on redundancy)

Operating availability >99.8% by 2007

Mean time between failures of operating cryogenic system >30 years using redundancy and increased component reliability

Source: Cryogenic Roadmap, U.S. Department of Energy Superconductivity Program For Electric Systems, Executive Summary June 2001)



• Secondary targetsGoals Objectives Outcomes

Size System and cryogenics 50% smaller by 2007

Utilisation of full HTS systems with increased power density

Variable cooling capacity

Cryogenics follow load using storage capacity or optimised variable speed drive techniques on HTS system by 2009

Significantly reduced penaly for operationg costs

Historic price decline with volume and experience

Reduced costs as HTS systems penetrate the market

Commercial units at reasonable cost

Transparency Customer acceptability by 2007 Low awareness of cryogenic system

Minimal disruption Customer acceptability by 2007 No interference of normal operations

Maintainability Customer acceptability by 2007 Average technicians can operate the system

Soft failure mode Customer acceptability by 2007 Cryosystem failures allow alternate operational schemes

Source: Cryogenic Roadmap, U.S. Department of Energy Superconductivity Program For Electric Systems, Executive Summary June 2001)



• The “Cryogenic Assessment report” recommended that:• Standardization of power devices and concomitant

cryocoolers can result in lower costs through higher volume production and product reliability

• Minimize cooled section moving parts in cryocooler designs, e.g., Stirling pulse tube

• Development of 1-2 kW cryocoolers (at 70-80K) able to operate at 30% of Carnot and cost $25/W

• Increase end-user (utility and industrial managers) familiarity and comfort with cryogenic system operations, maintenance and safety issues.

Source: Gouge, M.J., et al.; “Final Draft: Cryogenics Assessment Report”, Oak Ridge National Labs & University of Wisconsin; April 9. 2002.



• Four standard systems proposed in the new DOE cryogenics initiative:

All with oil free compressors >25% Carnot efficiency and $60 per Watt at 65K

Programme

Target Application e.g. companies

HTS-1 200W @ 25-40K

BSCCO motor generators

Programme not commenced

HTS-2 300W @ 50-65K

YBCO motor generators

Cryomech

HTS-3 300W @ 65-80K

YBCO transformers Qdrive

HTS-4 1500W @ 65-80K

Cables Qdrive/Praxair


100-1000W @ 65-80K

Component BSCCOHeat load, Top

YBCOHeat load, Top

Cable 3-5 kW/km at 70-80 K 3-5 kW/km at 70-80 K

Transformer(5-100 MVA)

50-100’s watt at 25-45 or 65-80 K

50-100’s watt at 60-80 K

Motors(1-10,000 HP)

50-200 watt at 25-40 K 50-200 watt at 50-65 K

Generators(10-500+ MWe)

100-500 watt at 25-40 K 100-500 watt at 50-65 K

FCLs 30 watt at 30 K750 watt at 80 K

~ 1000 watt at 50-80 K

SMES, magnetic separation, MRI

10’s of watts at 20-30 K 10-100 watt at 50-65 K

Source: MJ Gouge talk at 2002 DOE wire workshop 22.1.02



Application Current cryogenics

Future cryogenics

HTS industrial motor Reverse Brayton, G-M single-stage cryocoolers

G-M single-stage cryocoolers, pulse tube cryocooler

HTS generator N/A G-M single-stage cryocoolers, pulse tube cryocooler

HTS transformer G-M 2-stage cryocooler, LN with sub-cooling

G-M single-stage and pulse tube cryocoolers, LN with sub-cooling

HTS cable Open-cycle LN with sub-cooling, Reverse Brayton

Reverse Brayton,Claude, large capacity cryocooler

Fault current limiter G-M single-stage cryocoolers

TBD

SMES, magnetic separation, MRI, flywheel bearings

G-M 2-stage cryocooler G-M single-stage cryocoolers, pulse tube cryocooler


Costs

Source: Mulholland et al, DOE June 2003


Market demand

Source: Mulholland et al, DOE June 2003


The market

Projected market demand for cryogenic refrigerators ($k)

Year Motors Transformers

Generators

Cables Total

2007 58 58

2009 2 83 249 333

2011 7 294 849 1151

2013 32 1081 3319 4432

2015 142 49 3331 11320 14842

2019 1868 1231 10861 54100 68060

2021 4012 6187 11953 72149 94301

2023 5533 22114 11902 77709 117258

2025 6125 37128 11729 77546 132529

Source: Analysis of Future Prices and Markets For High temperature Superconductors (Mulholland et al, June 2003)


And do I believe market forecasts?


Alliances

Date (start to end)

Purpose Cost Country Academic/Federal Company

2003-2006 Develop more advanced manufacturing processes

and higher performance forthe commercial application of new type of high-temp.

superconductor wire.

$2.5m US DOE’s National labs:Argonne, Los Alamos

and Oak Ridge

American Superconductor

2004 Electricity transmission grid reliability system to

owner of power gridIn Orkney Islands

? US Scottish and Southern

Energy

American Superconductor

2003- A 350-meter HTS cable that will be installed in the distribution system operated by Niagara

Mohawk, a National Grid Company,

$26m US IGC, Super Power, Sumitomo Electric Industries, BOC and

Nexans

2003-2006 Develop a new HTS faultcurrent limiter to protect

utility grids from damagingsurges in current.

$6m US DOE’s National labs:Argonne, Los Alamos

and Oak Ridge

IGC, Super Power, Sumitomo Electric Industries, BOC and

Nexans

2003-2006 Develop a new HTS faultcurrent limiter for shipboard

service.

£0.7m UK IRC Cambridge Rolls-Royce plc, VA Tech, Diboride Conductors,

[Space-Cryomagnetics]

2003-2009 To develop advancedcryogenic systems to

Support new HTS.

$8m US DOE’s Oak Ridge Lab.

Praxair and Cryomech, Inc.


The companies

• Stirling BV• Sumitomo• Qdrive / Praxair• Air Liquide• Daiken• APD• Advanced Research Systems (ARS)• CTI• Suzuki Shogun• Aisan Seiki• Ricor• …• This doesn’t look quite so complicated when you focus on

power applications


The companiesSpecifications For Selected Large Cryocoolers

Product Type Input Power

Weight

Cooling Capacity COP

Cryomech AL200 G-M 5 KW 160 kg 180 W @ 80 K120 W @ 60 K

10%9.6%

Cryomech AL300G-M

7.2 KW 118.8 kg

200 W @ 50K250 W @ 60K320 W @ 80K

_

Cryomech AL330G-M

7.2 KW 118.8 kg

100 W @ 30 K190 W @ 50 K280 W @ 80 K

12%

CTI M 1050 I Stage GM 5.5 KW 126 kg 100 W @ 80 K 5%

APD DE-108 G-M 4.5 KW 100 kg 100 W @ 77 K 6%

Q drive 2S241K Stirling-type Pulse Tube Coolers

5.3 KW 198 kg 200 W @ 77 K _


13 KW 455 kg 500 W @ 77 K _


24 kw 590 kg 1000 W @ 77 K _

Stirling C&R LPC-01

Stirling 12 KW 850 kg 500 W @ 65 K 15%


The companies

Product Type Input Power

Weight Cooling Capacity COP

Stirling C&R LPC-01

Stirling 12 KW 850 kg 500 W @ 65 K 15%

Stirling C&R LPC-02

Stirling 25 KW 1500 kg 1300 W @ 65 K 18%

Stirling C&R LPC-04

Stirling 60 KW 3750 kg 2800 W @ 65 K 17%

Stirling C&R LPC-08

Stirling 135 KW 7500 kg 5800 W @ 65 K 16%

Stirling C&R SPC-01 Stirling

11 KW7.6 KW5KW 600 kg

1050 W @ 80 K2,250 W @ 150 K3,450 W @ 250 K

26%29%13%

Stirling C&R SPC-04 Stirling

45 KW31 KW20 KW 1255 kg

4,500 W @ 80 K9,500 W @ 150 K14,500 W @ 250 k

27%31%15%

Aisin Seki Model SC

LinearStirling 14 KW _ 1000 W @ 77 K 20%

Aisin Seki Model SS

LinearStirling 6 KW _ 400 W @ 77 K 20%

Specifications For Selected Large Cryocoolers Contd.

Source: Marty Nisenoff


Cryomech

• Cryomech, Inc. manufactures single and double-stage Gifford-McMahon and Pulse Tube cryorefrigerators.

• They have developed the AL300 and the AL330, and claim that they have the highest efficiency and cooling capacity to date of any available GM cryocooler at temperatures from 20 to 60K.

• Current research includes the development of a new generation of Stirling-type (valveless) pulse tube cryocoolers for 60 to 80K and higher efficiency Gifford-McMahon cryocoolers for 20 to 40K

Source: SpaceDaily 29.7.2003 Image copyright and courtesy Cryomech, Inc.

AL300 ColdHead-blue


Stirling Cryogenics

• Manufacture Stirling cycle coolers• LPC 1-8 (1 stage): 500W – 5.8kW

@ 65K (4 models)• GPC 1-4 (2 stage): 40-160W @

20K, 100-400W @ 80K (2 models)

• Research ongoing in Stirling type Pulse Tube Coolers

• Recent Siemens project• Siemens is testing High

Temperature Superconducting Transformers for trains. These transformers operate at a temperature of 65K.

• Based on the SPC-4 cryogenerator, Stirling developed a cooling system using subcooled pressurized liquid nitrogen as a coolant. By using subcooled liquid nitrogen, no evaporation occurs and thus an optimal cooling of the transformer is established.

Image copyright and courtesy Stirling Cryogenics


Qdrive

• Develops acoustic coolers (Stirling-type Pulse Tube Coolers)

• Linear drive is claimed to have benefits for reliability, eliminating lubricants and cold moving parts

• Licensed >1kW systems to Praxair to access market

• Praxair recently introduced a LN2 liquefier based on an “HTS3” 200W cooler for around $70k

The first 200W@77Kmachine for HTS-3 (the large

can on top is just vacuum, the drive is

on the bottom)

The first large unit (1200 watts

at 130K, for LNG, on a

20kW drive), the basis for HTS-4

Images copyright and courtesy CFIC-Qdrive, 2003


Helix – CTI Cryogenics

• See the market for vacuum applications as more immediate and growing

• Recently acquired Granville-Phillips to provide vacuum measurement offering

• Some cold heads are used for HTS applications, but no focus in this area


Other companies

• APD• Daiken?• Ricor• Hymatic• …


There are still cooler choices

Pulse tubes have their disadvantages:

e.g. Cryomech• GM-PTC 60W @ 77K has 3.8kW input• GM 60W @ 77K has 2.2kW input• They expect to achieve 85% of GM efficiency

e.g. Stirling Cryogenics• Early Stirling PTC has 50% of the efficiency of

a regular Stirling cryocooler


Liquid cryogens

• Systems can still use:• Liquid cryogens• Liquid cryogens with recondensors• Liquid cryogens with shield coolers• Liquid cryogens with miniature liquefiers

• LN2, subcooled LN2 @ 63.5K • Subcooled liquid air @ 57K and other LOX/LN2

mixtures @ 50.5K, all at 1 bar pressure• And what about Neon and LOX?Source: Prof. Ralph Scurlock, Southampton


Concluding thoughts

• The cryogenics community needs an incentive to The cryogenics community needs an incentive to focus on the subjectfocus on the subject• identify desired common design for high capacity identify desired common design for high capacity

refrigerationrefrigeration• fund several development & demo projects including both fund several development & demo projects including both

improvement of today’s technology and acoustic improvement of today’s technology and acoustic technologytechnology

• The HTS Community needs an incentive to focus onThe HTS Community needs an incentive to focus on• AC lossAC loss• TerminationsTerminations

• The USA is now responding to this challenge – but The USA is now responding to this challenge – but where’s Europe?where’s Europe?


Concluding thoughts

• Future industry consolidation• Are we really taking cryogenics seriously?• What about the use of liquid cryogens in

conjunction with cryocoolers?• And what about new designs of cryostat?• Where are the Europeans?• Is there an opportunity in the 20-50K

region?

©2003 Qi3 Ltd 23.10.03Superconductivity UK Cryogenic Refrigeration Costs and Prospects K Nathan...

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