Cryogenic Refrigeration
Costs and Prospects
K Nathan Hill
Managing Director, Qi3
nathan.hill@qi3.co.uk
23.10.03
Superconductivity UK
©2003 Qi3 Ltd
Contents
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The cryogenic challenge
Where are the manufacturers coming from?
Cryocooler development targets
Who’s active in the area?
Concluding remarks
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The cryogenic challenge
U.S. Patent Office; “Apparatus and Method for Detecting Cancer in
A modern MRI magnet, 2003
Tissue”; Raymond Damadian 1974
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The cryogenic challenge
• 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
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The cryogenic challenge
• Cryocoolers are in multiple use
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MRI shield cooling
Gas liquefaction
Device cooling
Semiconductor applications
Research cryostats
• So why not in HTS?
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The cryogenic challenge
• Funding for cooler development has come from
•
•
•
•
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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)
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The cryogenic challenge
• Factors affecting cooling requirements
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•
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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
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Patents
Cryogenic Cooling System patents filed in the U.S.
18
Cryogenic Cooling System Patents
16
Cryocooler
14
12
10
8
6
4
2
20
02
20
00
19
98
19
96
19
94
19
92
19
90
19
88
19
86
19
84
19
82
19
80
19
78
19
76
0
19
74
Number of Patents Filed
20
Year
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Cryocooler development targets
• Cryogenic systems providing 100-1000 Watts of cooling
power at 65-80K are required if devices utilizing hightemperature superconductors (HTS) are to become a
part of the national electric power delivery and
utilisation system
Now
Required
20% 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
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Cryocooler development targets
• Primary targets
Goals
Objectives
Outcomes
Increased 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)
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Cryocooler development targets
• Secondary targets
Goals
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)
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The cryogenic challenge
• 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.
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The cryogenic challenge
• Four standard systems proposed in the new DOE cryogenics initiative:
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
All with oil free compressors >25% Carnot efficiency and $60 per Watt at 65K
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100-1000W @ 65-80K
Component
Cable
BSCCO
Heat load, Top
3-5 kW/km at 70-80 K
YBCO
Heat load, Top
3-5 kW/km at 70-80 K
Transformer
(5-100 MVA)
50-100’s watt at 25-45 or
65-80 K
50-100’s watt at 60-80 K
Motors
(1-10,000 HP)
50-200 watt at 25-40 K
50-200 watt at 50-65 K
Generators
(10-500+ MWe)
100-500 watt at 25-40 K
100-500 watt at 50-65 K
FCLs
30 watt at 30 K
750 watt at 80 K
SMES, magnetic
separation, MRI
10’s of watts at 20-30 K
~ 1000 watt at 50-80 K
10-100 watt at 50-65 K
Source: MJ Gouge talk at 2002 DOE wire workshop 22.1.02
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The cryogenic challenge
Application
Current cryogenics Future cryogenics
HTS industrial motor
Reverse Brayton, G-M
single-stage cryocoolers
G-M single-stage cryocoolers,
pulse tube cryocooler
HTS generator
N/A
G-M single-stage cryocoolers,
pulse tube cryocooler
HTS transformer
G-M 2-stage cryocooler, LN
with sub-cooling
G-M single-stage and pulse
tube cryocoolers, LN with subcooling
HTS cable
Open-cycle LN with subcooling, Reverse Brayton
Reverse Brayton,
Claude, large capacity
cryocooler
Fault current limiter
G-M single-stage
cryocoolers
TBD
SMES, magnetic separation,
MRI, flywheel bearings
G-M 2-stage cryocooler
G-M single-stage cryocoolers,
pulse tube cryocooler
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Costs
Source: Mulholland et al, DOE June 2003
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Costs
Source: Mulholland et al, DOE June 2003
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Market demand
Source: Mulholland et al, DOE June 2003
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The market
Projected market demand for cryogenic refrigerators ($k)
Year
Motors
Transformers
Generators Cables
2007
Total
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)
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And do I believe market forecasts?
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Alliances
Date
(start to end)
Purpose
Cost
Country
Academic/Federal
Company
2003-2006
Develop more advanced
manufacturing processes
and higher performance for
the 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 grid
In 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
2003-2006
Develop a new HTS fault
current limiter to protect
utility grids from damaging
surges in current.
$6m
US
DOE’s National labs:
Argonne, Los Alamos
and Oak Ridge
2003-2006
Develop a new HTS fault
current limiter for shipboard
service.
£0.7m
UK
IRC Cambridge
2003-2009
To develop advanced
cryogenic systems to
Support new HTS.
$8m
US
DOE’s Oak Ridge Lab.
23.10.03
IGC, Super Power, Sumitomo
Electric Industries, BOC and
Nexans
Superconductivity UK
IGC, Super Power, Sumitomo
Electric Industries, BOC and
Nexans
Rolls-Royce plc, VA Tech,
Diboride Conductors,
[Space-Cryomagnetics]
Praxair and Cryomech, Inc.
©2003 Qi3 Ltd
The companies
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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
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The companies
Specifications For Selected Large Cryocoolers
Product
Cryomech AL200
Type
G-M
Cryomech AL300
Input
Power
Weight
COP
5 KW
160 kg
180 W @ 80 K
120 W @ 60 K
10%
9.6%
7.2 KW
118.8 kg
200 W @ 50K
250 W @ 60K
320 W @ 80K
_
7.2 KW
118.8 kg
100 W @ 30 K
190 W @ 50 K
280 W @ 80 K
12%
G-M
Cryomech AL330
Cooling Capacity
G-M
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
_
Q drive 2S297K
Stirling-type Pulse
Tube Coolers
13 KW
455 kg
500 W @ 77 K
_
Q drive 2S362K
Stirling-type Pulse
Tube Coolers
24 kw
590 kg
1000 W @ 77 K
_
Stirling C&R LPC-01
Stirling
12 KW
850 kg
500 W @ 65 K
15%
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The companies
Specifications For Selected Large Cryocoolers Contd.
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
11 KW
7.6 KW
5KW
600 kg
1050 W @ 80 K
2,250 W @ 150 K
3,450 W @ 250 K
26%
29%
13%
1255 kg
4,500 W @ 80 K
9,500 W @ 150 K
14,500 W @ 250 k
27%
31%
15%
Stirling C&R SPC-01
Stirling C&R SPC-04
Stirling
Aisin Seki Model SC
Aisin Seki Model SS
45 KW
31 KW
20 KW
Linear
Stirling
14 KW
_
1000 W @ 77 K
20%
Linear
Stirling
6 KW
_
400 W @ 77 K
20%
Source: Marty Nisenoff
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Cryomech
• Cryomech, Inc. manufactures single and doublestage 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
AL300 ColdHead-blue
Source: SpaceDaily 29.7.2003
Image copyright and courtesy Cryomech, Inc.
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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
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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
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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
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Other companies
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APD
Daiken?
Ricor
Hymatic
…
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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
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Liquid cryogens
• Systems can still use:
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Liquid
Liquid
Liquid
Liquid
cryogens
cryogens with recondensors
cryogens with shield coolers
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
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Concluding thoughts
• The cryogenics community needs an incentive to focus on
the subject
• identify desired common design for high capacity refrigeration
• fund several development & demo projects including both
improvement of today’s technology and acoustic technology
• The HTS Community needs an incentive to focus on
• AC loss
• Terminations
• The USA is now responding to this challenge – but where’s
Europe?
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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?
23.10.03
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