Cryogenic Refrigeration Costs and Prospects K Nathan Hill Managing Director, Qi3 nathan.hill@qi3.co.uk 23.10.03 Superconductivity UK

Contents The cryogenic challenge Where are the manufacturers coming from? Cryocooler development targets Who’s active in the area? Concluding remarks 23.10.03 Superconductivity UK

The cryogenic challenge A modern MRI magnet, 2003 U.S. Patent Office; “Apparatus and Method for Detecting Cancer in Tissue”; Raymond Damadian 1974 23.10.03 Superconductivity UK

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 23.10.03 Superconductivity UK

The cryogenic challenge Cryocoolers are in multiple use MRI shield cooling Gas liquefaction Device cooling Semiconductor applications Research cryostats So why not in HTS? 23.10.03 Superconductivity UK

The cryogenic challenge 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) 23.10.03 Superconductivity UK

The cryogenic challenge 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 23.10.03 Superconductivity UK

Patents 23.10.03 Superconductivity UK

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 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 23.10.03 Superconductivity UK

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) 23.10.03 Superconductivity UK

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 No interference of normal operations Maintainability Average technicians can operate the system Soft failure mode Cryosystem failures allow alternate operational schemes Source: Cryogenic Roadmap, U.S. Department of Energy Superconductivity Program For Electric Systems, Executive Summary June 2001) 23.10.03 Superconductivity UK

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. 23.10.03 Superconductivity UK

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 23.10.03 Superconductivity UK

Source: MJ Gouge talk at 2002 DOE wire workshop 22.1.02 100-1000W @ 65-80K Component BSCCO Heat load, Top YBCO Cable 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 ~ 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 23.10.03 Superconductivity UK

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 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 23.10.03 Superconductivity UK

Source: Mulholland et al, DOE June 2003 Costs Source: Mulholland et al, DOE June 2003 23.10.03 Superconductivity UK

Source: Mulholland et al, DOE June 2003 Costs Source: Mulholland et al, DOE June 2003 23.10.03 Superconductivity UK

Source: Mulholland et al, DOE June 2003 Market demand Source: Mulholland et al, DOE June 2003 23.10.03 Superconductivity UK

The market Projected market demand for cryogenic refrigerators ($k) Year Motors Transformers Generators Cables Total 2007 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) 23.10.03 Superconductivity UK

And do I believe market forecasts? 23.10.03 Superconductivity UK

Alliances 23.10.03 Superconductivity UK 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 ? Scottish and Southern Energy 2003- A 350-meter HTS cable that will be installed in the distribution system operated by Niagara Mohawk, a National Grid Company, $26m IGC, Super Power, Sumitomo Electric Industries, BOC and Nexans Develop a new HTS fault current limiter to protect utility grids from damaging surges in current. $6m current limiter for shipboard service. £0.7m UK IRC Cambridge Rolls-Royce plc, VA Tech, Diboride Conductors, [Space-Cryomagnetics] 2003-2009 To develop advanced cryogenic systems to Support new HTS. $8m DOE’s Oak Ridge Lab. Praxair and Cryomech, Inc. 23.10.03 Superconductivity UK

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 23.10.03 Superconductivity UK

Specifications For Selected Large Cryocoolers The companies Specifications For Selected Large Cryocoolers Product Type Input Power Weight Cooling Capacity COP Cryomech AL200 G-M 5 KW 160 kg 180 W @ 80 K 120 W @ 60 K 10% 9.6% Cryomech AL300 7.2 KW 118.8 kg 200 W @ 50K 250 W @ 60K 320 W @ 80K _ Cryomech AL330 100 W @ 30 K 190 W @ 50 K 280 W @ 80 K 12% CTI M 1050 I Stage GM 5.5 KW 126 kg 100 W @ 80 K 5% APD DE-108 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 13 KW 455 kg 500 W @ 77 K Q drive 2S362K 24 kw 590 kg 1000 W @ 77 K Stirling C&R LPC-01 Stirling 12 KW 850 kg 500 W @ 65 K 15% 23.10.03 Superconductivity UK

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 25 KW 1500 kg 1300 W @ 65 K 18% Stirling C&R LPC-04 60 KW 3750 kg 2800 W @ 65 K 17% Stirling C&R LPC-08 135 KW 7500 kg 5800 W @ 65 K 16% Stirling C&R SPC-01 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% Stirling C&R SPC-04 45 KW 31 KW 20 KW 1255 kg 4,500 W @ 80 K 9,500 W @ 150 K 14,500 W @ 250 k 27% 31% Aisin Seki Model SC Linear 14 KW _ 1000 W @ 77 K 20% Aisin Seki Model SS 6 KW 400 W @ 77 K Source: Marty Nisenoff 23.10.03 Superconductivity UK

Image copyright and courtesy Cryomech, Inc. 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 AL300 ColdHead-blue Image copyright and courtesy Cryomech, Inc. 23.10.03 Superconductivity UK

Image copyright and courtesy 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 23.10.03 Superconductivity UK

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 23.10.03 Superconductivity UK

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 23.10.03 Superconductivity UK

Other companies APD Daiken? Ricor Hymatic … 23.10.03 Superconductivity UK

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 23.10.03 Superconductivity UK

Liquid cryogens Systems can still use: LN2, subcooled LN2 @ 63.5K 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 23.10.03 Superconductivity UK

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? 23.10.03 Superconductivity UK

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 Superconductivity UK