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Design concepts of refrigeration systems for cooling components of microwave receiving systems to 80 to 100 deg Kelvin - transmission line
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The development of a multifrequency upconverter-maser system for the DSN has created the need to develop a closed-cycle refrigerator (CCR) capable of providing more than 3 watts of refrigeration capability at 4.5 K. In addition, operating concerns such as the high cost of electrical power consumption and the loss of maser operation due to CCR failures require that improvements be made to increase the efficiency and reliability of the CCR. One refrigeration method considered is the replacement of the Joule-Thomson expansion circuit with a magnetic refrigeration. Magnetic refrigerators can provide potentially reliable and highly efficient refrigeration at a variety of temperature ranges and cooling power. The concept of magnetic refrigeration is summarized and a literature review of existing magnetic refrigerator designs which have been built and tested and that may also be considered as possibilities as a 4 K to 15 K magnetic refrigeration stage for the DSN closed-cycle refrigerator is provided.
For many years, chlorofluorocarbons (CFC's) have been used by the Department of Energy's (DOE) Oak Ridge Y-12 Plant in air conditioning and process refrigeration systems. However, Title 6 of the Clean Air Act Amendments (CAAA) and Executive Order 12843 (Procurement Requirements and Policies for Federal Agencies for Ozone Depleting Substances) signed by President Clinton require, as policy, that all federal agencies maximize their use of safe, alternate refrigerants and minimize, where economically practical, the use of Class 1 refrigerants. Unfortunately, many government facilities and industrial plants have no plan or strategy in place to make this changeover, even though their air conditioning and process refrigeration equipment may not be sustainable after CFC production ends December 31, 1995. The Y-12 Plant in Oak Ridge, Tennessee, has taken an aggressive approach to complying with the CAAA and is working with private industry and other government agencies to solve tough manufacturing and application problems associated with CFC and hydrochlorofluorocarbon (HCFC) alternatives. Y-12 was the first DOE Defense Program (DP) facility to develop a long-range Stratospheric Ozone Protection Plan for refrigerant management for compliance with the CAAA. It was also the first DOE DP facility to complete detailed engineering studies on retrofitting and replacing all air conditioning and process refrigeration equipment to enable operation with alternate refrigerants. The management plan and engineering studies are models for use by other government agencies, manufacturing plants, and private industry. This presentation identifies some of the hidden pitfalls to be encountered in the accelerated phaseout schedule of CFC's and explains how to overcome and prevent these problems. In addition, it outlines the general issues that must be considered when addressing the phase-out of ozone depleting substances and gives some 'lessons learned' by Y-12 from its Refrigerant Management Program. Discussion topics include requirements for developing a refrigerant management plan and establishing priorities for cost-effective compliance with the CAAA, as well as ways in which employees can be empowered to develop a comprehensive refrigerant management plan. The result of this employee empowerment was a cooperative labor-management effort that is beneficial for Y-12, DOE, and the environment.
A dual refrigeration system for cooling a sink device is described, which automatically thermally couples the cold refrigerator to the sink device while thermally isolating the warm refrigerator from the sink device. The system includes two gas gap heat switches that each thermally couples one of the refrigerators to the sink device, and a pair of sorption pumps that are coupled through tubes to the heat switches. When the first refrigerator is operated and therefore cold, the first pump which is thermally coupled to it is also cooled and adsorbs gas to withdraw it from the second heat switch, to thereby thermally isolate the sink device from the warm second refrigerator. With the second refrigerator being warm, the second pump is also warm and desorbs gas, so the gas lies in the first switch, to close that switch and therefore thermally couple the cold first refrigerator to the sink device. Thus, the heat switches are automatically switched according to the temperature of the corresponding refrigerator.
This paper reviews the development of the three types of pulse tube refrigerators: basic, resonant, and orifice types. The principles of operation are given. It is shown that the pulse tube refrigerator is a variation of the Stirling-cycle refrigerator, where the moving displacer is substituted by a heat transfer mechanism or by an orifice to bring about the proper phase shifts between pressure and mass flow rate. A harmonic analysis with phasors is described which gives reasonable results for the refrigeration power, yet is simple enough to make clear the processes which give rise to the refrigeration. The efficiency and refrigeration power are compared with those of other refrigeration cycles. A brief review is given of the research being done at various laboratories on both one- and two-stage pulse tubes. A preliminary assessment of the role of pulse tube refrigerators is discussed.
Low temperature refrigeration is an increasingly vital technology for NASA s Space Science program since most detectors being developed for x-ray, IR and sub-millimeter missions must be cooled to below 100 mK in order to meet the requirements for energy and spatial resolution. For space applications, magnetic refrigeration has an inherent advantage over alternative techniques because it does not depend on gravity. Adiabatic demagnetization refrigerators, or ADRs, are relatively simple, solid state devices. The basic elements are a magnetocaloric refrigerant (usually an encapsulated paramagnetic salt) located in the bore of a superconducting magne$, and a heat switch linking the salt to a heat sink. The alignment of magnetic spins with the magnetic field causes the refrigerant to warm as the magnetic field increases and cool as the field decreases. Thus the simple process of magnetizing the refrigerant to high field with the heat switch closed, then demagnetizing it with the heat switch open allows one to obtain temperatures well below 100 mK using a heat sink as warm as 4.2 K. The refrigerant can maintain a low temperature for a length of time depending on the applied and parasitic heat loads, its mass, and the initial magnetic field strength. Typically ADRs are designed for 12-24 hours of hold time, after which they must be warmed up and recycled. The drawback to single-shot ADRs is that the cooling power per unit mass is relatively low. Refrigerants that are suitable for low temperature operation necessarily have low magnetic ion density, and therefore low entropy density. Since ADRs store entropy, systems with even modest cooling powers (a few microwatts) at temperatures below 100 mK tend to be massive, averaging 10-15 kg.
A lower stage chemisorption refrigeration system physically and functionally coupled to an upper stage physical adsorption refrigeration system is disclosed. Waste heat generated by the lower stage cycle is regenerated to fuel the upper stage cycle thereby greatly improving the energy efficiency of a two-stage sorption refrigerator. The two stages are joined by disposing a first pressurization chamber providing a high pressure flow of a first refrigerant for the lower stage refrigeration cycle within a second pressurization chamber providing a high pressure flow of a second refrigerant for the upper stage refrigeration cycle. The first pressurization chamber is separated from the second pressurization chamber by a gas-gap thermal switch which at times is filled with a thermoconductive fluid to allow conduction of heat from the first pressurization chamber to the second pressurization chamber.
With the February, 1992 announcement by President Bush to move the deadline for outlawing CFC (chloro-fluoro-carbon) refrigerants from the year 2000 to the year 1996, the refrigeration and air-conditioning industries have been accelerating their efforts to find alternative refrigerants. Many of the alternative refrigerants being evaluated require synthetic lubricants, are less efficient, and have toxicity problems. One option to developing new, alternative refrigerants is to combine existing non-CFC refrigerants to form a nonazeotropic mixture, with the concentration optimized for the given application so that system COP (Coefficient Of Performance) may be maintained or even improved. This paper will discuss the dilemma that industry is facing regarding CFC phase-out and the problems associated with CFC alternatives presently under development. A definition of nonazeotropic mixtures will be provided, and the characteristics and COP benefits of nonazeotropic refrigerant mixtures will be explained using thermodynamic principles. Limitations and disadvantages of nonazeotropic mixtures will be discussed, and example systems using such mixtures will be reviewed.
Low temperature refrigeration is an increasingly vital technology for NASA's Space Science program since most detectors being developed for x-ray, IR and sub-millimeter missions must be cooled to below 100 mK in order to meet the requirements for energy and spatial resolution. For space applications, magnetic refrigeration has an inherent advantage over alternative techniques because it does not depend on gravity. Adiabatic demagnetization refrigerators, or ADRs, are relatively simple, solid state devices. The basic elements are a magnetocaloric refrigerant (usually an encapsulated paramagnetic salt) located in the bore of a superconducting magnet, and a heat switch linking the salt to a heat sink. The alignment of magnetic spins with the magnetic field causes the refrigerant to warm as the magnetic field increases and cool as the field decreases. Thus the simple process of magnetizing the refrigerant to high field with the heat switch closed, then demagnetizing it with the heat switch open allows one to obtain temperatures well below 100 mK using a heat sink as warm as 4.2 K. The refrigerant can maintain a low temperature for a length of time depending on the applied and parasitic heat loads, its mass, and the initial magnetic field strength. Typically ADRs are designed for 12-24 hours of hold time, after which they must be warmed up and recycled.
In the midst of developing battery-free, solar-powered refrigeration and air conditioning systems for habitats in space, David Bergeron, the team leader for NASA's Advanced Refrigerator Technology Team at Johnson Space Center, acknowledged the need for a comparable solar refrigerator that could operate in conjunction with the simple lighting systems already in place on Earth. Bergeron, a 20-year veteran in the aerospace industry, founded the company Solus Refrigeration, Inc., in 1999 to take the patented advanced refrigeration technology he co-developed with his teammate, Johnson engineer Michael Ewert, to commercial markets. Now known as SunDanzer Refrigeration, Inc., Bergeron's company is producing battery-free, photovoltaic (PV) refrigeration systems under license to NASA, and selling them globally.
A lower stage chemisorption refrigeration system physically and functionally coupled to an upper stage physical adsorption refrigeration system. Waste heat generated by the lower stage cycle is regenerated to fuel the upper stage cycle thereby greatly improving the energy efficiency of a two-stage sorption refrigerator. The two stages are joined by disposing a first pressurization chamber providing a high pressure flow of a first refrigerant for the lower stage refrigeration cycle within a second pressurization chamber providing a high pressure flow of a second refrigerant for the upper stage refrigeration cycle. The first pressurization chamber is separated from the second pressurization chamber by a gas-gap thermal switch which at times is filled with a thermoconductive fluid to allow conduction of heat from the first pressurization chamber to the second pressurization chamber.
A compact refrigerator designed specifically for cooling a microwave maser low-noise amplifier is capable of removing heat at a continuous rate of 180 mW at a temperature of 2.5 K. This refrigerator is a combination of (1) a commercial Gifford-McMahon (GM) refrigerator nominally rated for cooling to 4 K and (2) a Joule-Thomson (J-T) circuit. The GM refrigerator pre-cools the J-T circuit, which provides the final stage of cooling. The refrigerator is compact and capable of operating in any orientation. Moreover, in comparison with a typical refrigerator heretofore used to cool a maser to 4.5 K, this refrigerator is simpler and can be built at less than half the cost.
At the 1979 Cryogenic Engineering Conference, attention was given to conceptual designs of spaceborne cryogenic refrigeration systems which can provide long-term, unattended operation. Since that time, efforts have continued to translate one of those concepts into an engineering model. The present investigation is concerned with a refrigerator which was designed to generate 5 W of cooling power at a temperature of 65 K. The compression heat of the refrigerator is dissipated at a temperature of 300 K, and the output of the system is to be maintained reliably for a period of five years or longer. The refrigerator design is based on the Stirling cycle, which has an ideal efficiency equal to that of the Carnot cycle. Attention is given to some background information concerning a cryogenic refrigerator, the design of the refrigerator components, and the development status. The magnetic bearings and the linear motors have been tested at the component level.
Projected performance requirements for cryogenic spacecraft sensor cooling systems which demand higher reliability and longer lifetimes are outlined. The gas/solid sorption refrigerator is viewed as a potential solution to cryogenic cooling needs. A software model of an entire gas sorption refrigerator system was developed. The numerical model, evaluates almost any combination and order of refrigerator components and any sorbent-sorbate pair or which the sorption isotherm data are available. Parametric curves for predicting system performance were generated for two types of refrigerators, a LaNi5-H2 absorption cooler and a Charcoal-N2 adsorption cooler. It is found that precooling temperature and heat exchanger effectiveness affect the refrigerator performance. It is indicated that gas sorption refrigerators are feasible for a number of space applications.
Photolithographic techniques were employed to fabricate small Joule-Thomson refrigerators in laminated substrates. The gas passages of a J-T refrigerator are formed by etching channels as narrow as 50 microns and as shallow as 5 microns in glass plates which are laminated together. Circular refrigerators on the order of 1.5 centimeters in diameter and .75 millimeters thick were produced which cool down to cryogenic temperatures in a few seconds, using Argon or Nitrogen, with no vacuum or radiation insulation. Smaller refrigerators are developed for both faster cooldown and low refrigeration capacity applications. By using this technology, custom refrigerators can be designed to meet specific application requirements.
The application of refrigeration at low temperatures ranging from production of liquid helium for medical imaging systems to cooling of infrared sensors on surveillance satellites is discussed. Cooling below about 15 K with regenerative refrigerators is difficult because of the decreasing thermal mass of the regenerator compared to that of the working material. In order to overcome this difficulty with helium gas as the working material, a heat exchanger plus a Joule-Thomson or other exponder is used. Regenerative magnetic refrigerators with magnetic solids as the working material have the same regenerator problem as gas refrigerators. This problem provides motivation for the development of nonregenerative magnetic refrigerators that span approximately 1 K to approximately 0 K. Particular emphasis is placed on high reliability and high efficiency. Calculations indicate considerable promise in this area. The principles, the potential, the problems, and the progress towards development of successful 4 to 20 K magnetic refrigerators are discussed.
A very long-life, lightweight and efficient hydride absorption refrigerator system was built to operate at ten Kelvin and below. The system consists of four basic stages of refrigeration. The first stage is accomplished by an active refrigeration system. The second stage is operated by a hydride absorption system, wherein a heated hydride powder drives off high pressure hydrogen through a Joule-Thomson/heat exchanger expansion loop such that the hydrogen is partially liquefied. In the third stage, the vapor pressure over the collected liquid hydrogen is lowered by absorbing the hydrogen vapor onto a different low pressure, worn hydride. With a 1.7 torr partial pressure of hydrogen gas in the hydride, liquid hydrogen is solidified and sublimes at 10 K. Long-life adiabatic demagnetization refrigerators, helium desorption, or helium diaphragm compressors are used to cool to 4 K or below. It is shown that the hydride concepts provide an extremely efficient means of refrigeration to 10 K, and that an entire sorption refrigeration process can be accomplished solely by using low grade heat energy at about 150 C.