CRYOGENICS

Contents:
*What is cryogenics *Related terms *cryogenic processing *Advantages *Disadvantages *various applications *conclusions

Submitted by: M.SHANMUGARAJ P.A.VASANTH

K.L.N college of engg WHAT IS CRYOGENICS:

The word cryogenics literally means "the production of icy cold The branches of physics and engineering that involve the study of very low temperatures, how to produce them, and how materials behave at those temperatures. Using this technology very low temperatures is produced on earth. It has wide range of applications in many fields.

RELATED TERMS:
Cryobiology: The branch of biology involving the study of the effects of low temperatures on organisms (most often for the purpose of achieving (cryopreservation). Cryonics: The emerging medical technology of cryopreserving humans and animals with the intention of future revival. Researchers in the field seek to apply the results of many sciences, including cryobiology, cryogenics, rheology, emergency medicine, etc. Cryoelectronics The field of research regarding superconductivity at low temperatures. Cryotronics The practical application of cryoelectronics.

CRYOGENIC PROCESSING:
cryogenic processing is a fascinating and truly spectacular means to increase wear resistance & life on all metal and some plastics. Deep cryogenics is the ultra low temperature processing of materials to enhance their desired metallurgical and structural properties. The cryogenic process is not a surface treatment. It affects the entire mass of the part, making it stronger throughout and dramatically reducing wear. A cryogenic treatment is the process of reducing the temperature of components over an extended period of time to extreme cold levels, usually slightly below 190 C (310.0 F), which is why it is called a cryogenic process. Liquid nitrogen (LN2) is a common fluid for the process being relatively inexpensive and making up more than 70% of our atmosphere. As the liquid nitrogen boils off from liquid to gas at around 195 C (319.0 F), the components in its proximity are also cooled. The process is controlled by microprocessors so that thermal shock is not generated at the same time resulting in damage to components. Before these microprocessors were created, people would dip parts in liquid nitrogen and virtually turn them to brittle instantaneously. As the material cools its molecular structure is drawn together through contraction and stress and dislocation brought about by production methods is removed or reduced. cryogenic treatment was able to remove residual stresses. Cryogenic treatment removes heat from an object which then allows the object to enter its most relaxed state or a condition with the least amount of kinetic energy. After heat treatment, steels still have a certain percentage of retained austenite

which can be transformed into martensite via cryogenic treatment. Other effects are the production of martensite and the precipitation of Eta type carbides. All metals including copper and aluminum, not just steel benefit from the residual stress relief that cryogenic treatment promotes It has been found and proved that cryogenic treatment improves wear resistance of many alloy steels to a great extent

ADVANTAGES OF USING CRYOGENICS:

Requires only one permanent treatment Changes the entire grain structure of the metal, not just the surfaces Refinishing or regrinds do not affect permanent improvements Eliminates thermal shock through a dry, computer controlled process Transforms most retained austenite to hard martensite Forms micro-fine carbide fillers to enhance carbide structures Increases durability and wear life Decreases residual stresses in tool steels Decreases brittleness Increases tensile strength, toughness and stability Relaxes internal stresses Works on new or used tools Reduced down time, less maintenance and higher productivity Deep cryo processing is compatible with other treatments (TiN, Chrome, Teflon etc.) High alloy steel cutting tools stay sharper longer, fewer micro-cracks, less chipping Results in the orderly arrangement of crystals, increases internal bonding energy, and achieves a structural balance throughout the mass of the material Decreases wear and tear of the materials

DISADVANTAGES OF USING CRYOGENICS:

To complete cryogenic processing effectively takes time - upwards of 30 to 50 hours, and it cannot be converted to a continuous process. It can't extend the wear life of most natural materials like wood, natural rubber, and leather. It can't make products stronger but it can and does increase wear resistance significantly. Sometimes that very wear resistance has unintended consequences. "The garment industry had stopped the usage of cryotreated sewing needles because they were 'destroying their sewing machines.' The sewing machines had a platen under the deck on either side of the needle. Normally, if a needle became misaligned, it hit the platen and spanned, stopping the machine. With cryogenically treated needles, misaligned needles pierced the platens and became stuck or worse, kept going. Downtime increased because the company's maintenance department had to replace needle-embedded platens."

VARIOUS APPLICATIONS:

Cryogenic process has a wide range of applications from industrial tooling to improvement of musical signal transmission. Some of the benefits of cryogenic treatment include longer part life, less failure due to cracking, improved thermal properties, better electrical properties including less electrical resistance, reduced coefficient of friction, less creep and walk, improved flatness, and easier machining. *CRYOGENIC FUELS PRODUCTION: Cryogenic cooling of devices and material is usually achieved via the use of liquid nitrogen, liquid helium, or a cryocompressor (which uses high pressure helium lines). Newer devices such as pulse cryocoolers and Sterling cryocoolers have been devised. The most recent development in cryogenics is the use of magnets as regenerators as well as refrigerators. These devices work on the principle known as the magneto caloric effect. The technology of air separation with the help of cryogenic temperatures is by far not new. The principle of cryogenic plants operation is based on the air liquefaction and its subsequent separation with the recovery of nitrogen, oxygen, and argon. This method of gas production is called deep air freezing. The feed air is initially compressed, and, after passing though the heat exchangers, is expanded in the turbine expander or on the expansion valve with the resulting temperature decrease down to the 93 K point, where it is turned into liquid. Subsequent separation of liquefied air, which mainly consists of liquid nitrogen and liquid oxygen, is based on the difference in the boiling points of its components: oxygen 90.18 K, nitrogen 77.36 K. By gradual evaporation of liquid air, nitrogen is being preferentially evaporated, while the residual liquid is becoming increasingly saturated with oxygen. The process is then multiply repeated at the air separation rectifying tray with the production of liquid oxygen, nitrogen, and argon of the required purity. PRODUCTION OF NITROGEN:

PRODUCTION OF OXYGEN:

Similarly its used to produce liquid gases like helium orgon neon etc

USES: Another use of cryogenics is cryogenic fuels. Cryogenic fuels, mainly liquid hydrogen have been used as rocket fuels. Liquid oxygen is used as an oxidizer of hydrogen, but oxygen is not, strictly speaking, a fuel. For example, NASA's workhorse space shuttle uses cryogenic hydrogen fuel as its primary means of getting into orbit, as did all of the rockets built for the Soviet space program by Sergei Korolev. (This was a bone of contention between him and rival engine designer

Valentin Glushko, who felt that cryogenic fuels were impractical for large-scale rockets such as the ill-fated N-1 rocket spacecraft.) Russian aircraft manufacturer Tupolev developed a version of its popular design Tu-154 with a cryogenic fuel system, known as the Tu-155. The plane uses a fuel referred to as liquefied natural gas or LNG, and made its first flight in 1989. *INDUSTIAL APPLICATIONS: FOOD INDUSTRY: Food Freezing: The mass production of frozen food (chicken,Prawns, Beefburgers etc..,) relies on large volumes of liquid nitrogen being sprayed on the item concerned while it travels along a stainless steel mesh conveyor belt in a specially constructed tunnel. The speed of the conveyor belt and the flow of the liquid nitrogen refrigerant are the two main controls as well as the control of the uniformity of the size of the items being frozen. For large scale industrial food producers, this method is the most preferered for reasons of economy and because the flavour is locked into the product by the quick freezing process. It is not unusual for process lines to consume tons of liquid nitrogen per day. Statebourne is able to supply specialist storage tanks and vacuum insulated pipeline systems for this process. Freeze Drying: By subjecting food (typically coffee, soups, stews, military rations etc,) to a vacuum, moisture is withdrawn and the food becomes light and dry. Properly packaged the food can be stored over long periods until it is needed when water is added. However, during the process of production most of the flavor is drawn off with the moisture and oils when the product is under vacuum. To rectify this, the oils containing the flavor are trapped in a cryogenic cold trap and later re-introduced to the product moments before the final closure during packaging. The cold trap is a part of the vacuum systems pipe line along which the drawn off gases must pass and which is cooled by liquid nitrogen. Cryostor vessels or larger Static Storage Tanks made by Statebourne are used to store the liquid nitrogen. The very cold walls on the inside of the pipe cause the vapours containing the flavor to condense and freeze, trapping them for later recovery.

CRYOGENIC VALVES:

cryogenic carbon steel socket weld globe valve. Valves and are generally made of plastic or steel, the latter being the most widely used in chemical and petrochemical applications. Steel grades range from the most common type, namely carbon steel, with standard stainless steel being the second most common. Stainless steel alloys, which include nickel or copper are used in applications that require higher corrosion or heat resistance. In such cases, the most commonly used valve configurations -- ball valves, gate valves, check valves, globe valves and butterfly valves -- are often forged or cast as duplex valves, super duplex valves, alloy 20 valves, monel valves, inconel valves, incoloy valves and 254 SMO valves (6Mo valves). Titanium valves are also used in some highly corrosive applications. Titanium is not a stainless steel alloy.and it has many more applications in various industrie. *APPLICATIONS IN AEROSPACE ENGG Cryogenic technology involves the use of rocket propellants at extremely low temperatures. The combination of liquid oxygen and liquid hydrogen offers the highest energy efficiency for rocket engines that need to produce large amounts of thrust. But oxygen remains a liquid only at temperatures below minus 1830 Celsius and hydrogen at below minus 2530Celsius. Building a rocket stage with an engine that runs on such propellants means overcoming engineering challenges.

Aviation/Aerospace: A wide variety of applications are employed in this industry. Low temperature nitrogen gas is ideal for both electronic and mechanical component and systems testing simulating operational conditions. Either argon gas or nitrogen is used to inert atmospheres in special critical heat treatment routines for jet engine turbine blades in production and re-conditioning (Cryostor) (Static Storage Tanks), and some finely tolerance bearing metal components are positioned using shrink fitting techniques (Open Dewars). In operational use, aircraft tyres are filled with nitrogen(not compressed air) and in military aircraft, nitrogen gas is used to inert the space over the fuel in the tanks. Additionally, liquid oxygen is stored on board as a low weight source of breathing gas for the pilot. In all these cases, Statebourne cryogenic vessels will be employed in support to store the liquid gases (Special products).most of the rockets lie gslv, pslv etc use these technology only. Balloons and Airships: Helium gas is used often in very large volumes for filling balloons and airships. To accomplish the filling operation from cylinders of compressed gas would be a logistical nightmare, so it is more common for helium gas to be transported to site liquefied at around -269C in special cryogenic containers (Helistor Dewars). At very low pressures the liquid is decanted and immediately vaporizes when it is directed into the buoyancy chamber. Statebourne manufacture liquid helium containers for static and transport applications to the latest TPED European Transport Regulations.

*MEDCAL APPLICATIONS:

Blood Banking: Normally, for the more common groups of blood, storage is maintained at about 2C to 4C in conventional refrigerators which give it a limited shelf life. For the rarer types which are not so readily replaceable, blood is stored at very low temperatures, typically -165C or below in liquid nitrogen cooled refrigerators. The blood is collected in special bags and then frozen at a controlled rate protected in a metal wallet or cassette to prevent damage when frozen. the cassette is placed in a racking storage system in the cold nitrogen vapor inside the refrigerator. Dermatology: A branch of medicine dealing with skin, Dermatology uses Cryotherapy as a means of removing and curing skin lesions such as warts and verrucas. The practice involves treating the affected area with liquid nitrogen cooled tips or jets of liquid aimed through a very fine spray head effectively destroying the rogue cells. These fall away in time and are replaced by normal cell growth in the healing process. Equipment for the storage and handling of liquid nitrogen in dermatological practice is available from Statebourne Artificial Insemination: The frozen storage of semen and embryos for later use in fertilization procedures offers many opportunities for medical and vetinerary science. Typically for livestock improvement programme in agriculture worldwide, liquid nitrogen is used as the ideal refrigerant. Liquid nitrogen is inert, reliable and relatively inexpensive. For human fertility treatments, similar equipment and procedures are used *ENGNEERING APPLICATIONS Chromatography: This is a technique of separating and analyzing the components of a mixture of liquids or gases using a special instrument. Nitrogen gas, due to its properties is used as a control in the process and gas generated by boiling liquid provides a particularly high purity, which is essential. The provision of this gas is best made by the use of a Cryostor liquid nitrogen container manufactured by Statebourne which has built in the capability of vaporizing the liquid and providing the required controlled steady flow. Firefighting: For stubborn fires possibly electrically or chemically fueled, special foams has been found to be effective. Foam using nitrogen in place of air for its generation has been found to be even more effective. Liquid nitrogen carried in a pressure vessel with vaporizers for converting the liquid to gas can provide the power for mixing and firing the foam. (Cryocyl) (Transportable Tanks). Cryocyl Transportable Tanks will maintain their pressure automatically and deliver up to 25Nm3/hr of nitrogen gas without additional vaporizers.

Astronomy: Liquid nitrogen is often found in centres of this discipline. Stored liquid nitrogen is used as a source for clean dry gas which is produced by evaporation to provide a steady flow of vapour over optical surfaces. The purpose of this application is to avoid the collection of dust or condensation on highly polished lenses or reflectors. Laboratory type low pressure storage vessels (Cryostor) are most commonly used. Liquid nitrogen is also used as a source of refrigeration to cool detectors to improve performance and reduce noise. Statebournes Cryostor container vessels are frequently used.

Electronics: An industry that depends heavily on the use of both gaseous and liquid nitrogen, electronics production relies on cheap quality control techniques for its mass production systems. Extreme cold provided by liquid nitrogen is used to shock test assemblies to ensure there are no electrical connection faults and inert atmospheres provided by nitrogen gas ensure no contamination by dirt or oxidization during the manufacturing process where cleanliness is vital. Storage tanks for liquid nitrogen and other cryogenic gases are manufactured and supplied by Statebourne.(Cryostor) (Cryocyl) (Static Storage Tanks)

CONCLUSION:
The future of cryogenics materials will be very exciting and dynamic. It will be driven by traditions, trends, costs, performance, legislation. Of these, the most critical issue is costs. Cryogenics materials will be part of the dynamic future. By considering the entire cryogenics Materials.We must not only continue to make incremental improvements in present materials but develop whole new technologies of manufacturing and processing for to achieve the highest performance in cryogenics materials field.