New trends in electron

accelerators development

Zbigniew Zimek

Centre for Radiation Research and Technology

Institute of Nuclear Chemistry and Technology

Dorodna 16, 03-195 Warsaw, Poland

PlasTEP seminar: „New trends in application of modern electron beam generation in air pollution”

Warsaw, 14 01 12 2014

INTRODUCTION

PROGRESS IN INDUSTRIAL ACCELERATORS DEVELOPMENT - Adaptation of the accelerators primary built for

scientific experiments; - Electron energy and beam power increase in certain

accelerators constructions; - Accelerators for R&D, pilot plants and industrial

facilities; - Computer control system for accelerator start up, full

operation and technological process management; - Reliability improvement according to industrial

standards; - Accelerator technology perfection (electrical efficiency,

cost); - Accelerators for MW power beam level; - Compact and more efficient accelerator constructions; - Very low energy, powerfull accelerators.

Penetration [g/cm2] = 0.37(Energy [MeV]-0.2) for one side treatment and equal entrance and exit doses

Productivity [kg/h] =

3600 x Power [kW] x

Utilization efficiency

/Dose [kGy]

Average beam power

Electron energy

Although there are many different types of accelerators offering a wide range of performances ratings, only few would be suitable for particular application (Marshall R. Cleland, 1992).

Criterions of accelerators selection Criterion of selection Fundamental accelerator parameters Electron energy Average beam power Terms of accelerator purchase Price Producer Terms of delivery and installation Warranty conditions Exploitation cost Auxiliary accelerator parameters Scan performances Auxiliary parameters Measure and control Main components and systems Accelerator external supply service

Remarks The basic requirements which define technological abilities and facility productivity Economical aspects of accelerator purchase which define investment and exploitation costs; period of time needed for facility completion Auxiliary parameters which may characterize accelerator quality and provide necessary data for facility design

Facility general assumptions Irradiation zone dimensions and arrangement, Process throughput, Operation schedule, Seasonal requirements, Vertical or horizontal beam direction, Reliability of the accelerator (availability), Remote accelerator operation, Factory assembling test and commissioning

conditions, Warranty conditions, Post warranty service, Staff training, Facility certification (equipment, safety, personnel).

Radiation process effectiveness Acceptable price of 1 W electron

beam power

Type of radiation process

Product characteristics

100-250 $/W Semiconductors modification

Low dose

Small scale

High unit price

100-50 $/W Radiation sterilization

Medium dose

Large scale

Medium unit price

<2.5 $/W Flue gas treatment

Low dose

Very large scale

No commercial value

Accelerators for radiation processing

Direct accelerator Single cavity Linear accelerator

HV cable from Coaxial cable from Waveguide from

DC power supply RF generator source of microwaves

Accelerators for radiation processing (achievements)

Accelerator

type

Parameter

Direct

DC

RF

100 - 200

MHz

Linear

microwaves

1.3–9.3 GHz

Av. beam

current

Energy range

Beam power

Electrical

efficiency

<1.5 A

0.05 – 5

MeV

~500 kW

60 – 80 %

<100 mA

0.3 – 10

MeV

700 kW

20 – 50 %

<100 mA

2 – 10 MeV

100 kW

10 – 20 %

DIRECT ACCELERATORS transformer type

List of transformer accelerator producers PCT Prod. & Mfg., LLC, formerly RPC Industries, USA

ESI - Energy Science, USA

RDI - Radiation Dynamics, USA (IBA)

Wasik Associates, USA

AEB Inc., USA (closed down),

NHV - Nissin High Voltage, Japan

SHI - Sumitomo Heavy Industries, Japan

Electron Crosslinking AB, Sweden

High Voltage Engineering Europe, Netherlands

BINP - Institute of Nuclear Physic, Russia

SIEA - Sci. Inst. of Electrophysical Apparatus, Russia

Vivirad, France

Res. Inst. of Automation for Machine-Building, China

Inst. of Nuclear Studies, Establishment for Nuclear Equipment, Poland

EB TECH Co., Ltd., Korea – BINP collaboration

Capability of D.C. Power Supply for transformer accelerators

Accelerator Power line

transformer

Cockckroft-

Walton

HF

Transformer

Dynamitron

Ratings 150-1000kV

10-1000 mA

300-5000 kV

30-1000 mA

500-1000 kV

30 mA

500-5000 kV

1-70 mA

Frequency 50/60 Hz 1-3 kHz 20-50 kHz 50-100 kHz

Insulation Oil/SF6 SF6 SF6 SF6

Efficiency >90 % 70-80 % 85 % 30-60 %

Remarks Low energy

High power

High energy

High power

Large

High energy

Low power

Compact

High energy

Low eff.

Voltage 50-75 kV Beam power 8-50 W

USHIO / AIT

Miniature Electron Beam Tube Min-EB

14

27 cm 3

3 c

m

Advanced Electron Beam Inc. emitter module

15

Window Support Grid

Heated Filaments

41 cm x 6.3 cm beam window

21 cm diameter module 79 cm overall length

AEB Inc. emitter development

Window Support Grid

AEB Inc. LOW ENERGY ELECTRON MODULE

AEB Inc. Emitter Module

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Advanced Electron Beams Inc. had been a maker of electron emitter equipment for sterilization of packaging and other applications, which aim to use less energy and other resources than conventional approaches.

AEB Inc. was founded in 1999 supported by 50 M$ and closed down in 2012.

"It was a really innovative, transformative technology that had lots of applications",

"It just was too hard to take the science and industrialize the science”,

„Technology just proved to be too difficult to commercialize„.

Zbigniew ZIMEK, INCT, Warsaw, Poland 19

Energy 200 keV Power 700 W

Current 3,5 mA Scanning up to 20cm

AC power 10 kVA Size 40x40x80 cm

Acclerating section

Beam scanner

STERSTAR

Linac Technologies

Facility for surface sterilization

Zbigniew ZIMEK, INCT, Warsaw, Poland 20

Low energy „in line” facility for surface sterilization

Electron energy 200 keV Beam power 1 kW Accelerator dimension: 0.45x0.7x1.10 m Unit dimension: 75x200x250 cm

Manufacturer: IBA

Low energy accelerators for

surface treatment

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CASCADE ACCELERATOR

HV electrode

Generator Isolator

Safety rings

Motor

Gun Section

Multiplier

Prressure tank

Efficiency 67% Goal: 2 MeV; 200 kW

23

ELV 12 coreless transformer accelerator

Electron energy 1 MeV Beam power 400 kW Frequency 1000 Hz One power supply Three scanners

BINP, Russia

HV electron accelerator Electron-25

1 MeV; 500 kW

1 – pressure tank, 2 – focusing coil, 3 – scanning magnet, 4 – scanner, 5 – output foil.

Mobile accelerator systems

SINGLE CAVITY ACCELERATORS single pass or multi-pass systems

RF accelerator producers (100 - 200 MHz)

INP - Institute of Nuclear Physic, Russia

IBA - Ion Beam Application, Belgium

Denki Kogyo Co, Japan

KAPRA – Research Association, Korea

ILU 6 ELECTRON ACCELERATOR INP, Russia

Energy 1,2-2,5 MeV Beam power 20 kW Frequency 127 MHz

Scanner

Resonator

1 – vacuum tank, 2 – copper toroidal cavity, 3 – magnetic lens, 4 – ion pumps, 5 – grid-cathode unit, 6 – outlet device, 7– coupling loop support, 8 – vacuum

capacitor, 9 – RF generators.

ILU 10 accelerator 5 MeV, 60 kW

ILU-10

Energy 5 MeV

Beam power 50 kW

ILU 12 ELECTRON ACCELERATOR

Electron energy: 5 MeV Beam power: 100/300 kW Frequency: 176 MHz RF power: 450 kW

Auslender V.L. et all., EPAC 2002, Paris, France

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ILU 12

ILU 14

Variant 1 2

Generator tube 5xGI-50A 5xGI-50A

Energy, MeV 10 7.5

Beam power, kW 100 100

Accelerating structure efficiency, % 61 77

Total efficiency, % 26 32

ILU 14

10 MeV ELECTRON ACCELERATOR

RHODOTRON TYPE

1. Resonator 2. Tetrod 3. Water cooling system 4. Support 5. Electromagnet 6. Vacuum pump

Frequency 107.5 MHz

TT 1000: do 700 kW; 7 MeV (100 mA) do 500 kW; 5 MeV (100 mA) TT 300: do 200 kW; 10 MeV (20 mA) do 135 kW; 5 MeV (27 mA) TT 200: do 100 kW; 10 MeV (10 mA) do 100 kW; 5 MeV (20 mA) TT 100 35 kW; 10 MeV (3.5 mA)

Rhodotron TT 300, IBA, USA

Electron energy: 5-7 MeV Beam power: 200 kW

NFI; Japan: Irradiation Room with EB and X-ray Ports

IBA Rhodotron 5 MeV; 500 kW

(X-ray)

38

Accelerator type FANTRON-I

Electron energy 10 MeV Beam power 100 kW Frequency 159 MHz Efficiency 45 %

70 cm

H-j. Kwon i inni, EPAC, 2000 M-j.Park i inni, EPAC, 2000

LINEAR ELECTRON ACCELERATORS

Linear electron accelerator producers (microwaves 1.3-9.3 GHz)

Varian, USA L-3 Communicationsm, PSD, USA RPC Technologies, USA American Science & Engineering, Inc., USA Mitsubishi Heavy Industries, Japan Mevex, Canada Technical Systems Ltd, UK Thomson CSF, France Res. Inst. of Electrophysical Apparatus, Russia RIA TORYI, Russia Res. Inst. of Automation for Machine-Building, China Inst. of Nuclear Studies, Establishment for Nuclear

Equipment, Poland

41

Res. Inst. of Electrophysical Apparatus, Russia

Parameters

MODEL

UEL-10-

10S UEL-8-5S

UEL-3-

2.5S UEL-3-1S

RF Energy

Source

Klystron

KIU-147A

Magnetron

MI-262

Klystron

KIU-168

Magnetron

M5193

Working

frequency,

MHz

2856 3200 2856 2998

Energy, MeV 10 8 3 3

Beam power,

kW 10 5 2.5 1

Pulse

repetition 300 500 360 300

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Accelerator UEL-10-10S; 10 MeV, 10 kW

43

Standing wave linear accelerators L3 Communication (SureBeam), USA

Energy/beam

power

Frequency RF

source

Energy

source

Switch

5 MeV/15 kW S Klistron PFN Tyratron

10 MeV/18 kW S Klistron PFN Tyratron

5 MeV/150 kW L Klistron Indukc. IGCT

10MeV/150kW L Klistron Indukc. IGCT

44

Sterilization facility

Energy 3 MeV Beam power 3 kW Scanning 50 cm Height 1 m Width 0,3 m Manufacturer: LINAC TECHNOLOGIES

STERBOX

46

SterStar™ in-line electron beam surface sterilization uses 3 KeVAC low-energy accelerators, 200 keV energy beam, to sterilize the product surface only. SterBox™ in-line electron beam sterilization tunnel uses 1 or 2 MeVAC medium-energy accelerators, each producing a 3 MeV, 4 MeV or 5 MeV energy beam. This unit provides complete sterilization of single-use medical devices or pharmaceutical products. Beam energy and materials handling systems are customized for the product to be sterilized. SterRoom™ e-beam sterilization system contains one or two high-energy high power CIRCE accelerators with a 10 MeV 20 kW beam, suitable for production plants or service centers. LINAX™ x-ray generator is an OEM product with a 4 MeV to 10 MeV accelerator. It is used by integrators for imaging of trucks and containers, and testing of large industrial parts.

GETINGE LINAC

47

LINEAR ELECTRON ACCELERATOR Mitsubishi Heavy Industries Ltd.

Electron energy 4 MeV; Length 60 cm; Weight 20 kg

48

American Science & Engineering, Inc.

Energy 4 MeV; X-band 9303 MHz; control interface PLC; Acceleration section RF length 40 cm

49

Continous way (cw) electron accelerator Beam current 50 mA Electron energy 0,6 MeV Beam power 30 kW Length 0,8 m Frequency 2,45 GHz Efficiency 40 %

A.S. Alimov i inni, 2000

Beam energy: 1.2 MeV Beam current: 0 to 50 mA Maximum beam power: 60 kW Length: 1.3 m Gun/klystron HV 15 kV Power consumption: ~150 kW Electrical efficiency: ~40%

SINP MSU 60 KW, 1.2 MEV COMPACT CW LINAC FOR RADIATION TECHNOLOGIES

51

High freqency sources

Klystron Pulse power Average

power

Frequency Efficiency

TH 2158 5 MW 45 kW 2856 MHz 48 %

TH 2104 5 MW 250 kW 1300 MHz 45 %

TH 2089 cw 1100 kW 352 MHz 62 %

TH 2158

TH2104

TH 2089

52

OUTPUT AND BEAM SCANNING DEVICES

1 2 3 4 5

A. B.

Different configuration of accelerator output device (A – triangular scanning, B – parallel beam): 1 – electron beam; 2 – scanning magnet, 3 –

scanner; 4 – correction electromagnet; 5 – output foil

54

BEAM SCANNING ILU 6

1, 3 – Vacuum system; 2, 4 – Scanning and switching magnet; 5 – Exit window; 6 – Irradiated cables or wires

Double beam path scanning horn

Golubenko Y. et all., INP 97-7, Russia

DOUBLE SIDE BEAM SCANNER (IBA)

DOUBLE SIDE BEAM SCANNER

58

ELECTRON-10 (0.5-0.75 MeV; 50 kW) 1 – Primary winding; 2 – Secondary winding; 3 – Pressure vessel; 4 – Electron source; 5 – Accelerating tube; 6 – Scanning device; 7 – Vacuum pump; 8 – Vacuum chamber; 9 – Outlet window; 10 – Turning magnet; 11 – Radiation shielding.

A.S. Ivanov, V.P. Ovchinnikov, M.P. Svinin, N.G. Tolstun, PAC 1993, Washington, USA

59

LINEAR SCANNING SYSTEM

CAARI 2002 Denton, Texas November 13, 2002

VACUUM CHAMBER

ELECTRON BEAM

ELECTROMAGNET TITANIUM

FOIL

60

ECONOMIC ASPECTS OF ACCELERATOR IMPLEMENTATION

Producer

(accelerator type)

Energy

[MeV]

Beam

[mA]

Power

[kW]

Price

[M$]

Price

[$/W]

IBA, Belgium (UHF) 10 15 150 6.1 40.7

RDI, U.S.A. (DC) 5 50 250 4.9 19.6

NHV, Japan (DC) 5 30 150 5.0 33.3

Vivirad,France(DC) 5 200 1000 4.4 4.4

INP, Russia (UHF) 5 10 50 1.2 24.0

NIIEFA,Russia (DC) 1 500 500 1,9 3.8

INP, Russia (DC) 1 400 400 2.0 5.0

61

Remarks Characteristics steps can be recognized in the past of

accelerator development. Present stage of accelerator technology perfection includes: cost effectiveness, reliability, compactness, very low energy and introduction of MW beam power level,

Major industrial accelerator producers are located in USA, Russia, Japan and Belgium. Several other countries including China and Poland are capable to produce accelerators on limited scale,

Any practical accelerator construction must be compromise between size, efficiency and cost,

The progress in accelerator technology is not a quick process but can be easily noticed in longer time scale,

Appropriate accelerator selection should be performed to meet all technical and economical conditions for successful process implementation,

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Highly trained personnel is not required to run modern accelerators because of simplicity of their operation under computer support,

Accelerator reliability is very important for any industrial facility. Life time of certain accelerator components should be extended to meet industrial standards,

Spare parts and major maintenance service are usually available from the manufacturer of the accelerator,

High frequency accelerators are more costly to operate due to their more complex construction and much more expensive spare parts like klystrons and magnetrons,

New accelerators constructions can frequently offer better economic and technical characteristics but only long time operation can revile weak points of certain accelerator construction in practical industrial conditions.