Low-Cost Cryocooler Pumps Out Cheap DIY Liquid Nitrogen

July 15, 2024 by Dan Maloney 18 Comments

A word of caution if you’re planning to try this cryocooler method for making liquid nitrogen: not only does it involve toxic and flammable gasses and pressures high enough to turn the works into a bomb, but you’re likely to deplete your rent account with money you’ll shell out for all the copper tubing and fittings. You’ve been warned.

In theory, making liquid nitrogen should be as easy as getting something cold enough that nitrogen in the air condenses. The “cold enough” part is the trick, and it’s where [Hyperspace Pirate]’s cryocooler expertise comes into play. His setup uses recycled compressors from cast-off air conditioners and relies on a mixed-gas Joule-Thomson cycle. He plays with several mixtures of propane, ethylene, methane, argon, and nitrogen, with the best results coming from argon and propane in a 70:30 percent ratio. A regenerative counterflow heat exchanger, where the cooled expanding gas flows over the incoming compressed gas to cool it, does most of the heavy lifting here, and is bolstered by a separate compressor that pre-cools the gas mixture to about -30°C before it enters the regenerative system.

There’s also a third compressor system that pre-cools the nitrogen process gas, which is currently supplied by a tank but will eventually be pulled right from thin air by a pressure swing adsorption system — basically an oxygen concentrator where you keep the nitrogen instead of the oxygen. There are a ton of complications in the finished system, including doodads like oil separators and needle valves to control the flow of liquid nitrogen, plus an Arduino to monitor and control the cycle. It works well enough to produce fun amounts of LN₂ on the cheap — about a quarter of the cost of commercially made stuff — with the promise of efficiency gains to come.

It does need to be said that there’s ample room for peril here, especially containing high pressures within copper plumbing. Confidence in one’s brazing skills is a must here, as is proper hydro testing of components. That said, [Hyperspace Pirate] has done some interesting work here, not least of which is keeping expenses for the cryocooler to a minimum.

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Dry Ice From Seashells, The Hard (But Cheap) Way

December 6, 2023 by Dan Maloney 11 Comments

[Hyperspace Pirate] wants to make his own dry ice, but he wants it to be really, really cheap. So naturally, his first stop is… the beach?

That’s right, the beach, because that’s where to find the buckets of free seashells that he turned into dry ice. Readers may recall previous efforts at DIY dry ice, which used baking soda and vinegar as a feedstock. We’d have thought those were pretty cheap materials for making carbon dioxide gas, but not cheap enough for [Hyperspace Pirate], as the dry ice he succeeded in making from them came out to almost ten bucks a pound. The low yield of the process probably had more to do with the high unit cost, in truth, so cheaper feedstocks and improved yield would attack the problem from both ends.

With a supply of zero-cost calcium carbonate from the beach and a homemade ZVS-powered induction heater tube furnace at the ready, [Hyperspace Pirate] was ready to make quicklime and capture the CO₂ liberated in the process. That proved to be a little more difficult than planned since the reaction needed not just heat but a partial vacuum to drive the CO₂ off. An oil-free vacuum pump helped, yielding a little CO₂, but eventually he knuckled under and just doused the shells in vinegar. This had the fun side effect of creating calcium acetate, which when distilled not only corrodes the copper still plumbing but also makes a lousy but still flammable grade of acetone. Once enough CO₂ was stored in a couple of beach balls, the process of cooling and condensing it into dry ice was pretty much the same as the previous method, except for taking advantage of the Joule-Thomson cryocooler he built a while back.

The result is a hundred or so grams of dry ice snow, which isn’t great but still shows promise. [Hyperspace Pirate] feels like the key to improving this process is more heat to really drive the calcination reaction. Might we suggest a DIY tube furnace for that job?

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Creating A Joule-Thomson Cryocooler And A Little Bit Of History At Home

July 7, 2023 by Maya Posch 11 Comments

The fun part about crycoolers is that there are so many different and exciting ways to make stuff cold, based on a wide variety of physics. This is why after first exploring the Stirling/GM cycle and vapor-compression to create a cryocooler that he could liquefy nitrogen with, [Hyperspace Pirate] is exploring a Joule-Thomson cooler, which is also misspelled as ‘Joule-Thompson’ by those who don’t mind take some liberties with history. Either way, the advantage of the adiabatic Joule-Thomson effect is that it is significantly simpler than the other methods — having been invented in the 19th century and used for the earliest forms of refrigeration.

This is what peak Joule-Thomson prototype cooler performance looks like.

The big difference between it and other technologies is that the effect is based on throttling the flow of a gas as it seeks to expand, within specific temperature and pressure ranges to ensure that the temperature change effect is positive (i.e. the temperature of the gas decreases). The net result is that of a cooling effect, which as demonstrated in the video can be used with successive stages involving different gases, or a gas mixture, to reach a low enough temperature at which nitrogen (contained in the same gas mixture) liquefies and can be collected.

Although not a very efficient process, if your local electricity costs allow it, running the compressor in a closed loop version isn’t that expensive and worth it for the science alone. Naturally, as with any experimental setup involving a range of gases, a compressor and other components, getting it to run perfectly on the first try is basically impossible, which is why this is so far Part 1 of another series on cryocoolers at home (or in the garage).

If you’re interested in the previous work [Hyperspace Pirate] has done with DIY cyrocoolers, take a look at our coverage from earlier this year.

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A DIY Pulse Tube Cryocooler In The Quest For Home-Made Liquid Nitrogen

January 1, 2023 by Maya Posch 5 Comments

What if you have a need for liquid nitrogen, but you do not wish to simply order it from a local supplier? In that case you can build your very own pulse tube cryocooler, as [Hyperspace Pirate] is in the process of doing over at YouTube. You can catch part 1 using a linear motor and part 2 using a reciprocating piston-based version also after the break. Although still very much a work-in-progress, the second version of the cryocooler managed to reduce the temperature to a chilly -75°C.

The pulse tube cryocooler is one of many types of systems used for creating a cooling effect. Commercially available refrigerators and freezers tend to use Rankine cycle coolers due to their low cost and effectiveness at (relatively) warmer temperatures. For cryogenic temperatures, Stirling engines are commonly used, although they find some use in refrigeration as well. All three share common elements, but they differ in their efficiency over a larger temperature range.

In this video series, the viewer is taken through the physics behind these coolers and the bottlenecks which prevent them from simply cooling down to zero Kelvin. Despite the deceptive simplicity of pulse tube cryocoolers — with just a single piston, a regenerator mesh, and some tubing — making them work well is an exercise in patience. We’re definitely looking forward to the future videos in this series as it develops.

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About As Cold As It Gets: The Webb Telescope’s Cryocooler

May 5, 2022 by Dan Maloney 26 Comments

If you were asked to name the coldest spot in the solar system, chances are pretty good you’d think it would be somewhere as far as possible from the ultimate source of all the system’s energy — the Sun. It stands to reason that the further away you get from something hot, the more the heat spreads out. And so Pluto, planet or not, might be a good guess for the record low temperature.

But, for as cold as Pluto gets — down to 40 Kelvin — there’s a place that much, much colder than that, and paradoxically, much closer to home. In fact, it’s only about a million miles away, and right now, sitting at a mere 6 Kelvin, the chunk of silicon at the focal plane of one of the main instruments aboard the James Webb Space telescope makes the surface of Pluto look downright balmy.

The depth of cold on Webb is all the more amazing given that mere meters away, the temperature is a sizzling 324 K (123 F, 51 C). The hows and whys of Webb’s cooling systems are chock full of interesting engineering tidbits and worth an in-depth look as the world’s newest space telescope gears up for observations.

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