Brookhaven National Laboratory Redesigns Superconducting Magnet Storage System to Boost Capacity and Cut Costs

The U.S. Department of Energy's Brookhaven National Laboratory's redesigned superconducting magnet storage system is expected to save approximately US$420,000 (about HK$3,276,000) while increasing storage capacity for equipment needed by future particle accelerators. The four-tier structure can accommodate up to 45,000 pounds of magnets in limited space. The design was developed by Robert Desjardins, a fourth-year mechanical engineering technology student at the Rochester Institute of Technology (RIT), during a 10-week summer internship.

The design will help Brookhaven store approximately 80 magnets being removed from the Relativistic Heavy Ion Collider (RHIC). This equipment is slated for reuse in the Electron-Ion Collider (EIC), which is expected to begin operations in the mid-2030s. Each superconducting magnet measures approximately 20 feet in length and weighs over 10,000 pounds.

New Design Boosts Storage Capacity

The new rack design increases storage capacity from three magnets to four without requiring additional floor space.

The original storage racks, designed in the 1990s, could hold only three magnets. Brookhaven needed a taller structure to accommodate additional magnets while meeting load-bearing and safety requirements. Desjardins used computer-aided engineering models to redesign the racks, reviewed existing blueprints, and collaborated with manufacturers to evaluate the proposed structure. "The original racks were designed in the 1990s and could only hold three magnets," Desjardins said. "They wanted to increase capacity to four." The redesign also required extensive simulations to assess structural strength, load-bearing capacity, and seismic performance.

Simulation Checks Ensure Safety

These checks aimed to determine whether the racks could safely support the heavy equipment, including under earthquake-related forces. Desjardins collaborated with Brookhaven mechanical engineer Jonathon Greene, an RIT alumnus who oversaw the project. According to Greene, the revised design lowered costs while increasing the storage system's height. "Robert reduced the cost of the original design while increasing the height," Greene said. "That saved us about US$420,000 (about HK$3,276,000)." The reported savings are attributed to the storage rack redesign, though the information provided does not detail how the savings were calculated, nor does it provide independent verification of the figure.

Brookhaven's RHIC has operated for more than 26 years, enabling scientists to study matter under extreme conditions. Some of its superconducting magnets will be retained for the new Electron-Ion Collider rather than discarded. The EIC's development aims to investigate the internal structure of protons and atomic nuclei. The accelerator will collide electrons with ions, allowing researchers to examine the behavior of quarks and gluons inside matter. Retaining existing magnets is part of the laboratory's preparation for the transition between the two facilities. The redesigned racks will provide storage space for the equipment pending reuse.

During development, Desjardins presented design updates to Brookhaven engineers and scientists, answering questions on material selection, safety assessments, and simulation results. Brookhaven also documented the four-tier rack prototype. However, the materials provided do not confirm whether all required racks have been manufactured or whether the full inventory of approximately 80 magnets has been transferred to storage.

The project demonstrates how a relatively simple structural redesign can increase storage density and reduce infrastructure costs while supporting the construction of major scientific facilities.

The Importance of Structural Redesign for Scientific Research

Brookhaven National Laboratory's redesign of its superconducting magnet storage system not only boosts storage capacity but also demonstrates the potential for effective resource utilization in limited space. This technological innovation is crucial for the operation of future particle accelerators, as it enables support for larger-scale scientific experiments without increasing costs. In this way, the laboratory can better prepare for the transition to new facilities and ensure the continued use of existing equipment, thereby advancing scientific research.