How Synecom restored performance and eliminated virgin gas demand at INFN Legnaro
1. Context
The National Laboratories of Legnaro (INFN – National Institute for Nuclear Physics) represent one of Europe’s premier research hubs for nuclear physics and particle accelerator technology. Among its strategic infrastructures is the Moby Dick particle accelerator, a system relying on massive quantities of SF6 gas as an essential insulating fluid to ensure the safe and continuous operation of its high-voltage equipment. Over years of continuous operation, SF6 gas undergoes progressive degradation, accumulating moisture, solid particulates, and harmful decomposition byproducts that compromise system stability and electrical insulation capabilities.
2. Objective
Design and execute a complete on-site recovery and regeneration operation for the SF6 gas within the Moby Dick accelerator to:
- recover and purify the existing 35-ton gas inventory without resorting to full gas replacement;
- remove all moisture, chemical impurities, and decomposition byproducts;
- restore fluid performance parameters to meet strict particle accelerator technical specifications;
- eliminate atmospheric emissions risk during extraction, treatment, and re-injection;
- execute all activities in-situ at the INFN Legnaro facility to drastically minimize facility downtime.
3. Challenge
- Massive Gas Volume & On-Site Constraint: Processing approximately 35 tons of SF6 directly within the research center without removing the gas from the site.
- Hazardous Byproduct Handling: Managing dangerous decomposition products (e.g., SO₂, HF, H₂S) generated through high-voltage electrical stress.
- Uptime & Shift Optimization: Orchestrating continuous 24/7 multi-shift operations to minimize critical accelerator downtime.
- Environmental & Quality Controls: Maintaining continuous real-time diagnostic monitoring over fluid parameters during treatment.
4. Solution
Synecom designed and deployed an advanced, closed-loop mobile gas regeneration system tailored for high-volume Big Science applications. The solution included:
- deployment of a fully equipped mobile regeneration plant directly to the INFN Legnaro site;
- comprehensive preliminary and ongoing gas diagnostics;
- multi-stage dedicated filtration to eliminate moisture, fine particulates, and toxic decomposition compounds;
- closed-loop processing featuring gas separation, clean gas recovery, controlled compression, and re-injection;
- strict hazardous waste isolation, collecting residual byproducts into dedicated cylinders for certified off-site thermal destruction.
5. Sustainable Engineering Contribution
Synecom applied a full circular economy model directly to large-scale scientific infrastructure:
- Zero Gas Replacement: Averted the manufacture, logistics, and purchase of 35 tons of virgin SF6—an energy-intensive gas with an extremely high Global Warming Potential (GWP).
- Emissions & Waste Reduction: Reduced the overall environmental footprint by eliminating unnecessary gas transport and drastically cutting the volume of fluid destined for disposal.
- In-Situ Lifecycle Extension: Extended the operational lifecycle of the existing SF6 inventory while upholding virgin-grade technical standards.
6. Implementation
The project was executed through a structured, round-the-clock operational strategy:
- direct connection of Synecom’s mobile unit to the Moby Dick accelerator storage tanks;
- continuous 24/7 multi-shift operations to process the entire 35-ton inventory rapidly;
- progressive multi-stage filtration and closed-loop purification cycles;
- system integrity testing and high-precision leak checks utilizing specialized SYNECOM diagnostic instrumentation;
- controlled re-filling and re-commissioning of the regenerated gas.
7. Quality & Environmental Control
Quality assurance was maintained through rigorous real-time monitoring and diagnostic protocols:
- Parameter Tracking: Continuous measurement of SF6 purity, dew point (moisture), SO₂, HF, H₂S, CO, N₂, and O₂;
- Hermetic Operations: Sealed closed-loop transfer protocols preventing fugitive emissions during processing;
- Diagnostic Verification: Advanced leak testing using proprietary SYNECOM instrumentation;
- Final Certification: Comprehensive quality validation and formal certification confirming that the regenerated SF6 met required purity standards before system restart.
8. Results
- 35 Tons Regenerated: Total on-site recovery and purification of the 35-ton SF6 inventory.
- >99.9% Purity Achieved: Restored SF6 purity to values exceeding 99.9%, matching virgin gas specifications.
- Zero Virgin Gas Purchased: Completely eliminated the need to acquire 35 tons of new SF6.
- Minimized Downtime: Successfully executed via continuous 24/7 shifts, preventing prolonged facility shutdown.
- Reduced Environmental Footprint: Avoided massive CO₂-equivalent footprint associated with virgin SF6 production, transport, and total waste destruction.
9. Strategic Value
This project demonstrates how specialized F-gas management and applied circular economy principles can deliver measurable strategic value to top-tier scientific institutions. Synecom acted as a specialized technology partner capable of:
- performing high-complexity chemical engineering on-site within sensitive scientific research facilities;
- delivering substantial cost savings while enhancing facility sustainability profiles;
- proving that high-voltage infrastructures can achieve technical performance without sacrificing environmental responsibility.
