Case Study: Fermi National Accelerator Laboratory achieves doubled proton beam intensity with COMSOL Multiphysics

Doubling Beam Intensity Unlocks Rare Opportunities for Discovery at Fermi National Accelerator Laboratory

Fermi National Accelerator Laboratory needed to double proton throughput in its 40‑year‑old Booster synchrotron as part of the Proton Improvement Plan, but upgrading the ferrite‑tuned RF cavities risked overheating and reduced component life at higher repetition rates and accelerating voltages. To evaluate RF, thermal, and mechanical performance and guide the upgrade, FNAL engineers used Comsol (COMSOL Multiphysics) to model the cavities and tuners.

Using Comsol's COMSOL Multiphysics, the team built a CAD‑based, one‑quarter symmetric multiphysics model, validated it against measured cavity Q, and quantified heating and power: at 55 kV/7 Hz tuner peak temperature was 65°C; increasing to 15 Hz raised tuner temps by >30°C, and 60 kV/15 Hz added ~10°C, while dissipated power rose from 16.6 kW to 39.1 kW. Comsol’s simulations identified needed cooling upgrades (increased airflow, more piping, lower water temperature) and guided design choices that reduce risk, time, and cost, enabling the Booster to pursue doubled beam intensity and remain operational through its 55th year.

Fermi National Accelerator Laboratory

Mohamed Awida Hassan

Engineer