If you’re using liquid helium in your facility, you already know one thing for sure: it’s cold. Really cold. At 4.2 Kelvin (that’s -452°F), liquid helium is the coldest substance you’ll likely encounter in an industrial or research setting. If you’ve been watching helium prices rise over the last several years, you also know something else: it's expensive.
So, if you’re wondering, “Is it worth looking into a helium recovery system?” our answer is: Yes. With prices rising and supply limited, helium recovery systems offer a smart, sustainable solution. In this blog, we cover why helium is costly, how recovery systems work, typical ROI, and how a consulting engineer can support successful implementation.
Liquid helium is critical for systems which need to stay supercooled to function, and while other gases like nitrogen are used for cryogenics, only helium reaches the ultra-low temperatures needed for superconductivity. Nuclear magnetic resonance spectrometers, magnetic resonance imaging, particle accelerators, space observatories and telescopes are some of the technologies that require helium to function source (Bluefors).
The main reasons that helium is expensive are:
Helium recovery systems are widely used outside the United States, particularly in research and industrial facilities aiming to reduce helium consumption. These systems allow you to capture, purify, and re-liquefy the helium gas that vents off during system operation. Instead of losing it to the atmosphere (where it literally floats away forever), you get to reuse it.
The basic process involves the following steps:
In a multi-use point system, gaseous helium is collected in a buffer volume which may include an atmospheric recovery bag or gas cylinders that the helium gets compressed into and stored.
The re-liquefier uses a cryocooler and associated compressor/condenser package to remove heat from the recovered, purified helium such that it is ready for transfer and reuse at the equipment, saving you money!
In general, system install costs range from $300k to over $1M, depending on scale and complexity. With helium prices hovering between $40 and $60 per liter in recent years, paybacks can be surprisingly short.
We’ve seen ROI in as little as 2 to 4 years for high-use facilities and if you’re trying to insulate your budget from volatile supply chain risks, recovery systems are an excellent way to stabilize cost long-term.
Installing a helium recovery system isn’t as simple as plugging in new equipment. Many times, we’ve been called onto a project after parts have been ordered, and scramble to verify building suitability and design a system as quickly as possible.
You’ll need:
Planning a helium recovery system requires input from experienced consulting engineers who can assess facility readiness, ventilation, and integration needs.
A good consulting engineer will work with you early to map your system, quantify losses, identify recapture opportunities, and coordinate with the OEM or system vendor. We’ll also help you with facility readiness—from space planning to installation logistics and commissioning support.
Our very own mechanical engineer Ash Krieder, PhD., PE, shared his thoughts on helium recovery design in this Hallam blog from 2024: Design Considerations for a Helium Recovery Plant. Hallam-ICS also has experience integrating helium recovery systems, as detailed in this case study on our work for Harvard University.
If rising helium prices are affecting your operations, a helium recovery system can provide long-term cost savings, contribute to your carbon reduction strategy, and protect against supply disruptions.
Even if you’re not ready to commit to a full install today, a helium usage audit and feasibility study can be a great starting point. You’ll better understand your losses and where the savings opportunities are.
In short: yes, liquid helium is cool. But saving $500k+ per year by recovering it? That’s even cooler.
About the Author
Jonathan is a graduate of SUNY Buffalo with a BS in Mechanical Engineering and a registered Professional Engineer in the states of New York, Massachusetts, and Connecticut. He joined Hallam-ICS’s NY office as an Engineering Manager in 2023 and brings over a decade of MEP consulting experience across a wide variety of project types serving the commercial, industrial, and pharmaceutical markets.
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About Hallam-ICS
Hallam-ICS is an engineering and automation company that designs MEP systems for facilities and plants, engineers control and automation solutions, and ensures safety and regulatory compliance through arc flash studies, commissioning, and validation. Our offices are located in Massachusetts, Connecticut, New York, Vermont and North Carolina Texas, Florida and our projects take us world-wide.