Upon the termination of the Fermilab Collider program, the current Recycler anti-proton storage ring will be converted to a proton pre-injector for the Main Injector synchrotron. This is scheduled to increase the beam power for the 120 GeV Neutrino program to upwards of 700 KW. Due to momentum aperture requirements, a Recycler to Main Injector transport line will be constructed wholly within a horizontal dispersion free region in the 30 straight section. The concept design will be presented in this paper.

During the design of the Fermilab Main Injector synchrotron it was recognized that the aperture was limited at the beam transfer and extraction points by the combination of the Lambertson magnets and the reused Main Ring quadrupoles located between the Lambertsons. Increased intensity demands on the Main Injector from antiproton production for the collider program, slow spill to the meson fixed target program, and high intensity beam to the high energy neutrino program have led us to replace the aperture-limiting quadrupoles with newly built magnets that have the same physical length but a larger aperture. The magnets run on the main quadrupole bus, and must therefore have the same excitation profile as the magnets they replaced. We present here the design of the magnets, their magnetic performance, and the accelerator performance.

Results of modeling with the 3-D STRUCT and MARS 15 codes of beam loss localization and related radiation effects are presented for the slipstacking injection to the Fermilab Main Injector. Simulations of proton beam loss are done using multi-turn tracking with realistic accelerator apertures, nonlinear fields in the accelerator magnets and time function of the RF manipulations to explain the results of beam loss measurements. The collimation system consists of one primary and four secondary collimators. It intercepts a beam power of 1.6 kW at a scraping rate of 5% of 5.5E+13 ppp, with a beam loss rate in the ring outside the collimation region of 1 W/m or less. Based on thorough energy deposition and radiation modeling, a corresponding collimator design was developed that satisfies all the radiation and engineering constraints.