Ground-Based Cryogenic Leak Test of Fittings for Cryogenic Fluid Management
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Engineering topics
Publications and source records attributed to Adam Swanger.
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Passive thermal control is vital in space, especially for extended missions involving cryogen storage needing protection from sunlight. This presentation covers the development of a thermal coating with wavelength-selective characteristics using polymeric materials that scatter sunlight with minimal absorption, resulting in high solar reflectance. Furthermore, these coatings allow emission in infrared wavelengths, making them suitable for deep-space missions requiring extended storage. The study chose polymer and surface morphology suitable as solar reflectors that are lightweight, compact, and easily manufacturable, focusing on different multilayered nanofibers made using polytetrafluoroethylene and polyethylene-oxide (PTFE-PEO), polyvinylidene fluoride-hexafluoropropylene (PVDF-HFP), and silica (SiO2). To understand how these materials interact with sunlight, we analyze light propagation through several layers of electrospun nanofibers to determine spectral reflectance, absorptance, and transmittance by solving the Maxwell equations. The model is also compared with measurements of spectral reflectance and transmittance of the various electrospun nanofibers using spectrophotometers interfaced with integrating spheres in the ultraviolet, visible, near-infrared, and mid-infrared wavelengths. The presentation will also describe the design and analysis, fabrication of the nanofibers using electrospinning, and several experimental characterization techniques to determine suitability for space applications. The nanofibers are tested using various tools to determine their suitability for cryogenic applications in space. Lastly, the samples were tested under low vacuum conditions and exposing them to sunlight inside a vacuum chamber maintained at 300 K. Relative to the incoming solar flux (1000 W/m2), only 1% of the energy was absorbed under these operating conditions. With further optimization and testing under high vacuum cryogenic environments, the samples could demonstrate much lower absorption or higher reflection of incoming solar radiation, which can translate to low temperatures suitable for cryogen storage.
This study discusses a practical system utilizing the principle of physisorption where hydrogen is weakly bound to the surface of a nanoporous silica aerogel blanket as an alternative to high-pressure and cryogenic hydrogen storage. Three different experiments are conducted to simulate various scenarios of such a storage method: change in pressure and change of scale. Transient responses of the charging and discharging cycles are of particular interest. It is observed that hydrogen uptake can be increased by up to 36-38 % at ambient conditions and 77 K when utilizing the aerogel blankets. Packing density, or the artificial increase of surface per volume, increases storage capacity as it is a mainly surface-driven phenomenon. High-pressure testing up to 50 bar showed benefits of the aerogel addition whereas the maximum uptake improvement was observed for 2 bar with a 105.3 % improvement over an empty vessel at identical conditions corresponding to 6.43 wt%. The scale-up of the system is highly sensitive to the design of the internal cooling design as aerogels are poor thermal conductors reducing the transient response of such systems. Furthermore, the high mass of metal-based pressure vessels further delays the thermal response. This makes the system suitable for day to week-long hydrogen storage but not for peak-shaving or load balancing.
Introduction Hydrophobicity is the tendency of a fluid to repel another material or fluid. Hydrophobiciy can be measured through the wetting angle of the fluid on the surface of the other material. The greater the wetting angle, the more hydrophobic the surface is against the fluid. Hydrophobicity properties can be caused by one of two means, either through physical properties or chemical properties [\citenum{NARBUTT2020121}]. Physical hydrophobicity due to the surface of a solid creating surface roughness/patterning, minimizing the contact area between the fluid and the surface. This can be observed throughout nature, such as the surface of lotus leaves or butterfly wings. This physical property can be induced on a variety of surfaces, namely through laser etching, allowing a surface to be finely lineated to imitate these natural surfaces while controlling quantity, depth, and patterns of the etching on the surface [\citenum{10.1063/1.4905616}]. Physical hydrophobicity is therefore dependent on several variables, including the surface that the fluid is on and properties of the fluid itself, such as density and surface tension, both of which are dependent on temperature and/or pressure. Chemical hydrophobicity [\citenum{MadeiraHydrophobocicicici}] is due to the inherent chemical properties of the materials being used. This is most commonly due to the molecular structures changing the polarity of the materials. Depending on a nonpolar material will repel a polar material, proving to be hydrophobic, conversely if the polarity of the materials is the same (polar – polar, nonpolar – nonpolar), they will attract each other. Cryogenics refers to the behavior of materials at very low temperatures (<\ang{-100} C) [\citenum{ZOHURI20181}]. In space applications many things are inherently cryogenic, therefore this is an important field. There has been little research in how hydrophobicity changes at cryogenic temperatures. Cryogenic fluids are commonly used as fuels for spacecraft, therefore, integrating a hydrophobic surface can increase the transfer rate of the fuel. To test this, several experiments were set up to determine the hydrophobic properties of cryogenic fluids, including nitrogen (LN2), argon (LAr), oxygen (LOx), hydrogen (LH2), and methane (CH4), at cryogenic temperatures. Etched Wafer Testing A silicon wafer cut from a crystal of silicon [100] was used to model the potential hydrophobicity of various cryogenic fluids. Silicon [100] references to the crystallographic orientation of the silicon crystals in the wafer. These wafers were then laser etched to create a surface that is more likely to be hydrophobic. To test the hydrophobicity of the wafers at cryogenic temperatures, the temperatures of the wafers must be reduced to the same temperature as the cryogenic fluid being used to prevent rapid boil-off. To achieve this a double-walled vacuum insulated glass chamber was utilized. The chamber is open, with a double-walled glass that can be placed in a vacuum to remove condensation from the outside to allow easier viewing of the experiment. Furthermore, the silicon wafer's temperature must be lowered to the temperature of LN2, as well as maintain the temperature throughout the experiment. To achieve this a piece of 6061 aluminum was used, creating a stand-off for the wafer and it would allow for the insulation of the temperature of the wafers. The container was then filled with LN2 and once the LN2 stabilized the vaporization and the levels of LN2 dropped under the height of the wafer, the wafer was then allowed to air dry. Once the wafer was dry from the LN2, drops of LN2 were placed on the surface of the wafer for observation. During the first trial, the LN2 that was dropped on the surface displayed nonhydrophobic behaviors, spreading out along the surface, with a minimal wetting angle (too small to be measured). This process was repeated for liquid argon. Further testing with other cryogenic liquids will require different testing apparatuses due to being more volatile. Furthermore, several papers [\citenum{voltvolt7}] have suggested that running a voltage can induce a hydrophobic effect throughout a surface, further testing will include a voltage (constant and oscillating) to determine if voltage influences inducing hydrophobicity at cryogenic temperatures. Chemical Testing Coating the interior walls of the fuel tanks and fuel lines can successfully create a hydrophobic surface. The inherent problem is finding a material that can be used to coat the surface, furthermore, at these temperatures, the coating will remain solid, which could pose issues in maintaining the hydrophobic properties. To test this water (polar) is hydrophobic against oils and fats (nonpolar), therefore the same experiment as the etched wafer testing was conducted to determine if the hydrophobic properties will persist as the nonpolar material remains solid and the polar material remains a fluid. The water remained hydrophobic, allowing testing can expand to the cryogenic fluids. However, another hurdle is faced in finding a chemically opposite material to the cryogenic fluids being tested. As many of the cryogenic fluids being tested are diatomic, they are inherently nonpolar, therefore, the material used for the hydrophobic coating must be polar. Polar greases and lubricants are difficult to come by, however, lithium stearate, appears to be a potential candidate for creating a coated hydrophobic surface for cryogenic fluids at cryogenic temperatures.
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The Cryogenic Flux Capacitor (CFC) is a cold, dense energy storage core that is being studied in the cryo-compressed, about 300 bar and 80K, region of gaseous hydrogen (GH 2 ) storage and liquid hydrogen (LH 2 ) region near the normal boiling point. Hydrogen storage is improved by physically bonding the molecules within the nanoscale pores of the aerogel composite blanket material. The process of bonding or debonding is governed by principles of physical adsorption (physisorption) and thermodynamics. The large surface area afforded by the nanoporous aerogel (~1,000 m 2 /g) allows its storage performance to easily exceed capacities of high-pressure GH 2 storage for an equivalent volume. With the integrated aerogel, subscale tests have shown that storage is increased by about 36% over a simple tank filled with GH 2 at the same operating temperature and pressure. For LH 2 conditions, the CFC is shown to operate at improved densities, but testing is ongoing. For the techno-economic analysis (TEA), the source of hydrogen is compared between onsite steam methane reforming (SMR) and onsite solar photovoltaic (PV) panels providing power to electrolyzers to produce green GH 2 . The TEA compares pure hydrogen produced at a small scale for a 25 MW power system and at a large scale in a 500 MW power system. The system allowed for hydrogen imports and exports at a set price with a tank sized for 10 hours of power production. The two power producing technologies are a combined cycle gas turbine (CCGT) and hydrogen fuel cells. The SMR system uses natural gas as an input and includes a carbon capture and storage (CCS) system. The levelized cost of electricity (LCOE), levelized cost of hydrogen (LCOH), and levelized cost of storage (LCOS) are developed based on the capital cost and operating cost of the systems. The results are shown for current costs using a 2021 benchmark and DOE projections for cost improvements by 2030. The TEA showed that onsite hydrogen generation from SMR has an LCOH of about 1.4 to 2 USD per kg over the life of the plant and the PV hydrogen production LCOH is about 5.2 to 5.5 USD per kg. The LCOS of conventional GH 2 systems is estimated to be $210/MWh and cost of storage for LH 2 systems is $205/MWh for fuel cell systems and $249/MWh for CCGT systems. CFC improved the LCOS of all these systems to $198/MWh, $191/MWh and $233/MWh respectively. The LCOE also improved with conventional systems between $171/MWh and $228/MWh improved by CFC to between $167/MWh and $212/MWh. Using projections for improvement in costs following DOE’s goals by 2030, green hydrogen improved to as low as $78/MWh LCOS and LCOE for conventional cases. CFC improved over conventional storage with the lowest LCOS being $62/MWh and the lowest LCOE being $73/MWh. These results correspond to an LCOH of $2/kg. Finally, the TEA shows how LCOE is improved for hydrogen conditioning and storage over conventional systems and caverns in the 10 to 50 hour range.
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