In-Situ Resource Utilization (ISRU) Liquefaction Overview
This presentation gives an overview of liquefaction, the challenges associated with this subsystem, and the current work being done at NASA to advance this subsystem.
Engineering topics
Publications and source records attributed to Desai, Pooja.
This presentation gives an overview of liquefaction, the challenges associated with this subsystem, and the current work being done at NASA to advance this subsystem.
A prototype integrated liquid oxygen/liquid methane propulsion system was hot-fire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). This test campaign served two purposes: 1) Characterize the performance of the Plum Brook facility in vacuum accumulator mode and 2) Collect the unique data set of an integrated LOX/Methane propulsion system operating in high altitude and thermal vacuum environments (a first). Data from this propulsion system prototype could inform the design of future spacecraft in-space propulsion systems, including landers. The test vehicle for this campaign was the Integrated Cryogenic Propulsion Test Article (ICPTA), which was constructed for this project using assets from the former Morpheus Project rebuilt and outfitted with additional new hardware. The ICPTA utilizes one 2,800 lbf main engine, two 28 lbf and two 7 lbf reaction control engines mounted in two pods, four 48-inch propellant tanks (two each for liquid oxygen and liquid methane), and a cold helium system for propellant tank pressurization. Several hundred sensors on the ICPTA and many more in the test cell collected data to characterize the operation of the vehicle and facility. Multiple notable experiments were performed during this test campaign, many for the first time, including pressure-fed cryogenic reaction control system characterization over a wide range of conditions, coil-on-plug ignition system demonstration at the vehicle level, integrated main engine/RCS operation, and a non-intrusive propellant mass gauging system. The test data includes water-hammer and thermal heat leak data critical to validating models for use in future vehicle design activities. This successful test campaign demonstrated the performance of the updated Plum Brook In-Space Propulsion thermal vacuum chamber and incrementally advanced the state of LOX/Methane propulsion technology through numerous system-level and subsystem experiments.
NASAs current Mars architectures are assuming the production and storage of 23 tons of liquid oxygen on the surface of Mars over a duration of 500+ days. In order to do this in a mass efficient manner, an energy efficient refrigeration system will be required. Based on previous analysis NASA has decided to do all liquefaction in the propulsion vehicle storage tanks. In order to allow for transient Martian environmental effects, a propellant liquefaction and storage system for a Mars Ascent Vehicle (MAV) was modeled using Thermal Desktop. The model consisted of a propellant tank containing a broad area cooling loop heat exchanger integrated with a reverse turbo Brayton cryocooler. Cryocooler sizing and performance modeling was conducted using MAV diurnal heat loads and radiator rejection temperatures predicted from a previous thermal model of the MAV. A system was also sized and modeled using an alternative heat rejection system that relies on a forced convection heat exchanger. Cryocooler mass, input power, and heat rejection for both systems were estimated and compared against sizing based on non-transient sizing estimates.
NASAs current Mars architectures are assuming the production and storage of 23 tons of liquid oxygen on the surface of Mars over a duration of 500+ days. In order to do this in a mass efficient manner, an energy efficient refrigeration system will be required. Based on previous analysis NASA has decided to do all liquefaction in the propulsion vehicle storage tanks. In order to allow for transient Martian environmental effects, a propellant liquefaction and storage system for a Mars Ascent Vehicle (MAV) was modeled using Thermal Desktop. The model consisted of a propellant tank containing a broad area cooling loop heat exchanger integrated with a reverse turbo Brayton cryocooler. Cryocooler sizing and performance modeling was conducted using MAV diurnal heat loads and radiator rejection temperatures predicted from a previous thermal model of the MAV. A system was also sized and modeled using an alternative heat rejection system that relies on a forced convection heat exchanger. Cryocooler mass, input power, and heat rejection for both systems were estimated and compared against sizing based on non-transient sizing estimates.
Parallel-fed propellant tanks are an advantageous configuration for many spacecraft. Parallel-fed tanks allow the center of gravity (cg) to be maintained over the engine(s), as opposed to serial-fed propellant tanks which result in a cg shift as propellants are drained from tank one tank first opposite another. Parallel-fed tanks also allow for tank isolation if that is needed. Parallel tanks and feed systems have been used in several past vehicles including the Apollo Lunar Module. The design of the feedsystem connecting the parallel tank is critical to maintain balance in the propellant tanks. The design must account for and minimize the effect of manufacturing variations that could cause delta-p or mass flowrate differences, which would lead to propellant imbalance. Other sources of differential draining will be discussed. Fortunately, physics provides some self-correcting behaviors that tend to equalize any initial imbalance. The question concerning whether or not active control of propellant in each tank is required or can be avoided or not is also important to answer. In order to provide data on parallel-fed tanks and differential draining in flight for cryogenic propellants (as well as any other fluid), a vertical test bed (flying lander) for terrestrial use was employed. The Morpheus vertical test bed is a parallel-fed propellant tank system that uses passive design to keep the propellant tanks balanced. The system is operated in blow down. The Morpheus vehicle was instrumented with a capacitance level sensor in each propellant tank in order to measure the draining of propellants in over 34 tethered and 12 free flights. Morpheus did experience an approximately 20 lb/m imbalance in one pair of tanks. The cause of this imbalance will be discussed. This paper discusses the analysis, design, flight simulation vehicle dynamic modeling, and flight test of the Morpheus parallel-fed propellant. The Apollo LEM data is also examined in this summary report of the flight data.
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