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NASA NTRSDate not supplied

Impact of Thermochromic Coatings on Thermal Management for Human Spacecraft Applications

Thermochromic variable emittance coatings (VECs) allow for passive, dynamic thermal management of space vehicles due to their temperature dependent optical properties. Ideally, a thermochromic material should exhibit low mid-IR emissivity for lower temperatures and switch to high mid-IR emissivity for higher temperatures; one promising material that demonstrates these characteristics is Lanthanum Strontium Manganite (LSM). The transition temperatures of LSM are dependent on the Lanthanum-to-Strontium ratio x, La1-xSrxMnO3. La0.8Sr0.2MnO3, which has an emittance of 0.5 for < 270 K, then a linear increase in emittance to 0.8 over an increase of 70 K where it will saturate at ~340K, is commonly utilized but this is tunable by changing the Sr concentration. The tunability of the transition temperature range of LSM motivates a need to understand the optimal thermal transition range for human spacecraft. Additionally, LSM has high solar absorptance and to combat this issue the VEC will be micropatterned on top of a highly solar reflective layer of Barium Sulfate (BaSO4). Consequently, this work will elucidate the tradeoffs between solar absorptance and variable emittance for this technology since the micropattern adversely couples the solar absorptance to the mid-IR emittance. This work develops a computational model using Thermal Desktop to study the utility of VECs on human spacecraft, such as Orion, subjected to mission phases such as lunar transit and Gateway docking. The model considers both external heat loads, from solar irradiation and planetary IR, as well as vehicle heat loads, from avionics and crew, as an input into the body mounted thermochromic radiators. There are several design targets for VECs, i.e. achieving the largest change in emittance, finding the optimal temperature range for the transition, and achieving the highest emittance in the high temperature phase. This work prioritizes these design targets for LSM to achieve the optimal heat rejection for a human spacecraft. The VECs are compared with static emittance coatings and the efficiency gains are quantified. Thermochromic VECs will ultimately lead to simplifications of active cooling systems which synergistically correlates to mass reduction and less energy consumption for space vehicles.

Joseph Peoples↗

NASA NTRS2011

An Active Broad Area Cooling Model of a Cryogenic Propellant Tank with a Single Stage Reverse Turbo-Brayton Cycle Cryocooler

As focus shifts towards long-duration space exploration missions, an increased interest in active thermal control of cryogenic propellants to achieve zero boil-off of cryogens has emerged. An active thermal control concept of considerable merit is the integration of a broad area cooling system for a cryogenic propellant tank with a combined cryocooler and circulator system that can be used to reduce or even eliminate liquid cryogen boil-off. One prospective cryocooler and circulator combination is the reverse turbo-Brayton cycle cryocooler. This system is unique in that it has the ability to both cool and circulate the coolant gas efficiently in the same loop as the broad area cooling lines, allowing for a single cooling gas loop, with the primary heat rejection occurring by way of a radiator and/or aftercooler. Currently few modeling tools exist that can size and characterize an integrated reverse turbo-Brayton cycle cryocooler in combination with a broad area cooling design. This paper addresses efforts to create such a tool to assist in gaining a broader understanding of these systems, and investigate their performance in potential space missions. The model uses conventional engineering and thermodynamic relationships to predict the preliminary design parameters, including input power requirements, pressure drops, flow rate, cycle performance, cooling lift, broad area cooler line sizing, and component operating temperatures and pressures given the cooling load operating temperature, heat rejection temperature, compressor inlet pressure, compressor rotational speed, and cryogenic tank geometry. In addition, the model allows for the preliminary design analysis of the broad area cooling tubing, to determine the effect of tube sizing on the reverse turbo-Brayton cycle system performance. At the time this paper was written, the model was verified to match existing theoretical documentation within a reasonable margin. While further experimental data is needed for full validation, this tool has already made significant steps towards giving a clearer understanding of the performance of a reverse turbo-Brayton cycle cryocooler integrated with broad area cooling technology for zero boil-off active thermal control.

Guzik, Monica C.↗

NASA NTRS1991

Advanced thrust chamber technology for in-space propulsion system

Two new concepts, the afterburning technique and the spray optimization method for the purpose of upgrading the combustion efficiency and C efficiency, are examined to assess the technical merits and hurdles that need to be resolved. Details of combustion and aerodynamic processes of monomethylhydrazine and nitrogen tetroxides in a toroidal shaped combustion chamber of a variable thrust engine, devised with a wall impingement cooling system and the secondary injection of an oxidizer from the chamber wall for an afterburning, are investigated for the selected secondary injection conditions. With an appropriate injection condition, the combustion efficiency was found to be almost 23 percent higher than that of an engine without afterburning.

Chiu, H. H.↗

DOE OSTI2020

Liquid helium fluid dynamics studies. Final Technical Report

Future high energy physics accelerators depend on a number of advanced technologies to open the many doors of scientific discovery. Among these advanced technologies, superconducting magnets and superconducting radio frequency (SRF) cavities are the backbone of the accelerator and detector systems. But all these low temperature systems depend critically on successful and reliable operation of their supporting technologies, among which the liquid helium cooling system is of the utmost importance. To improve the quality of these systems both in terms of efficiency and reliability, a robust helium cryogenics research and development (R&D) effort is required. The proposed research to be conducted by the FSU cryogenics group aims to produce fundamental knowledge that meets this R&D need. The projects that we have completed over the past grant period at Florida State University consist of experimental research on liquid helium fluid dynamics and heat transfer problems relevant to the development of future superconducting particle physics accelerators. Liquid helium is the coolant used in all such facilities and in many of these facilities He II (the low temperature phase of liquid helium also known as superfluid helium) is preferred due to its outstanding heat transfer characteristics. The work consists of two main experimental studies that probe both fundamental as well as practical aspects of liquid helium cooling. The first is a broad and fundamental study of the heat and mass transfer processes that can occur during a sudden catastrophic loss of vacuum (SCLV) incident in a superconducting accelerator. SCLV refers to the remote but extremely critical accident scenario where atmospheric pressure air is allowed to flood into the insulating vacuum system and impinge on the liquid helium cooled surfaces in the accelerator. Safe performance and recovery from such accidents is essential to the reliable operation of superconducting accelerators. The dynamics of this process is quite complex and so our approach is to conduct a series of well-orchestrated experiments that probe the various physical phenomena that can occur during an SCLV event. The experiments are coupled with analytic and numerical analysis in an effort to develop a general understanding of the process and to assist with future accelerator design and development. The second activity is directed toward fundamental understanding of heat and mass transfer in He II, which is essential to the design of superconducting magnets and radio frequency cavities in accelerators. The work consists of flow visualization of the dynamics of He II using laser assisted techniques. Two complementary techniques are used to study the fundamentals of the turbulent state. The first technique uses neutrally buoyant solid hydrogen particles to probe the flow fields of the superfluid and normal fluid components. The other technique uses laser excited He2* molecules as tracers of the normal fluid motion within the He II. The activities also included an effort to use visualization techniques to locate transient hot spots in radio frequency superconducting cavities. Such work provides valuable information about the heat transfer process in He II and its impact on the performance of superconducting devices. The research effort at Florida State University is not directly in support of a specific high energy physics experiment or facility. Rather, the work is general and coordinated with HEP accelerator laboratories to provide valuable insight that can assist with future accelerator development.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Development of a 300 MWe Utility Scale Oxy-Fuel sCO2 Turbine

A 300 MWe direct-fired supercritical carbon dioxide (sCO2) oxy-fuel turbine is being developed that will burn natural gas-fired, coal syngas and even hydrogen mixtures capable of 1,150ºC turbine inlet temperature at 300 bar. This design will significantly improve the state-of-the-art for thermal efficiency and results in a high-pressure stream of CO2 with 98%+ carbon capture, making the power plant near emission-free and more efficient than Natural Gas Combined Cycle (NGCC) plants with carbon capture. This power plant will be capable of burning coal through gasification and cleanup of the synthesis gas (syngas). sCO2 power cycles are a transformational technology for the energy industry, providing higher efficiency heat source energy conversion for conventional and alternative energy sources. This novel cycle significantly reduces capital costs because of smaller equipment footprints, design modularity, and allows for rapid cyclic load and source following to balance solar and wind energy power swings. Oxy-fuel sCO2 cycles take these advantages even further, utilizing higher firing temperatures, improved efficiency, and simpler carbon capture strategies. This turbine will require cooled turbine nozzles and blades as well as advanced thermal management systems to accommodate these high temperatures. The cooled blade heat transfer correlations required new test programs at higher Reynolds number than air-breathing gas turbines for impingement, serpentine, and pin-fin regions. Novel blade optimization was performed to maximize aerodynamic efficiency, while minimizing cooling flows. A turbine layout was generated utilizing individual combustor cans with cooled liners feeding into a 6-stage axial flow turbine with cooled stator nozzles and turbine blades. The case design and thermal management preliminary design will be described.

Moore, Jeffrey↗

DOE OSTI2024

Shallow Geothermal Resources for Cooling Applications at the University of Hawai‘i

Scientists at Berkeley Lab have teamed up with The University of Hawai‘i at Manoa (UH Manoa) through the U.S. Department of Energy’s (DOE’s) Energy Transitions Initiative Partnership Project (ETIPP) to evaluate the technological and market feasibility of shallow geothermal heat exchanger (GHE) technology for building cooling, energy efficiency, and emissions reduction applications in Hawai’i. The team is assessing the data necessary to model the feasibility of deploying this technology, the actual models that will be used, and what hurdles need to be overcome to install a demonstration case. UH has an abundance of geologic and geothermal data and is looking to the national labs’ expertise to execute this analysis. UH is also interested in investigating policy, regulatory, and business conditions advantageous for implementation of a pilot project, and more broad deployment of this technology in Hawai‘i. In many locations around the world, the demands for heating and cooling are roughly balanced over the course of the year, so GHEs do not cause significant long-term changes in subsurface temperature. This is not the case in Hawai’i, where the demand for heating is very small, meaning that over time, GHEs will add heat to the subsurface. If temperatures increase significantly, GHE systems will not work as designed. Regional groundwater flow has the potential to sweep heated water away from boreholes, thereby maintaining the functionality of the GHE system. Significant regional groundwater flow requires two things: a sufficiently large driving hydraulic head gradient (usually closely related to surface topography), and sufficient porosity and permeability to enable groundwater to flow in large enough quantities to enable near-borehole temperatures to be maintained at ambient values. Hawai‘i’s volcanic terrain offers ample surface topographic variation. The lava itself shows an extremely large range of porosity and permeability, making it crucial to select sites with large enough values of these properties. Numerical modeling of coupled groundwater and heat flow can be used to determine how large is large enough. Both closed-loop and open-loop systems are being investigated. Another option being considered is using cool seawater as the source of chill. Currently work is progressing on two fronts. A hydrogeologic model for a closed-loop system is being developed for the Stan Sheriff Center at the UH Manoa campus, where a subsurface karst system immediately downgradient of the borefield may provide efficient removal of heated groundwater. The team will also develop a technoeconomic model for this site to compare the cost of cooling using a GHE system with the costs of operating the current air conditioning system. At the state scale, geographic information system (GIS) layers of various attributes relevant for GHE are being combined to develop an overall favorability map for employing GHE in Hawai‘i.

Doughty, C↗

NASA NTRS2002

Low Temperature Regenerators for Zero Boil-Off Liquid Hydrogen Pulse Tube Cryocoolers

Recently, a great deal of attention has been focused on zero boil-off (ZBO) propellant storage as a means of minimizing the launch mass required for long-term exploration missions. A key component of ZBO systems is the cooler. Pulse tube coolers offer the advantage of zero moving mass at the cold head, and recent advances in lightweight, high efficiency cooler technology have paved the way for reliable liquid oxygen (LOx) temperature coolers to be developed which are suitable for flight ZBO systems. Liquid hydrogen (LH2) systems, however, are another matter. For ZBO liquid hydrogen systems, cooling powers of 1-5 watts are required at 20 K. The final development from tier for these coolers is to achieve high efficiency and reliability at lower operating temperatures. Most of the life-limiting issues of flight Stirling and pulse tube coolers are associated with contamination, drive mechanisms, and drive electronics. These problems are well in hand in the present generation coolers. The remaining efficiency and reliability issues reside with the low temperature regenerators. This paper will discuss advances to be made in regenerators for pulse tube LH2 ZBO coolers, present some historical background, and discuss recent progress in regenerator technology development using alloys of erbium.

Salerno, Louis J.↗

DOE OSTI2024

Dynamic Modeling of Power Conversion Stages for an Exascale Supercomputer

In this paper a power conversion and energy consumption model for an exascale supercomputer is investigated. Power consumption, energy loss and efficiency are derived for the 27.2 MW liquid-cooled, centralized, High Performance Computing (HPC) power system, which is supplied directly from the 480 V three-phase mains. Two energy conversion stages are analyzed, measured and modeled. The model is developed in order to be adapted and implemented in a digital twin platform utilizing a Resource Allocator and Power Simulator (RAPS) module. RAPS enables estimation of potential energy savings in the direct AC power supply architecture via both conventional rectifier load sharing (commonly used in HPC systems), as well as smart rectifier load sharing. Moreover, besides the direct AC supply architecture analysis, the full direct DC supply architecture with with 1 kV DC bus were also studied. Comparison of 10 hour time frame operation of the system, with direct 480 V AC voltage supply with conventional and smart load sharing and medium dc voltage supply were done. For the direct AC supply architecture, with conventional and smart load sharing the predicted power loss was approximately 840 kW and 820 kW, respectively and the predicted total system efficiency was 92.87% and 93.05%, respectively. For the direct DC supply architecture with the 1000 V DC supply bus power loss was approximately 340 kW and the predicted total system efficiency was 97.02%.

Wojda, Rafal↗

DOE OSTI2023

Efficient Air Dehumidification Can Save 15%-50% of Cooling Energy in Commercial Buildings

Current approach to dehumidification in commercial buildings with chilled/hot water AHU systems is to overcool return + supply air to dewpoint, and then reheat before supply to zone. This is energy inefficient, with reheat often being gas-fired. To reduce energy consumption, building operators will often operate at little-to-no outside air, sacrificing IAQ. Decarbonizing commercial buildings requires solutions to reduce and fully electrify dehumidification energy consumption. The Altaire ADAPT and Conservant HEDS systems aim to solve this problem by decoupling humidity control from cooling reduces energy consumption while enabling improved IAQ management.

commercial buildings↗

NASA NTRS2017

Development of a Space-Flight ADR Providing Continuous Cooling at 50 mK with Heat Rejection at 10 K

Future astronomical instruments will require sub-Kelvin detector temperatures to obtain high sensitivity. In many cases large arrays of detectors will be used, and the associated cooling systems will need performance surpassing the limits of present technologies. NASA is developing a compact cooling system that will lift heat continuously at temperatures below 50 mK and reject it at over 10 K. Based on Adiabatic Demagnetization Refrigerators (ADRs), it will have high thermodynamic efficiency and vibration-free operation with no moving parts. It will provide more than 10 times the current flight ADR cooling power at 50 mK and will also continuously cool a 4 K stage for instruments and optics. In addition, it will include an advanced magnetic shield resulting in external field variations below 5 T. We describe the cooling system here and report on the progress in its development.

space-flight↗

NASA NTRS2017

Development of a Space-Flight ADR Providing Continuous Cooling at 50 Mk with Heat Rejection at 10 K

sub-Kelvin ADR↗

NASA NTRS2019

Development of a Space-Flight ADR Providing Continuous Cooling at 50 mK with Heat Rejection at 10 K

Future astronomical instruments will require sub-Kelvin detector temperatures to obtain high sensitivity. In many cases large arrays of detectors will be used, and the associated cooling systems will need performance surpassing the limits of present technologies. NASA is developing a compact cooling system that will lift heat continuously at temperatures below 50 mK and reject it at over 10 K. Based on Adiabatic Demagnetization Refrigerators (ADRs), it will have high thermodynamic efficiency and vibration-free operation with no moving parts. It will provide more than 10 times the current flight ADR cooling power at 50 mK and will also continuously cool a 4 K stage for instruments and optics. In addition, it will include an advanced magnetic shield resulting in external field variations below 5 ÂµT. We describe the cooling system here and report on the progress in its development.

Tuttle, Jim↗

DOE OSTI2021

Risk-Informed Analysis for Enhanced Resilient Nuclear Power Plant with Initiatives including ATF, FLEX, and Advanced Battery Technology

This report documents the activities performed by the Idaho National Laboratory (INL) during fiscal year (FY) 2021 for the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program, Risk-Informed Systems Analysis (RISA) Pathway, Enhanced Resilient Plant (ERP) Systems research. The purpose of the RISA Pathway research and development is to support plant owner-operator decisions with the aim to improve the economics, reliability, and maintain the high levels of safety of current nuclear power plants over periods of extended plant operations. The concept of ERP refers to the combinations of accident-tolerant fuel (ATF), optimal use of diverse and flexible coping strategy (FLEX), enhancements to plant components and systems, the incorporation of augmented or new passive cooling systems, the advanced battery technology with extended capacity, as well as improved fuel cycle efficiency. The objective of the ERP research effort is to use the RISA methods and toolkit in industry applications, including methods development and early demonstration of technologies, in order to enhance existing reactors? safety features and to substantially reduce operating costs through risk-informed approaches to plant design modifications to the plant and their characterization. The ERP R&D efforts in FY 2021 are focused on three industry initiatives, including accident-tolerant fuel (ATF), optimal use of diverse and flexible coping strategy (FLEX), and advanced battery technology with extended capacity.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS2000

Space Operation of the MOLA Laser

Interest in lasers for space applications such as active remote sensing in Earth orbit, planetary science, and inter-satellite laser communications is growing. These instruments typically use diode-pumped solid state lasers for the laser transmitter. The mission specifications and constraints of space qualification, place strict requirements on the design and operation of the laser. Although a laser can be built in the laboratory to meet performance specifications relatively routinely, tile mission constraints demand unique options and compromises in the materials used, and design to ensure the success of the mission. Presently, the best laser architecture for a light weight, rugged, high peak power and efficient transmitter is a diode laser pumped ND:YAG laser. Diode lasers can often obviate the need for water cooling, reduce the size and weight of the laser, increase the electrical to optical efficiency, system reliability, and lifetime. This paper describes the in-space operation and performance of the Mars Orbiter Laser Altimeter (MOLA) laser transmitter, representing the current state-of-the-art in space-based solid- state lasers.

Afzal, Robert S.↗

DOE OSTI2022

A turnkey gaseous helium-cooled superconducting CORC ® dc power cable with integrated current leads

Abstract High-temperature superconducting (HTS) direct current (dc) power cable systems, capable of delivering power exceeding 10 MW while being cooled with cryogenic helium gas, have been developed for applications on naval electric ships, electric aircraft and in data centers. Current injection from room temperature into the superconducting power cable causes by far the greatest heat load to the cryogenic system. Efficient current leads with integrated helium gas heat exchangers were developed to inject a current exceeding 1 kA from room temperature into a superconducting Conductor on Round Core (CORC ® ) power cable, without the need for liquid nitrogen pre-cooling. A 2 m long single-pole CORC ® power cable system that included current leads was cooled using a Stirling cryocooler with a closed-loop helium gas circulation system. The turnkey power cable system allowed cool down from room temperature to its operating temperature of 60 K–70 K within 5 h, after which continuous operation at 1.2 kA was demonstrated. The successful development and demonstration of a CORC ® power cable with current leads containing integrated helium gas heat exchangers enables widespread implementation of HTS MW-class, high current density superconducting dc power cables in many applications with constrained space that require a power dense solution.

Physics↗

DOE OSTI2021

Experimental validation of an organic rankine-vapor compression cooling cycle using low GWP refrigerant R1234ze(E)

There is a significant global opportunity to capture and utilize low grade waste heat to reduce fossil fuel consumption, greenhouse gas emissions, and improve energy efficiency across a wide range of industries. In this work, an advanced type of thermally activated cooling system, an organic Rankine-vapor compression cycle (ORVC) with novel heat integration strategies, was designed and tested at a relevant scale for industrial waste heat recovery (300 kW th cooling capacity). The ORVC linked an organic Rankine power cycle and a vapor compression cooling cycle using a turbine and compressor that shared a single shaft. The ORVC test facility absorbed waste heat from a liquid stream at 91 °C to simulate engine coolant in diesel generator sets, rejected heat to a glycol stream at 30 °C, and generated chilled water at 7 °C. A cooling capacity of 264 kW ± 3.5 kW was experimentally validated with a COP of 0.56 ± 0.01 during steady-state operation at the design temperatures. The thermal efficiency, accounting for pump work, of the Rankine cycle was 7.7% ± 0.22% and the COP of the vapor compression cycle was 5.25 ± 0.09. The centrifugal turbo-compressor operated at 31.5 kRPM ± 0.3 kRPM, with a turbine and compressor isentropic efficiencies of 76.7% ± 0.90% and 84.8% ± 0.54%, respectively, with near-perfect power transmission between these components. The pressure drop in the piping and heat exchangers were significantly larger than expected which had a detrimental impact on the performance of the ORVC. In addition, the condenser on the cooling cycle could not deliver the subcooling as specified from the design point modeling. Furthermore, the results from the sensitivity analysis showed that the higher condenser glycol outlet temperature had the largest impact on performance, which is consistent with other analytical models in the literature. When the ORVC simulations were updated with experimental values for isentropic efficiencies of the turbomachinery, the thermal COP was 0.66 which represents an estimate of the predicted performance if test facility limitations are overcome.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Timed to save: the added value of accounting for hourly incidence of electricity savings from residential space-conditioning measures

Abstract Previous research has recognized that the value of measures that reduce electricity usage depends upon the timing of the savings generated, but the lack of hourly savings shapes has limited the demonstration of this concept. We develop empirical hourly savings shapes for residential space-conditioning measures from nearly 18,000 efficiency projects in California and show how they combine with the diurnal and seasonal variation in electricity system costs. We find that these measures (cooling replacements; windows, doors, and skylights; and other envelope measures) tend to save electricity when system costs are highest and that the hourly savings account for 1.4–1.5 times as much value as non-time-sensitive estimates of efficiency would predict. We present these impact multipliers for each measure to quantify the additional value revealed by the time-sensitive approach. We show that this additional value is similar in an evolving electricity grid with storage, rather than natural gas generation, as the marginal resource.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2005

Evaluation of an Active Clearance Control System Concept

Reducing blade tip clearances through active tip clearance control in the high pressure turbine can lead to significant reductions in emissions and specific fuel consumption as well as dramatic improvements in operating efficiency and increased service life. Current engines employ scheduled cooling of the outer case flanges to reduce high pressure turbine tip clearances during cruise conditions. These systems have relatively slow response and do not use clearance measurement, thereby forcing cold build clearances to set the minimum clearances at extreme operating conditions (e.g., takeoff, reburst) and not allowing cruise clearances to be minimized due to the possibility of throttle transients (e.g., step change in altitude). In an effort to improve upon current thermal methods, a first generation mechanically-actuated active clearance control (ACC) system has been designed and fabricated. The system utilizes independent actuators, a segmented shroud structure, and clearance measurement feedback to provide fast and precise active clearance control throughout engine operation. Ambient temperature performance tests of this first generation ACC system assessed individual seal component leakage rates and both static and dynamic overall system leakage rates. The ability of the nine electric stepper motors to control the position of the seal carriers in both open- and closed-loop control modes for single and multiple cycles was investigated. The ability of the system to follow simulated engine clearance transients in closed-loop mode showed the system was able to track clearances to within a tight tolerance (0.001 in. error).

Steinetz, Bruce M.↗