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Flow sensor distinguishes flowing gases from liquids. Sensor allows liquids to pass, but would signal valve to turn off flow of gases. Concept developed for propulsion systems in which liquid fuel is forced out of storage tank by high-pressure gas. Controller stops flow of gas from fuel tank after liquid has been depleted.
The evaluation of candidate cryogenic fuel systems for space shuttle vehicles is discussed. A set of guidelines was used to establish a matrix of possible combinations for the integration of potential cryogenic systems. The various concepts and combinations which resulted from the integration efforts are described. The parameters which were considered in developing the matrix are: (1) storage of cryogenic materials, (2) fuel lines, (3) tank pressure control, (4) thermal control, (5) fluid control, and (6) fluid conditioning. Block diagrams and drawings of the candidate systems are provided. Performance predictions for the systems are outlined in tables of data.
Current Martian missions call for the production of oxygen for breathing, and fuel and oxygen for propulsion to be produced from atmospheric carbon dioxide (CO2). Adsorption and freezing are the two methods considered for capturing CO2 from the atmosphere. However, the nitrogen (N2) and argon (Ar), which make up less than 5 percent of the atmosphere, cause difficulties with both of these processes by blocking the CO2. This results in the capture process rapidly changing from a pressure driven process to a diffusion controlled process. To increase the CO2 capture rates, some type of mechanical pump is usually proposed to remove the N2 and Ar. The N2 and Ar are useful and have been proposed for blanketing and pressurizing fuel tanks and as buffer gas for breathing air for manned missions. Separation of the Martian gases with the required purity can be accomplished with a combination of membranes. These membrane systems do not require a high feed pressure and provide suitable separation. Therefore, by use of the appropriate membrane combination with the Martian atmosphere supplied by a compressor a continuous Supply Of CO2 for fuel and oxygen production can be supplied. This phase of our program has focused on the selection of the membrane system. Since permeation data for membranes did not exist for Martian atmospheric pressures and temperatures, this information had to be compiled. The general trend as the temperature was lowered was for the membranes to become more selective. In addition, the relative permeation rates between the three gases changed with temperature. The end result was to provide design parameters that could be used to separate CO2 from N2 and Ar. This paper will present the membrane data, provide the design requirements for a compressor, and compare the results with adsorption and freezer methods.
Current Martian missions call for the production of oxygen for breathing, and fuel and oxygen for propulsion to be produced from atmospheric carbon dioxide (CO2). Adsorption and freezing are the two methods considered for capturing CO, from the atmosphere. However, the nitrogen (N2) and argon (Ar), which make up less than 5 percent of the atmosphere, cause difficulties with both of these processes by blocking the CO2, This results in the capture process rapidly changing from a pressure driven process to a diffusion controlled process. To increase the CO, capture rates, some type of mechanical pump is usually proposed to remove the N2 and Ar. The N2 and Ar are useful and have been proposed for blanketing and pressurizing fuel tanks and as buffer gas for breathing air for manned missions. Separation of the Martian gases with the required purity can be accomplished with a combination of membranes. These membrane systems do not require a high feed pressure and provide suitable separation. Therefore, by use of the appropriate membrane combination with the Martian atmosphere supplied by a compressor a continuous supply of CO2 for fuel and oxygen production can be supplied. This phase of our program has focused on the selection of the membrane system. Since permeation data for membranes did not exist for Martian atmospheric pressures and temperatures, this information had to be compiled. The general trend as the temperature was lowered was for the membranes to become more selective. In addition, the relative permeation rates between the three gases changed with temperature. The end result was to provide design parameters that could be used to separate CO2 from N2 and Ar. This paper will present the membrane data, provide the design requirements for a compressor, and compare the results with adsorption and freezer methods.
Inspection, proof pressure, and functional testing of check valve used in tank vent line of liquid hydrogen fuel system
The development of an advanced photovoltaic power system that would have application for a manned lunar base is currently planned under the Surface Power element of Pathfinder. Significant mass savings over state-of-the-art photovoltaic/battery systems are possible with the use of advanced lightweight solar arrays coupled with regenerative fuel cell storage. The solar blanket, using either ultrathin GaAs or amorphous silicon solar cells, would be integrated with a reduced-g structure. Regenerative fuel cells with high-pressure gas storage in filament-wound tanks are planned for energy storage. An advanced PV/RFC power system is a leading candidate for a manned lunar base as it offers a tremendous weight advantage over state-of-the-art photovoltaic/battery systems and is comparable in mass to other advanced power generation technologies.
A Lunar Surface Power Working Group was formed to review candidate systems for providing power to the first lunar outpost habitat. The working group concluded that the most attractive candidate included a photovoltaic unit, a fuel cell, a regenerator to recycle the reactants, and storage of oxygen and hydrogen gases. Most of the volume (97 percent) and weight (64 percent) are taken up by the reactants and their storage tank. The large volume is difficult to accommodate, and therefore, the working group explored ways of reducing the volume. An alternative approach to providing separate high pressure storage tanks is to use two of the descent stage propellant storage tanks, which would have to be wrapped with graphite fibers to increase their pressure capability. This saves 90 percent of the volume required for storage of fuel cell reactants. Another approach is to use the descent storage propellant tanks for storage of the fuel cell reactants as cryogenic liquids, but his requires a gas liquefication system, increases the solar array by 40 percent, and increases the heat rejection rate by 170 percent compared with storage of reactants as high pressure gases. For a high power system (greater than 20 kW) the larger energy storage requirements would probably favor the cryogenic storage option.
The proposed paper will cover ongoing work at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) on integrated power and propulsion for advanced human exploration. Specifically, it will present findings of the integrated design, testing, and operational challenges of a liquid oxygen / liquid methane (LOx/LCH4) propulsion brassboard and Solid Oxide Fuel Cell (SOFC) system. Human-Mars architectures point to an oxygen-methane economy utilizing common commodities, scavenged from the planetary atmosphere and soil via In-Situ Resource Utilization (ISRU), and common commodities across sub-systems. Due to the enormous mass gear-ratio required for human exploration beyond low-earth orbit, (for every 1 kg of payload landed on Mars, 226 kg will be required on Earth) increasing commonality between spacecraft subsystems such as power and propulsion can result in tremendous launch mass and volume savings. Historically, propulsion and fuel cell power subsystems have had little interaction outside of the generation (fuel cell) and consumption (propulsion) of electrical power. This was largely due to a mismatch in preferred commodities (hypergolics for propulsion; oxygen & hydrogen for fuel cells). Although this stove-piped approach benefits from simplicity in the design process, it means each subsystem has its own tanks, pressurization system, fluid feed system, etc. increasing overall spacecraft mass and volume. A liquid oxygen / liquid methane commodities architecture across propulsion and power subsystems would enable the use of common tankage and associated pressurization and commodity delivery hardware for both. Furthermore, a spacecraft utilizing integrated power and propulsion could use propellant residuals - propellant which could not be expelled from the tank near depletion due to hydrodynamic considerations caused by large flow demands of a rocket engine - to generate power after all propulsive maneuvers are complete thus utilizing previously wasted mass. Such is the case for human and robotic planetary landers. Although many potential benefits through integrated power & propulsion exist, integrated operations have yet to be successfully demonstrated and many challenges have already been identified the most obvious of which is the large temperature gradient. SOFC chemistry is exothermic with operating temperatures in excess of 1,000 K; however, any shared commodities will be undoubtedly stored at cryogenic temperatures (90-112 K) for mass efficiency reasons. Spacecraft packaging will drive these two subsystems in close proximity thus heat leak into the commodity tankage must be minimized and/or mitigated. Furthermore, commodities must be gasified prior to consumption by the SOFC. Excess heat generated by the SOFC could be used to perform this phase change; however, this has yet to be demonstrated. A further identified challenge is the ability of the SOFC to handle the sudden power spikes created by the propulsion system. A power accumulator (battery) will likely be necessary to handle these sudden demands while the SOFC thermally adjusts. JSC's current SOFC test system consists of a 1 kW fuel cell designed by Delphi. The fuel cell is currently undergoing characterization testing at the NASA JSC Energy Systems Test Area (ESTA) after which a Steam Methane Reformer (SMR) will be integrated and the combined system tested in closed-loop. The propulsion brassboard is approximately the size of what could be flown on a sounding rocket. It consists of one 100 lbf thrust "main" engine developed for NASA by Aerojet and two 10 lbf thrusters to simulate a reaction control system developed at NASA JSC. This system is also under development and initial testing at ESTA. After initial testing, combined testing will occur which will provide data on the fuel cell's ability to sufficiently handle the power spikes created by the propulsion system. These two systems will also be modeled using General-Use Nodal Network Solver (GUNNS) software. Once anchored with test data, this model will be used to extrapolate onto other firing profiles and used to size the power accumulator.
Heated-hybrid generated gas pressurization system for liquid propellant transfer in rocket vehicles
The regenerative fuel cell development effort at Glenn Research Center (GRC) involves the integration of a dedicated fuel cell and electrolyzer into an energy storage system test rig. The test rig consists of a fuel cell stack, an electrolysis stack, cooling pumps, a water transfer pump, gas recirculation pumps, phase separators, storage tanks for oxygen (O2) and hydrogen (H2), heat exchangers, isolation valves, pressure regulators, interconnecting tubing, nitrogen purge provisions, and instrumentation for control and monitoring purposes. The regenerative fuel cell (RFC) thus formed is a completely closed system which is capable of autonomous cyclic operation. The test rig provides direct current (DC) load and DC power supply to simulate power consumption and solar power input. In addition, chillers are used as the heat sink to dissipate the waste heat from the electrochemical stack operation. Various vents and nitrogen (N2) sources are included in case inert purging is necessary to safe the RFC test rig.
Three designs were considered to satisfy the design objective. These designs were the current design, a Land Based Pressurized Feed System, and a fuel recirculation system. A computer code was developed to analyze the current feed system and assist in the analysis of the two experimental systems. After comparing the three concepts, the land Based Pressurized Feed System seemed to be the most promising new development. This design coupled with the piping configuration described in the report provides a justifiable fuel feed system which satisfies all the necessary requirements.
Over its life the International Space Station (ISS) has received gas (nitrogen, oxygen, and air) from various sources. Nitrogen and oxygen are used in the cabin to maintain total pressure and oxygen partial pressures within the cabin. Plumbed nitrogen is also required to support on-board experiments and medical equipment. Additionally, plumbed oxygen is required to support medical equipment as well as emergency masks and most importantly EVA support. Gas are supplied to ISS with various methods and vehicles. Vehicles like the Progress and ATV deliver nitrogen (both as a pure gas and as air) and oxygen via direct releases into the cabin. An additional source of nitrogen and oxygen is via tanks on the ISS Airlock. The Airlock nitrogen and oxygen tanks can deliver to various users via pressurized systems that run throughout the ISS except for the Russian segment. Metabolic oxygen is mainly supplied via cabin release from the Elektron and Oxygen Generator Assembly (OGA), which are water electrolyzers. As a backup system, oxygen candles (Solid Fuel Oxygen Generators-SFOGs) supply oxygen to the cabin as well. In the past, a major source of nitrogen and oxygen has come from the Shuttle via both direct delivery to the cabin as well as to recharge the ISS Airlock tanks. To replace the Shuttle capability to recharge the ISS Airlock tanks, a new system was developed called Nitrogen/Oxygen Recharge System (NORS). NIORS consists of high pressure (7000 psi) tanks which recharge the ISS Airlock tanks via a blowdown fill for both nitrogen and oxygen. NORS tanks can be brought up on most logistics vehicles such as the HTV, COTS, and ATV. A proper balance must be maintained to insure sufficient gas resources are available on-orbit so that all users have the required gases via the proper delivery method (cabin and/or plumbed).
The office of Space, DOE, appointed a Lunar Surface Power Working Group to review candidate systems for the First Lunar Outpost habitat. The working group met for a total of five days in the fall of 1992 and concluded that the candidate involving a photovoltaic unit, a fuel cell, a regenerator to recycle the reactants, and storage of oxygen and hydrogen gases was the most attractive for this application. Most of the volume (97 percent) and weight (63 percent) are taken up by the reactants and their storage tanks. Therefore, in my work for the Group, and in this report, I have concentrated on finding ways to reduce these volumes and weights. Three options were considered: (1) the baseline case considered in the preliminary system design, that of separate high pressure (200 bar) storage tanks; (2) the use of two of the descent storage propellant tanks wrapped with graphite fibers to increase the pressure capability; and (3) the use of cryogenic storage of reactants in the propellant tanks. The first option results in high storage tank mass and volume. The second option saves 90 percent of the volume by making use of the propellant tanks, but it has little if any weight advantages; the weight saved by not providing extra tanks for reactant storage is nearly entirely added back by the weight of the additional material (graphite fibers) to strengthen the propellant tanks. Use of the descent storage propellant tanks for storage of the fuel cell reactants as cryogenic liquids requires a gas liquefaction system. The weight of this system is expected to be less than that of the storage tanks but it would require development and testing to prove its reliability. The solar array would have to be 40 percent larger and the heat projection range would be 170 percent larger than for storage of reactants as high pressure gases. For a high power system (greater than 20 kW) the larger energy storage requirement would probably favor the cryogenic storage option.
A bidirectional pressure-regulator system has been devised for use in a regenerative fuel cell system. The bidirectional pressure-regulator acts as a back-pressure regulator as gas flows through the bidirectional pressure-regulator in one direction. Later, the flow of gas goes through the regulator in the opposite direction and the bidirectional pressure-regulator operates as a pressure- reducing pressure regulator. In the regenerative fuel cell system, there are two such bidirectional regulators, one for the hydrogen gas and another for the oxygen gas. The flow of gases goes from the regenerative fuel cell system to the gas storage tanks when energy is being stored, and reverses direction, flowing from the storage tanks to the regenerative fuel cell system when the stored energy is being withdrawn from the regenerative fuel cell system. Having a single bidirectional regulator replaces two unidirectional regulators, plumbing, and multiple valves needed to reverse the flow direction. The term "bidirectional" refers to both the bidirectional nature of the gas flows and capability of each pressure regulator to control the pressure on either its upstream or downstream side, regardless of the direction of flow.
The Space Shuttle RCS (reaction control system) is required to provide propulsion thrust for precise attitude control and three-axis translation. This capability must be provided for external tank separation, on-orbit operation, deorbit, and reentry. In order to meet these requirements a bipropellant, pressure-fed system utilizing monomethylhydrazine as fuel, and nitrogen tetroxide as oxidizer has been selected. The RCS engines include 38 primary thrusters rated at 870 lbf thrust and 6 vernier thrusters rated at 25 lbf thrust. The system is divided into three removable modules (one forward and two aft) to achieve maintenance and turnaround requirements. In order to provide additional mission flexibility, the aft modules can be connected together or interconnected with the OMS (orbital maneuvering system).
The experiments were conducted at Glenn's Small Multipurpose Research Facility (SMIRF, ref. 5). The experimental setup was placed in the facility's vacuum tank to prevent heat leaks and subsequent boiloff of the liquid helium. Supporting systems maintained the temperature and pressure of the liquid helium bath where the solid particles were created. Solid hydrogen particle formation was tested from February 23 to April 2, 2001. Millimeter-sized solid-hydrogen particles were formed in a Dewar of liquid helium as a prelude to creating atomic fuels and propellants for aerospace vehicles. Atomic fuels or propellants are created when atomic boron, carbon, or hydrogen is stored in solid hydrogen particles. The current testing characterized the solid hydrogen particles without the atomic species, as a first step to creating a feed system for the atomic fuels and propellants. This testing did not create atomic species, but only sought to understand the solid hydrogen particle formation and behavior in the liquid helium. In these tests, video images of the solid particle formation were recorded, and the total mass flow rate of the hydrogen was measured. The mass of hydrogen that went into the gaseous phase was also recorded using a commercially available residual gas analyzer. The temperatures, pressures, and flow rates of the liquids and gases in the test apparatus were recorded as well. Testing conducted in 1999 recorded particles as small as 2 to 5 mm in diameter. The current testing extended the testing conditions to a very cold Dewar ullage gas of about 20 to 90 K above the 4 K liquid helium. With the very cold Dewar gas, the hydrogen freezing process took on new dimensions, in some cases creating particles so small that they seemed to be microscopic, appearing as infinitesimally small scintillations on the videotaped images.
An analytical study was conducted on the use of broadened specification hydrocarbon fuels in present day aircraft. A short range Boeing 727 mission and three long range Boeing 747 missions were used as basis of calculation for one-day-per-year extreme values of fuel loading, airport ambient and altitude ambient temperatures with various seasonal and climatic conditions. Four hypothetical fuels were selected; two high-vapor-pressure fuels with 35 kPa and 70 kPa RVP and two high-freezing-point fuels with -29 C and -18 C freezing points. In-flight fuel temperatures were predicted by Boeing's aircraft fuel tank thermal analyzer computer program. Boil-off rates were calculated for the high vapor pressure fuels and heating/insulation requirements for the high freezing point fuels were established. Possible minor and major heating system modifications were investigated with respect to heat output, performance and economic penalties for the high freezing point fuels.
The thermal stability of unsymmetrical dimethylhydrazine was investigated in a static system simulating conditions in an almost-empty fuel tank. The self-ignition temperature and spontaneous decomposition temperature of the pure fuel were determined at atmospheric pressure to be 454 and 740 F. respectively, with the larger (740 F) value, obtained in an inert atmosphere of nitrogen, representing the minimum temperature that would cause a rapid exothermic reaction. The addition of 40 weight percent dimethylenetriamine to unsymmetrical dimethylhydrazine did not significantly affect these properties.