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Several rules to guide choice of materials, and methods of welding, electroplating, and heat treatment will provide a method for minimizing failures in storage tanks and related hardware. Failures are caused by high-pressure hydrogen effects, the formation of hydrides in titanium, and hydrogen absorption through various metals processing techniques.
High pressure gas storage simulation runs were made to compute the elapsed time from T-O disconnect (transfer to onboard reactant) to the caution and warning pressures for the primary oxygen (O2) and hydrogen (H2) systems of Orbiter Vehicle (OV) 101. The simulation runs were made for approach and landing test flights Captive/Active 1 and Captive/Active 3.
Current practices and future requirements for the storage, transmission and distribution of hydrogen are reviewed in order to identify inadequacies to be corrected before hydrogen can achieve its full potential as a substitute for fossil fuels. Consideration is given to the storage of hydrogen in underground solution-mined salt caverns, portable high-pressure containers and dewars, pressure vessels and aquifers and as metal hydrides, hydrogen transmission in evacuated double-walled insulated containers and by pipeline, and distribution by truck and internal distribution networks. Areas for the improvement of these techniques are indicated, and these technological deficiencies, including materials development, low-cost storage and transmission methods, low-cost, long-life metal hydrides and novel methods for hydrogen storage, are presented as challenges for research and development.
The innovation consists of a thermodynamic system for extracting in situ oxygen vapor from lunar regolith using a solar photovoltaic power source in a reactor, a method for thermally insulating the reactor, a method for protecting the reactor internal components from oxidation by the extracted oxygen, a method for removing unwanted chemical species produced in the reactor from the oxygen vapor, a method for passively storing the oxygen, and a method for releasing high-purity oxygen from storage for lunar use. Lunar oxygen exists in various types of minerals, mostly silicates. The energy required to extract the oxygen from the minerals is 30 to 60 MJ/kg O. Using simple heating, the extraction rate depends on temperature. The minimum temperature is approximately 2,500 K, which is at the upper end of available oven temperatures. The oxygen is released from storage in a purified state, as needed, especially if for human consumption. This method extracts oxygen from regolith by treating the problem as a closed batch cycle system. The innovation works equally well in Earth or Lunar gravity fields, at low partial pressure of oxygen, and makes use of in situ regolith for system insulation. The innovation extracts oxygen from lunar regolith using a method similar to vacuum pyrolysis, but with hydrogen cover gas added stoichiometrically to react with the oxygen as it is produced by radiatively heating regolith to 2,500 K. The hydrogen flows over and through the heating element (HE), protecting it from released oxygen. The H2 O2 heat of reaction is regeneratively recovered to assist the heating process. Lunar regolith is loaded into a large-diameter, low-height pancake reactor powered by photovoltaic cells. The reactor lid contains a 2,500 K HE that radiates downward onto the regolith to heat it and extract oxygen, and is shielded above by a multi-layer tungsten radiation shield. Hydrogen cover gas percolates through the perforated tungsten shielding and HE, preventing oxidation of the shielding and HE, and reacting with the oxygen to form water vapor. The water vapor is filtered through solid regolith to remove unwanted extraction byproducts, and then condensed to a liquid state and stored at 300 to 325 K. Conversion to usable oxygen is achieved by pumping liquid water into a high-pressure electrolyzer, storing the gaseous oxygen at high pressure for use, and diverting the hydrogen back to the reactor or to storage. The results from this design effort show that this oxygen-generating concept can be developed in an efficient system with low specific mass. Advantages include use of regolith as an oxygen source, filter, and thermal insulator. The system can be tested in Earth gravity and can be expected to operate similarly in lunar gravity. The system is scalable, either by increasing the power level and output of a standard module, or by employing multiple modules.
Test apparatus exposes disk specimens to hydrogen in controlled, repeatable way simulating conditions in use. Disk specimen constitutes thin wall between pressure and vacuum chambers. Test proceeds until hydrogen weakens disk enough that it ruptures. Aluminum impact plate absorbs debris from ruptured disk. Apparatus replicates aspects of service environments relevant to embrittlement by hydrogen in such equipment as storage tanks, valves, and fluid-handling components containing hydrogen at high absolute or gauge pressure. Hydrogen inside permeates stressed material and produces gradient of concentration as hydrogen diffuses through material to low-pressure side.
The Space Station atmosphere is to have an 'earth-like' composition, and nitrogen is to be routinely supplied to replace losses. The required nitrogen is to be provided by an innovative method, involving a catalytic dissociation of liquid N2H4 and separation of the product nitrogen and hydrogen mixture. The considered technique of nitrogen storage and resupply has several advantages in comparison to methods using either cryogenic liquid or high pressure nitrogen. One advantage is related to savings with respect to launch weight, while a second advantage is provided by the obtained hydrogen which is available for other uses within the Space Station.
Cryogenic gas storage systems were developed for the liquid storage of oxygen, hydrogen, nitrogen, and helium. Cryogenic storage is attractive because of the high liquid density and low storage pressure of cryogens. This situation results in smaller container sizes, reduced container-strength levels, and lower tankage weights. The Gemini and Apollo spacecraft used cryogenic gas storage systems as standard spacecraft equipment. In addition to the Gemini and Apollo cryogenic gas storage systems, other systems were developed and tested in the course of advancing the state of the art. All of the cryogenic storage systems used, developed, and tested to date for manned-spacecraft applications are described.
The technical possibility of fueling motive power equipment with hydrogen as an alternative to petroleum is studied, and the economics of operating hydrogen-fueled systems are evaluated. Technical considerations include the areas of fuel storage and distribution systems, engine design changes, and a test and evaluation program. A conversion methodology, which conforms to the scheme of high-pressure injection of hydrogen directly into the cylinder late in the compresssion stroke and injection of pilot diesel fuel for ignition, is illustrated with detailed diagrams.
For over 20 years, the Cryogenics Test Laboratory at NASA Kennedy Space Center (KSC) (CSA CSM) has stood as a one-of-a kind capability for research, development, and application of cross-cutting technologies to meet both government and industry needs. With four overarching technology focus areas—Thermal insulation systems, Integrated refrigeration systems, Advanced propellant transfer systems, and Low-temperature materials and applications—and a theme of Energy Efficient Cryogenics, the Cryo Test Lab has pioneered technologies such as Integrated Refrigeration and Storage (IRAS) for advanced liquid hydrogen (LH2) operations; aerogel blanket insulation, the world’s best insulation material in ambient pressure and soft-vacuum; and the patented-pending Cryogenic Flux Capacitor3 for high-density storage, and on-demand supply of cryogenic fluids.
1. Kennedy Space Center (KSC) is developing a mobile launching system with autonomous propellant loading capabilities for liquid-fueled rockets. An autonomous system will be responsible for monitoring and controlling the storage, loading and transferring of cryogenic propellants. The Physics Simulation Software will reproduce the sensor data seen during the delivery of cryogenic fluids including valve positions, pressures, temperatures and flow rates. The simulator will provide insight into the functionality of the propellant systems and demonstrate the effects of potential faults. This will provide verification of the communications protocols and the autonomous system control. 2. The High Pressure Gas Facility (HPGF) stores and distributes hydrogen, nitrogen, helium and high pressure air. The hydrogen and nitrogen are stored in cryogenic liquid state. The cryogenic fluids pose several hazards to operators and the storage and transfer equipment. Constant monitoring of pressures, temperatures and flow rates are required in order to maintain the safety of personnel and equipment during the handling and storage of these commodities. The Gas House Autonomous System Monitoring software will be responsible for constantly observing and recording sensor data, identifying and predicting faults and relaying hazard and operational information to the operators.
A method is discussed of generating nitrogen for cabin leakage makeup aboard space vehicles having longer duration missions. The nitrogen generation concept is based on using liquid hydrazine as the stored form of nitrogen to reduce the higher tankage and expendables weight associated with high pressure gaseous or cryogenic liquid nitrogen storage. The hydrazine is catalytically dissociated to yield a mixture of nitrogen and hydrogen. The nitrogen/hydrogen mixture is then separated to yield the makeup nitrogen. The excess supply of hydrogen would be available for use in the reduction of metabolic carbon dioxide. A detailed comparison was completed of Palladium/Silver and Polymer Electrochemical-based Nitrogen Generation Systems. The palladium/silver-based system was judged better than the Polymer Electrochemical Nitrogen Generation System because of lower expendable weight and palladium/silver nitrogen/hydrogen separation represents 'off-the-shelf' technology.
A research and development program was successfully completed towards the development of a method of generating nitrogen for cabin leakage makeup aboard space vehicles. The nitrogen generation concept used liquid hydrazine as the stored form of nitrogen. This reduced tankage and expendables weight associated with high pressure gaseous and cryogenic liquid nitrogen storage. The hydrazine was catalytically dissociated to yield a mixture of nitrogen and hydrogen. The latter was separated to provide the makeup nitrogen. The hydrogen will be used in the reduction of metabolic carbon dioxide.
Nickel-hydrogen batteries are rapidly becoming accepted for use in low-earth-orbit and geosynchronous orbit applications. With their increased use it has become evident that the storage procedures commonly used for nickel-cadmium cells are not adequate for the nickel-hydrogen system. The capacity loss exhibited by nickel electrodes from various manufacturers when exposed to different storage conditions was determined. A comprehensive test matrix was developed to evaluate capacity loss in nickel electrodes from four different manufacturers. Two types of tests were run; individual electrode tests, which involved flooded capacity and impedance measurements before and after storage under varied conditions of temperature, hydrogen pressure, and electrolyte concentration; and cell tests which primarily evaluated the effects of state-of-charge on storage. The cell tests evaluated capacity loss on cells stored open circuit, shorted and trickle charged at C/100 following a full charge. The results indicate that capacity loss varies with the specific electrode manufacturing process, storage temperature and hydrogen pressure. In general, electrodes stored at low temperatures or low hydrogen pressures exhibited a smaller loss in capacity over the twenty-eight day storage period than those stored at high pressure and high temperature. The capacity loss appears to correlate with the level of cobalt in the nickel electrode, with the most significant loss of capacity occurring in electrodes with higher cobalt levels. Impedance measurements appear to correlate well with the capacity loss observed for a given type of electrode but do not correlate well with the capacity loss between electrodes fabricated by different manufacturers. There was a definite correlation between the electrode potential measured immediately following storage and the measured capacity loss.
Project Definition: Design a high flow pneumatic regulation panel to be used with helium and hydrogen. The panel will have two circuits, one for gaseous helium (GHe) supplied from the GHe Movable Storage Units (MSUs) and one for gaseous hydrogen (GH2) supplied from an existing GH2 Fill Panel. The helium will supply three legs; to existing panels and on the higher pressure leg and Simulated Flight Tanks (SFTs) for the lower pressure legs. The hydrogen line will pressurize a 33,000 gallon vacuum jacketed vessel.
Experimental results are presented for the self pressurization and thermal stratification of a 4.89 cu m liquid hydrogen storage tank subjected to low heat flux (2.0 and 3.5 W/sq m) in normal gravity. The test tank was representative of future spacecraft tankage, having a low mass to volume ratio and high performance multilayer thermal insulation. Tests were performed at fill levels of 29 and 49 pcts. (by volume) and complement previous tests at 83 pct. fill. As the heat flux increases, the pressure rise rate at each fill level exceeds the homogeneous rate by an increasing ratio. Herein, this ratio did not exceed a value of 2. The slowest pressure rise rate was observed for the 49 pct. fill level at both heat fluxes. This result is attributed to the oblate spheroidal tank geometry which introduces the variables of wetted wall area, liquid-vapor interfacial area, and ratio of side wall to bottom heating as a function of fill level or liquid depth. Initial tank thermal conditions were found to affect the initial pressure rise rate. Quasi steady pressure rise rates are independent of starting conditions.
Experimental results are presented for the self pressurization and thermal stratification of a 4.89 cu m liquid hydrogen storage tank subjected to low heat flux (2.0 and 3.5 W/sq m) in normal gravity. The test tank was representative of future spacecraft tankage, having a low mass to volume ratio and high performance multilayer thermal insulation. Tests were performed at fill levels of 29 and 49 pcts. (by volume) and complement previous tests at 83 pct. fill. As the heat flux increases, the pressure rise rate at each fill level exceeds the homogeneous rate by an increasing ratio. Herein, this ratio did not exceed a value of 2. The slowest pressure rise rate was observed for the 49 pct. fill level at both heat fluxes. This result is attributed to the oblate spheroidal tank geometry which introduces the variables of wetted wall area, liquid-vapor interfacial area, and ratio of side wall to bottom heating as a function of fill level or liquid depth. Initial tank thermal conditions were found to affect the initial pressure rise rate. Quasi steady pressure rise rates are independent of starting conditions.
An analytical investigation was made of the problems associated with the long-term storage and control of flow of cryogenic propellants for electrothermal engines. Storage of 35 to 174 pounds of propellant for three years is made difficult by the high ratio of surface area to storage tank volume, and the resulting high rate of heat leak. Vented and non-vented storage, storage as high pressure gas, and the use of refrigeration were considered. Recommended storage methods are: for ethane and ammonia vented storage - by venting propellant stored in excess of mission requirements; for hydrogen and helium - by non-vented storage of cold supercritical vapor; and for methane by storage as a non-vented two-phase mixture. The optimum propellant density in the storage tank and optimum insulation thickness were also determined. Design charts were developed for hydrogen and helium, for estimating the maximum pressure expected in non-vented storage tanks, as function of mission requirements. Separation of the constituent phases of liquid-vapor mixtures is achieved by throttling the two-phase mixture to a lower pressure (and temperature) and vaporizing the liquid in the mixture by heat exchange with the contents of the storage tank. The time limitations for continuous use of this method are discussed. Linde super insulations SI-44 or SI -91 are recommended for insulation. Precooling the insulation to temperatures below the steady state level with cold helium vapor before or during fueling of the storage tank eliminates the flow of heat to the tank contents during countdown and take-off. The masses, sizes, and power requirements of the recommended systems are low. The controls are simple and reliable. From the equations and charts in this report the components of the system for a particular mission can be sized. Recommendations are given for experimental work required for the development and testing of such components.
The NASA Glenn Research Center has constructed a closed-cycle hydrogen-oxygen PEM regenerative fuel cell (RFC) to explore its potential use as an energy storage device for a high altitude solar electric aircraft. Built up over the last 2 years from specialized hardware and off the shelf components the Glenn RFC is a complete "brassboard" energy storage system which includes all the equipment required to (1) absorb electrical power from an outside source and store it as pressurized hydrogen and oxygen and (2) make electrical power from the stored gases, saving the product water for re-use during the next cycle. It consists of a dedicated hydrogen-oxygen fuel cell stack and an electrolyzer stack, the interconnecting plumbing and valves, cooling pumps, water transfer pumps, gas recirculation pumps, phase separators, storage tanks for oxygen (O2) and hydrogen (H2), heat exchangers, isolation valves, pressure regulators, nitrogen purge provisions, instrumentation, and other components. It specific developmental functions include: (1) Test fuel cells and fuel cell components under repeated closed-cycle operation (nothing escapes; everything is used over and over again). (2) Simulate diurnal charge-discharge cycles (3) Observe long-term system performance and identify degradation and loss mechanisms. (4) Develop safe and convenient operation and control strategies leading to the successful development of mission-capable, flight-weight RFC's.