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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Helium Conservation by Diffusion Limited Purging of Liquid Hydrogen Tanks

Recently, the new 1.2-million-gallon liquid hydrogen (LH 2 ) storage tank at the Kennedy Space Center Launch Complex 39 was purged, replacing nitrogen with helium, using a piston purge process. This purging approach had been used on Space Shuttle External Tanks (ET) in the past, but not on one of the large LH 2 tanks. The result was a huge success, potentially saving more than 1 million cubic feet of helium and significant labor. To better understand this result, a diffusion-based purge model was developed. The model predictions accurately match the helium concentration data, providing understanding of the helium savings and suggesting how to better optimize the purging of this large tank for future operations. The model was then applied to the piston purging of the Space Shuttle ETs, showing that these purges were not optimal, but that the amount of wasted helium was not excessive and that additional helium might have been saved by small changes to the process. The Space Shuttle Program (SSP) has ended, but these results are applicable to the purging of future large cylindrical LH 2 tanks. Finally, data have been obtained on inerting the Space Launch System (SLS) Core Stage (CS) LH 2 tank, replacing hydrogen with helium after an aborted launch. This is a more complicated case, but the model predicts that substantial helium might be saved by modifying the current purging process.

Helium Conservation↗
NASA NTRSDate not supplied

Numerical Simulation of No Vent Chill and Fill of a Large Liquid Hydrogen Tank

On orbit transfer of cryogenic liquids is necessary for many future space missions. The techniques required to transfer cryogens in micro gravity are quite different from ground system applications. In normal gravity, cryogenic tanks are usually filled from the bottom at nearly atmospheric pressure. The vapor generated due to heat transfer from warm tank walls, is allowed to vent from the top of the tank while the tank is being filled. If the normal gravity technique is used on orbit, the uncertainty of liquid and vapor distributions in unsettled condition may result in dumping of large amounts of liquid propellant overboard. The Vented Chill and No Vent Fill (VCNVF) process is a methodology [1] used to reduce propellant loss by holding the vent valve open during initial wall chilldown, preventing over-pressurization of the tank and stalling of the incoming flow, but closing the tank vent valve after chilling the tank wall sufficiently. An accurate simulation of no vent tank chill and fill is necessary to estimate the amount of propellant necessary to chill the tank, determine the maximum sustainable flowrate to fill the tank without stalling, and establish a timeline for the filling process. Numerical modeling of filling a cryogenic tank is complex because the flow is two-phase and the process involves both boiling and condensation with heat transfer between solid and fluid. In recent years, progress has been made to develop a numerical modeling technique [2,3,4] that has been verified by comparing with the test data from a small flight tank using liquid nitrogen [5]. The purpose of the present paper is to apply this technique in a larger tank with liquid hydrogen and compare with the test data of Chato [1]. The K-site Test Facility [1], shown in Figure 1, consists of a Test Tank, spray system, instrumentation, and the vacuum chamber. The test tank selected was ellipsoidal with an 87 inch major diameter and a 1.2 to 1 major to minor axis ratio. The two ends are joined by a short 1.5 inch cylindrical section. The tank is made of 2219 aluminum chemically milled to a nominal thickness of 0.087 inches. The tank weighs 329.25 pounds, and the tank volume is 175 ft 3 . The GFSSP model of the Test Tank is shown in Figure 2. Node 13 is a boundary node that represents the supply tank which is supplying liquid hydrogen at a given pressure and temperature. The total measured flowrate is evenly distributed through Branches 131 through 139. Nodes 1 through 9 represent the test tank and they are connected with metal solid nodes 14 through 22 through fluid-to-solid conductors that allow convective heat transfer between the solid and fluid nodes. The predicted tank pressure, filling rate, wall temperature and fluid temperature will be compared with test data.

Alok Majumdar↗
NASA NTRS1996

Acoustic Emission Monitoring of the DC-XA Composite Liquid Hydrogen Tank During Structural Testing

The results of acoustic emission (AE) monitoring of the DC-XA composite liquid hydrogen tank are presented in this report. The tank was subjected to pressurization, tensile, and compressive loads at ambient temperatures and also while full of liquid nitrogen. The tank was also pressurized with liquid hydrogen. AE was used to monitor the tank for signs of structural defects developing during the test.

Wilkerson, C.↗
NASA NTRS2013

Large-Scale Liquid Hydrogen Tank Rapid Chill and Fill Testing for the Advanced Shuttle Upper Stage Concept

Cryogenic upper stages in the Space Shuttle program were prohibited primarily due to a safety risk of a 'return to launch site' abort. An upper stage concept addressed this concern by proposing that the stage be launched empty and filled using shuttle external tank residuals after the atmospheric pressure could no longer sustain an explosion. However, only about 5 minutes was allowed for tank fill. Liquid hydrogen testing was conducted within a near-ambient environment using the multipurpose hydrogen test bed 638.5 ft3 (18m3) cylindrical tank with a spray bar mounted longitudinally inside. Although the tank was filled within 5 minutes, chilldown of the tank structure was incomplete, and excessive tank pressures occurred upon vent valve closure. Elevated tank wall temperatures below the liquid level were clearly characteristic of film boiling. The test results have substantial implications for on-orbit cryogen transfer since the formation of a vapor film would be much less inhibited due to the reduced gravity. However, the heavy tank walls could become an asset in normal gravity testing for on-orbit transfer, i.e., if film boiling in a nonflight weight tank can be inhibited in normal gravity, then analytical modeling anchored with the data could be applied to reduced gravity environments with increased confidence.

Flachbart, R. H.↗
DOE OSTI2023

Modeling of Liquid Hydrogen Tank Cooled with Para-Orthohydrogen Conversion

With the accelerating development of liquid-hydrogen storage facilities, the problem of boil-off hydrogen losses becomes very important. A promising method to reduce these losses is to utilize the endothermic para-orthohydrogen conversion of vented hydrogen, which can effectively decrease heat loads on a hydrogen tank. To model such a process, a hybrid computational model has been developed, based on the application of computational fluid dynamics for an ullage space, where knowledge of thermal stratification is important, and reduced-order models for other system elements. The simulation results for a spheroidal tank in selected conditions indicated a 10–25% reduction of boil-off losses due to cooling produced by vented hydrogen undergoing para-ortho-conversion.

08 HYDROGEN↗
NASA NTRS1999

Rapid Chill and Fill of a Liquid Hydrogen Tank Demonstrated

The NASA Lewis Research Center, in conjunction with Boeing North American, has been supporting the High Energy Upper Stage (HEUS) program by performing feasibility studies at Lewis Supplemental Multilayer Insulation Research Facility (SMIRF). These tests were performed to demonstrate the feasibility of chilling and filling a tank with liquid hydrogen in under 5 minutes. The goal of the HEUS program is to release a satellite from the shuttle cargo bay and then use a cryogenic (high-energy) upper stage to allow the satellite to achieve final orbit. Because of safety considerations, the propellant tanks for the upper stage will be launched warm and dry. They will be filled from the shuttle's external tank during the mission phase after the solid rocket boosters have jettisoned and prior to jettison of the external tank. Data from previous shuttle missions have been analyzed to ensure that sufficient propellant would be available in the external tank to fill the propellant tank of the proposed vehicle upper stage. Because of mission time-line considerations, the propellant tanks for the upper stage will have to be chilled down and filled in approximately 5 minutes. An existing uninsulated flight weight test tank was installed inside the vacuum chamber at SMIRF, and the chamber was evacuated to the 10(exp -5) torr range to simulate space vacuum conditions in the cargo bay with the doors open. During prerun operations, the facility liquid hydrogen (LH2) supply piping was prechilled with the vent gas bypassing the test article. The liquid hydrogen supply dewar was saturated at local ambient pressure and then pressurized with ambient temperature gaseous helium to the test pressure. A control system was used to ensure that the liquid hydrogen supply pressure was maintained at the test pressure.

Kudlac, Maureen T.↗
NASA NTRS2007

Spherical Cryogenic Hydrogen Tank Preliminary Design Trade Studies

A structural analysis, sizing optimization, and weight prediction study was performed by Collier Research Corporation and NASA Glenn on a spherical cryogenic hydrogen tank. The tank consisted of an inner and outer wall separated by a vacuum for thermal insulation purposes. HyperSizer (Collier Research and Development Corporation), a commercial automated structural analysis and sizing software package was used to design the lightest feasible tank for a given overall size and thermomechanical loading environment. Weight trade studies were completed for different panel concepts and metallic and composite material systems. Extensive failure analyses were performed for each combination of dimensional variables, materials, and layups to establish the structural integrity of tank designs. Detailed stress and strain fields were computed from operational temperature changes and pressure loads. The inner tank wall is sized by the resulting biaxial tensile stresses which cause it to be strength driven, and leads to an optimum panel concept that need not be stiffened. Conversely, the outer tank wall is sized by a biaxial compressive stress field, induced by the pressure differential between atmospheric pressure and the vacuum between the tanks, thereby causing the design to be stability driven and thus stiffened to prevent buckling. Induced thermal stresses become a major sizing driver when a composite or hybrid composite/metallic material systems are used for the inner tank wall for purposes such as liners to contain the fuel and reduce hydrogen permeation.

Arnold, Steven M.↗
NASA NTRS2006

Engineering Analysis Studies for Preliminary Design of Lightweight Cryogenic Hydrogen Tanks in UAV Applications

A series of engineering analysis studies were conducted to investigate the potential application of nanoclay-enhanced graphite/epoxy composites and polymer cross-linked silica aerogels in cryogenic hydrogen storage tank designs. This assessment focused on the application of these materials in spherical tank designs for unmanned aeronautic vehicles with mission durations of 14 days. Two cryogenic hydrogen tank design concepts were considered: a vacuum-jacketed design and a sandwiched construction with an aerogel insulating core. Analyses included thermal and structural analyses of the tank designs as well as an analysis of hydrogen diffusion to specify the material permeability requirements. The analyses also provided material property targets for the continued development of cross-linked aerogels and nanoclay-enhanced graphite/epoxy composites for cryogenic storage tank applications. The results reveal that a sandwiched construction with an aerogel core is not a viable design solution for a 14-day mission. A vacuum-jacketed design approach was shown to be far superior to an aerogel. Aerogel insulation may be feasible for shorter duration missions. The results also reveal that the application of nanoclay-enhanced graphite/epoxy should be limited to the construction of outer tanks in a vacuum-jacketed design, since a graphite/epoxy inner tank does not provide a significant weight savings over aluminum and since the ability of nanoclay-enhanced graphite/epoxy to limit hydrogen permeation is still in question.

Sullivan, Roy M.↗