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DOE OSTI2024

Comparative Analysis of Heat Exchangers for High Temperature High Pressure Helium Component Testing

Helium gas loops have been designed and built to gain a better understanding of the gas thermohydraulic phenomena that take place in a helium system. Some of these loops are used for validation and testing of components for high temperature gas-cooled reactors (HTGRs). However, most of them operate at lower pressure and temperature than an HTGR. While these loops can provide valuable information about gas-cooled reactor components, the operating envelope of the experiment is constrained by the maximum operating conditions of the helium loop. In response to the lack of an experimental facility that can provide the infrastructure needed to validate and test components at nominal pressures and temperatures of HTGRS, the HElium Component Testing Out-of-pile Research (HECTOR) facility was designed at Idaho National Laboratory with the assistance of University of Idaho and Walsh Engineering. With the capability to test at temperatures up to 800°C and pressures of 8MPa, HECTOR serves as a critical tool for the advancement of HTGR technology. The facility's primary role is to provide a controlled, high-fidelity environment for the assessment of component resilience and efficiency under nominal HTGR conditions. In the quest to enhance the efficiency and performance of HECTOR, a comparative analysis of three distinct types of heat exchangers—shell and tube, offset strip fin, and printed-circuit—was conducted, focusing primarily on two critical metrics: the required surface area and pressure drop characteristics. The shell and tube heat exchanger, renowned for its robust design and widespread industrial application, was evaluated against the offset strip fin and the cuttingedge printed-circuit heat exchangers, both of which are lauded for their compactness and thermal effectiveness. This comparative study aims to provide detailed insights into the thermal management capabilities of each heat exchanger type under the conditions inherent to HECTOR, thereby facilitating an informed selection for systems demanding high operational integrity and efficiency.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS2018

Iodine Propellant Feed System Flow Modeling

The use of solid iodine as a propellant in Hall-effect thrusters (HETs) is currently being investigated for small-satellite applications. CubeSats offer an inexpensive mode of access to space; however, they currently lack significant propulsion capability. A high specific impulse (I (sub sp)) propulsion system would permit a significant change in velocity, delta v, to be imparted for orbital maintenance, transfers, or de-orbit maneuvers. An electric propulsion system that uses iodine as a propellant has a number of advantages. It has an exceptionally high rho times I (sub sp) figure of merit (density multiplied by the specific impulse), meaning that it can achieve a large total delta v with a relatively low combination of propellant mass and propellant tank volume. Also, the propellant feed system operates at low pressures (a few psia at most), as opposed to the use of super-critical xenon stored at very high pressure. Low pressure operation can lower system mass while greatly reducing the risk of propellant tank rupture, making low pressure a vitally important property for propellants on secondary payloads like CubeSats, where risks must be minimized. The iSAT mission aims to demonstrate iodine-fed HET technology, flying it in space onboard a 12U 912-unit) CubeSat. In the iSAT propellant feed system (PFS), solid iodine is sublimed through heating to produce gaseous propellant that is conducted through tubing to the thruster and cathode. The sublimation process is governed by the iodine (I2) vapor pressure, which is shown as a function of temperature in figure 1. As gaseous I2 flows out of the tank, the gas pressure in the volume containing the solid iodine propellant is reduced until a balance between the flow of iodine out of the tank and the sublimation rate of solid iodine at the equilibrium gas pressure and chosen tank temperature is reached.

Martin, A. K.↗

NASA NTRS2021

Effect of Reactant Pressure on Proton Exchange Membrane Fuel Cell Performance

It is an objective of the National Aeronautics and Space Administration (NASA) to return to the moon and to create sustained lunar operations. Since many applicable lander and upper stage vehicles utilize cryogenic hydrogen and oxygen propellants, it is appealing to incorporate fuel cells into potential mission concepts. A fuel cell could generate electricity, heat, and water from the residual hydrogen and oxygen propellants. Such a concept depends on the capability of the fuel cell to utilize dry, propellant-grade reactants at reduced pressures compared to typical fuel cell operating conditions. This report describes a NASA evaluation of two passive water removal, non-flow-through proton exchange membrane (PEM) fuel cells: a twelve-cell 50 sq. cm active area stack and a seven-cell 150 sq. cm active area stack. Both stacks operated on research grade hydrogen and oxygen reactants supplied at pressures ranging from 20 psia up to the 45-48 psia design operating point, reliably supporting current densities of at least 450 mA/sq. cm at reduced pressures. Polarization curves, fitted with a semi-empirical equation for overpotential, show an increase in effective ohmic resistance and decrease in reversible cell potential, hydrogen crossover current, and Tafel slope when operating at lower pressures, resulting in a reduction in cell voltage at all current densities. Fitted parameters are compared to published values and rationalized with first principles explanations.

fuel cells↗

DOE OSTI2024

Optimal operation of multi-plant steam district heating systems for enhanced efficiency and sustainability

Despite their crucial role in supplying heat and power to universities, industries, and healthcare facilities, many steam-based district heating systems rely on outdated control methods. Among these, multi-central plant districts are particularly challenging due to the complexities of coordinating multiple plants, optimizing load distributions, and managing system downtime. In response, new operational strategies are developed to enhance the efficiency and sustainability of steam districts while utilizing existing resources. These strategies include reducing plant operational pressure without compromising the reliable supply to buildings and optimizing load allocation across multiple plants. The load allocation considers boiler part-load efficiency, runtime, network losses, and building pressure set points, and is compared with traditional multi-boiler controls. To support this exploration, new dynamic Modelica models are developed. In addition, methods to reduce modeling complexities are incorporated, enhancing their suitability for practical applications. A holistic district-wide analysis using a real university case study demonstrates a 4.7% fuel savings by lowering boiler operational pressure from 900 kPa to 600 kPa, along with a 13.3% reduction in condensation losses across the distribution network. Furthermore, the load allocation approach results in a 13.1% reduction in fuel consumption during peak winter periods and 15.3% during shoulder periods, with corresponding decreases in carbon emissions and fuel costs. This approach can also save maintenance costs by reducing the boiler runtime by 49.6%. In conclusion, this research underscores the benefits of retrofitting aging steam district heating systems, offering immediate operational improvements by enhancing efficiency, meeting regulatory compliance, and extending infrastructure lifespans while delaying costly overhauls.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Promoted Ru/PrOx Catalysts for Mild Ammonia Synthesis

Ammonia synthesis is one of the most important chemical reactions. Due to thermodynamic restrictions and the reaction requirements of the current commercial iron catalysts, it is also one of the worst reactions for carbon dioxide emissions and energy usage. Ruthenium-based catalysts can substantially improve the environmental impact as they operate at lower pressures and temperatures. In this work, we provide a screening of more than 40 metals as possible promoter options based on a Ru/Pr2O3 catalyst. Cesium was the best alkali promoter and was held constant for the series of double-promoted catalysts. Ten formulations outperformed the Ru-Cs/PrOx benchmark, with barium being the best second promoter studied and the most cost-effective option. Designs of experiments were utilized to optimize both the pretreatment conditions and the promoter weight loadings of the doubly promoted catalyst. As a result, optimization led to a more than five-fold increase in activity compared to the unpromoted catalyst, therefore creating the possibility for low-ruthenium ammonia synthesis catalysts to be used at scale. Further, we have explored the roles of promoters using kinetic analysis, X-ray Photoelectron Spectroscopy (XPS), and in situ infrared spectroscopy. Here, we have shown that the role of barium is to act as a hydrogen scavenger and donor, which may permit new active sites for the catalyst, and have demonstrated that the associative reaction mechanism is likely used for the unpromoted Ru/PrOx catalyst with hydrogenation of the triple bond of the dinitrogen occurring before any dinitrogen bond breakage.

Chemistry↗

NASA NTRS1996

Johnson Space Center's Regenerative Life Support Systems Test Bed

The Regenerative Life Support Systems (RLSS) Test Bed at NASA's Johnson Space Center is an atmospherically closed, controlled environment facility for human testing of regenerative life support systems using higher plants in conjunction with physicochemical life support systems. The facility supports NASA's Advanced Life Support (ALS) Program. The facility is comprised of two large scale plant growth chambers, each with approximately 11 m2 growing area. The root zone in each chamber is configurable for hydroponic or solid media plant culture systems. One of the two chambers, the Variable Pressure Growth Chamber (VPGC), is capable of operating at lower atmospheric pressures to evaluate a range of environments that may be used in a planetary surface habitat; the other chamber, the Ambient Pressure Growth Chamber (APGC) operates at ambient atmospheric pressure. The air lock of the VPGC is currently being outfitted for short duration (1 to 15 day) human habitation at ambient pressures. Testing with and without human subjects will focus on 1) integration of biological and physicochemical air and water revitalization systems; 2) effect of atmospheric pressure on system performance; 3) planetary resource utilization for ALS systems, in which solid substrates (simulated planetary soils or manufactured soils) are used in selected crop growth studies; 4) environmental microbiology and toxicology; 5) monitoring and control strategies; and 6) plant growth systems design. Included are descriptions of the overall design of the test facility, including discussions of the atmospheric conditioning, thermal control, lighting, and nutrient delivery systems.

NASA Discipline Number 61-10↗

NASA NTRS1991

Johnson Space Center's regenerative life support systems test bed

The Regenerative Life Support System (RLSS) Test Bed at NASA's Johnson Space Center is an atmospherically closed, controlled environment facility for the evaluation of regenerative life support systems using higher plants in conjunction with physicochemical life support systems. When completed, the facility will be comprised of two large scale plant growth chambers, each with approximately 10 m(exp 2) growing area. One of the two chambers, the Variable Pressure Growth Chamber (VPGC), will be capable of operating at lower atmospheric pressures to evaluate a range of environments that may be used in Lunar or Martian habitats; the other chamber, the Ambient Pressure Growth Chamber (APGC) will operate at ambient atmospheric pressure. The root zone in each chamber will be configurable for hydroponic or solid state media systems. Research will focus on: (1) in situ resource utilization for CELSS systems, in which simulated lunar soils will be used in selected crop growth studies; (2) integration of biological and physicochemical air and water revitalization systems; (3) effect of atmospheric pressure on system performance; and (4) monitoring and control strategies.

Henninger, Donald L.↗

DOE OSTI2023

Hybrid Electrochemical Hydrogen/Metal Hydride Compressor (Final Technical Report)

Various alternatives to traditional mechanical compressor systems have been considered, including MHC and EHC. Both MHCs and EHCs are solid-state systems that have no moving parts other than valves. Both are quiet and have low maintenance requirements. However, strength and material issues as well as water and heat management issues have challenged EHCs, especially, when operated at very high pressures. Similarly, low efficiency, especially, when staging is required to attain high, pressure ratios, has challenged MHCs and has made them too complex and expensive. Material degradation, due to hydrogen impurity effects, has also created issues for MHCs. One novel alternative evaluated here is to combine EHC and MHC technologies in a way to maximize their advantages and to minimize each of their challenges to improve the overall systems performance on a path to meet or exceed current DOE targets. A hybrid EH/MH compressor takes advantage of lower maintenance and operating costs as well as increased reliability associated with both the MHC and EHC technologies over traditional mechanical compressors. Neither the MHC nor the EHC have any moving parts other than valves. The hybrid system also takes advantage of the higher efficiency and lower cost of the EHC by operating at lower delivery pressures combined with the robust and simple operation of a single-stage, MH compressor at higher pressures. Both MHC and EHC technologies are scalable and can be used for a variety of hydrogen compression and delivery applications.

08 HYDROGEN↗

NASA NTRS1992

Extravehicular mobility unit subcritical liquid oxygen storage and supply system

The storage of life support oxygen in the Extravehicular Mobility Unit in the liquid state offers some advantages over the current method of storing the oxygen as a high pressure gas. Storage volume is reduced because of the increased density associated with liquid. The lower storage and operating pressures also reduce the potential for leakage or bursting of the storage tank. The potential for combustion resulting from adiabatic combustion of the gas within lines and components is substantially reduced. Design constraints on components are also relaxed due to the lower system pressures. A design study was performed to determine the requirements for a liquid storage system and prepare a conceptual design. The study involved four tasks. The first was to identify system operating requirements that influence or direct the design of the system. The second was to define candidate storage system concepts that could possibly satisfy the requirements. An evaluation and comparison of the candidate concepts was conducted in the third task. The fourth task was devoted to preparing a conceptual design of the recommended storage system and to evaluate concerns with integration of the concept into the EMU. The results are presented.

Anderson, John↗

NASA NTRS2002

Membrane Separation Processes at Low Temperatures

The primary focus of Kennedy Space Center's gas separation activities has been for carbon dioxide, nitrogen, and argon used in oxygen production technologies for Martian in-situ resource utilization (ISRU) projects. Recently, these studies were expanded to include oxygen for regenerative life support systems. Since commercial membrane systems have been developed for separation of carbon dioxide, nitrogen, and oxygen, initially the studies focused on these membrane systems, but at lower operating temperatures and pressures. Current investigations art examining immobilized liquids and solid sorbents that have the potential for higher selectivity and lower operating temperatures. The gas separation studies reported here use hollow fiber membranes to separate carbon dioxide, nitrogen, and argon in the temperature range from 230 to 300 K. Four commercial membrane materials were used to obtain data at low feed and permeate pressures. These data were used with a commercial solution-diffusion modeling tool to design a system to prepare a buffer gas from the byproduct of a process to capture Martian carbon dioxide. The system was designed to operate, at 230 K with a production rate 0.1 sLpm; Feed composition 30% CO2, 44% N2, and 26% Ar; Feed pressure 104 kPa (780); and Permeate pressure 1 kPa (6 torr); Product concentration 600 ppm CO2. This new system was compared with a similar system designed to operate at ambient temperatures (298 K). The systems described above, along with data, test apparatus, and models are presented.

Parrish, Clyde↗

NASA NTRS1999

Aeroacoustic Resonance with Convergent-Divergent Nozzles

Convergent-divergent nozzles, when run at off-design conditions, often undergo flow resonance accompanied by the emission of a tone. Apart from screech occurring at higher operating pressures, resonance is also common at lower Mach numbers near transonic as well as subsonic conditions. With data from six nozzles of different size and design Mach number, the present paper documents the characteristics of the latter phenomenon that is morphologically quite different from conventional screech. The resonance is due to a feedback loop internal to the nozzle and is apparently driven by unsteady laminar boundary layer separation near the throat of the nozzle. Appropriate boundary layer tripping prior to the throat is found to eliminate or alter most of the tones. The Helmholtz number of the resonance, based on the throat-to-exit length, is found to attain a value of approximately 0.15 at M(sub j)=1 for all nozzles. However, its variation with M(sub j) may be different and depend on the nozzle geometry. With nozzles having larger throat-to-exit angle of divergence, the frequency is found to increase, in some cases having stage jumps to lower frequencies, with increasing operating pressure. With nozzles having smaller angle of divergence, the frequency variation exhibits an increase followed by a decrease involving one prominent stage occurring around transonic (M(sub j)= 1) condition. While the mechanisms remain far from completely clear, a model involving downstream propagating aerodynamic disturbance together with acoustic feedback explains the overall frequency characteristics for most cases.

Zaman, K. B. M. Q.↗

NASA NTRS1991

A comparison of cooling methods for the airframe nozzle of a single-stage-to-orbit aircraft

A comparison is made between two different cooling schemes, including a complete system thermal analysis and weight accounting for each. A hydrogen-direct system operates at a higher pressure (34.5 Mpa) and greater temperature rise in the coolant. There is no temperature limit on the coolant itself and high injector temperatures may be achieved, but the pressure lines must be routed over great distances (10 m). The system is simple, and the coolant is almost weightless. In contrast, an indirect system operates at a lower pressure (3.8n MPa) and the liquid coolant has a much greater thermal capacity. The greater thermal capacity causes much less of a temperature rise in the coolant. The chosen coolant is Syltherm 800. This nontoxic fluid is compatible with any metal, including titanium. The loop requires a separate fuel/coolant heat exchanger and coolant pump. The indirect system offers some distinct safety advantages but is heavier than the direct hydrogen coolant system.

Jones, Stuart C.↗

NASA NTRS1986

Characteristics and performance of the ESTEC large space simulator cryogenic system

The final concept and performance characteristics of the Large Space Simulator (LSS) at ESTEC, The Netherlands are discussed. The LSS cryogenics system has proven its operational capabilities under simulated heat load conditions and provides sufficient margin for future elevated requirements. The acceptance test proved that nominal operating pressures can be lower than the design parameters, providing increased system safety and reliability. The ease of access for repair and the incorporated redundancy will limit system downtime. Finally, the system design resulted in a low consumption of LN sub 2, which is an important factor in keeping the operational costs at a low level.

Amlinger, H.↗

NASA NTRS1995

Supersonic-Spray Cleaner

Spraying system for cleaning mechanical components uses less liquid and operates at pressures significantly lower. Liquid currently used is water. Designed to replace chlorofluorocarbon (CFC) solvent-based cleaning and cleanliness verification methods. Consists of spray head containing supersonic converging/diverging nozzles, source of gas at regulated pressure, pressurized liquid tank, and various hoses, fittings, valves, and gauges. Parameters of nozzles set so any of large variety of liquids and gases combined in desired ratio and rate of flow. Size and number of nozzles varied so system built in configurations ranging from small hand-held spray heads to large multinozzle cleaners. Also used to verify part adequately cleaned. Runoff liquid from spray directed at part collected. Liquid analyzed for presence of contaminants, and part recleaned if necessary.

Caimi, Raoul E. B.↗

DOE OSTI2023

Coherent fluctuations in a partially magnetized small magnetron discharge operating on molecular nitrogen

We report experimental data on rotating plasma disturbances in a quasi-steady direct-current magnetron discharge operating with molecular nitrogen at pressures of 27, 40, 67, and 133 Pa. Experiments with a segmented anode measuring the local current flow reveal up to 12 coherent structures (“spokes”) propagating in the +E×B and −E×B azimuthal directions. The current–voltage characteristics are studied and found to follow a negative resistance profile at the lower discharge currents. The existence of coherent structures and the number of spokes observed depend on the discharge current and operating pressure. Lower pressures are more favorable to the retrograde −E×B spoke rotation, which is observed in the 27, 40, and 67 Pa discharges. The results are interpreted with a gradient-driven drift wave model, and using the dispersion relation, we show that the propagation direction depends on the orientation of the local electric field within the plasma. Using an electron fluid model, we show how experimental conditions can lead to field reversals that generate −E×B spoke rotation in the lower pressure discharges.

Physics↗

NASA NTRS2023

Development Unit for In-Space Pneumatic Helium Transfer Compressor

High-pressure gaseous helium (GHe) plays a critical role in spacecraft propulsion due to its near exclusive use for pressurization of propellant tanks. Several different designs for helium compressor technologies have been developed for use on Earth; however, significant design changes are required to meet the power, thermal/heat dissipation, vacuum, vibration/shock, size, mass, and efficiency requirements needed for space and launch environments. Currently, no capability exists for mass efficient on-orbit GHe (or xenon) transfer, nor has it ever been attempted. This effort proposed several challenging requirements for the vendor to develop a one-of-a-kind pneumatic compressor prototype. In order to develop a compressor prototype at a TRL 4, a partnership with Air Squared, Inc. was established. This CIF project concluded with the receipt of a prototype along with a proposed design for a flight unit; however, it will not be built due to funding limitations. The vendor had moderate success with initial testing of the prototype at lower pressures (with shimming configured for low pressure). There were delays with testing since the unit was built for higher pressures and the low pressure shimming was challenging to implement. It was found that operation of the compressor at lower pressures caused increased friction on the motor shaft which resulted in the unit drawing more power (current). This was initially thought to be a motor or controller defect. Subsequent high pressure testing at KSC showed that the friction was reduced for the optimal design point (with a high pressure shimming configuration) and the motor (and controller) performed nominally. Following the vendor testing, the unit was tuned/shimmed for a nominal inlet pressure and shipped to KSC for high pressure testing using the custom-designed setup in the Vehicle Assembly Building. The unit performed well, showing the capability to achieve over higher pressure of compression. The pressure differential could likely increase, however, the maximum output of the power supply used for testing was reached, limiting the compressor motor’s capability. Following the GN2 testing, the test setup was converted to GHe with at high pressure. It was shown that although the unit was unable to achieve similar high pressure differentials due to reverse leakage of the GHe through the scroll tip seals, it did achieve the desired GHe compression. This may still be useful for some applications, however, for the purpose of on-orbit GHe transfer, the single stage design would need to be changed to include multiple stages to achieve the compression goals initially proposed by the project.

Brian Nufer↗

NASA NTRS1985

An experimental data base for material selection and design of high-speed, high-pressure, oxygen turbomachinery

New technologies for space-based, reusable, throttleable, cryogenic, orbit transfer propulsion are being evaluated. A variable-thrust (200 to 3000 lbF), 2000 psi chamber pressure, LO2/LH2 engine has been selected to demonstrate the 20-hour, 500-restart life goal, and a specific impulse of 480 lbF-sec/lbM. The advanced design uses warm oxygen to power a fully integrated turbopump that delivers 4500 psi LO2. The selected engine cycle provides the following advantages over conventional expander cycle designs which use H2 to drive the LH2 and LO2 pumps; higher engine operating pressures and performance in a smaller envelope, lower turbine operating temperatures, elimination of interpropellant seals and purges, and an extended throttling range. The design approach and results of testing to characterize materials for use in high-pressure gaseous oxygen are discussed. Test methods include particle impact testing in a sonic-flow, hot GO2 streams and forced, high-speed friction rubbing testing. Materials are exposed to oxygen and nitrogen atmospheres at pressures of 100, 1000, and 3000 psi to identify separately the gas cooling effects from the metal oxidation effects at the rubbing surface. The selection of candidate design materials is based on an analytical parameter defined as the burn factor. Typical materials tested include carbon steel, stainless steel, nickel, copper, and monel alloys.

Schoenman, L.↗

DOE OSTI2025

Review of the potential and challenges of MOF-based adsorption heat pumps for sustainable cooling and heating in the buildings

Heat pumps are regarded as the most suitable means to meet the future demand of heating and cooling in the building, as they require small input of electrical energy and output high thermal energy. Vapor compression heat pump (VCHP) and transcritical-CO 2 heat pump are the two major heat pump technologies currently dominating the market. However, VCHP system suffers from its fugitive emission of hydrofluorocarbon (HFC) refrigerants, and transcritical-CO 2 system requires high operating pressure (typically 9–13 MPa). For low-to-medium temperature heating and cooling applications thermally driven adsorption heat pump (AHP) provides a better alternative to VCHP and transcritical-CO 2 system as AHP uses natural refrigerants and operates at a much lower pressure. But currently available AHP technology has the limitation of low coefficient of performance (COP). Advances in synthesizing metal-organic frameworks (MOF) with high gas adsorption capacity have created an opportunity to address the problem of low COP of current AHP technology. Here, this article reviews the progress made in the past decade in utilizing MOF and conventional adsorbents with different working fluids in AHP technology and compares their performance. The article also summarizes the key challenges for the MOF-based AHP technology and provides the authors’ perspective to address these challenges.

30 DIRECT ENERGY CONVERSION↗