A study of finned tube gas-to-liquid heat exchangers for Brayton cycles in space
Gas-to-liquid heat exchangers, for liquid cooled Brayton cycle space power plant, with finned tubing
BRAYTON CYCLE↗
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Liquid MHD power conversion
Nonrotating Rankine cycle for liquid metal magnetohydrodynamic power conversion
POWER CONVERSION↗
Summary of gas bearing applications in the field of space electric power systems.
The NASA-Lewis Research Center is investigating the technology of closed Brayton cycle electric power systems for space. The turbine-alternator-compressor power conversion unit for such a system is designated Brayton Rotating Unit (BRU). In parallel to power system testing, a BRU improvement effort was initiated. A major portion of this effort involves the testing and evaluation of different bearing systems. A description of each bearing is presented along with results of the evaluation to date and a comparison of the merits and limitations of each bearing.
Dunn, J. H.↗
A Review of Tribomaterial Technology for Space Nuclear Power Systems
The National Aeronautics and Space Administration (NASA) has recently proposed a nuclear closed-cycle electric power conversion system for generation of 100-kW of electrical power for space exploration missions. A critical issue is the tribological performance of sliding components within the power conversion unit that will be exposed to neutron radiation. This paper presents a review of the main considerations that have been made in the selection of solid lubricants for similar applications in the past as well as a recommendations for continuing development of the technology.
Stanford, Malcolm K.↗
Study of toluene stability for an Organic Rankine Cycle (ORC) space-based power system
The design, fabrication, assembly, and endurance operation of a dynamic test loop, built to evaluate the thermal stability of a proposed Organic Rankine Cycle (ORC) working fluid, is discussed. The test fluid, toluene, was circulated through a heater, simulated turbine, regenerator, condenser and pump to duplicate an actual ORC system. The maximum nominal fluid temperature, 750 F, was at the turbine simulator inlet. Samples of noncondensible gases and liquid toluene were taken periodically during the test. The samples were analyzed to identify the degradation products formed and the quantity of these products. From these data it was possible to determine the degradation rate of the working fluid and the generation rate of noncondensible gases. A further goal of this work was to relate the degradation observed in the dynamic operating loop to degradation obtained in isothermal capsule tests. This relationship was the basis for estimating the power loop degradation in the Space Station Organic Rankine Cycle system.
Havens, Vance↗
Development of a solar-powered residential air conditioner: System optimization preliminary specification
Investigations aimed at the optimization of a baseline Rankine cycle solar powered air conditioner and the development of a preliminary system specification were conducted. Efforts encompassed the following: (1) investigations of the use of recuperators/regenerators to enhance the performance of the baseline system, (2) development of an off-design computer program for system performance prediction, (3) optimization of the turbocompressor design to cover a broad range of conditions and permit operation at low heat source water temperatures, (4) generation of parametric data describing system performance (COP and capacity), (5) development and evaluation of candidate system augmentation concepts and selection of the optimum approach, (6) generation of auxiliary power requirement data, (7) development of a complete solar collector-thermal storage-air conditioner computer program, (8) evaluation of the baseline Rankine air conditioner over a five day period simulating the NASA solar house operation, and (9) evaluation of the air conditioner as a heat pump.
Rousseau, J.↗
Dynamic design of gas sorption J-T refrigerator
A long-life Joule-Thomson refrigerator which is heat powered, involves no sealing, and has few mechanical parts is desirable for long-term sensor cooling in space. In the gas-sorption J-T refrigerator, cooling is achieved by gas sorption (either adsorption or absorption) processes. Currently, a modular, single-stage refrigerator is being designed and built to be operated at 20 K. The design was analyzed using a dynamic model, which is described here. The model includes the kinetics of the compressors and the heat switches, the heat transfer of the pre-coolers and the heat exchangers, the on/off ratio of the check valves, and the impedance of the J-T valve. The cooling power, the cycle time, and the operating conditions were obtained in terms of the power input, the heat sink temperature, and the J-T impedance.
Chan, C. K.↗
Strategy for Developing Technologies for Megawatt-class Nuclear Electric Propulsion Systems
In late fiscal year 2020, the Space Nuclear Propulsion (SNP) project began the process of formulating an investment strategy to support development of the technologies required for a high-power (megawatt-class) nuclear electric propulsion (NEP) system capable of performing human-scale missions. This activity was initiated concurrent with several high-level studies and assessments were either under way or had just concluded. Studies of human-scale Mars missions have been performed several times over the past two decades. One of the most recent studies examined opposition-class human Mars missions to occur in the late 2030s timeframe [1,2]. The mission architecture assumed a hybrid NEP/chem-propelled vehicle that used a high specific impulse (Isp) NEP-system and a liquid oxygen (LOx)-liquid methane high thrust chemical stage (two 110 kN (25 klbf) thrust, 365 s Isp engines) for maneuvers performed to enter and exit gravity wells. Trajectory analyses performed in this study showed that such a mission could be performed with 2-4 MWe directed into the electric propulsion system (operating for 20,000+ hours), with the large range representing different opposition-class Mars mission opportunities and permutations on the trajectory design, concept of operations, and technology choices. In 2020, the NASA Engineering and Safety Center (NESC) performed a study to evaluate the maturity of the different technologies required for nuclear propulsion systems [3]. The executive summary of this report provided the following top-level conclusions: • “The majority of critical technologies for… NEP/Chem… systems are relatively immature” • “TRLs [technology readiness levels] in the literature are often overestimated” • “The majority of critical technologies… for NEP/Chem… systems are at a relatively high level of advancement degree of difficulty (AD2 > 4) for maturation, requiring a dual development approach” • “The proper assessment of baseline TRL and AD2 values and the estimation of requirements and resources required for advancement have been consistent issues for NEP,” • “Non-advocate reviews should occur at the start of a technology program and at all key milestones.” In 2021, the National Academies of Science, Engineering, and Medicine (NASEM) issued a separate report [4] identifying the “primary technical and programmatic challenges, merits, and risks for maturing space nuclear propulsion technologies of interest to a future human Mars exploration mission.” That work contained several important findings, including: • “Developing a MWe-class NEP system for the baseline mission would require increasing power by orders of magnitude relative to NEP system flight- or ground-based technology demonstrations completed to date.” • “Subscale in-space flight testing of NEP systems cannot address many of the risks and potential failure modes associated with the baseline mission NEP system. With sufficient M&S [modeling & simulation] and ground testing, including modular subsystem tests at full scale and power, flight qualification requirements can be met by the cargo missions that will precede the first crewed mission to Mars. Fully integrated ground testing may not be required.” • “As a result of low and intermittent investment over the past several decades, it is unclear if even an aggressive program would be able to develop an NEP system capable of executing the baseline mission in 2039.” These efforts motivated the SNP project to investigate the technologies available for a megawatt-class high power nuclear electric propulsion system. That system is illustrated schematically in Figure 1 and is comprised of five separate top-level critical technology elements (CTEs). 1. Nuclear Reactor – Thermal power source for the system, utilizing high-assay low enriched uranium (HALEU) as the nuclear fuel. Reactor radiation shielding is also included in this CTE. 2. Power Conversion – Operates as a thermodynamic cycle, accepting nuclear reactor thermal power as an input and converting it to mechanical power. 3. Power Management and Distribution (PMAD) – Accepts as an input mechanical power from the power conversion system, which is used to generate electrical power. The PMAD system also distributes the generated electrical power to all other parts of the spacecraft, including the high-power EP system. The PMAD system may also perform duties such as isolation, fault detection, and power transformation/rectification for different spacecraft systems, including the thrusters. 4. Electric Propulsion (EP) – Accepts as an input electrical power, which is used to accelerate a propellant to high speeds to produce thrust. This system includes the power processing unit (PPU), which converts the power it receives to the correct current and voltage required by the thrusters, and the propellant storage and feed systems, which contain and meter the flow of propellant to the thrusters. 5. Thermal Management (Radiators/Heat Rejection) – The cold side of the thermodynamic power conversion cycle, accepts thermal power from the power conversion system and radiatively rejects that heat to space. In this paper, we describe the SNP project formulation and investment strategy that aims to accomplish the research and development required to advance the technology readiness for each CTE. The strategy relies heavily upon experimental testing supported by modeling and simulation to yield realistic assessments of the technologies, which in turn will be used to inform future NEP system-level design decisions and any potential technology downselects.
Kurt A Polzin↗
Evaluation of Rankine cycle air conditioning system hardware by computer simulation
A computer program for simulating the performance of a variety of solar powered Rankine cycle air conditioning system components (RCACS) has been developed. The computer program models actual equipment by developing performance maps from manufacturers data and is capable of simulating off-design operation of the RCACS components. The program designed to be a subroutine of the Marshall Space Flight Center (MSFC) Solar Energy System Analysis Computer Program 'SOLRAD', is a complete package suitable for use by an occasional computer user in developing performance maps of heating, ventilation and air conditioning components.
Healey, H. M.↗
Methods of reducing energy consumption of the oxidant supply system for MHD/steam power plants
An in-depth study was conducted to identify possible improvements to the oxidant supply system for combined cycle MHD power plants which would lead to higher thermal efficiency and reduction in the cost of electricity, COE. Results showed that the oxidant system energy consumption could be minimized when the process was designed to deliver a product O2 concentration of 70 mole percent. The study also led to the development of a new air separation process, referred to as liquid pumping and internal compression. MHD system performance calculations show that the new process would permit an increase in plant thermal efficiency of 0.6 percent while allowing more favorable tradeoffs between magnetic energy and oxidant system capacity requirements.
A. J Juhasz↗
Methods of reducing energy consumption of the oxidant supply system for MHD/steam power plants
An in-depth study was conducted to identify possible improvements to the oxidant supply system for combined cycle MHD power plants which would lead to higher thermal efficiency and reduction in the cost of electricity, COE. Results showed that the oxidant system energy consumption could be minimized when the process was designed to deliver a product O2 concentration of 70 mole percent. The study also led to the development of a new air separation process, referred to as 'liquid pumping and internal compression'. MHD system performance calculations show that the new process would permit an increase in plant thermal efficiency of 0.6 percent while allowing more favorable tradeoffs between magnetic energy and oxidant system capacity requirements.
Juhasz, A. J.↗
Reliability of Upright and Supine Power Measurements Using an Inertial Load Cycle Ergometer
Practical, reliable, and time efficient methods of measuring muscular power are desirable for both research and applied testing situations. The inertial-load cycling method (ILC; Power/Cycle, Austin, TX) requires subjects to pedal as fast as possible against the inertial load of a flywheel for only 3-5 seconds, which could help reduce the time and effort required for maximal power testing. PURPOSE: 1) To test the intramachine reliability of ILC over 3 separate sessions, 2) to compare postural stance (upright vs. supine) during testing, and 3) to compare the maximal power (Pmax) output measured using ILC to that obtained from traditional isokinetic and leg press testing. METHODS: Subjects (n = 12) were tested on 4 non-consecutive days. The following tests were done on the first day of testing: isometric knee extension, isokinetic knee extension at several speeds, isokinetic power/endurance at 180/sec (Biodex System 4), leg press maximal isometric force, and leg press power/endurance. The other 3 days consisted exclusively of ILC testing. Subjects performed 6 ILC tests in an upright position and 6 ILC tests in a supine position on each day. The starting position was counterbalanced. Mixed-effects linear modeling was used to determine if any differences existed between testing days and between upright and supine for Pmax and revolutions per minute at Pmax (RPMpk). Mixed-modeling was also used to calculate intraclass correlation coefficients (ICC) to determine the reliability of the ILC on each testing day for Pmax and RPMpk (ICCs were calculated separately for upright and supine). gKendall fs Tau a h was used to determine the association between ILC Pmax and isokinetic and leg press data. RESULTS: For Pmax, significant differences were found between days 1 and 2 (upright: p = 0.018; supine: p = 0.014) and between days 1 and 3 (upright: p = 0.001; supine: p = 0.002), but not between days 2 and 3 (upright: p = 0.422; supine: p = 0.501). Pmax ICC values were greater than or equal to 0.97 for all days in both positions. Also, no significant differences between upright and supine postures were found for Pmax. No significant differences between days were found for RPMpk; however, there was a significant posture effect (upright greater than supine). Moderate correlations were observed between ILC Pmax and isokinetic and leg press tests (upright: 0.64-0.79, supine: 0.52-0.82). CONCLUSIONS: Overall, ILC is a very reliable test. Since a significant difference was found between day 1 and the other ILC testing days, it is suggested that day 1 of ILC testing should be used as a familiarization session to allow for subject learning. No significant difference in Pmax was seen from test 3 to test 6. However, an increase of 1.3% was observed from test 4 to test 6. Therefore, although 4 tests may be sufficient for most subjects to produce Pmax, in some cases 6 tests may be required. PRACTICAL APPLICATIONS: No differences were seen in Pmax between upright and supine positions despite differing RPMpk. This suggests that ILC testing can be used to provide reliable testing both in an upright position (appropriate for athletes) and in research (e.g., bed rest) or rehabilitation settings where supine testing is necessary. Future research should evaluate whether peak power measurements obtained with the ILC are sensitive to changes such as that observed with training and de-training.
Wickwire, P. J.↗
Parametric study of prospective early commercial MHD power plants (PSPEC). General Electric Company, task 1: Parametric analysis
The performance and cost of moderate technology coal-fired open cycle MHD/steam power plant designs which can be expected to require a shorter development time and have a lower development cost than previously considered mature OCMHD/steam plants were determined. Three base cases were considered: an indirectly-fired high temperature air heater (HTAH) subsystem delivering air at 2700 F, fired by a state of the art atmospheric pressure gasifier, and the HTAH subsystem was deleted and oxygen enrichment was used to obtain requisite MHD combustion temperature. Coal pile to bus bar efficiencies in ease case 1 ranged from 41.4% to 42.9%, and cost of electricity (COE) was highest of the three base cases. For base case 2 the efficiency range was 42.0% to 45.6%, and COE was lowest. For base case 3 the efficiency range was 42.9% to 44.4%, and COE was intermediate. The best parametric cases in bases cases 2 and 3 are recommended for conceptual design. Eventual choice between these approaches is dependent on further evaluation of the tradeoffs among HTAH development risk, O2 plant integration, and further refinements of comparative costs.
Marston, C. H.↗
Coupled generator and combustor performance calculations for potential early commercial MHD power plants
A parametric study of the performance of the MHD generator and combustor components of potential early commercial open-cycle MHD/steam power plants is presented. Consideration is given to the effects of air heater system concept, MHD combustor type, coal type, thermal input power, oxygen enrichment of the combustion, subsonic and supersonic generator flow and magnetic field strength on coupled generator and combustor performance. The best performance is found to be attained with a 3000 F, indirectly fired air heater, no oxygen enrichment, Illinois no. 6 coal, a two-stage cyclone combustor with 85% slag rejection, a subsonic generator, and a magnetic field configuration yielding a constant transverse electric field of 4 kV/m. Results indicate that optimum net MHD generator power is generally compressor-power-limited rather than electric-stress-limited, with optimum net power a relatively weak function of operating pressure.
Dellinger, T. C.↗
Energy Conversion Alternatives Study (ECAS), Westinghouse phase 1. Volume 8: Open-cycle MHD
Electric power plant costs and efficiencies are presented for three basic open-cycle MHD systems: (1) direct coal fired system, (2) a system with a separately fired air heater, and (3) a system burning low-Btu gas from an integrated gasifier. Power plant designs were developed corresponding to the basic cases with variation of major parameters for which major system components were sized and costed. Flow diagrams describing each design are presented. A discussion of the limitations of each design is made within the framework of the assumptions made.
Hoover, D. Q.↗
Development of Lightweight Radiators for Lunar Based Power Systems
This report discusses application of a new lightweight carbon-carbon (C-C) space radiator technology developed under the NASA Civil-Space Technology Initiative (CSTI) High Capacity Power Program to a 20 kWe lunar based power system. This system comprises a nuclear (SP-100 derivative) heat source, a Closed Brayton Cycle (CBC) power conversion unit with heat rejection by means of a plane radiator. The new radiator concept is based on a C-C composite heat pipe with integrally woven fins and a thin walled metallic liner for containment of the working fluid. Using measured areal specific mass values (1.5 kg/m2) for flat plate radiators, comparative CBC power system mass and performance calculations show significant advantages if conventional heat pipes for space radiators are replaced by the new C-C heat pipe technology.
Juhasz, Albert J.↗
Hubble Space Telescope Crew Rescue Analysis
In the aftermath of the 2003 Columbia accident NASA removed the Hubble Space Telescope (HST) Servicing Mission 4 (SM4) from the Space Shuttle manifest. Reasons cited included concerns that the risk of flying the mission would be too high. There was at the time no viable technique to repair the orbiter s thermal protection system if it were to be damaged by debris during ascent. Furthermore in the event of damage, since the mission was not to the International Space Station, there was no safe haven for the crew to wait for an extended period of time for a rescue. The HST servicing mission was reconsidered because of improvements in the ascent debris environment, the development of techniques for the astronauts to perform on orbit repairs to damage thermal protection, and the development of a strategy to provide a crew rescue capability. However, leading up to the launch of servicing mission, the HST crew rescue capability was a recurring topic. For HST there was a limited amount of time available to perform a crew rescue because of the limited consumables available on the Orbiter. The success of crew rescue depends upon several factors including when a problem is identified, when and to what extent power down procedures are begun, and where the rescue vehicle is in its ground processing cycle. Severe power downs maximize crew rescue success but would eliminate the option for the orbiter servicing the HST to attempt a landing. Therefore, crew rescue success needed to be weighed against preserving the ability of the orbiter to have landing option in case there was a problem with the rescue vehicle. This paper focuses on quantification of the HST mission loss of crew rescue capability using Shuttle historical data and various power down capabilities. That work supported NASA s decision to proceed with the HST service mission, which was successfully completed on May 24th 2009.
Hamlin, Teri L.↗
Study of a 300-kilowatt Rankine-cycle advanced nuclear-electric space-power system
System analysis of lithium-cooled Rankine cycle nuclear-electric space power unit
Barna, G. J.↗