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DOE OSTI2014

Oil-free centrifugal hydrogen compression technology demonstration

One of the key elements in realizing a mature market for hydrogen vehicles is the deployment of a safe and efficient hydrogen production and delivery infrastructure on a scale that can compete economically with current fuels. The challenge, however, is that hydrogen, being the lightest and smallest of gases with a lower viscosity and density than natural gas, readily migrates through small spaces and is difficult to compresses efficiently. While efficient and cost effective compression technology is crucial to effective pipeline delivery of hydrogen, the compression methods used currently rely on oil lubricated positive displacement (PD) machines. PD compression technology is very costly, has poor reliability and durability, especially for components subjected to wear (e.g., valves, rider bands and piston rings) and contaminates hydrogen with lubricating fluid. Even so called “oil-free” machines use oil lubricants that migrate into and contaminate the gas path. Due to the poor reliability of PD compressors, current hydrogen producers often install duplicate units in order to maintain on-line times of 98-99%. Such machine redundancy adds substantially to system capital costs. As such, DOE deemed that low capital cost, reliable, efficient and oil-free advanced compressor technologies are needed. MiTi’s solution is a completely oil-free, multi-stage, high-speed, centrifugal compressor designed for flow capacity of 500,000 kg/day with a discharge pressure of 1200 psig. The design employs oil-free compliant foil bearings and seals to allow for very high operating speeds, totally contamination free operation, long life and reliability. This design meets the DOE’s performance targets and achieves an extremely aggressive, specific power metric of 0.48 kW-hr/kg and provides significant improvements in reliability/durability, energy efficiency, sealing and freedom from contamination. The multi-stage compressor system concept has been validated through full scale performance testing of a single stage with helium similitude gas at full speed in accordance with ASME PTC-10. The experimental results indicated that aerodynamic performance, with respect to compressor discharge pressure, flow, power and efficiency exceeded theoretical prediction. Dynamic testing of a simulated multistage centrifugal compressor was also completed under a parallel program to validate the integrity and viability of the system concept. The results give strong confidence in the feasibility of the multi-stage design for use in hydrogen gas transportation and delivery from production locations to point of use.

08 HYDROGEN↗

DOE OSTI2017

High Fidelity, “Faster than Real-Time” Simulator for Predicting Power System Dynamic Behavior - Final Technical Report

The “High Fidelity, Faster than RealTime Simulator for Predicting Power System Dynamic Behavior” was designed and developed by Illinois Institute of Technology with critical contributions from Electrocon International, Argonne National Laboratory, Alstom Grid and McCoy Energy. Also essential to the project were our two utility partners: Commonwealth Edison and AltaLink. The project was a success due to several major breakthroughs in the area of largescale power system dynamics simulation, including (1) a validated faster than real time simulation of both stable and unstable transient dynamics in a largescale positive sequence transmission grid model, (2) a threephase unbalanced simulation platform for modeling new grid devices, such as independently controlled singlephase static var compensators (SVCs), (3) the world’s first high fidelity threephase unbalanced dynamics and protection simulator based on Electrocon’s CAPE program, and (4) a firstofits kind implementation of a singlephase induction motor model with stall capability. The simulator results will aid power grid operators in their true time of need, when there is a significant risk of cascading outages. The simulator will accelerate performance and enhance accuracy of dynamics simulations, enabling operators to maintain reliability and steer clear of blackouts. In the longterm, the simulator will form the backbone of the newly conceived hybrid realtime protection and control architecture that will coordinate local controls, widearea measurements, widearea controls and advanced realtime prediction capabilities. The nation’s citizens will benefit in several ways, including (1) less down time from power outages due to the fasterthanrealtime simulator’s predictive capability, (2) higher levels of reliability due to the detailed dynamics plus protection simulation capability, and (3) more resiliency due to the three phase unbalanced simulator’s ability to model threephase and single phase networks and devices.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2017

Development of Long-Pulse Heating and Current Drive Actuators and Operational Techniques Compatible with a High-Z Divertor and First Wall

Accurate measurement of the edge electron density profile is essential to optimizing antenna coupling and assessment of impurity contamination in studying long-pulse plasma heating and current drive in fusion devices. Measurement of the edge density profile has been demonstrated on the US fusion devices such as C-Mod, DIII-D, and TFTR amongst many devices, and has been used for RF loading and impurity modeling calculations for many years. University of Science and Technology of China (USTC) has recently installed a density profile reflectometer system on the EAST fusion device at the Institute of Plasma Physics, Chinese Academy of Sciences in China based on the University of California Los Angeles (UCLA)-designed reflectometer system on the DIII-D fusion device at General Atomics Company in San Diego, California. UCLA has been working with USTC to optimize the existing microwave antenna, waveguide system, microwave electronics, and data analysis to produce reliable edge density profiles. During the past budget year, progress has been made in all three major areas: effort to achieve reliable system operations under various EAST operational conditions, effort to optimize system performance, and effort to provide quality density profiles into EAST’s database routinely.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2010

Development of a Turnkey Hydrogen Fueling Station Final Report

The transition to hydrogen as a fuel source presents several challenges. One of the major hurdles is the cost-effective production of hydrogen in small quantities (less than 1MMscf/month). In the early demonstration phase, hydrogen can be provided by bulk distribution of liquid or compressed gas from central production plants; however, the next phase to fostering the hydrogen economy will likely include onsite generation and extensive pipeline networks to help effect a pervasive infrastructure. Providing inexpensive hydrogen at a fleet operator’s garage or local fueling station is a key enabling technology for direct hydrogen Fuel Cell Vehicles (FCVs). The objective of this project was to develop a comprehensive, turnkey, stand-alone, commercial hydrogen fueling station for FCVs with state-of-the-art technology that is cost-competitive with current hydrocarbon fuels. Such a station would promote the advent of the hydrogen fuel economy for buses, fleet vehicles, and ultimately personal vehicles. Air Products, partnering with the U.S. Department of Energy (DOE), The Pennsylvania State University, Harvest Energy Technology, and QuestAir, developed a turnkey hydrogen fueling station on the Penn State campus. Air Products aimed at designing a station that would have 65% overall station efficiency, 82% PSA (pressure swing adsorption) efficiency, and the capability of producing hydrogen at $3.00/kg (gge) H2 at mass production rates. Air Products designed a fueling station at Penn State from the ground up. This project was implemented in three phases. The first phase evaluated the various technologies available in hydrogen generation, compression, storage, and gas dispensing. In the second phase, Air Products designed the components chosen from the technologies examined. Finally, phase three entailed a several-month period of data collection, full-scale operation, maintenance of the station, and optimization of system reliability and performance. Based on field data analysis, it was determined by a proprietary hydrogen-analysis model that hydrogen produced from the station at a rate of 1500 kg/day and when produced at 1000 stations per year would be able to deliver hydrogen at a price of $3.03/kg (gge) H2. The station’s efficiency was measured to be 65.1%, and the PSA was tested and ran at an efficiency of 82.1%, thus meeting the project targets. From the study, it was determined that more research was needed in the area of hydrogen fueling. The overall cost of the hydrogen energy station, when combined with the required plot size for scaled-up hydrogen demands, demonstrated that a station using steam methane reforming technology as a means to produce on–site hydrogen would have limited utility in the marketplace. Alternative hydrogen supplies, such as liquid or pipeline delivery to a refueling station, need to be included in the exploration of alternative energy site layouts. These avenues need to be explored before a definitive refueling station configuration and commercialization pathway can be determined.

08 HYDROGEN↗

DOE OSTI2021

Measurement report: Properties of aerosol and gases in the vertical profile during the LAPSE-RATE campaign

Abstract. Unmanned aerial systems (UASs) are increasingly being used as observation platforms for atmospheric applications. The Lower Atmospheric Process Studies at Elevation – a Remotely-piloted Aircraft Team Experiment (LAPSE-RATE) in Alamosa, Colorado, USA, on 14–20 July 2018 investigated and validated different UASs, measurement sensors and setup configurations. Flight teams from the Finnish Meteorological Institute (FMI) and Kansas State University (KSU) participated in LAPSE-RATE to measure and investigate properties of aerosol particles and gases in the lower atmosphere. During the experiment, the performance of different UAS configurations were investigated and confirmed to operate reliably, resulting in a scientifically sound observational dataset. As an example, concentration of aerosols – including two new particle formation events, CO2 and water vapor, and meteorological parameters in the atmospheric vertical profile were measured during the short experiment. Such observations characterizing atmospheric phenomena of this specific environment would have not been possible in any other way and, thus, demonstrate the power of UASs as new, promising tools in atmospheric and environmental research.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1973

Low-thrust mission risk analysis, with application to a 1980 rendezvous with the comet Encke

A computerized failure process simulation procedure is used to evaluate the risk in a solar electric space mission. The procedure uses currently available thrust-subsystem reliability data and performs approximate simulations of the thrust sybsystem burn operation, the system failure processes, and the retargeting operations. The method is applied to assess the risks in carrying out a 1980 rendezvous mission to the comet Encke. Analysis of the results and evaluation of the effects of various risk factors on the mission show that system component failure rates are the limiting factors in attaining a high mission relability. It is also shown that a well-designed trajectory and system operation mode can be used effectively to partially compensate for unreliable thruster performance.

Yen, C. L.↗

NASA NTRS1976

Reconfigurable redundancy management for aircraft flight control

A highly fault tolerant digital computer system has been configured based on extensive experience with flight proven, redundant digital flight control systems. The feasibility of minimizing hardware complexity is shown while maintaining high levels of fault tolerance. The emerging hardware design combines reconfiguration concepts with conventional hardware redundancy techniques and special operational software to provide dual fail operate performance with a basic triplex system. The design provides high reliability and flight safety, enhances maintainability, and reduces life cycle cost while offering improved performance for future aircraft.

Bosch, J. A.↗

NASA NTRS1980

Phase 1 of the near term hybrid passenger vehicle development program. Appendix B: Trade-off studies, volume 1

Tradeoff study activities and the analysis process used are described with emphasis on (1) review of the alternatives; (2) vehicle architecture; and (3) evaluation of the propulsion system alternatives; interim results are presented for the basic hybrid vehicle characterization; vehicle scheme development; propulsion system power and transmission ratios; vehicle weight; energy consumption and emissions; performance; production costs; reliability, availability and maintainability; life cycle costs, and operational quality. The final vehicle conceptual design is examined.

Traversi, M.↗

NASA NTRS1994

Payload holddown and release mechanism

A payload holddown and release mechanism, designated the Model 1172, was designed and built at G&H Technology during the winter of 1992/1993. The mechanism is able to restrain and release a 45-pound payload with minimal tipoff. The payload is held in place by a stainless steel band and released using electrically triggered non-explosive actuators. These actuators provide reliable operation with negligible shock and no special handling requirements. The performance of the mechanism was demonstrated in two flight tests. Data showed pitch and yaw tipoff rates of less than 0.07 radian (4 degree) per second. The Model 1172 design is an efficient replacement for conventional payload deployment devices, especially where low transmitted shock is required.

Chaput, Dale↗

NASA NTRS1994

An acoustic charge transport imager for high definition television applications

The primary goal of this research is to develop a solid-state television (HDTV) imager chip operating at a frame rate of about 170 frames/sec at 2 Megapixels/frame. This imager will offer an order of magnitude improvements in speed over CCD designs and will allow for monolithic imagers operating from the IR to UV. The technical approach of the project focuses on the development of the three basic components of the imager and their subsequent integration. The camera chip can be divided into three distinct functions: (1) image capture via an array of avalanche photodiodes (APD's); (2) charge collection, storage, and overflow control via a charge transfer transistor device (CTD); and (3) charge readout via an array of acoustic charge transport (ACT) channels. The use of APD's allows for front end gain at low noise and low operating voltages while the ACT readout enables concomitant high speed and high charge transfer efficiency. Currently work is progressing towards the optimization of each of these component devices. In addition to the development of each of the three distinct components, work towards their integration and manufacturability is also progressing. The component designs are considered not only to meet individual specifications but to provide overall system level performance suitable for HDTV operation upon integration. The ultimate manufacturability and reliability of the chip constrains the design as well. The progress made during this period is described in detail.

Hunt, W. D.↗

NASA NTRS1994

An acoustic charge transport imager for high definition television applications

The primary goal of this research is to develop a solid-state high definition television (HDTV) imager chip operating at a frame rate of about 170 frames/sec at 2 Megapixels per frame. This imager offers an order of magnitude improvement in speed over CCD designs and will allow for monolithic imagers operating from the IR to the UV. The technical approach of the project focuses on the development of the three basic components of the imager and their integration. The imager chip can be divided into three distinct components: (1) image capture via an array of avalanche photodiodes (APD's), (2) charge collection, storage and overflow control via a charge transfer transistor device (CTD), and (3) charge readout via an array of acoustic charge transport (ACT) channels. The use of APD's allows for front end gain at low noise and low operating voltages while the ACT readout enables concomitant high speed and high charge transfer efficiency. Currently work is progressing towards the development of manufacturable designs for each of these component devices. In addition to the development of each of the three distinct components, work towards their integration is also progressing. The component designs are considered not only to meet individual specifications but to provide overall system level performance suitable for HDTV operation upon integration. The ultimate manufacturability and reliability of the chip constrains the design as well. The progress made during this period is described in detail in Sections 2-4.

Hunt, W. D.↗

NASA NTRS1999

Technology and Advanced Development for a Non-Toxic Orbital Maneuvering System and Reaction Control System for Orbiter Upgrade

NASA intends to pursue technology applications to upgrade the Space Shuttle Orbiter OMS and RCS systems with non-toxic propellants. The primary objectives of an upgraded OMS/RCS are improved safety and reliability, reduced operations and maintenance costs while meeting basic OMS/RCS operational and performance requirements. The OMS/RCS has a high degree of direct interaction with the crew and requires subsystem and components that are compatible with integration into the orbiter vehicle with regard to external mold-line, power and thermal control The non-toxic propulsion technology is also applicable to future Human Exploration and Development of Space (HEDS) missions. The HEDS missions have similar requirements for attitude control and lander descent/ascent propulsion and which will emphasize the use of In-Situ Resource for propellants. When used as a regenerative coolant as in the Shuttle Orbiter OMS combustion chamber, non-toxic fuels such as ethanol are limited in their cooling capacity by the bulk temperature rise permitted to prevent film boiling or possible coking. Typical regeneratively cooled chambers are constructed from highly conductive copper, which maximizes heat transfer, or from low conductivity materials like stainless steel that can also exacerbate cooling problems. For an ethanol cooled application the heat transfer into the fluid must be controlled to reduce the fuel coolant bulk temperature rise. An approach to provide this control is the subject of this report. This report is being issued to document work done by Aerojet on NASA contract NAS 8-98042. Specifically, this project investigates of the use of ethanol, a designated non-toxic fuel, as a coolant for the Space Shuttle Orbital Maneuvering System Engine combustion chamber. The project also addresses a cost reducing fabrication technique for construction of such a combustion chamber. The study contained three major sub-tasks: an analytical investigation and trade study which included layout of a flight type chamber concept, the fabrication and evaluation of formed platelet liner panels and the preparation and testing of mechanical properties specimens representative of a novel hot gas wall concept.

Hayes, W. A.↗

NASA NTRS1999

Technology Maturity Towards Highly Reusable Space Transportation Goals

The National Aeronautics and Space Administration's (NASA) Advanced Space Transportation Program (ASTP) has advanced key propulsion and launch vehicle systems technologies towards enabling the concepts identified by the Highly Reusable Space Transportation (HRST) Study as having significant potential for reducing the cost of access to space. The Marshall Space Flight Center (MSFC) manages the ASTP for the NASA Aero-Space Technology Enterprise. The HRST Study was conducted from 1995 through 1997 to evaluated launch concepts with the potential to reduce launch cost to $100 to $200 per pound of payload to low Earth orbit in the 2016 to 2022 timeframe. The HRST represents a generation of launch vehicles beyond the Lockheed-Martin VentureStar concept with a goal of another factor of ten reduction in launch cost below the next generation Reusable Launch Vehicle. Several concepts were developed and evaluated during the initial HRST studies. At the completion of the concept development phase in 1997, four task forces were formed to integrate the results of the study. These task forces were System Concept Definition, Operations Assessment. Cost Assessment and Technology Assessment. The Operations Assessment task force published its final report in November 1998. The Operations Assessment task force evaluated both single stage to orbit (SSTO) and two-stage to orbit (TSTO) concepts. SSTO concepts included horizontal takeoff and horizontal landing, vertical takeoff and vertical landing and vertical takeoff and horizontal landing. Horizontally launched concepts including launch assist options. SSTO concepts included airbreathing and all rocket as well as combination propulsion systems. The Operations Assessment considered the significance of performance margin, flight rate capability, reliability, launch assist, design optimization and technology development. These studies serve as a guide for the ASTP to prioritize technology development towards future highly reusable launch systems. Although the ASTP supports the development of technology that is focused at a near term fully reusable launch vehicle, the core of the technology development is looking ahead to future generations of launch vehicles that will enable dramatic growth in civil and commercial space enterprise. The primary focus of the paper is to status the key enabling technologies including rocket based combined cycle (RBCC) propulsion, magnetic launch assist, long life, low weight rocket propulsion, integral hot structures. robust thermal protection systems and integrated vehicle health management. The ASTP technology roadmap is leading rapidly towards system demonstration and eventual future X vehicle flight demonstrations.

Lyles, Garry↗

NASA NTRS1999

Summary of LO2/Ethanol OMS/RCS Technology and Advanced Development 99-2744

NASA is pursuing non-toxic propellant technologies applicable to RLV and Space Shuttle orbital maneuvering system (OMS) and reaction control system (RCS). The primary objectives of making advancements in an OMS/RCS system are improved safety, reliability, and reduced operations and maintenance cost, while meeting basic operational and performance requirements. An OMS/RCS has a high degree of direct interaction with the vehicle and crew and requires subsystem and components that are compatible with integration into the vehicle with regard to external mold-line, power, and thermal control. In July 1997, a Phase I effort for the technology and advanced development of an upgrade of the space shuttle was conducted to define the system architecture, propellant tank, feed system, RCS thrusters, and OMS engine. Phase I of the project ran from July 1997 to October 1998. Phase II is currently being planned for the development and test of full-scale prototype of the system in 1999 and 2000. The choice of pressure-fed liquid oxygen (LO2) and ethanol is the result of numerous trade studies conducted from 1980 to 1996. Liquid oxygen and ethanol are clean burning, high-density propellants that provide a high degree of commonality with other spacecraft subsystems including life support, power, and thermal control, and with future human exploration and development of space missions. The key to this pressure-fed system is the use of subcooled liquid oxygen at 350 psia. In this approach, there is 80 degrees R of subcooling, which means that boil-off will not occur until the temperature has risen 80 R. The sub-cooling results naturally from loading propellants at 163 R, which is the saturation temperature at 14.7 psia, and then pressurizing to 350 psia on the launch pad. Thermal insulation and conditioning techniques are then used to limit the LO2 temperature to 185 R maximum, and maintain the sub-cooling. The other key is the wide temperature range of ethanol, -173 F to +300 F, which can provide heat to gasify liquid oxygen or provide a good coolant.

Curtis, Leslie A.↗

NASA NTRS2011

Combustion Dynamics and Control for Ultra Low Emissions in Aircraft Gas-Turbine Engines

Future aircraft engines must provide ultra-low emissions and high efficiency at low cost while maintaining the reliability and operability of present day engines. The demands for increased performance and decreased emissions have resulted in advanced combustor designs that are critically dependent on efficient fuel/air mixing and lean operation. However, all combustors, but most notably lean-burning low-emissions combustors, are susceptible to combustion instabilities. These instabilities are typically caused by the interaction of the fluctuating heat release of the combustion process with naturally occurring acoustic resonances. These interactions can produce large pressure oscillations within the combustor and can reduce component life and potentially lead to premature mechanical failures. Active Combustion Control which consists of feedback-based control of the fuel-air mixing process can provide an approach to achieving acceptable combustor dynamic behavior while minimizing emissions, and thus can provide flexibility during the combustor design process. The NASA Glenn Active Combustion Control Technology activity aims to demonstrate active control in a realistic environment relevant to aircraft engines by providing experiments tied to aircraft gas turbine combustors. The intent is to allow the technology maturity of active combustion control to advance to eventual demonstration in an engine environment. Work at NASA Glenn has shown that active combustion control, utilizing advanced algorithms working through high frequency fuel actuation, can effectively suppress instabilities in a combustor which emulates the instabilities found in an aircraft gas turbine engine. Current efforts are aimed at extending these active control technologies to advanced ultra-low-emissions combustors such as those employing multi-point lean direct injection.

DeLaat, John C.↗

NASA NTRS2003

Piezoelectrically Actuated Shutter for High Vacuum

A piezoelectrically actuated shutter is undergoing development for use in experiments on laser cooling of atoms. The shutter is required to be compatible with ultrahigh vacuum [pressure of 10(exp -9) torr (.1.3 x 10(exp -7) Pa) or less] and to be capable of performing reliably in the vacuum for at least one year. In operation, the shutter would enable the collection and launch of successive samples of cold atoms and would enable the interrogation of the immediately preceding sample while preventing disturbance of the atoms of that sample by light from the collection region. A major constraint is imposed on the design and operation of the shutter by a requirement that it not generate a magnetic field large enough to perturb an atomic clock. An electromagnetically actuated shutter could satisfy all requirements except this one. Hence, it was decided to use piezoelectric instead of electromagnetic actuation. The shutter (see figure) includes two commercial piezoelectrically driven flexure stages that produce a travel of 0.5 mm. Levers mechanically amplify the travel to the required level of 1 cm. Problems that remained to be addressed at the time of reporting the information for this article included lifetime testing and correction of a tendency for shutter blades to bounce open.

Thompson, Robert↗

NASA NTRS2018

Upgrades to the International Space Station Water Processor Assembly

The International Space Station Water Processor Assembly provides contaminant control and deionization to the Water Recovery System. The Water Processor Assembly presently utilizes sorbent-based Multifiltration Beds and a downstream Catalytic Reactor for these operations. Upgrades and process improvements are desired to improve performance, increase reliability, and decrease consumable resupply. To this end, reverse osmosis membrane separation technologies were evaluated to reduce influent contaminant loads, candidate additives to inhibit wastewater biofilm formation were studied, and life stability testing was completed for a recently developed high-activity catalyst. Evaluation of an adsorption media integration concept was also completed. The performance and applicability of these new technologies within the Water Processor Assembly, as well as their suitability for exploration missions, are discussed herein.

Kayatin, Matthew J.↗

NASA NTRS2022

Lunar Simulant Deposition Technique for Dust Tolerance Studies

A renewed interest in lunar exploration has spawned an array of development efforts for lunar surface assets. These systems depend on the reliable operation of mechanisms and components that may be susceptible to performance degradations or failure due to dust. The Uniform Dust Deposition System was developed at the NASA Glenn Research Center to provide repeatable, uniform, and automated deposition of simulants on surfaces of interest for dust mitigation testing. The system is capable of depositing simulants on test articles up to 60 cm in diameter and 15 cm high in a dry air environment with less than 1 percent relative humidity while keeping users safe from aerosolized dust. The automation of the system allows for high testing throughput while not sacrificing test quality and allows the user to reduce data in parallel. The additional development of a simulant preparation technique complements the repeatability of the deposition physics during testing. The system includes an imaging subsystem that leverages the power of machine learning to count simulant particles and measure their size, thereby allowing for accurate predictions of surface deposition densities (coefficient of determination R^(2) = 0.93) from images alone. The coverage of dust on a surface was shown to be uniform (coefficient of variation CV < 0.11), allowing developers to accurately evaluate the performance of their technology with a prescribed amount of lunar simulant, information that can be used to develop and refine models. The accuracy of the system is currently less than desired for a single deposition run, with a standard deviation (SD) ranging from 18 to 24 mg, or 0.839 to 1.184 mg/sq. cm , for a 5-cm-diameter area. However, the accuracy can be improved by performing multiple deposition runs to build dust to a desired level. Testing has shown that a SD of 0.2 to 0.6 mg, or 0.076 to 0.227 mg/sq. cm, can be achieved for a 5-cm-diameter area using this technique.

Stephen Gerdts↗