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NASA NTRS2017

An Overview of Recent Cryogenic Fluid Management Developments

Long-term storage, supply, and transfer of cryogenic fluids are critical capabilities needed to advance the human exploration of space. Technologies and advanced development programs have been pursued to address issues likely to confront the designers and developers of future cryogenic fluid management (CFM) subsystems and propulsion systems. NASA and aerospace industries have continued to conduct research and development for the propulsion applications of cryogenic fluids. From the well known in-space applications, to new applications involving superconducting motors within multiple different aircraft, and a renewed interest in production of oxygen on Mars, NASA continues to probe cryogenic applications within propulsion. This article presents brief reviews of several of the current CFM efforts to support future space missions. NASA GRC is currently focusing on understanding some of the finer points in the application of multilayer insulation. GRC recently finished the activation of a new calorimeter that operates at 20 K with a warm boundary that can operate either around 90 K or at 300 K. Current testing is focused on investigating multiple different seam concepts, initially between temperatures of 300 K and 20 K, and between 20 K and 90 K. One of the larger recent NASA investments has been on the Structural Heat Intercept, Insulation, and Vibration Experiment Rig (SHIIVER). SHIIVER is a 4 m diameter tank that is approximately 1/2 scale of the planned upper stage of the new Space Launch System (SLS) rocket. SHIIVER is focused on demonstrating the thermal benefits of multilayer insulation on the tank domes and boil-off vapor cooling on structural cylinders that hold the tank in-line on the rocket. It will also quantify any damage that may incur during the acoustic environment of over 160 decibels that SLS will experience on its trip to Earth orbit. In support of the possible production of oxygen out of the Mars' atmosphere, a team comprised of four NASA centers (GRC, MSFC, JSC, and KSC) collaborated to investigate multiple different hardware combinations, refrigeration cycles, and integration techniques to minimize power and mass of the storage and liquefaction system. Moreover, high efficiency, high capacity cryocoolers are an element of CFM which is essential for achieving NASA's future long duration missions. Currently in development is a 20W at 20K unit for use with liquid hydrogen. It is scheduled for delivery to NASA in the summer of 2017. Two Phase I SBIRS have recently concluded resulting in the preliminary design of two different 90K units, each having a refrigeration capacity of approximately 150W. Once the development efforts are complete, these high capacity 90K units will be integrated into the design of NASA's Liquid Oxygen (LOX)/Methane applications such as the Lander and Ascent Vehicles, or possibly an in-space stage. CFM technology is critical to the success of missions to Mars, Planetary Exploration, and In-Situ Resource Utilization (ISRU) for cryogenic propellant production. NASA is focusing on the development of CFM technologies needed to provide necessary data and relevant experience to support informed decisions on implementation of design of cryogenic systems for long term space missions. Lessons learned from the described CFM developments would lead to enhanced safety and reliability and enabling technologies which could allow NASA to meet future space exploration goals.

Hedayat, A.↗
NASA NTRS2011

Thermal Performance of Low Layer Density Multilayer Insu1ation Using Liquid Nitrogen

In order to support long duration cryogenic propellant storage, the Cryogenic Fluid Management (CFM) Project of the Exploration Technology Development Program (ETDP) is investigating the long duration storage propertie$ of liquid methane on the lunar surface. The Methane Lunar Surface Thermal Control (MLSTC) testing is using a tank of the approximate dimensions of the Altair ascent tanks inside of a vacuum chamber to simulate the environment in low earth orbit and on the lunar surface. The thermal performance testing of multilayer insulation (MLI) coupons that are fabricated identically to the tank applied insulation is necessary to understand the performance of the blankets and to be able to predict the performance of the insulation prior to testing. This coupon testing was completed in Cryostat-100 at the Cryogenics Test Laboratory. The results showed the properties of the insulation as a function of layer density, number of layers, and warm boundary temperature. These results aid in the understanding of the performance parameters o fMLI and help to complete the body of literature on the topic.

Johnson, Wesley L.↗
NASA NTRS2014

Self-Pressurization and Spray Cooling Simulations of the Multipurpose Hydrogen Test Bed (MHTB) Ground-Based Experiment

This paper presents a CFD (computational fluid dynamics) model for simulating the self-pressurization of a large scale liquid hydrogen storage tank. In this model, the kinetics-based Schrage equation is used to account for the evaporative and condensing interfacial mass flows. Laminar and turbulent approaches to modeling natural convection in the tank and heat and mass transfer at the interface are compared. The flow, temperature, and interfacial mass fluxes predicted by these two approaches during tank self-pressurization are compared against each other. The ullage pressure and vapor temperature evolutions are also compared against experimental data obtained from the MHTB (Multipuprpose Hydrogen Test Bed) self-pressurization experiment. A CFD model for cooling cryogenic storage tanks by spraying cold liquid in the ullage is also presented. The Euler- Lagrange approach is utilized for tracking the spray droplets and for modeling interaction between the droplets and the continuous phase (ullage). The spray model is coupled with the VOF (volume of fluid) model by performing particle tracking in the ullage, removing particles from the ullage when they reach the interface, and then adding their contributions to the liquid. Droplet ullage heat and mass transfer are modeled. The flow, temperature, and interfacial mass flux predicted by the model are presented. The ullage pressure is compared with experimental data obtained from the MHTB spray bar mixing experiment. The results of the models with only droplet/ullage heat transfer and with heat and mass transfer between the droplets and ullage are compared.

cryogenic fluid storage↗
NASA NTRSDate not supplied

Modeling and Simulation of Tank Pressure Control using Zero-Boil Off Active Thermal Control for LOXSAT Technology Demonstration Mission

To-date, research and modeling of cryogenic fluid management technologies (CFM) for spaceflight has been limited to ground tests, short-duration zero-g simulations (e.g. drop towers), and small-scale experiments on-orbit. There has not been a large-scale flight demonstration of a flight-like system. As future NASA missions to take humans further from Earth will require large, in-space cryogenic propulsion vehicles, it is imperative to begin collecting flight data for these systems to accurately model and design future vehicles. To meet this goal, NASA awarded tipping point technology demonstration awards to Eta Space, Lockheed Martin, Space Exploration Technologies (SpaceX), and United Launch Alliance (ULA) to demonstrate on-orbit storage and transfer of cryogenic propellant. For its award, Eta Space is developing LOXSAT-1. It is a small satellite that will be launched on a Rocket Lab Electron rocket. The spacecraft consists of a Rocket Lab Photon spacecraft bus with a primary payload of a spherical liquid oxygen (LOX) storage tank with thermodynamic control systems. The primary objective of the mission is to demonstrate zero-boil-off storage of liquid oxygen. To accomplish this objective, the payload is equipped with an active thermal control system fluid loop that consists of propellant management device (PMD), positive-displacement pump, heat exchanger connected to a cryocooler, and a spray bar mixing injector. When the fluid loop is operating, fluid is drawn from the tank by the PMD and pumped through the heat exchanger, lowering the fluid temperature below the fluid temperature in the tank. This subcooled liquid is then injected back into the tank through the spray bar. The subcooled injected liquid has two effects. If it is sprayed into the ullage space, the injected liquid will form into jets or droplets and exchange heat with the ullage gas. This will cool and condense the gas, reducing the pressure in the tank. Additionally, the liquid that is not sprayed through the ullage, as well as any remaining liquid spray from the ullage, will rejoin the liquid mass of the tank, lowering the bulk temperature of the liquid. These combines effects provide for zero-boil off pressure control by lowering the tank pressure and the liquid saturation pressure simultaneously, ensuring the liquid stays subcooled. To model these complex mechanics and predict the performance of the active thermal control system, NASA is providing Eta Space with 3 parallel models of the tank. The approach of providing 3 different models allows for cross-checking and comparisons between the three to better understand how different modeling assumptions and selection semi-empirical factors affects the modeling result. Additionally, developing 3 models provides three different schemes for numerical simulation, providing confidence that results depict real physical phenomenon and not numerical quirks of the program. Within the tank thermodynamics, there are two primary areas of heat transfer we concern ourselves with: the heat transfer between the ullage space and the droplet spray, and between the ullage space and bulk liquid. For the droplet heat transfer, there are multiple sets of assumptions that can be made and correlations that can be used. Currently, two working models - the TankSIM model and Easy5 model – provide for an overview of the different approaches available. The TankSIM model and Easy5 model use two different models for droplet heating and evaporation that illustrate how the models use different types of mechanisms to arrive at the same answer. For the TankSIM model, droplets are treated as spheres of constant radius. Heat is transferred from the ullage to the droplet and warms the droplet until it reaches saturation, then the droplet begins evaporating and reducing its radius and mass. To calculate the heat transfer coefficient between the droplet and ullage, the Ranz-Marshall correlation is used. To determine the number of droplets in the ullage, a resident mass approach is used. This approach averages the number of droplets such that residuals at the start-up and shut-off of the spray bar cancel out. This same approach is used in the Easy5 model. The GFSSP model implements a linked list to track individual droplet “nodes” within the model. For the Easy5 model, the droplet is assumed to have an interface at a temperature equal to the saturation temperature corresponding to the pressure of the gas phase. The heat transfer from the gas to the interface and the interface to the droplet bulk is then calculated, and the net mass transfer between the droplet and interface is determined by performing an energy balance across the interface. For the gas side of the interface, the Ranz-Marshall correlation is used. For the liquid side of the interface, a variety of correlations were tried, including Kronig and Brink (1950) and effective conductivity models. As a result of these assumptions, the Easy5 model currently predicts faster depressurization, as at saturated vapor conditions, the heat transfer coeffect on the liquid side for the Easy5 model is greater than the heat transfer coefficient predicted by Ranz-Marshall used in the TankSIM code. This greater heat flux translates into faster condensation of the saturated ullage gas. At the bulk liquid to ullage interface, the models are in much closer agreement. Both models model the ullage as a sphere centered within the bulk liquid in the tank, and both use the energy-jumping boundary condition to model heat and mass transfer across the interface. There are slight differences in how the interface temperature is calculated, however. The Easy5 model assumes the temperature of the interface is equal to the saturation temperature associated with the pressure of the gas phase. The TankSIM model calculates this temperature with Alabovskii’s equation, which provides a correction factor for interface temperatures. Analysis tasks are focused on determining rates of depressurization within the tank during active cooling operation. To maintain net positive suction head at the pump inlet, the tank pressure cannot fall faster than the saturation pressure associated with the temperature of the bulk liquid. Additionally, there is interest in analyzing the performance of the loop at different pump speeds and cryocooler input powers. Adjusting the flowrate affects both the performance of the heat exchanger between the cryocooler and pumped liquid, and the heat transfer between the droplet spray and the ullage. Ideally, a pump speed and cryocooler power can be selected that will allow the tank to operate in zero-boil-off mode with a very narrow range of storage pressure.

zero boil-off↗
NASA NTRS1997

Cryogenics and the Human Exploration of Mars

Current plans within NASA involve extending the human exploration of space from low earth orbit into the solar system, with the first human exploration of Mars presently planned in 2011. Integral to all hum Mars mission phases is cryogenic fluid management. Cryogenic fluids will be required both as propellant and for In-Situ Resource Utilization (ISRU). Without safe and efficient cryogen storage human Mars missions will not be possible. Effective control and handling of cryogenic fluids is the key to affordable Mars missions, and advancing active thermal control technology is synergistic with all of NASA's exploration initiatives and with existing and future instrument cooling programs, including MTPE and Origins. Present mission scenarios for human exploration require cryogenic propellant storage for up to 1700 days and for up to 60 metric tons. These requirements represent increases of an order of magnitude over previous storage masses and lifetimes. The key cryogenic terminology areas to be addressed in human Mars missions are long-term propellant storage, cryogenic refrigeration, cryogenic liquefaction, and zero gravity fluid management. Long-term storage for the thermal control of cryogenic propellants is best accomplished with a mix of passive and active technologies. Passive technologies such as advanced multilayer insulation (MLI) concepts will be combined with the development of active coolers (cryogenic refrigerators). Candidates for long-life active cooling applications include Reverse Turbo-Brayton, Stirling, and Pulse-Tube coolers. The integration of passive and active technologies will form a hybrid system optimized to minimize the launch mass while preserving the cryogenic propellants. Since cryogenic propellants are the largest mass that Mars missions must launch from earth, even a modest reduction in the percentage of propellant carried results in a significant weight saving. This paper will present a brief overview of cryogenic fluid management technology as it applies to the current human Mars mission scenarios.

Salerno, Louis J.↗
NASA NTRS2019

Rewet Temperature Correlations for Liquid-Nitrogen Boiling Pipe Flows Across Varying Flow Conditions and Orientations

In many convective liquid-vapor phase change heat transfer engineering applications, cryogenic fluids are widely used in industrial processes, spacecraft and cryosurgery systems, and so on. For example, cryogens are usually used as liquid fuels such as liquid hydrogen and oxygen in the rocket industry, liquid nitrogen (LN2) and helium are frequently used to cool superconducting magnetic device for medical applications. In these systems, proper transport, handling, and storage of cryogenic fluids are of extreme importance. Among all the cryogenic transport processes performed in room temperatures, quenching, also termed chilldown, is a unavoidable initial, transient phase-change heat transfer process that brings the system down to the cryogenic condition. The Leidenfrost temperature or rewet temperature that signals the end of film boiling is practically considered the completion point of a quenching process. Therefore, rewet temperature has been considered the most important parameter for the engineering design of cryogenic thermal management systems. As most of the previous correlations for predicting the Leidenfrost temperature and the rewet temperature have been basically developed for water, they are shown to disagree with recent liquid nitrogen pipe chilldown experiments in upward and downward flow directions over a wide range of flow rates, pressures, and degrees of inlet subcooling. In addition to a complete review of the literature, two new correlations are presented in this work, one based on bubble growth and another based on the theoretical maximum limit of superheat. Each correlation performs well over the entire data set.

liquid nitrogen↗
NASA NTRS2015

CFD Modeling of the Multipurpose Hydrogen Test Bed (MHTB) Self-Pressurization and Spray Bar Mixing Experiments in Normal Gravity: Effect of the Accommodation Coefficient on the Tank Pressure

A CFD model for simulating the self-pressurization of a large scale liquid hydrogen storage tank is utilized in this paper to model the MHTB self-pressurization experiment. The kinetics-based Schrage equation is used to account for the evaporative and condensi ng interfacial mass flows in this model. The effect of the accommodation coefficient for calculating the interfacial mass transfer rate on the tank pressure during tank selfpressurization is studied. The values of the accommodation coefficient which were considered in this study vary from 1.0e-3 to 1.0e-1 for the explicit VOF model and from 1.0e-4 to 1.0e-3 for the implicit VOF model. The ullage pressure evolutions are compared against experimental data. A CFD model for controlling pressure in cryogenic storage tanks by spraying cold liquid into the ullage is also presented. The Euler-Lagrange approach is utilized for tracking the spray droplets and for modeling the interaction between the droplets and the continuous phase (ullage). The spray model is coupled with the VOF model by performing particle tracking in the ullage, removing particles from the ullage when they reach the interface, and then adding their contributions to the liquid. Droplet-ullage heat and mass transfer are modeled. The flow, temperature, and interfacial mass flux, as well as droplets trajectories, size distribution and temperatures predicted by the model are presented. The ul lage pressure and vapor temperature evolutions are compared with experimental data obtained from the MHTB spray bar mixing experiment. The effect of the accommodation coefficient for calculating the interfacial and droplet mass transfer rates on the tank pressure during mixing of the vapor using spray is studied. The values used for the accommodation coefficient at the interface vary from 1.0e-5 to 1.0e-2. The droplet accommodation coefficient values vary from 2.0e-6 to 1.0e-4.

cryogenic fluid storage↗
NASA NTRS2016

Modeling Droplet Heat and Mass Transfer during Spray Bar Pressure Control of the Multipurpose Hydrogen Test Bed (MHTB) Tank in Normal Gravity

A CFD model for simulating pressure control in cryogenic storage tanks through the injection of a subcooled liquid into the ullage is presented and applied to the 1g MHTB spray bar cooling experiments. An Eulerian-Lagrangian approach is utilized to track the spray droplets and capture the interaction between the discrete droplets and the continuous ullage phase. The spray model is coupled with the VOF model by performing particle tracking in the ullage, removing particles from the ullage when they reach the interface, and then adding their contributions to the liquid. A new model for calculating the droplet-ullage heat and mass transfer is developed. In this model, a droplet is allowed to warm up to the saturation temperature corresponding to the ullage vapor pressure, after which it evaporates while remaining at the saturation temperature. The droplet model is validated against the results of the MHTB spray-bar cooling experiments with 50% and 90% tank fill ratios. The predictions of the present T-sat based model are compared with those of a previously developed kinetic-based droplet mass transfer model. The predictions of the two models regarding the evolving tank pressure and temperature distributions, as well as the droplets' trajectories and temperatures, are examined and compared in detail. Finally, the ullage pressure and local vapor and liquid temperature evolutions are validated against the corresponding data provided by the MHTB spray bar mixing experiment.

mass transfer↗
NASA NTRS2015

Numerical Investigation of Microgravity Tank Pressure Rise Due to Boiling

The ability to control self-pressurization in cryogenic storage tanks is essential for NASAs long-term space exploration missions. Predictions of the tank pressure rise in Space are needed in order to inform the microgravity design and optimization process. Due to the fact that natural convection is very weak in microgravity, heat leaks into the tank can create superheated regions in the liquid. The superheated regions can instigate microgravity boiling, giving rise to pressure spikes during self-pressurization. In this work, a CFD model is developed to predict the magnitude and duration of the microgravity pressure spikes. The model uses the Schrage equation to calculate the mass transfer, with a different accommodation coefficient for evaporation at the interface, condensation at the interface, and boiling in the bulk liquid. The implicit VOF model was used to account for the moving interface, with bounded second order time discretization. Validation of the models predictions was carried out using microgravity data from the Tank Pressure Control Experiment, which flew aboard the Space Shuttle Mission STS-52. Although this experiment was meant to study pressurization and pressure control, it underwent boiling during several tests. The pressure rise predicted by the CFD model compared well with the experimental data. The ZBOT microgravity experiment is scheduled to fly on February 2016 aboard the ISS. The CFD model was also used to perform simulations for setting parametric limits for the Zero-Boil-Off Tank (ZBOT) Experiments Test Matrix in an attempt to avoid boiling in the majority of the test runs that are aimed to study pressure increase rates during self-pressurization. *Supported in part by NASA ISS Physical Sciences Research Program, NASA HQ, USA

pressure rise↗
NASA NTRS1976

Spacelab cryogenic propellant management experiment

The conceptual design of a Spacelab cryogen management experiment was performed to demonstrate toe desirability and feasibility of subcritical cryogenic fluid orbital storage and supply. A description of the experimental apparatus, definition of supporting requirements, procedures, data analysis, and a cost estimate are included.

Cady, E. C.↗
NASA NTRS2014

Potential Follow on Experiments for the Zero Boil Off Tank Experiment

Cryogenic Storage &Transfer are enabling propulsion technologies in the direct path of nearly all future human or robotic missions; It is identified by NASA as an area with greatest potential for cost saving; This proposal aims at resolving fundamental scientific issues behind the engineering development of the storage tanks; We propose to use the ISS lab to generate & collect archival scientific data:, raise our current state-of-the-art understanding of transport and phase change issues affecting the storage tank cryogenic fluid management (CFM), develop and validate state-of-the-art CFD models to innovate, optimize, and advance the future engineering designs

Thermodynamics↗
NASA NTRS2015

Measuring the Heat Load on the Flight ASTRO-H Soft Xray Spectrometer Dewar

The Soft Xray Spectrometer (SXS) instrument on-board the ASTRO-H X-ray mission is based on microcalorimeters operating at 50 mK. Low temperature is achieved by use of an adiabatic demagnetization refrigerator (ADR) cyclically operating up to a heat sink at either 1.2 K or 4.5 K. The 1.2 K heat sink is provided by a 40 liter superfluid helium dewar. The parasitic heat to the helium from supports, plumbing, wires, and radiation, and the cyclic heat dumped by the ADR operation determine the liquid helium lifetime. To measure this lifetime we have used various techniques to rapidly achieve thermal equilibrium and then measure the boil-off rate of the helium. We have measured a parasitic heat of 650 microwatts and a cyclic heat of 100 microwatts for a total of 750 microwatts. This closely matches the predicted heat load. Starting with a fill level at launch of more than 33 liters results in a lifetime of greater than 4 years for the liquid helium. The techniques and accuracy for this measurement will be explained in this paper.

cryogenic Equipment↗
NASA NTRS2015

Cryogenic Autogenous Pressurization Testing for Robotic Refueling Mission 3

A wick-heater system has been selected for use to pressurize the Source Dewar of the Robotic Refueling Mission Phase 3 on-orbit cryogen transfer experiment payload for the International Space Station. Experimental results of autogenous pressurization of liquid argon and liquid nitrogen using a prototype wick-heater system are presented. The wick-heater generates gas to increase the pressure in the tank while maintaining a low bulk fluid temperature. Pressurization experiments were performed in 2013 to characterize the performance of the wick heater. This paper describes the experimental setup, pressurization results, and analytical model correlations.

cryogenics↗
NASA NTRS2015

Comparison of Computational Results with a Low-g, Nitrogen Slosh and Boiling Experiment

This paper compares a fluid/thermal simulation, in Fluent, with a low-g, nitrogen slosh and boiling experiment. In 2010, the French Space Agency, CNES, performed cryogenic nitrogen experiments in a low-g aircraft campaign. From one parabolic flight, a low-g interval was simulated that focuses on low-g motion of nitrogen liquid and vapor with significant condensation, evaporation, and boiling. The computational results are compared with high-speed video, pressure data, heat transfer, and temperature data from sensors on the axis of the cylindrically shaped tank. These experimental and computational results compare favorably. The initial temperature stratification is in good agreement, and the two-phase fluid motion is qualitatively captured. Temperature data is matched except that the temperature sensors are unable to capture fast temperature transients when the sensors move from wet to dry (liquid to vapor) operation. Pressure evolution is approximately captured, but condensation and evaporation rate modeling and prediction need further theoretical analysis.

Cryogenic Fluid Storage↗
NASA NTRS2015

CFD Modeling of the Multipurpose Hydrogen Test Bed (MHTB) Self-Pressurization and Spray Bar Mixing Experiments in Normal Gravity: Effect of Accommodation Coefficient on the Tank Pressure

In this paper, a computational model that describes pressure control phase of a typical MHTB experiment will be presented. The fidelity of the model will be assessed by comparing the models predictions with MHTB experimental data. In this paper CFD results for MHTB spray bar cooling case with 50 tank fill ratio will be presented and analyzed. Effect of accommodation coefficient for calculating droplet-ullage mass transfer will be evaluated.

cryogenic fluid storage↗
NASA NTRS2015

RRM3 Fluid Management Device

The current development progress of the fluid management device (FMD) for the Robotic Resupply Mission 3 (RRM3) cryogen source Dewar is described. RRM3 is an on-orbit cryogenic transfer experiment payload for the International Space Station. The fluid management device is a key component of the source Dewar to ensure the ullage bubble is located away from the outlet during transfer. The FMD also facilitates demonstration of radio frequency mass gauging within the source Dewar. The preliminary design of the RRM3 FMD is a number of concentric cones of Mylar which maximizes the volume of liquid in contact with the FMD in the source Dewar. This paper describes the design of the fluid management device and progress of hardware development

cryogenic fluids↗
NASA NTRS2015

Comparison of Computational Results with a Low-g, Nitrogen Slosh and Boiling Experiment

The proposed paper will compare a fluid/thermal simulation, in FLUENT, with a low-g, nitrogen slosh experiment. The French Space Agency, CNES, performed cryogenic nitrogen experiments in several zero gravity aircraft campaigns. The computational results have been compared with high-speed photographic data, pressure data, and temperature data from sensors on the axis of the cylindrically shaped tank. The comparison between these experimental and computational results is generally favorable: the initial temperature stratification is in good agreement, and the two-phase fluid motion is qualitatively captured.

Boiling---Phase Transformations↗
NASA NTRS2016

Modeling Ullage Dynamics of Tank Pressure Control Experiment during Jet Mixing in Microgravity

A CFD model for simulating the fluid dynamics of the jet induced mixing process is utilized in this paper to model the pressure control portion of the Tank Pressure Control Experiment (TPCE) in microgravity1. The Volume of Fluid (VOF) method is used for modeling the dynamics of the interface during mixing. The simulations were performed at a range of jet Weber numbers from non-penetrating to fully penetrating. Two different initial ullage positions were considered. The computational results for the jet-ullage interaction are compared with still images from the video of the experiment. A qualitative comparison shows that the CFD model was able to capture the main features of the interfacial dynamics, as well as the jet penetration of the ullage.

active control↗