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Computations of turbulent evaporating sprays

A computational study of turbulent evaporating sprays is reported. The major focus is to examine the sensitivity of the vaporization behavior of turbulent sprays to the transient liquid-phase processes. Three models considered to represent these processes are the thin skin, infinite diffusion, and diffusion limit models. Favre-averaged equations with k-epsilon-g turbulence model are employed for the gas phase. The Lagrangian approach with a stochastic separated flow method is used for the liquid phase where the effects of gas turbulence on droplet trajectories and interphase transport rates are considered using random-walk computations. Also the variable-property effects are considered in detail. Results indicate that, depending upon the boiling temperature and heat of vaporization of the fuel considered, the vaporization behavior of turbulent sprays may be quite sensitive to the modeling of transient liquid-phase processes. Thus, it is important that for most hydrocarbon fuels these processes be adequately represented in any comprehensive spray computations. The present results also provide further support to the conclusions of earlier studies which have been based on simplified spray configurations.

Aggarwal, S. K.↗

A model for droplet heating and evaporation of water-in-oil emulsified fuel

Water-in-oil (W/O) emulsified fuel is a promising alternative fuel by inducing flash boiling of water at high temperature that can improve the atomization of fuel spray. The heating and evaporation process of emulsified fuel droplet is affected by the diffusion and coalescence of small dispersed water droplets in oil during the heating. In this study, a model is developed for the droplet heating and evaporation of W/O emulsified fuel with these key physics considered. The diffusivity of dispersed water droplets in oil is calculated using the Stokes-Einstein equation. The deactivation temperature of surfactant is selected as a criterion for the water coalescence since the water coalescence is due to the deactivation of surfactant. The process of water coalescence is simplified that the dispersed water droplets coalesce into one single water sub-droplet at the center of the oil droplet instantly as the droplet temperature reaches the deactivation temperature of surfactant. The model is validated against experimental data of single droplet under different heating temperatures, surfactant concentrations, and sizes of dispersed water droplets. Based on the proposed model, the effects of fuel properties and heating conditions on the droplet heating and evaporation are analyzed.

Droplet coalescence↗

effect of ambient pressure on the behavior of single-component fuels in a gasoline multi-hole injector

The injection characteristics of neat ethanol and pure isooctane are studied under different ambient pressure and temperature conditions. Injection underflash-boiling conditions can enhance liquid atomization and evaporation, providing the possibility of improvement in the fuel/air mixing. These superheated conditions often introduce phenomena that are not taken into account in the standard modeling of sprays for engine applications. The present work proposes a numerical investigation of the behavior of Engine Combustion Network's 8-hole spray-G injector, starting at the subcooled nominal condition and reducing the ambient pressure at constant low temperature to reach the flare flash-boiling condition. To initialize the properties of the injected fuel, the flow in the nozzle is simulated with a Eulerian approach, handling the two phases with a mixture model and the phase change, due to cavitation and flash boiling, with the Homogenous Relaxation Model. A map of the mixture's kinematic and thermal behavior is obtained at the interface between the injector and the chamber to initialize the Lagrangian simulations. A literature-based vaporization model is implemented to obtain the proper description of the characteristic features of a multi-hole spray under super-heated conditions, like plume-plume interaction. The numerical representation of the spray is validated in terms of penetration and radial spreading on DBI images, reproducing the light attenuation profiles caused by the presence of the liquid spray. Simulations show that coupled nozzle flow and spray calculations capture the spray morphology and shape better compared to calculations performed without considering the nozzle flow simulation details, especially under flare flash conditions.

Nocivelli, Lorenzo↗

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.

Cameron J. Hines↗

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↗

Boiling Transitions During Droplet Contact on Superheated Nano/Micro-Structured Surfaces

Manipulating surface topography is one of the most promising strategies for increasing the efficiency of numerous industrial processes involving droplet contact with superheated surfaces. In such scenarios, the droplets may immediately boil upon contact, splash and boil, or could levitate on their own vapor in the Leidenfrost state. In this work we report the outcomes of water droplets coming in gentle contact with designed nano/micro-textured surfaces at a wide range of temperatures as observed using high-speed optical and X-ray imaging. Further, we report a paradoxical increase in the Leidenfrost temperature ($T_{\text{LFP}}$) as the texture spacing is reduced below a critical value (~10 μm) that represents a minima in $T_{\text{LFP}}$. Although droplets on such textured solids appear to boil upon contact, our studies suggest that their behavior is dominated by hydrodynamic instabilities implying that the increase in $T_{\text{LFP}}$ may not necessarily lead to enhanced heat transfer. On such surfaces, the droplets display a new regime characterized by splashing accompanied by a vapor jet penetrating through the droplets before they transition to the Leidenfrost state. We provide a comprehensive map of boiling behavior of droplets over a wide range of texture spacings that may have significant implications towards applications such as electronics cooling, spray cooling, nuclear reactor safety and containment of fire calamities.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Numerical Modeling of No Vent Filling of a Cryogenic Tank

This paper presents a multi-node finite volume model of the chilling and filling of a cryogenic tank using the Generalized Fluid System Simulation Program (GFSSP), a general purpose flow network code. Vented Chill and No Vent Fill (VCNVF) tests were conducted at Marshall Space Flight Center where a flight-like tank was filled with liquid nitrogen from a supply tank. In the VCNVF tests, the tank was partially chilled while the vent valve was open. After the partial chilling, the vent valve was closed and the tank was filled without any venting. An integrated numerical model of the test set up was developed. The model included the transfer line from the supply tank, the target tank with the spray nozzle and solid walls, and the discharge line with the vent valve. The tank was discretized into multiple fluid nodes and branches to represent the ullage and liquid nitrogen and multiple solid nodes to represent the tank wall and structure. The heat transfer between solid to fluid was calculated from pool boiling correlations which include film, transition, and nucleate boiling, as well as natural convection during pre- and post-boiling. The model also accounts for the condensation of vapor in the tank when it comes in contact with the liquid spray. The predicted pressure, resident mass, wall and ullage temperature in the tank were compared with the test data.

Alok Majumdar↗

Numerical Modeling of No Vent Filling of a Cryogenic Tank

This paper presents a multi-node finite volume model of the chilling and filling of a cryogenic tank using the Generalized Fluid System Simulation Program (GFSSP), a general purpose flow network code. Vented Chill and No Vent Fill (VCNVF) tests were conducted at Marshall Space Flight Center where a flight-like tank was filled with liquid nitrogen from a supply tank. In the VCNVF tests, the tank was partially chilled while the vent valve was open. After the partial chilling, the vent valve was closed and the tank was filled without any venting. An integrated numerical model of the test set up was developed. The model included the transfer line from the supply tank, the target tank with the spray nozzle and solid walls, and the discharge line with the vent valve. The tank was discretized into multiple fluid nodes and branches to represent the ullage and liquid nitrogen and multiple solid nodes to represent the tank wall and structure. The heat transfer between solid to fluid was calculated from pool boiling correlations which include film, transition, and nucleate boiling, as well as natural convection during pre- and post-boiling. The model also accounts for the condensation of vapor in the tank when it comes in contact with the liquid spray. The predicted pressure, resident mass, wall and ullage temperature in the tank were compared with the test data.

Alok Majumdar↗

A thermally-limited bubble growth model for the relaxation time of superheated fuels

Here, we propose a novel approach to evaluate the relaxation time of vapor bubble growth in the context of the flash boiling of a superheated liquid. In alternative to the empirical correlation derived from superheated water experiments almost fifty years ago, the new model describes the thermally-dominated growth of vapor bubbles in terms that are dependent on the local Jakob number (the ratio of sensible heat to latent heat during phase change) and the number density of vapor bubbles. The model is tested by plugging the resulting relaxation time into the Homogenous Relaxation Model (HRM). Flash-boiling simulations carried out with HRM are compared with n-pentane (C 5 H 12 ) injection and boil-off experiments conducted with a real-size, axial-hole, transparent gasoline injector discharging into a constant-pressure vessel. The long-distance microscopy images from the experiments, processed to derive the projected liquid volume (PLV) of the spray, provide a unique set of time-resolved validation data for direct fuel injection simulations. At conditions ranging from flaring to mild and minimal flash boiling, we show that switching to the new relaxation time improves the agreement with the measured PLV profiles with respect to the standard empirical model. Particularly at flaring conditions, the predicted increase in gas cooling caused by rapid vapor production is shown to be more consistent with the observed boil-off.

42 ENGINEERING↗

On the effect of mixing-driven vaporization in a homogeneous relaxation modeling framework

The homogeneous relaxation model (HRM) is one of the most widely used models to describe the liquid–gas phase transition in multiphase flows due to the occurrence of cavitation. However, in its original formulation, the HRM does not account for the presence of ambient gas species, which generally limits its applicability to the injector's internal flow where ambient gases are negligible. In this work, a mixing-driven vaporization (MDV) model was developed to extend the capability of the HRM in handling the mixing effect in the regions external to the nozzle, where vapor–liquid equilibrium for multi-species mixtures of fuel and ambient gas is considered. Herein, to assess the model performance, simulations of the Engine Combustion Network's Spray G injector were performed with the HRM and the MDV model under both flash-boiling and evaporating conditions. It was found that the MDV model led to a better match against x-ray measurements of fuel density in the near-nozzle region. In contrast to the HRM, the MDV model was able to reproduce the vaporization process in the mixing zone at the edge of the fuel jet, which aligns with the expected physics. This resulted in substantial differences in the prediction of other flow characteristics such as mixture temperature and pressure. Furthermore, this work demonstrates that evaporation timescales have a considerable effect on the MDV model's predictions, as shown by a parametric study in which a time factor was introduced to mimic the effect of different timescales due to different phase change mechanisms.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Vapor Cooling of a Structural Skirt for a Large-Scale Hydrogen Tank

The demonstration of vapor cooling on a structural skirt was one of the main objectives of the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) testing. SHIIVER consisted of a 4-meter diameter stainless steel tank with an aluminum forward skirt. The forward skirt was cooled by directing effluent vapor from the tank through two flow channels that each went 360 degrees around the interior of the skirt in a helical pattern. Flow rates, temperatures, and pressures in the system were measured allowing for the calculation of heat load removed via cooling stream and heat load reduction into the tank. Testing occurred at fill levels between 25% and 90% full using both liquid hydrogen and liquid nitrogen. Boil-off rate was varied independent of the skirt performance by adding multilayer insulation over the spray-on-foam insulation on the tank domes, while leaving the barrel insulated only with spray-on-foam. The results from the testing, which demonstrate vapor cooling reversed heat flow from the skirt into the tank and reduces total propellant heat load by as much as 19%, are analyzed and discussed.

Cryogenic Fluid Management↗

(Project 18-15531) Repair and Mitigation of Chloride-Induced Pitting and Chloride-Induced Stress Corrosion Cracking in Used Spent Nuclear Fuel Dry Cask Canister Materials (Final Technical Report)

Several experimental techniques were utilized to understand the corrosion and SCC performance of possible techniques for repairing cracks and pits in SS304 utilized for dry cask storage of spent nuclear fuel. The repairs examined included cold spray, FSW, soldering, and VFAW. The corrosion and SCC assessment techniques utilized for comparing repairs against the base material were 4-pt bending SCC testing in boiling MgCl 2 at stress levels between 0 MPa and 350 MPa, immersion testing in 40% RH brine solution meant to mimic a service-like environment, SSRT SCC testing in 40% RH brine solution. For FSW alone, scanning electrochemical cell microscopy and microelectrochemical syringe cell were utilized to understand the corrosion performance across the weld, in the retreating/advancing sides, and base material. Based on the results of this study, the FSW and cold spray repair techniques proved most viable for SCC repair in SS304 dry cask storage applications and continuing research is highly recommended to understand and quantify in further detail their SCC performance compared to unrepaired SS304. Additionally, solder and VFAW (patch or incline) would not be recommended based on the corrosion and SCC findings in this study.

42 ENGINEERING↗

Application of an Elongated Kelvin Model to Space Shuttle Foams

Spray-on foam insulation is applied to the exterior of the Space Shuttle s External Tank to limit propellant boil-off and to prevent ice formation. The Space Shuttle foams are rigid closed-cell polyurethane foams. The two foams used most extensively on the Space Shuttle External Tank are BX-265 and NCFI24-124. Since the catastrophic loss of the Space Shuttle Columbia, numerous studies have been conducted to mitigate the likelihood and the severity of foam shedding during the Shuttle s ascent to space. Due to the foaming and rising process, the foam microstructures are elongated in the rise direction. As a result, these two foams exhibit a non-isotropic mechanical behavior. In this paper, a detailed microstructural characterization of the two foams is presented. The key features of the foam cells are summarized and the average cell dimensions in the two foams are compared. Experimental studies to measure the room temperature mechanical response of the two foams in the two principal material directions (parallel to the rise and perpendicular to the rise) are also reported. The measured elastic modulus, proportional limit stress, ultimate tensile stress and the Poisson s ratios for the two foams are compared. The generalized elongated Kelvin foam model previously developed by the authors is reviewed and the equations which result from this model are presented. The resulting equations show that the ratio of the elastic modulus in the rise direction to that in the perpendicular-to-rise direction as well as the ratio of the strengths in the two material directions is only a function of the microstructural dimensions. Using the measured microstructural dimensions and the measured stiffness ratio, the foam tensile strength ratio and Poisson s ratios are predicted for both foams. The predicted tensile strength ratio is in close agreement with the measured strength ratios for both BX-265 and NCFI24-124. The comparison between the predicted Poisson s ratios and the measured values is not as favorable.

Sullivan, Roy M.↗

Spray process of multi-component gasoline surrogate fuel under ECN Spray G conditions

As modern gasoline direct injection (GDI) engines utilize sophisticated injection strategies, a detailed understanding of the air-fuel mixing process is crucial to further improvements in engine emission and fuel economy. In this study, a comprehensive evaluation of the spray process of single-component iso-octane (IC8) and multi-component gasoline surrogate E00 (36 % n-pentane, 46 % iso-octane, and 18 % n-undecane, by volume) fuels was conducted using an Engine Combustion Network (ECN) Spray G injector. High-speed extinction, schlieren, and microscopy imaging campaigns were carried out under engine-like ambient conditions in a spray vessel. Experimental results including liquid/vapor penetration, local liquid volume fraction, droplet size, and projected liquid film on the nozzle tip were compared under ECN G1 (573 K, 3.5 kg/m 3 ), G2 (333 K, 0.5 kg/m 3 ), and G3 (333 K, 1.01 kg/m 3 ) conditions. In addition to the experiments, preferential evaporation process of the E00 fuel was elucidated by Large–Eddy Simulations (LES). The three-dimensional liquid volume fraction measurement enabled by the computed tomographic reconstruction showed substantial plume collapse for E00 under the G2 and G3 conditions having wider plume growth and plume-to-plume interaction due to the fuel high vapor pressure. Here, the CFD simulation of E00 showed an inhomogeneity in the way fuel components vaporized, with more volatile components carried downstream in the spray after the end of injection. The high vapor pressure of E00 also results in ~4 μm smaller average droplet diameter than IC8, reflecting a higher rate of initial vaporization even though the final boiling point temperature is higher. Consistent with high vapor pressure, E00 had a wider plume cone angle and enhanced interaction with the wall to cover the entire surface of the nozzle tip in a film. However, the liquid fuel underwent faster evaporation, so the final projected tip wetting area was smaller than the IC8 under the flash-boiling condition.

33 ADVANCED PROPULSION SYSTEMS↗

Alternative Liquid DSA Containers for Sludge Slurry Storage in the SRNL Shielded Cells

A pending revision of the Documented Safety Analysis (DSA) for the Savannah River National Laboratory (SRNL) defines “DSA containers'’ for liquid sludge slurries as containers not susceptible to a flashing spray release in a fire and requires that a list of DSA containers be maintained. High Level Waste (HLW) samples are typically received from the Savannah River Site (SRS) tank farm after retrieval from the storage tanks. Glass bottles are preferred for long-term storage of radioactive liquid sludge slurry samples but are not on the DSA container list. An evaluation has been conducted to identify vessel lids for the glass bottles that would vent prior to pressurization and liquid superheating in a fire event. Low melting Field's Metal eutectic alloy with a melting point of 62°C has been identified as a preferred material of construction for vessel lids for this application because the material is resistant to puncture and is expected to have good chemical compatibility and radiation stability in the shielded cells environment. A test vessel was designed to evaluate the alloy and confirm that it would melt before the water in the vessel reaches the boiling point. The tests confirmed: 1) that the reported melting point of the alloy was accurate, 2) that a top fashioned from this material will melt creating an open atmosphere in the vessel headspace prior to sample boiling under moderate and fast heating rates, and 3) that nonuniform heating of the bottle from the bottom also results in melting of the alloy prior to boiling. Based on the results, neither an engulfing fire with standing or toppled bottles or a fire producing localized heat at the vessel bottom would result in flashing spray conditions. It is recommended that glass vessels of various volumes ranging from 125 mL to 1 gallon with modified tops containing the specified Field's Metal eutectic alloy which are appropriately designed to avoid flashing spray material releases be added to the DSA container list. These vessels will be utilized in the Shielded Cells for the storage of radioactive liquid samples of sludge slurries. Use of these vessels will also be advantageous for other liquid samples containing accountable amounts of nuclear material throughout other SRNL laboratories. Similarly constructed paraffin vessel lids could also potentially be added to the approved list, though additional testing would be required.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Alternative Liquid DSA Containers for Sludge Slurry Storage in the SRNL Shielded Cells

A pending revision of the Documented Safety Analysis (DSA) for the Savannah River National Laboratory (SRNL) defines “DSA containers” for liquid sludge slurries as containers not susceptible to a flashing spray release in a fire and requires that a list of DSA containers be maintained. High Level Waste (HLW) samples are typically received from the Savannah River Site (SRS) tank farm after retrieval from the storage tanks. Glass bottles are preferred for long-term storage of radioactive liquid sludge slurry samples but are not on the DSA container list. An evaluation has been conducted to identify vessel lids for the glass bottles that would vent prior to pressurization and liquid superheating in a fire event. Low melting Field’s Metal eutectic alloy with a melting point of 62 °C has been identified as a preferred material of construction for vessel lids for this application because the material is resistant to puncture and is expected to have good chemical compatibility and radiation stability in the shielded cells environment. A test vessel was designed to evaluate the alloy and confirm that it would melt before the water in the vessel reaches the boiling point. The tests confirmed: 1) that the reported melting point of the alloy was accurate, 2) that a top fashioned from this material will melt creating an open atmosphere in the vessel headspace prior to sample boiling under moderate and fast heating rates, and 3) that nonuniform heating of the bottle from the bottom also results in melting of the alloy prior to boiling. Based on the results, neither an engulfing fire with standing or toppled bottles or a fire producing localized heat at the vessel bottom would result in flashing spray conditions.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

After Math - Foamology and Flight Rationale

The Space Shuttle was developed by NASA to be a largely reusable launch system which could provide frequent access to low earth orbit. Like all previous launch systems, safe reentry for the crew and payload required the use of a thermal protection system (TPS). Unlike previous spacecraft though, the Shuttle's TPS was exposed from launch, making it sensitive to debris which could be generated by the vehicle on ascent. The most likely and potentially destructive source of debris was considered to be ice, which could build-up anywhere on the External Tank (ET) where there was exposed metal. Ice could form during ground operations after the cryogenic propellants had been loaded and then be knocked loose on ascent. In order to prevent both ice build-up and boil-off of the propellants, the entire ET and all protuberances (orbiter attach points, pressurization lines, propellant feed lines, etc.) were covered with a spray on foam insulation (SOFI) type TPS. Unfortunately the foam was also susceptible to liberation during ascent, and posed a debris risk of its own. During the early years of the Shuttle Program engineers spent a good deal of effort characterizing the amount of foam that was shed.

Steva, Thomas↗

Summary of Testing Results for the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER)

Testing was completed on the Structural Heat Intercept, Insulation, and Vibration Evaluation Rig (SHIIVER) between August 2019 and January 2020. SHIIVER was designed to be a test bed for the scaling of cryogenic fluid management technologies as applied to large upper stages and long duration in-space stages. The baseline SHIIVER design consists of uninsulated structural skirts attached to a propellant tank insulated with polyurethane Spray-On Foam Insulation (SOFI). The initial testing of the SHIIVER hardware was with liquid hydrogen and sought to demonstrate the use of boil-off vapor to intercept heat on a structural skirt, multilayer insulation (MLI) on the tank domes, and the radio frequency mass gauge (RFMG). Testing was completed in four stages: a baseline thermal vacuum test prior to installation of the MLI on the tank domes, a thermal vacuum test after the MLI installation, a reverberant acoustic test, and a subsequent thermal vacuum test to verify that no damage occurred during the reverberant acoustic testing. Each thermal vacuum test with chamber wall at ambient temperature and vacuum level in the 10-6 torr range was conducted continuously between approximately 90% full and 25% full. Test results showed that the vapor cooling reduced the heat load to the tank by approximately 10%, but the boil-off by less than 3% at 50% full, with and without MLI installed on the domes. The MLI installed on the domes reduced the heat load to the tank by approximately 40% at all fill levels, but the boil-off by approximately 25% at 90% full and 45% below 65% full. The RFMG performed well over all fill ranges, and several RF tank modes were used to gauge the mass of fluid in the tank. SHIIVER was then exposed to an acoustic environment of 147 dB OASPL (overall sound pressure level) in a reverberant chamber. The acoustic environment envelopes the upper stage internal acoustic level of several different modern launch vehicles. No structural or thermal performance changes were observed after exposure to the acoustic environment. Final thermal vacuum testing after the acoustic testing showed no degradation to the MLI due to the acoustic environment as measured via system heat loads

SHIIVER↗