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PLANCK is an ESA-led mission to map the cosmic microwave background using bolometric and hetrodyne instruments; both instruments require cooling, one to ~20K, the other to 0.1K.
At present, the life support system on the International Space Station Alpha vents overboard the carbon dioxide (CO2) produced by the crew members. Recovering the oxygen contained in the CO2 has the potential to reduce resupply mass by 2000 pounds per year or more, a significant weight that could be used for experimental payloads and other valuable items. The technologies used to remove CO2 from the air and to recover O2 from CO2 are flight-ready; however, the interface between the devices is a problem for the Space Station system. Ames Research Center has developed a new technology that solves the interface issue, possibly allowing closure of the oxygen loop in a spacecraft for the first time. CO2 produced by the crew is removed in the Carbon Dioxide Removal Assembly (CDRA). This device effectively produces a pure CO2 stream, but at a very low pressure. Elsewhere, the oxygen generation system which makes O2 by electrolyzing water produces a hydrogen stream. In principle the CO2 and H2 can react to form methane and water over a suitable catalyst. Water produced in this methane-formation reactor can be returned to the water electrolyzer, where the O2 can be returned to the cabin; however, the methane-formation reactor requires CO2 at a much higher pressure than that produced by the CDRA. Furthermore, the CO2 and H2 are often not available at the same time, due to power management and scheduling on the space station. In order to get the CO2 to the reactor at the right pressure and at the right time, a device or assembly that functions as a vacuum pump, compressor, and storage tank is required.
Performance data are presented for a flight-like, lightweight, high efficiency pulse tube cryogenic cooler. The cooler has a mass of less than 4.0 kg, and an efficiency of 12 W/W, which is 18% of Carnot at 95 K, nearly double the efficiency of previous cooler designs, The mass of the cooler has been reduced by approximately a factor of three. The design point cooling power is 10 watts at 95 K at a heat rejection temperature of 300 K. The no-load temperature is 45 K. The compressor is built by Hymatic Engineering, UK, and is of a horizontally opposed piston design using flexure bearings. The vertical pulse tube is built by TRW with the heat exchanger or cold block located approximately mid-way along the tube. The final assembly and integration is also performed by TRW. The inertance tube and dead volume are contained within one of the compressor end caps. The cooler was developed by TRW under a joint NASA-DOD program, and has a goal of 10 yr operating lifetime. Potential NASA applications will focus on using coolers of this type in Zero boil off (ZBO) cryogen storage topologies for next generation launch vehicles. Zero boil off systems will feature significant reductions in tank size and Initial Mass to Low Earth Orbit (IMLEO), thereby significantly reducing the cost of access to space, and enabling future missions. The coolers can be used directly in liquid oxygen (LOx) or liquid methane ZBO systems, as shield coolers in liquid hydrogen tanks, or as first stage coolers in two-stage liquid hydrogen (LH2) ZBO cooler systems. Finally, the coolers could find applications in exploration missions where either propellants or breathable oxygen are extracted from the planetary atmosphere using a Sabatier or similar process. The gases could then be liquefied for storage either directly in return vehicle propellant tanks or on the planetary surface. Data presented were taken with the cooler operating in a vacuum of 10 (exp -5) torr, at controlled rejection temperatures from 300 K down to 275 K using a cold water heat exchanger bolted to the cooler. Heat loads were varied between 0.5 W and 15 W by supplying current to a 50 omega resistor mounted on a copper cold plate which was bolted to the cooler cold block. Silicon diodes mounted on both the cold plate and the heat exchanger provided accurate temperature measurement to within plus or minus 0.25 K and plus or minus 0.5 K respectively, up to 100 K with plus or minus 1% accuracy above 100 K. Input power to the compressor was limited to 180 W, corresponding to a maximum stroke of 80%.
The present workshop on cryogenics discusses the anomalous on-orbit behavior of the Cosmic Background Explorer Dewar, the SHOOT orbital operations, cooling options for Astromag, and space IR telescope facility mission and cryogenic design. Attention is given to the design of a spaceworthy adiabatic demagnetization refrigerator, the evaluation of metal hydride compressors for applications in Joule-Thomson cryocoolers, diaphragm Stirling cryocooler developments, and a computer simulation model for Stirling refrigerators. Topics addressed include low-gravity thermal stratification of liquid helium on SHOOT, a screening program to select a resin for gravity probe-B composites, a simplified generic cryostat thermal model for predicting cryogen mass and lifetime, and the effect of gas mass flux on cryogenic liquid jet breakup. Also discussed are damping criteria for thermal acoustic oscillations in slush and liquid hydrogen systems, an STS-based cryogenic fluid management experiment, and the design and testing of a cryogenic mixer pump.
The design for the Mars Analysis and Return Vehicle with In-Situ Resource Utilization (MARVIN) project is outlined. The MARVIN mission is designed to collect samples of the Martian environment; to produce fuel from local Martian resources; and to use the fuel produced to return the samples to earth. It uses only existing technologies. Exploratory Technologies' mission-design efforts have focused on methods of orbit determination, sample collection, fuel production, power, communications, control, and structural design. Lambert Targeting provided Delta-V's, launch dates, and travel times. The landing site is the Tharsis Plateau, to the southeast of Olympus Mons, chosen for its substantial scientific value. Samples of soil, dust, and atmosphere are collected with lander-based collection devices: the soil sample, with a robotic arm similar to those used in the Viking missions; the atmospheric sample, from a bleed line to the compressor in the fuel-production facility; a dust sample, from the dust-collection container in the fuel-production facility; and a redundant dust sample, with a with a passive filter system, which relies upon neither a power source nor other collection methods. The sample-return capsule (SRC) houses these samples, which are triply contained to prevent contamination. Proven technology can be used to produce methane and oxygen for fuel with relative ease at the landing site: the Sabatier reactor produces methane and water by combining carbon dioxide and hydrogen (brought from earth); the Reverse Water-Gas Shift unit combines carbon dioxide and hydrogen to form carbon monoxide and water; a water-electrolysis unit splits the water into hydrogen and oxygen. The Mars-lander vehicle (MLV) transports the equipment from earth to Mars. The Mars-ascent vehicle (MAV) contains the SRC and the engine, which is the same for both the MLV and the MAV. All equipment that is unnecessary for the Mars-Earth trajectory remains on Mars. This report presents detailed sizing information, for which a spreadsheet has been developed. The trends suggest possibilities for expansion, and suggestions for future work in these areas are offered.
The procedures and unique hardware used to conduct an experimental investigation into the response of a small-turboshaft-engine compression system to various hot gas ingestion patterns are presented. The temperature distortion generator described herein uses gaseous hydrogen to create both steady-state and time-variant, or transient, temperature distortion at the engine inlet. The range of transient temperature ramps produced by the distortion generator during the engine tests was from less than 111 deg K/sec (200 deg R/sec) to above 611 deg K/sec (1100 deg R/sec); instantaneous temperatures to 422 deg K (760 deg R) above ambient were generated. The distortion generator was used to document the maximum inlet temperatures and temperature rise rates that the compression system could tolerate before the onset of stall for various circumferential distortions as well as the compressor system response during stall.
The procedures and unique hardware used to conduct an experimental investigation into the response of a small-turboshaft-engine compression system to various hot gas ingestion patterns are presented. The temperature distortion generator described herein uses gaseous hydrogen to create both steady-state and time-variant, or transient, temperature distortion at the engine inlet. The range of transient temperature ramps produced by the distortion generator during the engine tests was from less than 111 deg K/sec (200 deg R/sec) to above 611 deg K/sec (1100 deg R/sec); instantaneous temperatures to 422 deg K (760 deg R) above ambient were generated. The distortion generator was used to document the maximum inlet temperatures and temperature rise rates that the compression system could tolerate before the onset of stall for various circumferential distortions as well as the compressor system response during stall.
NASA's interest in human exploration of Mars has driven it to invest in 20K cryocooler technology to achieve zero boil-off of liquid hydrogen and 90K cryocooler technology to achieve zero boil-off liquid oxygen or liquid methane as well as to liquefy oxygen or methane that is produced on the surface of Mars. These investments have demonstrated efficiency progress, mass reductions, and integration insights. A history of the application of cryocooler technology to zero boil-off propellant storage is presented. A trade space on distributed cooling is shown, along with the progress of reverse turbo-Brayton cycle cryocoolers, where the specific power and specific mass have dropped, decreasing the mass and power of these cryocoolers. Additionally, the cryocooler technology advancements of recuperators and compressors are described. Finally, NASA's development ideas with respect to zero boil-off technology are discussed.
NASAs interest in human exploration of Mars has driven it to invest in 20K cryocooler technology to achieve zero boil-off of liquid hydrogen and 90K cryocooler technology to achieve zero boil-off liquid oxygen or liquid methane as well as to liquefy oxygen or methane that is produced on the surface of Mars. These investments have demonstrated efficiency progress, mass reductions, and integration insights. A history of the application of cryocooler technology to zero boil-off propellant storage is presented. A trade space on distributed cooling is shown, along with the progress of reverse turbo-Brayton cycle cryocoolers, where the specific power and specific mass have dropped, decreasing the mass and power of these cryocoolers. Additionally, the cryocooler technology advancements of recuperators and compressors are described. Finally, NASAs development ideas with respect to zero boil-off technology are discussed.
The Generalized Fluid System Simulation Program (GFSSP) is a general purpose computer program for analyzing steady state and time-dependent flow rates, pressures, temperatures, and concentrations in a complex flow network. The program is capable of modeling real fluids with phase changes, compressibility, mixture thermodynamics, conjugate heat transfer between solid and fluid, fluid transients, pumps, compressors, and external body forces such as gravity and centrifugal. The thermofluid system to be analyzed is discretized into nodes, branches, and conductors. The scalar properties such as pressure, temperature, and concentrations are calculated at nodes. Mass flow rates and heat transfer rates are computed in branches and conductors. The graphical user interface allows users to build their models using the 'point, drag, and click' method; the users can also run their models and post-process the results in the same environment. Two thermodynamic property programs (GASP/WASP and GASPAK) provide required thermodynamic and thermophysical properties for 36 fluids: helium, methane, neon, nitrogen, carbon monoxide, oxygen, argon, carbon dioxide, fluorine, hydrogen, parahydrogen, water, kerosene (RP-1), isobutene, butane, deuterium, ethane, ethylene, hydrogen sulfide, krypton, propane, xenon, R-11, R-12, R-22, R-32, R-123, R-124, R-125, R-134A, R-152A, nitrogen trifluoride, ammonia, hydrogen peroxide, and air. The program also provides the options of using any incompressible fluid with constant density and viscosity or ideal gas. The users can also supply property tables for fluids that are not in the library. Twenty-four different resistance/source options are provided for modeling momentum sources or sinks in the branches. These options include pipe flow, flow through a restriction, noncircular duct, pipe flow with entrance and/or exit losses, thin sharp orifice, thick orifice, square edge reduction, square edge expansion, rotating annular duct, rotating radial duct, labyrinth seal, parallel plates, common fittings and valves, pump characteristics, pump power, valve with a given loss coefficient, Joule-Thompson device, control valve, heat exchanger core, parallel tube, and compressible orifice. The program has the provision of including additional resistance options through User Subroutines. GFSSP employs a finite volume formulation of mass, momentum, and energy conservation equations in conjunction with the thermodynamic equations of state for real fluids as well as energy conservation equations for the solid. The system of equations describing the fluid network is solved by a hybrid numerical method that is a combination of the Newton-Raphson and successive substitution methods. The application and verification of the code has been demonstrated through 30 example problems.
We have developed models for predicting the performance of helium-based Joule-Thomson continuous-flow cryocoolers using charcoal-pumped sorption compressors. The models take as inputs the number of compressors, desired heat-lift, cold tip temperature, and available precooling temperature and provide design parameters as outputs. Future laboratory development will be used to verify and improve the models. We will present a preliminary design for a two-stage vibration-free cryocooler that is being proposed as part of a mid-infrared camera on NASA's Next Generation Space Telescope. Model predictions show that a 10 mW helium-carbon cryocooler with a base temperature of 5.5 K will reject less than 650 mW at 18 K. The total input power to the helium-carbon stage is 650 mW. These models, which run in MathCad and Microsoft Excel, can be coupled to similar models for hydrogen sorption coolers to give designs for 2-stage vibration-free cryocoolers that provide cooling from approx. 50 K to 4 K.
We have developed models for predicting the performance of helium-based Joule-Thomson continuous-flow cryocoolers using charcoal-pumped sorption compressors. The models take as inputs the number of compressors, desired heat-lift, cold tip temperature, and available precooling temperature and provide design parameters as outputs. Future laboratory development will be used to verify and improve the models. We will present a preliminary design for a two-stage vibration-free cryocooler that is being proposed as part of a mid-infrared camera on NASA's Next Generation Space Telescope. Model predictions show that a 10 mW helium-carbon cryocooler with a base temperature of 5.5 K will reject less than 650 mW at 18 K. The total input power to the helium-carbon stage is 650 mW. These models, which run in MathCad and Microsoft Excel, can be coupled to similar models for hydrogen sorption coolers to give designs for 2-stage vibration-free cryocoolers that provide cooling from approximately 50 K to 4 K.
The Sabatier Carbon Dioxide Reduction System (CRA) offers water recovery on a long duration space mission to reduce water resupply. Currently, NASA Johnson Space Center (JSC), NASA Marshall Space Flight Center (MSFC), Hamilton Sundstrand Space Systems International, Inc. (HSSSI), and Southwest Research Institute (SWRI) are working together to develop a Sabatier CRA for the International Space Station (ISS). This effort is being funded by the Office of Biological and Physical Research (Code U)/Advanced Life Support program which is administered by NASA JSC. The Sabatier CRA is the next step in closing the oxygen life support loop on future space missions. The Sabatier reaction combines the waste carbon dioxide (recovered from crew metabolism) with waste hydrogen (a byproduct of electrolysis to produce oxygen) to produce water and methane (CH4). On ISS, the methane would be vented overboard, however the methane can be utilized for propulsion during a planetary exploration mission. Based on a crew size of 7-equivalent people, the Sabatier CRA can produce as much a 2000 lb/year water. Use of the Sabatier CRA will significantly reduce the amount of water that needs to be resupplied to the ISS on a yearly basis, at a tremendous cost saving to the program. Additionally, by recycling this additional water, the Sabatier CRA enables additional launch capacity for science experiments to be brought up to the ISS. The NASA/Industry team noted above has been working to reduce technical risks associated with the Sabatier CRA system. To date the technical risks have been considerably reduced, bringing the Technology Readiness Level (TRL) from TRL 4 to TRL 5/6. In doing so, the team has developed the system schematic, system models, control scheme, produced engineering development unit (EDU) hardware, performed limited integration testing of the EDU's and verified system modeling through testing. Additionally, the system schematic has been evaluated for failure modes and hazards and had a successful technical review by the NASA Safety Board. The current focus is now related to development of the water/methane phase separator, liquid sensor and CO2 compressor piston seal life. The overall goal of the current effort is to bring the system up to a TRL6 by the end of GFY04. Although the Sabatier CRA is not currently baselined for use on the ISS, its benefits are significant enough such that volume within the Oxygen Generation System rack has been reserved for future installation. The value of the water the CRA recover will allow NASA the additional crew time and payload needed to pursue its mission of scientific research.
The Sabatier Methanation Reactor technology is of vital importance to the success of the human and robotic exploration program. In order to achieve an affordable program, the logistics supply to support the mission must be minimized to the fullest extent possible. One area of potential reduction with high return on investment is the closure of life support loops, particularly oxygen and water. The Sabatier system accomplishes this by utilizing hydrogen and carbon dioxide, waste products from the life support system, to produce water and methane. The recovered water is then recycled back into the life support system to provide oxygen; while the methane can be used for propulsion, or can be broken down further to recover the hydrogen. This technology is applicable not only to transit phases of exploration, but surface habitats as well as in-situ propellant production. The Sabatier Reactor system has been developed for ground based demonstration experiments extensively over the past 30 years. Over the past three years, NASA has funded development of the Sabatier Carbon Dioxide Reduction Assembly (CRA) for use on the ISS. Currently this system is at TRL 5 and it is expected that the system will be flown on the ISS as a flight experiment, The purpose of the flight experiment is to integrate the Sabatier CRA into a synchronized system with the oxygen generation system and the carbon dioxide concentrator. The flight experiment will verify the integration of the different systems working together plus it will verify the capability of the system to operate, and effectively separate its products in a micro-gravity environment. Subsequent to design validation, the flight experiment can remain onboard the ISS providing valuable water to offset logistics re-supply requirements. Some of the challenges facing the development of the Sabatier system include handling vibration induced particulates, microgravity phase separation and containment of hazardous gases. Plans for adequately addressing these issues will be presented. The Sabatier carbon dioxide reduction process will greatly benefit any of the extended duration human exploration missions because of the tremendous savings of consumables realized. Any of these mission scenarios, be they transit or surface based, must consider closing the life support loops in order to make the mission achievable, let alone affordable. Carbon dioxide reduction technology will be necessary for future outpost habitats, and the technology needs to be proven viable in a space application. The Sabatier methanation reaction is also a desirable method for producing propellant from the Mars atmosphere. The common system could be designed to accept carbon dioxide from an indoor air revitalization loop concentrator, or from an outdoor atmosphere compressor. Carbon dioxide reduction validation is but one step in the spiral development of the in-situ propellant production system desired for future planetary exploration.