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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 73 records · Page 4

A fuel cell energy storage system concept for the Space Station Freedom Extravehicular Mobility Unit

An update is given on work to design and build a Fuel Cell Energy Storage System (FCESS) bench-tested unit for the Space Station Freedom Extravehicular Mobility Unit (EMU). Fueled by oxygen and hydride-stored hydrogen, the FCESS is being considered as an alternative to the EMU zinc-silver oxide battery. Superior cycle life and quick recharge are the main attributes of FCESS. The design and performance of a nonventing, 28 V, 34 Ahr system with 7 amp rating are discussed.

Adlhart, Otto J.↗

The liquid hydrogen option for the subsonic transport - A status report

Studies dealing with the use of liquid hydrogen for fuel in subsonic air transport systems are reviewed. Topics of the studies include the possibility for economical production of hydrogen, the problems associated with the efficient liquefaction of the gas, the development of insulation materials and materials for long-lasting liquid hydrogen fuel tanks, the difficulties related to fueling processes and the installation of liquid hydrogen fuel stations at major air terminals, an assessment of the hazards connected with liquid hydrogen fuels, and the engineering and design problems involved in incorporating liquid hydrogen fuel systems into large subsonic passenger aircraft.

Korycinski, P. F.↗

System performance predictions for Space Station Freedom's electric power system

Space Station Freedom Electric Power System (EPS) capability to effectively deliver power to housekeeping and user loads continues to strongly influence Freedom's design and planned approaches for assembly and operations. The EPS design consists of silicon photovoltaic (PV) arrays, nickel-hydrogen batteries, and direct current power management and distribution hardware and cabling. To properly characterize the inherent EPS design capability, detailed system performance analyses must be performed for early stages as well as for the fully assembled station up to 15 years after beginning of life. Such analyses were repeatedly performed using the FORTRAN code SPACE (Station Power Analysis for Capability Evaluation) developed at the NASA Lewis Research Center over a 10-year period. SPACE combines orbital mechanics routines, station orientation/pointing routines, PV array and battery performance models, and a distribution system load-flow analysis to predict EPS performance. Time-dependent, performance degradation, low earth orbit environmental interactions, and EPS architecture build-up are incorporated in SPACE. Results from two typical SPACE analytical cases are presented: (1) an electric load driven case and (2) a maximum EPS capability case.

Kerslake, Thomas W.↗

Nickel-hydrogen batteries from Intelsat 5 to space station

The heritage of the Ni-H2 technology that makes the space station application feasible is discussed. It also describes a design for a potential space station Ni-H2 battery system. Specific design values presented here were developed by Ford Aerospace as part of the Rocketdyne team effort on the Phase B Definition and Preliminary Design of the Space Station Power System in support of NASA Lewis Research Center.

Vanommering, G.↗

Influence of Oxygenated Compounds on Reaction Products in a Microwave Plasma Methane Pyrolysis Assembly for Post-Processing of Sabatier Methane

The state-of-the-art Carbon Dioxide Reduction Assembly (CRA) was delivered to the International Space Station (ISS) in April 2010. The system is designed to accept carbon dioxide from the Carbon Dioxide Removal Assembly and hydrogen from the Oxygen Generation Assembly. The two gases are reacted in the CRA in a Sabatier reactor to produce water and methane. Venting of methane results in an oxygen resupply requirement of about 378 lbs per crew member per year. If the oxygen is supplied as water, the total weight for resupply is about 476 lb per crew member per year. For long-term missions beyond low Earth orbit, during which resupply capabilities will be further limited, recovery of hydrogen from methane is highly desirable. For this purpose, NASA is pursuing development of a Plasma Pyrolysis Assembly (PPA) capable of recovering hydrogen from methane. Under certain conditions, water vapor and carbon dioxide (nominally intended to be separated from the CRA outlet stream) may be present in the PPA feed stream. Thus, testing was conducted in 2010 to determine the effect of these "oxygenated" compounds on PPA performance, particularly the effect of inlet carbon dioxide and water variations on the PPA product stream. This paper discusses the test set-up, analysis, and results of this testing

Mansell, J. Matthew↗

Influence of Oxygenated Compounds on Reaction Products in a Microwave Plasma Methane Pyrolysis Assembly for Post-Processing of Sabatier Methane

The state-of-the-art Carbon Dioxide Reduction Assembly (CRA) was delivered to the International Space Station (ISS) in April 2010. The system is designed to accept carbon dioxide from the Carbon Dioxide Removal Assembly and hydrogen from the Oxygen Generation Assembly. The two gases are reacted in the CRA in a Sabatier reactor to produce water and methane. Venting of methane results in an oxygen resupply requirement of about 378 lbs per crew member per year. If the oxygen is supplied as water, the total weight for resupply is about 476 lb per crew member per year. For long-term missions beyond low Earth orbit, during which resupply capabilities will be further limited, recovery of hydrogen from methane is highly desirable. For this purpose, NASA is pursuing development of a Plasma Pyrolysis Assembly (PPA) capable of recovering hydrogen from methane. Under certain conditions, water vapor and carbon dioxide (nominally intended to be separated from the CRA outlet stream) may be present in the PPA feed stream. Thus, testing was conducted in 2010 to determine the effect of these oxygenated compounds on PPA performance, particularly the effect of inlet carbon dioxide and water variations on the PPA product stream. This paper discusses the test set-up, analysis, and results of this testing.

Mansell, J. Matthew↗

Space station propulsion test bed

A test bed was fabricated to demonstrate hydrogen/oxygen propulsion technology readiness for the intital operating configuration (IOC) space station application. The test bed propulsion module and computer control system were delivered in December 1985, but activation was delayed until mid-1986 while the propulsion system baseline for the station was reexamined. A new baseline was selected with hydrogen/oxygen thruster modules supplied with gas produced by electrolysis of waste water from the space shuttle and space station. As a result, an electrolysis module was designed, fabricated, and added to the test bed to provide an end-to-end simulation of the baseline system. Subsequent testing of the test bed propulsion and electrolysis modules provided an end-to-end demonstration of the complete space station propulsion system, including thruster hot firings using the oxygen and hydrogen generated from electrolysis of water. Complete autonomous control and operation of all test bed components by the microprocessor control system designed and delivered during the program was demonstrated. The technical readiness of the system is now firmly established.

Briley, G. L.↗

Innovative Advanced Hydrogen Mobile Fueler (Final Technical Report)

The US Department of Energy (DOE) funded a project to design, develop, deploy and analyze the economic viability of an innovative Advanced Hydrogen Mobile Fueler (AHMF). As part of the design activity the project team defined specifications based upon vehicle requirements and compliance with specific fueling performance criteria. The AHMF was originally designed to fuel 10-20 fuel cell vehicles (FCV) per day, consistent with the requirements of the H70 fueling category. The AHMF is able to operate without remote power connections, is modular for easy transport and deployment, and can provide expanded daily capacity and multi-day operations using delivered gaseous hydrogen. Toward the end of the project, due to request from the hydrogen industry and some necessary modifications of the AHMF, the system is now modified to fuel heavy duty vehicles. The project was conducted over two primary phases, each including several key tasks, subtasks, and project milestones. Phase 1 involved the design, development, and construction of the AHMF, moving from a conceptual design through to completion of assembly and testing. In addition to reviewing several different approaches, the team chose to take a conventional station design and modify it for mobile fueling. There were several innovative components included in the design. The high pressure storage was the first to achieve a US Department of Energy (DOE) Special Permit (SP 20391) to transport high pressure hydrogen (95 MPa) in a composite cylinder. The second novel system was a liquid nitrogen (LIN) cooling system with a compact heat exchanger. Without this change, the cooling system would not be able to fit into the AHMF. Phase 2 demonstrated the AHMF by fueling fuel cell buses at a fleet in Pomona, CA. The site was chosen because a temporary fueling solution was required while a fixed station was being installed. The existing permits for the fixed station and non-public access also was a determining factor. Over two months, the buses were fueled 320 times with over 5000 kg of hydrogen from tube trailers. Existing shore power was used, and the average electrical efficiency was 0.13 kWh/kg. The average liquid nitrogen (LIN) consumption was 90.68 scf/kg. The fueling and consumption data was provided to the National Renewable Energy Laboratory (NREL) for analysis. An economic analysis was performed and will be provided in a separate report. The project was successful, but not without challenges and lessons learned. The DOT special permit led the way for the use of high pressure, composite cylinders and is being by multiple other systems and applications. The pandemic along with time for the DOT special permit approval delayed the project for years. The team also believes that hydrogen mobile fueling has a use for the industry, especially during this upcoming phase of expansion. However, it does have its limitations due to high cost to build and operate, and the same permitting challenges as a fixed station. A fully capable system at the speeds and pressures of the AHMF may not be necessary for most applications and would help reduce the cost and increase storage capacity. The on-board generator can be easily replaced with shore power or the wide range of power generation solutions in the marketplace. One of the major results of the project was the development of new code language in National Fire Protection Agency (NFPA) 2 and the International Fire Code (IFC) for on-demand mobile fueling. This will provide guidance for Authorities Having Jurisdiction (AHJ) and user on how to permit temporary fueling sites across the nation.

08 HYDROGEN↗

A Next Generation Air Monitor: Combining Orion and ISS Requirements for a Common Major Constituent Analyzer

The Major Constituent Analyzer (MCA) is a mass spectrometer-based instrument designed to provide critical monitoring of six major atmospheric constituents; nitrogen, oxygen, hydrogen, carbon dioxide, methane, and water vapor on-board the International Space Station. The analyzer has been an integral part of the Environmental Control and Life Support System (ECLSS) since the station went on-line. The Orion Air Monitor (OAM) was derived from the MCA and heavily optimized for reduced mass, lower power, faster water vapor response, and maintenance-free operation. The resulting OAM is approximately the size of the analyzer portion of the MCA, orbital-replacement unit 02 (ORU 02), while incorporating the functions of three other modules: Data Processing and Communication (ORU 01), Verification Gas Assembly (ORU 08), and Low Voltage Power Supply (ORU 04). The overlap in MCA and OAM requirements makes it possible to derive a common Air Monitor design that spans both applications while minimally impacting the weight and power limits imposed by the Multipurpose Crew Vehicle (MPCV). Benefits to ISS include the retirement of ORUs 01, 04, and 08, reducing up-mass and eliminating EEE parts obsolescence issues through the extended ISS mission phases. Benefits to MPCV and future deployed habitats under the Constellation program include greater interchangeability across ECLSS subsystems. This paper discusses the results of the requirements development study, where a superset of ISS and Orion air monitoring requirements were distilled; evaluated against increases in OAM functionality, mass, and power; and traded-off where possible using simple operating mode modifications. A system architecture and preliminary design addressing the common requirements will be presented.

Burchfield, David E.↗

Large-scale Hydrogen Storage Risk Assessment

This project investigated risks involved in deploying a large-scale hydrogen storage system at the Port of Seattle (hereafter, the Port) for its on-terminal and maritime applications in an urban industrial setting. Alongside, the project attempted to address some of the barriers to risk assessment such as need for an exact system design for a systematic investigation, direct access to surrounding communities to gauge their perceptions, and an integrated software required to undertake a full-fledged risk assessment. These barriers were overcome using illustrative reference station designs, engaging with community-facing agencies through Port support, and pooling national laboratory capabilities available for risk assessments. The project identified relevant public safety risk metrics, compared various hydrogen carriers, engaged with community-facing agencies, and explored potential gaps in existing safety codes and standards. The primary impacts of this project include the development of risk assessment guidance for ports and utilities, informing them of the trade-offs in the choice of hydrogen carriers, and the ability to increase public capacity for dialog and engagement. This paves the way toward decarbonization of the Port activities, bringing about awareness around jobs in the market for risk assessments, and the need to ramp up community engagement long before any hydrogen system deployment is undertaken.

08 HYDROGEN↗

Capabilities and History of NASA Marshall Space Flight Center's Hydrogen Test Facility

The Hydrogen Test Facility (HTF) has conducted mechanical testing for aerospace materials at NASA's Marshall Space Flight Center for many years. One of the first facilities of its kind to run high-pressure cryogenic permeability tests in liquid hydrogen, HTF is now characterized as a unique national resource capable of overcoming hazardous conditions to perform tests directly in various hydrogen environments. At HTF, custom test systems are operated in eight structurally reinforced test cells from 0 to 68,948 kPa (0 to 10,000 psi) at -253 to 982 C (--423 to 1800 F) in hydrogen, air, helium, and nitrogen, with other environments available upon request. Standard mechanical procedures include compression, fatigue crack growth rate, four-point bend, high/low cycle fatigue, fracture toughness, shear, strain-to-crack, and tensile testing. Cryogenic permeability and thermal conductivity and gaseous creep testing are offered, as well as simulated service under different combinations of operating environment(s), stress, pressure, and ambient-to-extreme temperatures. Advanced tests are routinely developed upon demand, and special component testing is also available. Current efforts include the renovation of two high-pressure gaseous test cells to generate data for a J-2X engine designed for Constellation's Ares I and V vehicles. In the past, HTF has supported other critical NASA programs, such as Apollo, Space Shuttle, and Next Generation Launch Technologies. During the 1990's, hundreds of tests were conducted in liquid hydrogen and liquid nitrogen during development of the Space Shuttle's super lightweight tank, which provided the thrust required to achieve low Earth orbit for the International Space Station. This facility was designed and built in 1963. Originally called the Low Temperature Test Facility, it became known as the Cryogenic Test Facility in the late 1980's and HTF in the early 1990's.

Malone, T. W.↗

Laser powered interorbital vehicle

A preliminary design of a low-thrust Laser Powered Interorbital Vehicle (LPIV) intended for cargo transportation between an Earth space station and a lunar base is presented. The selected mission utilizes a spiral trajectory, characteristic of a low-thrust spacecraft, requiring eight days for a lunar rendezvous and an additional nine days for return. The ship's configuration consists primarily of an optical train, two hydrogen plasma engines, a 37.1 m box-beam truss, a payload module, and propellant tanks. The total mass of the vehicle, fully loaded, is 63,300 kg. A single plasma, regeneratively cooled engine design is incorporated into the two 500 N engines. These are connected to the spacecraft by turntables that allow the vehicle to thrust tangential to the flight path. Proper collection and transmission of the laser beam to the thrust chambers is provided through the optical train. This system consists of a 23-m-diameter primary mirror, a convex parabolic secondary mirror, a beam splitter, and two concave parabolic tertiary mirrors. The payload bay is capable of carrying 18,000 kg of cargo and is located opposite the primary mirror on the main truss. Fuel tanks carrying a maximum of 35,000 kg of liquid hydrogen are fastened to tracks that allow the tanks to be moved perpendicular to the main truss. This capability is required to prevent the center of mass from moving out of the thrust vector line. The laser beam is located and tracked by means of an acquisition, pointing, and tracking system that can be locked onto the space-based laser station. Correct orientation of the spacecraft with the laser beam is maintained by control moment gyros and reaction control rockets. In addition, an aerobrake configuration was designed to provide the option of using the atmospheric drag in place of propulsion for a return trajectory.

Clarke, M. T.↗

Ground Test Stand Development for One-step Electrochemical Production of High-Pressure Oxygen

NASA designed a test rig, High-Pressure Oxygen Generation Assembly (HPOGA) to test a novel method of electrolysis as an alternative technology to the state-of-the-art Oxygen Generation Assembly (OGA) currently on the International Space Station (ISS). This approach involves utilizing a specialized electrolysis cell stack designed to both generate and compress high-pressure oxygen up to 3600 PSIG. The design eliminates the need for an external compressor and hydrogen separator, streamlining the oxygen generation process. HPOGA tests the viability of an electrolysis cell stack for extended life usage. Within the system, there are several key subsystems: nitrogen, high/low pressure oxygen, hydrogen, water recirculation, and water injection. The water injection subsystem supplies deionized (DI) water to a centralized reservoir for consumption. Subsequently, a water recirculation loop transfers the DI water across the cathode side of the electrolysis cell stack with constant flow rate. The result is a supply of hydrogen in the water loop and oxygen accumulation on the anode side of the cell stack. Hydrogen is evaporated out as part of the hydrogen sub-system which also measures hydrogen/oxygen concentration for safety. The oxygen subsystem is responsible for managing high pressure oxygen, O2 exhaust, and conducting hydrogen/oxygen concentration measurements. The nitrogen subsystem serves dual functions, purging the hydrogen/oxygen subsystems, and regulating pressure in both high/low-pressure O2 sections via pneumatic back pressure regulators. Various sensors monitor pressure, temperature, humidity, gas concentration and flow rate in each subsystem. This paper presents the design and testing of a comprehensive test stand, which serves to operate and functionally verify the performance of the electrolysis cell while offering valuable lessons learned.

electrolysis↗

Space Station Freedom electrical performance model

The baseline Space Station Freedom electric power system (EPS) employs photovoltaic (PV) arrays and nickel hydrogen (NiH2) batteries to supply power to housekeeping and user electrical loads via a direct current (dc) distribution system. The EPS was originally designed for an operating life of 30 years through orbital replacement of components. As the design and development of the EPS continues, accurate EPS performance predictions are needed to assess design options, operating scenarios, and resource allocations. To meet these needs, NASA Lewis Research Center (LeRC) has, over a 10 year period, developed SPACE (Station Power Analysis for Capability Evaluation), a computer code designed to predict EPS performance. This paper describes SPACE, its functionality, and its capabilities.

Hojnicki, Jeffrey S.↗

Rotating-Pump Design Code

Pump Design (PUMPDES) is a computer program for designing a rotating pump for liquid hydrogen, liquid oxygen, liquid nitrogen, water, methane, or ethane. Using realistic properties of these fluids provided by another program called GASPAK, this code performs a station-by-station, mean-line analysis along the pump flow path, obtaining thermodynamic properties of the pumped fluid at each station and evaluating hydraulic losses along the flow path. The variables at each station are obtained under constraints that are consistent with the underlying physical principles. The code evaluates the performance of each stage and the overall pump. In addition, by judiciously choosing the givens and the unknowns, the code can perform a geometric inverse design function: that is, it can compute a pump geometry that yields a closest approximation of given design point. The code contains two major parts: one for an axial-rotor/inducer and one for a multistage centrifugal pump. The inducer and the centrifugal pump are functionally integrated. The code can be used in designing and/or evaluating the inducer/centrifugal-pump combination or the centrifugal pump alone. The code is written in standard Fortran 77.

Walker, James F.↗

Challenges in the designing, planning and deployment of hydrogen refueling infrastructure for fuel cell electric vehicles

Hydrogen can power transportation with near zero greenhouse gas emissions. With government support, early market development is now underway in several nations thanks to technological advances in fuel cell vehicles and electricity generation from renewable energy. Deploying a sustainable hydrogen refueling infrastructure faces methodological and practical challenges ranging from the creation of appropriate codes to managing the co-evolution of the refueling network and growth of the stock of hydrogen fuel cell vehicles. Furthermore, this paper presents a comprehensive review of the challenges facing the designing, planning and deployment of hydrogen refueling infrastructure progress to date and outlook for the future. The design and costs of refueling infrastructure as well as the lifecycle environmental effects of hydrogen vehicles depend on how hydrogen is produced and delivered to refueling stations. In recent years, important advances have been made in methods for planning the numbers, sizes and location of hydrogen stations. Institutional barriers are also gradually being overcome. Co-evolving the deployment of stations and the demand for fuel cell vehicles remains a crucial subject for future research.

33 ADVANCED PROPULSION SYSTEMS↗

Versatile Nuclear Thermal Propulsion (NTP)

A study was initiated to investigate propulsion stage and mission architecture options potentially enabled by fission energy. One initial concept is a versatile Nuclear Thermal Propulsion (NTP) system with a maximum specific impulse of 900 s and a maximum thrust (per engine) of 15 klbf. The system assumes a monopropellant stage (hydrogen), and is designed to also provide 300 lbf of thrust (potentially split between multiple thrusters) at an Isp > 500 s for orbital maneuvering and station keeping. Boost pumps are used to assist with engine decay heat removal and low thrust engine burns, and to compensate for partial tank depressurization during full thrust engine burns. Potential stage assembly orbits that take full advantage of launch vehicle payload mass and volume capabilities are being assessed. The potential for using NTP engines to also generate a small to moderate amount of electrical power is also being evaluated. A first generation versatile NTP stage could enable 8 of 9 upcoming opportunities for short (less than 24 month) round trip human missions to Mars. A second generation versatile NTP is under consideration that could potentially provide a maximum specific impulse of 1800 s at 15 klbf, and enable ambitious missions throughout the solar system. The second generation NTP system under consideration would also allow a choice of volatiles to be used as propellant. This would potentially allow in-situ resources such as water, ammonia, methane, or other compounds to be used directly as propellant by the second generation engine.

Houts, Michael G.↗

Versatile Nuclear Thermal Propulsion (NTP)

A study was initiated to investigate propulsion stage and mission architecture options potentially enabled by fission energy. One initial concept is a versatile Nuclear Thermal Propulsion (NTP) system with a maximum specific impulse of 900 s and a maximum thrust (per engine) of 15 klbf. The system assumes a monopropellant stage (hydrogen), and is designed to also provide 300 lbf of thrust (potentially split between multiple thrusters) at an Isp > 500 s for orbital maneuvering and station keeping. Boost pumps are used to assist with engine decay heat removal and low thrust engine burns, and to compensate for partial tank depressurization during full thrust engine burns. Potential stage assembly orbits that take full advantage of launch vehicle payload mass and volume capabilities are being assessed. The potential for using NTP engines to also generate a small to moderate amount of electrical power is also being evaluated. A first generation versatile NTP stage could enable 8 of 9 upcoming opportunities for short (less than 24 month) round trip human missions to Mars. A second generation versatile NTP is under consideration that could potentially provide a maximum specific impulse of 1800 s at 15 klbf, and enable ambitious missions throughout the solar system. The second generation NTP system under consideration would also allow a choice of volatiles to be used as propellant. This would potentially allow in-situ resources such as water, ammonia, methane, or other compounds to be used directly as propellant by the second generation engine.

Houts, Mike↗