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NASA NTRS2016

A Robust, Gravity-Insensitive, High-Temperature Condenser for Water Recovery

Regenerative life support systems are vital for NASA's future long-duration human space exploration missions. A Heat Melt Compactor (HMC) system is being developed by NASA to dry and compress trash generated during space missions. The resulting water vapor is recovered and separated from the process gas flow by a gravity-insensitive condenser. Creare is developing a high-temperature condenser for this application. The entire condenser is constructed from metals that have excellent resistance to chemical attack from contaminants and is suitable for high-temperature operation. The metal construction and design configuration also offer greatest flexibility for potential coating and regeneration processes to reduce biofilm growth and thus enhancing the reliability of the condenser. The proposed condenser builds on the gravity-insensitive phase separator technology Creare developed for aircraft and spacecraft applications. This paper will first discuss the design requirements for the condenser in an HMC system that will be demonstrated on the International Space Station (ISS). Then, it will present the overall design of the condenser and the preliminary thermal test results of a subscale condenser. Finally, this paper will discuss the predicted performance of the full-size condenser and the development plan to mature the technology and enhance its long-term reliability for a flight system.

Chen, Weibo↗

NASA NTRS1990

Supercritical microgravity droplet vaporization

Supercritical droplet vaporization is an important issue in many combustion systems, such as liquid fueled rockets and compression-ignition (diesel) engines. In order to study the details of droplet behavior at these conditions, an experiment was designed to provide a gas phase environment which is above the critical pressure and critical temperature of a single liquid droplet. In general, the droplet begins as a cold droplet in the hot, high pressure environment. In order to eliminate disruptions to the droplet by convective motion in the gas, forced and natural convection gas motion are required to be small. Implementation of this requirement for forced convection is straightforward, while reduction of natural convection is achieved by reduction in the g-level for the experiment. The resulting experiment consists of a rig which can stably position a droplet without restraint in a high-pressure, high temperature gas field in microgravity. The microgravity field is currently achieved by dropping the device in the NASA Lewis 2.2 second drop tower. The performance of the experimental device and results to date are presented.

Hartfield, J.↗

NASA NTRS2009

Providing Oxygen for the Crew of a Lunar Outpost

Oxygen (O2) is obviously essential for human space missions, but it is important to examine all the different ways it will be used and the potential sources that it may come from. This effort will lead to storage and delivery requirements and help to determine the optimum architecture from an overall systems engineering point of view. Accounting for all the oxygen in a Lunar Outpost mission includes meeting the metabolic needs of the crew while in the surface Habitat, leakage through the Habitat or Pressurized Rover walls, recharge of the space suit backpack and emergency situations. Current plans indicate that both primary and secondary O2 bottles for the space suit will be filled to a pressure of 20.7 MPa (3000 psia). Other uses of O2 require much lower pressure. Sources of O2 at a Lunar Outpost include compressed or liquefied O2 brought along specifically for life support, scavenged O2 from the Lander propulsion system, recovered O2 from waste water or exhaled carbon dioxide and O2 mined from the moon itself. Previously, eight technology options were investigated to provide the high pressure space suit O2. High pressure O2 storage was treated as the baseline technology and compared to the other seven. The other seven were cryogenic storage followed by high pressure vaporization, scavenging liquid oxygen (LOX) from Lander followed by vaporization, LOX delivery followed by sorption compression, low pressure water electrolysis followed by mechanical compression, high pressure water electrolysis, sharing a high pressure electrolyzer with a regenerative fuel cell power system, and making use of In- Situ Resource Utilization (ISRU). This system-level analysis was conducted by comparing equivalent system mass of the eight technologies in open and closed loop life support architectures. The most promising high pressure O2 generation technologies were recommended for development. Updates and an expansion of the earlier study have been made and the results are reported in this paper. Examples of recent analyses include feasibility of recovering space suit purge O2 in a Pressurized Rover and using sub-critical LOX for primary supply while using high-pressure gaseous O2 as the secondary supply for the space-suit. Preliminary analysis on scavenging LOX from the Lander and delivering it to the Habitat has also been incorporated into this integrated lunar fluids analysis

Ewert, Michael K.↗

NASA NTRS1977

Improved waste water vapor compression distillation technology

The vapor compression distillation process is a method of recovering potable water from crewman urine in a manned spacecraft or space station. A description is presented of the research and development approach to the solution of the various problems encountered with previous vapor compression distillation units. The design solutions considered are incorporated in the preliminary design of a vapor compression distillation subsystem. The new design concepts are available for integration in the next generation of support systems and, particularly, the regenerative life support evaluation intended for project Spacelab.

Johnson, K. L.↗

NASA NTRS1978

Development of a preprototype vapor compression distillation water recovery subsystem

The activities involved in the design, development, and test of a preprototype vapor compression distillation water recovery subsystem are described. This subsystem, part of a larger regenerative life support evaluation system, is designed to recover usable water from urine, urinal rinse water, and concentrated shower and laundry brine collected from three space vehicle crewmen for a period of 180 days without resupply. Details of preliminary design and testing as well as component developments are included. Trade studies, considerations leading to concept selections, problems encountered, and test data are also presented. The rework of existing hardware, subsystem development including computer programs, assembly verification, and comprehensive baseline test results are discussed.

Johnson, K. L.↗

NASA NTRS1972

Shock melting and vaporization of metals.

The effect of initial porosity on shock induction of melting and vaporization is investigated for Ba, Sr, Li, Fe, Al, U, and Th. For the less compressible of these metals, it is found that for a given strong shock-generation system (explosive in contact, or flyer-plate impact) an optimum initial specific volume exists such that the total entropy production, and hence the amount of metal liquid or vapor, is a maximum. Initial volumes from 1.4 to 2.0 times crystal volumes, depending on the metal sample and shock-inducing system, will result in optimum post-shock entropies.

Ahrens, T. J.↗

NASA NTRS1991

Conceptual design of a thermal control system for an inflatable lunar habitat module

NASA is considering the establishment of a manned lunar base within the next few decades. To house and protect the crew from the harsh lunar environment, a habitat is required. A proposed habitat is an spherical, inflatable module. Heat generated in the module must be rejected to maintain a temperature suitable for human habitation. This report presents a conceptual design of a thermal control system for an inflatable lunar module. The design solution includes heat acquisition, heat transport, and heat rejection subsystems. The report discusses alternative designs and design solutions for each of the three subsystems mentioned above. Alternative subsystems for heat acquisition include a single water-loop, a single air-loop, and a double water-loop. The vapor compression cycle, vapor absorption cycle, and metal hydride absorption cycle are the three alternative transport subsystems. Alternative rejection subsystems include flat plate radiators, the liquid droplet radiator, and reflux boiler radiators. Feasibility studies on alternatives of each subsystem showed that the single water-loop, the vapor compression cycle, and the reflux boiler radiator were the most feasible alternatives. The design team combined the three subsystems to come up with an overall system design. Methods of controlling the system to adapt it for varying conditions within the module and in the environment are presented. Finally, the report gives conclusions and recommendations for further study of thermal control systems for lunar applications.

Gadkari, Ketan↗

NASA NTRS1993

Investigation of lunar base thermal control system options

Long duration human exploration missions to the Moon will require active thermal control systems which have not previously been used in space. The two technologies which are most promising for long term lunar base thermal control are heat pumps and radiator shades. Recent trade-off studies at the Johnson Space Center have focused development efforts on the most promising heat pump and radiator shade technologies. Since these technologies are in the early stages of development and many parameters used in the study are not well defined, a parametric study was done to test the sensitivity to each assumption. The primary comparison factor in these studies was the total mass system, with power requirements included in the form of a mass penalty for power. Heat pump technologies considered were thermally driven heat pumps such as metal hydride, complex compound, absorption and zeolite. Also considered were electrically driven Stirling and vapor compression heat pumps. Radiator shade concepts considered included step shaped, V-shaped and parabolic (or catenary) shades and ground covers. A further trade study compared the masses of heat pump and radiator shade systems.

Ewart, Michael K.↗

NASA NTRS2009

Polymeric Bladder for Storing Liquid Oxygen

A proposed system for storing oxygen in liquid form and dispensing it in gaseous form is based on (1) initial subcooling of the liquid oxygen; (2) containing the liquid oxygen in a flexible vessel; (3) applying a gas spring to the flexible vessel to keep the oxygen compressed above the saturation pressure and, thus, in the liquid state; and (4) using heat leakage into the system for vaporizing the oxygen to be dispensed. In a typical prior system based on these principles, the flexible vessel is a metal bellows housed in a rigid tank, and the gas spring consists of pressurized helium in the tank volume surrounding the bellows. Unfortunately, the welds in the bellows corrugations are subject to fatigue, and, because bellows have large ullage, a correspondingly large fraction of the oxygen content cannot be expelled. In the proposed system, the flexible vessel would be a bladder made of a liquid- crystal polymer (LCP). (LCPs are strong and compatible with liquid oxygen.) In comparison with a metal bellows, a polymeric bladder would have less ullage and would weigh less. In experiments involving fatigue cycling at liquid-nitrogen temperatures, two LCPs were found to be suitable for this application.

Walker, David H.↗

NASA NTRS2000

Lubrication System Failure Baseline Testing on an Aerospace Quality Gear Mesh

Aerospace drive systems are required to survive a loss-of-lubrication test for qualification. In many cases emergency lubrication systems need to be designed and utilized to permit the drive system to pass this difficult requirement. The weight of emergency systems can adversely affect the mission capabilities of the aircraft. The possibility to reduce the emergency system weight through the use of mist lubrication will be described. Mist lubrication involves the delivery of a minute amount of an organic liquid as a vapor or fine mist in flowing compressed air to rubbing surfaces. At the rubbing surface, the vapor or mist reacts to form a solid lubricating film. The aim of this study was to establish a baseline for gear behavior under oil depleted conditions. A reactive vapor-mist lubrication method is described and proposed as a candidate emergency lubrication system.

Handschuh, Robert F.↗

NASA NTRS1994

Advanced diesel engine component development program, tasks 4-14

This report summarizes the Advanced Diesel Engine Component Development (ADECD) Program to develop and demonstrate critical technology needed to advance the heavy-duty low heat rejection engine concept. Major development activities reported are the design, analysis, and fabrication of monolithic ceramic components; vapor phase and solid film lubrication; electrohydraulic valve actuation; and high pressure common rail injection. An advanced single cylinder test bed was fabricated as a laboratory tool in studying these advanced technologies. This test bed simulates the reciprocator for a system having no cooling system, turbo compounding, Rankine bottoming cycle, common rail injection, and variable valve actuation to achieve fuel consumption of 160 g/kW-hr (.26 lb/hp-hr). The advanced concepts were successfully integrated into the test engine. All ceramic components met their functional and reliability requirements. The firedeck, cast-in-place ports, valves, valve guides, piston cap, and piston ring were made from silicon nitride. Breakthroughs required to implement a 'ceramic' engine included the fabrication of air-gap cylinder heads, elimination of compression gaskets, machining of ceramic valve seats within the ceramic firedeck, fabrication of cast-in-place ceramic port liners, implementation of vapor phase lubrication, and elimination of the engine coolant system. Silicon nitride valves were successfully developed to meet several production abuse test requirements and incorporated into the test bed with a ceramic valve guide and solid film lubrication. The ADECD cylinder head features ceramic port shields to increase insulation and exhaust energy recovery. The combustion chamber includes a ceramic firedeck and piston cap. The tribological challenge posed by top ring reversal temperatures of 550 C was met through the development of vapor phase lubrication using tricresyl phosphate at the ring-liner interface. A solenoid-controlled, variable valve actuation system that eliminated the conventional camshaft was demonstrated on the test bed. High pressure fuel injection via a common rail system was also developed to reduce particulate emissions.

Kaushal, Tony S.↗

NASA NTRS1980

Design, fabrication and testing of a dual catalyst ammonia removal system for a urine VCD unit

A three-man capacity catalytic system for the recovery of water from urine was designed, constructed, and tested, it was designed to operate with feed streams containing high concentrations of urine vapor and only 5 to 7% of oxygen for the oxidation of ammonia and volatile organic vapor.It can operate either in a flow-through or a recycle mode and is capable of accepting the urine vapor produced by a vapor compression distillation evaporator. Testing consisted of short preliminary and optimization test, an endurance test of 74 hours continuous operation, and recycle tests using both air and oxygen. The system was designed for a urine processing rate of 0.86 liters/hr; however, it was tested at rates up to 1.2 liter/hr. Untreated urine evaporated by an electrically heated evaporator was used. The quality of the recovered water meets the U.S. Drinking Water Standards, with the exception of a low pH. Accumulation of solids in the urine sludge is reduced to approximately 65% of the anticipated value.

Budinikas, P.↗

NASA NTRS1990

Mechanical testing of advanced coating system, volume 1

The Electron Beam Physical Vapor Deposition (EBPVD) coating material has a highly columnar microstructure, and as a result it was expected to have very low tensile strength. To be able to fabricate the required compression and tensile specimens, a substrate was required to provide structural integrity for the specimens. Substrate and coating dimensions were adjusted to provide sufficient sensitivity to resolve the projected loads carried by the EBPVD coating. The use of two distinctively different strain transducer systems, for tension and compression loadings, mandated two vastly different specimen geometries. Compression specimen and tensile specimen geometries are given. Both compression and tensile test setups are described. Data reduction mathematical models are given and discussed in detail as is the interpretation of the results. Creep test data is also given and discussed.

Cruse, T. A.↗

NASA NTRS2006

A Water Recovery System Evolved for Exploration

A new water recovery system designed towards fulfillment of NASA's Vision for Space Exploration is presented. This water recovery system is an evolution of the current state-of-the-art system. Through novel integration of proven technologies for air and water purification, this system promises to elevate existing technology to higher levels of optimization. The novel aspect of the system is twofold: Volatile organic contaminants will be removed from the cabin air via catalytic oxidation in the vapor phase, prior to their absorption into the aqueous phase, and vapor compression distillation technology will be used to process the condensate and hygiene waste streams in addition to the urine waste stream. Oxidation kinetics dictate that removal of volatile organic contaminants from the vapor phase is more efficient. Treatment of the various waste streams by VCD will reduce the load on the expendable ion exchange and adsorption media which follow, and on the aqueous-phase volatile removal assembly further downstream. Incorporating these advantages will reduce the weight, volume, and power requirements of the system, as well as resupply.

ORourke, Mary Jane E.↗

NASA NTRS1975

Vapor compression distillation module

A Vapor Compression Distillation (VCD) module was developed and evaluated as part of a Space Station Prototype (SSP) environmental control and life support system. The VCD module includes the waste tankage, pumps, post-treatment cells, automatic controls and fault detection instrumentation. Development problems were encountered with two components: the liquid pumps, and the waste tank and quantity gauge. Peristaltic pumps were selected instead of gear pumps, and a sub-program of materials and design optimization was undertaken leading to a projected life greater than 10,000 hours of continuous operation. A bladder tank was designed and built to contain the waste liquids and deliver it to the processor. A detrimental pressure pattern imposed upon the bladder by a force-operated quantity gauge was corrected by rearranging the force application, and design goals were achieved. System testing has demonstrated that all performance goals have been fulfilled.

Nuccio, P. P.↗

NASA NTRS1981

Mission concepts for Venus surface investigation

Mission concepts for the in situ investigation of the Venus atmosphere and surface in the period following the VOIR mission are discussed. The science issues in Venus exploration and possible means of meeting the scientific objectives are considered, including global mapping, surface composition determination, atmospheric composition determination and surface-atmosphere interactions. Particular attention is then given to the feasibility of buoyant stations for atmospheric observation, balloon-tether combinations for surface observations, and the active thermal control by a reversed Brayton cycle or a vapor compression cycle of a long-lived Venus lander. Of the concepts examined, it is found that only the balloon-tether system would be impractical for the mission outlined for it, while the other two concepts appear feasible.

Hoffman, S. J.↗

NASA NTRS1991

Transient performance of fan engine with water ingestion

In a continuing investigation on effects of rain-water ingestion into bypass fan engines, it is shown that the performance of axial-flow compressors and fans is fundamentally time-dependent during ingestion of water. A code named WINCOF-I has been developed for establishing the performance of axial-flow turbomachinery operating with air-water vapor-water droplet-water film mixture, Illustrative examples of predictions and effects are provided for the case of the air-compression system of a generic bypass fan engine. Utilizing performance maps so-generated, the effects of water ingestion into the generic engine have been determined under test cell conditions simulating ingestion, flight operation (altitude and flight Mach number), and power-demand setting.

Murthy, S. N. B.↗

NASA NTRS1991

Transient multidimensional analysis of nonconventional heat pipes with uniform and nonuniform heat distributions

A numerical analysis of transient heat pipe performance including nonconventional heat pipes with nonuniform heat distributions is presented. A body-fitted grid system was applied to a three-dimensional wall and wick model, which was coupled with a transient compressible quasi-one-dimensional vapor flow model. The numerical results were first compared with experimental data from cylindrical heat pipes with good agreement. Numerical calculations were then made for a leading edge heat pipe with localized high heat fluxes. Performance characteristics different from conventional heat pipes are illustrated and some operating limits concerning heat pipe design are discussed.

Cao, Y.↗