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Design of thermionic reactor power systems for nuclear electric propelled unmanned spacecraft
Conical radiator configuration requiring minimum parasitic launch support for thermionic reactor power system for a nuclear electric propelled Titan 3c/7
The SP-100 space nuclear power system development program and the NASA Civil Space Technology Initiative (CSTI) are discussed. The advanced technologies being developed for the CSTI high capacity nuclear reactor power system are outlined. The relationship between the CSTI and the Pathfinder project is considered.
During Phase II, the Engineering Development Phase, the SP-100 Project has defined and is pursuing a new approach to developing reliable power systems. The approach to developing such a system during the early technology phase is described along with some preliminary examples to help explain the approach. Developing reliable components to meet space reactor power system requirements is based on a top-down systems approach which includes a point design based on a detailed technical specification of a 100-kW power system. The SP-100 system requirements implicitly recognize the challenge of achieving a high system reliability for a ten-year lifetime, while at the same time using technologies that require very significant development efforts. A low-cost method for assessing reliability, based on an understanding of fundamental failure mechanisms and design margins for specific failure mechanisms, is being developed as part of the SP-100 Program.
Because of reports indicating improvements in the radiation tolerance of some electronic parts, a survey was recently performed by SP-100 project personnel to determine the advisability of revising SP-100 SRPS (space reactor power systems) allowable neutron and gamma dose rates in order to reduce the size and mass of the radiation shield and thereby achieve system mass reductions. The survey results indicate that recent developments to increase the radiation tolerance of a limited set of electronics parts do not justify increasing the allowable SP-100 dose rates for electronic components. Specifically, the recent improvements on a limited set of parts do not justify increasing the current SP-100 allowable specifications of 5 x 10 exp 5 rads gamma dose and 1 x 10 exp 13 neutrons/sq cm fluence. However, if the improvements of 108 rads for gammas and 10 exp 15 neutrons/sq cm can be extended to a wide range of parts, significant mass savings would result.
A review of the status of space nuclear reactor systems and their possible applications is presented. Such systems have been developed over the past twenty years and are capable of use in various military and civilian applications in the 5-1000-kWe power range. The capabilities and limitations of the currently proposed nuclear reactor systems are summarized. Statements of need are presented from DoD, DOE, and NASA. Safety issues are identified, and if they are properly addressed they should not pose a hindrance. Applications are summarized for the DoD, DOE, NASA, and the civilian community. These applications include both low- and high-altitude satellite surveillance missions, communications satellites, planetary probes, low- and high-power lunar and planetary base power systems, broadband global telecommunications, air traffic control, and high-definition television.
The effect of turbine-inlet temperature on rocket gross weight was investigated for three high-energy long-range rockets in order to explore the desirability of turbine cooling in rocket turbodrive applications. Temperatures above and below the maximum that is permissible in uncooled turbines were included. Turbine bleed rate and stage number were considered as independent variables. The gross weight of the hydrogen-reactor system was more sensitive to changes in turbine-inlet temperature than either the hydrogen-oxygen or the hydrogen-fluorine systems. Gross weight of the hydrogen-reactor system could be reduced by 2.6 percent by the use of cooling and a turbine-inlet temperature of 3000 R. The reductions in the first stages of the hydrogen-oxygen and hydrogen-fluorine systems were 0.7 and 0.2 percent, respectively. The effect of turbine-inlet temperature on rocket gross weight was small because the resulting turbine weight and bleed rate variations were small. Since these small gains must be balanced against considerations of greater cost, weight, and complexity as well as lessened reliability with a system utilizing a cooled turbine, none of the systems investigated showed gains warranting the use of turbine cooling.
The conceptual design of a nuclear space power system based on the ultrahigh temperature vapor core reactor with MHD energy conversion is presented. This UF4 fueled gas core cavity reactor operates at 4000 K maximum core temperature and 40 atm. Materials experiments, conducted with UF4 up to 2200 K, demonstrate acceptable compatibility with tungsten-molybdenum-, and carbon-based materials. The supporting nuclear, heat transfer, fluid flow and MHD analysis, and fissioning plasma physics experiments are also discussed.
An analytical model for hydrogen reduction of regolith was used to investigate the effects of several key variables on the energy and mass performance of reactors for a lunar in-situ resource utilization oxygen production plant. Reactor geometry, reaction time, number of reactors, heat recuperation, heat loss, and operating pressure were all studied to guide hardware designers who are developing future prototype reactors. The effects of heat recuperation where the incoming regolith is pre-heated by the hot spent regolith before transfer was also investigated for the first time. In general, longer reaction times per batch provide a lower overall energy, but also result in larger and heavier reactors. Three reactors with long heat-up times results in similar energy requirements as a two-reactor system with all other parameters the same. Three reactors with heat recuperation results in energy reductions of 20 to 40 percent compared to a three-reactor system with no heat recuperation. Increasing operating pressure can provide similar energy reductions as heat recuperation for the same reaction times.
Gaseous control systems for spaceborne nuclear reactors noting advantages over traditional control rods
ZrH reactor program and multikilowatt space oriented thermoelectric power conversion systems
This paper describes the concept and preliminary component testing of a gas-cooled, UN-fueled, pin-type reactor which uses He/Xe gas that goes directly into a recuperated Brayton system to produce electricity for nuclear electric propulsion. This Direct-Drive Gas-Cooled Reactor (DDG) is designed to be subcritical under water or wet- sand immersion in case of a launch accident. Because the gas-cooled reactor can directly drive the Brayton turbomachinery, it is possible to configure the system such that there are no external surfaces or pressure boundaries that are refractory metal, even though the gas delivered to the turbine is 1144 K. The He/Xe gas mixture is a good heat transport medium when flowing, and a good insulator when stagnant. Judicious use of stagnant cavities as insulating regions allows transport of the 1144-K gas while keeping all external surfaces below 900 K. At this temperature super-alloys (Hastelloy or Inconel) can be used instead of refractory metals. Super-alloys reduce the technology risk because they are easier to fabricate than refractory metals, we have a much more extensive knowledge base on their characteristics, and, because they have a greater resistance to oxidation, system testing is eased. The system is also relatively simple in its design: no additional coolant pumps, heat exchanger, or freeze-thaw systems are required. Key to success of this concept is a good knowledge of the heat transfer between the fuel pins and the gas, as well as the pressure drop through the system. This paper describes preliminary testing to obtain this key information, as well as experience in demonstrating electrically heated testing of simulated reactor components.
Conductively coupling the thermoelectric converter to the heat source and the radiator maximizes the utilization of the reactor and radiator temperatures and thereby minimizes the power system weight. This paper presents the design for the converter and the individual thermoelectric cells that are the building block modules for the converter. It also summarizes progress on the fabrication of initial cells and the results obtained from the preparation of a manufacturing plan. The design developed for the SP-100 system utilizes thermally conductive compliant pads that can absorb the displacement and distortion caused by the combinations of temperatures and thermal expansion coefficients. The converter and cell designs provided a 100 kWe system which met the system requirements. Initial cells were fabricated and tested.
A study to determine the feasibility of containing the fission products of a mobile reactor in the event of an impact is presented. The model simulated the reactor core, energy absorbing gamma shielding, neutron shielding and the containment vessel. It was impacted against an 18,000 pound reinforced concrete block at 1055 ft/sec. The model was significantly deformed and the concrete block demolished. No leaks were detected nor were any cracks observed in the model after impact.
A comparative analysis of health and safety risks is presented for the Satellite Power System and five alternative baseload electrical generation systems: a low-Btu coal gasification system with an open-cycle gas turbine combined with a steam topping cycle; a light water fission reactor system without fuel reprocessing; a liquid metal fast breeder fission reactor system; a central station terrestrial photovoltaic system; and a first generation fusion system with magnetic confinement. For comparison, risk from a decentralized roof-top photovoltaic system with battery storage is also evaluated. Quantified estimates of public and occupational risks within ranges of uncertainty were developed for each phase of the energy system. The potential significance of related major health and safety issues that remain unquantitied are also discussed.
Non-nuclear testing can be a valuable tool in the development of a space nuclear power system, providing system characterization data and allowing one to work through various fabrication, assembly and integration issues without the cost and time associated with a full ground nuclear test. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Testing with non-optimized heater elements allows one to assess thermal, heat transfer. and stress related attributes of a given system, but fails to demonstrate the dynamic response that would be present in an integrated, fueled reactor system. High fidelity thermal simulators that match both the static and the dynamic fuel pin performance that would be observed in an operating, fueled nuclear reactor can vastly increase the value of non-nuclear test results. With optimized simulators, the integration of thermal hydraulic hardware tests with simulated neutronic response provides a bridge between electrically heated testing and fueled nuclear testing. By implementing a neutronic response model to simulate the dynamic response that would be expected in a fueled reactor system, one can better understand system integration issues, characterize integrated system response times and response characteristics and assess potential design improvements at relatively small fiscal investment. Initial conceptual thermal simulator designs are determined by simple one-dimensional analysis at a single axial location and at steady state conditions; feasible concepts are then input into a detailed three-dimensional model for comparison to expected fuel pin performance. Static and dynamic fuel pin performance for a proposed reactor design is determined using SINDA/FLUINT thermal analysis software, and comparison is made between the expected nuclear performance and the performance of conceptual thermal simulator designs. Through a series of iterative analyses, a conceptual high fidelity design is developed: this is followed by engineering design, fabrication, and testing to validate the overall design process. Test results presented in this paper correspond to a "first cut" simulator design for a potential liquid metal (NaK) cooled reactor design that could be applied for Lunar surface power. Proposed refinements to this simulator design are also presented.
The overall objective of this project was to develop a novel carbothermal reduction process for production of oxygen from lunar ilmenite. The specific objective was to use a reaction sequence in which a wide variety of carbonaceous compounds (including carbonaceous wastes) can be used as reducing agents. During the first phase, two reactor systems were designed, constructed, and operated to study the reaction fundamental important in this process. One system is a small fluidized bed, and the other is a thermo-gravimetric reactor system. Preliminary experiments on synthetic ilmenite are conducted to study the effect of carbon type, carbon loading, temperature, and gas flow rate. Results indicate that a reaction path based on carbon gasification can be used to promote the overall kinetics. A unique temperature and concentration-programmed reaction procedure was being developed for rapid parametric study of the process.
A nuclear reactor vessel is supported by a Z-ring and a box ring girder. The two proposed structural configurations to transmit the loads from the Z-ring and the box ring girder to the foundation are shown. The cantilever concrete ledge transmitting the load from the Z-ring and the box girder via the cavity wall to the foundation is shown, along with the loads being transmitted through one of the six steel columns. Both of these two supporting systems were analyzed by using rigid format 9 of NASTRAN for dynamic loads, and the thermal stresses were analyzed by AXISOL. The six column configuration was modeled by a combination of plate and bar elements, and the concrete cantilever ledge configuration was modeled by plate elements. Both configurations were found structurally satisfactory; however, nonstructural considerations favored the concrete cantilever ledge.