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Nuclear Engine System Simulation (NESS). Volume 1: Program user's guide

A Nuclear Thermal Propulsion (NTP) engine system design analysis tool is required to support current and future Space Exploration Initiative (SEI) propulsion and vehicle design studies. Currently available NTP engine design models are those developed during the NERVA program in the 1960's and early 1970's and are highly unique to that design or are modifications of current liquid propulsion system design models. To date, NTP engine-based liquid design models lack integrated design of key NTP engine design features in the areas of reactor, shielding, multi-propellant capability, and multi-redundant pump feed fuel systems. Additionally, since the SEI effort is in the initial development stage, a robust, verified NTP analysis design tool could be of great use to the community. This effort developed an NTP engine system design analysis program (tool), known as the Nuclear Engine System Simulation (NESS) program, to support ongoing and future engine system and stage design study efforts. In this effort, Science Applications International Corporation's (SAIC) NTP version of the Expanded Liquid Engine Simulation (ELES) program was modified extensively to include Westinghouse Electric Corporation's near-term solid-core reactor design model. The ELES program has extensive capability to conduct preliminary system design analysis of liquid rocket systems and vehicles. The program is modular in nature and is versatile in terms of modeling state-of-the-art component and system options as discussed. The Westinghouse reactor design model, which was integrated in the NESS program, is based on the near-term solid-core ENABLER NTP reactor design concept. This program is now capable of accurately modeling (characterizing) a complete near-term solid-core NTP engine system in great detail, for a number of design options, in an efficient manner. The following discussion summarizes the overall analysis methodology, key assumptions, and capabilities associated with the NESS presents an example problem, and compares the results to related NTP engine system designs. Initial installation instructions and program disks are in Volume 2 of the NESS Program User's Guide.

Pelaccio, Dennis G.↗

Modeling of Cryogenic Heated-Tube Flow Boiling Experiments of Nitrogen and Methane with the Generalized Fluid System Simulation Program

Accurate modeling of cryogenic boiling heat transfer is vital for the development of extended-duration space missions. Such missions may require the transfer of cryogenic propellants from in-space storage depots or the cooling of nuclear reactors. Purdue University in collaboration with NASA has assembled a database of cryogenic flow boiling data points from heated-tube experiments dating back to 1959, which has been used to develop new flow boiling correlations specifically for cryogens. Computational models of several of these experiments have been constructed in the Generalized Fluid System Simulation Program (GFSSP), a network flow code developed at NASA’s Marshall Space Flight Center. The new Purdue-developed correlations cover the full boiling curve: onset of nucleate boiling, nucleate boiling, critical heat flux, and film boiling. These correlations have been coded into GFSSP user subroutines. The fluids modeled are methane and nitrogen. Predictions of wall temperature and heat transfer coefficient are presented and compared to the test data.

Multi-Phase Flow↗

Modeling of Cryogenic Heated-Tube Flow Boiling Experiments of Hydrogen and Helium With the Generalized Fluid System Simulation Program

Accurate modeling of cryogenic boiling heat transfer is vital for the development of extended-duration space missions. Such missions may require the transfer of cryogenic propellants from in-space storage depots or the cooling of nuclear reactors. Purdue University in collaboration with NASA has assembled a database of cryogenic flow boiling data points from heated-tube experiments dating back to 1959, which has been used to develop new flow boiling correlations specifically for cryogens. Computational models of several of these experiments have been constructed in the Generalized Fluid System Simulation Program (GFSSP), a network flow code developed at NASA’s Marshall Space Flight Center. The new Purdue-developed universal correlations cover the full boiling curve: onset of nucleate boiling, nucleate boiling, critical heat flux, and film boiling. These correlations have been coded into GFSSP user subroutines. The fluids modeled in this study are liquid hydrogen and liquid helium. Predictions of local wall temperature and pressure drop are presented and compared to the test data.

multi-phase flow↗

A 1055 ft/sec impact test of a two foot diameter model nuclear reactor containment system without fracture

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.

Puthoff, R. L.↗

Propulsion and Power Technologies for the NASA Exploration Vision: A Research Perspective

Future propulsion and power technologies for deep space missions are profiled in this viewgraph presentation. The presentation includes diagrams illustrating possible future travel times to other planets in the solar system. The propulsion technologies researched at Marshall Space Flight Center (MSFC) include: 1) Chemical Propulsion; 2) Nuclear Propulsion; 3) Electric and Plasma Propulsion; 4) Energetics. The presentation contains additional information about these technologies, as well as space reactors, reactor simulation, and the Propulsion Research Laboratory (PRL) at MSFC.

Litchford, Ron J.↗

Measurements of seeded argon-hydrogen plasma properties.

Seeded argon-hydrogen plasmas have been produced at Georgia Tech in order to experimentally measure composition, temperature, radiant heat output and opacity. The plasma, seeded with submicron tungsten particles, simulates the propellant of a gaseous core nuclear rocket. These measurements are needed to predict the dynamic behavior of the operating gas core reactor. The temperature range in which the seed has vaporized but the hydrogen itself has not yet become opaque is known as the seed-hydrogen opacity window. Preliminary opacity data in this temperature range will be presented.

Benns, R. A.↗

Nuclear light bulb propellant heating simulation using a tungsten/argon aerosol and radiation from a dc arc surrounded by a segmented mirror cavity

Experiments were conducted to simulate radiant heating of the propellant stream of a nuclear light bulb engine to obtain high bulk exit temperatures in the flowing simulated propellant stream by absorption of large fractions of the incident thermal radiation. A high-power, vortex-stabilized dc arc within an uncooled fused silica tube was used as the radiant energy source. It was surrounded by a mirror system to increase the radiation incident on the simulated propellant. The 12.7-cm-long by 2.3-cm-wide, diverging-duct test section had a transparent front wall and a reflecting rear wall. The central stream of seeded gas, a tungsten-particle/argon aerosol, had unseeded argon buffer layers on both sides to prevent coating of the duct walls. Arc operating times were approximately 0.5 sec with power levels up to 780 kW. Bulk exit temperatures were measured using a calorimeter downstream of the duct. The maximum simulated propellant bulk exit temperature obtained was 4515 K, compared with 3860 K in previous tests, 3300 to 3700 K expected in in-reactor tests in the Nuclear Furnace, and 6660 K in the reference nuclear light bulb engine. The maximum temperature in these tests was limited primarily by the amount of radiation incident on the test section (determined by the arc operating characteristics and the effectiveness of the mirror cavity).

Klein, J. F.↗

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Upgrade Activities

A key technology element in Nuclear Thermal Propulsion is the development of fuel materials and components which can withstand extremely high temperatures while being exposed to flowing hydrogen. NTREES provides a cost effective method for rapidly screening of candidate fuel components with regard to their viability for use in NTR systems. The NTREES is designed to mimic the conditions (minus the radiation) to which nuclear rocket fuel elements and other components would be subjected to during reactor operation. The NTREES consists of a water cooled ASME code stamped pressure vessel and its associated control hardware and instrumentation coupled with inductive heaters to simulate the heat provided by the fission process. The NTREES has been designed to safely allow hydrogen gas to be injected into internal flow passages of an inductively heated test article mounted in the chamber.

Emrich, William↗

Off-design temperature effects on nuclear fuel pins for an advanced space-power-reactor concept

An exploratory out-of-reactor investigation was made of the effects of short-time temperature excursions above the nominal operating temperature of 990 C on the compatibility of advanced nuclear space-power reactor fuel pin materials. This information is required for formulating a reliable reactor safety analysis and designing an emergency core cooling system. Simulated uranium mononitride (UN) fuel pins, clad with tungsten-lined T-111 (Ta-8W-2Hf) showed no compatibility problems after heating for 8 hours at 2400 C. At 2520 C and above, reactions occurred in 1 hour or less. Under these conditions free uranium formed, redistributed, and attacked the cladding.

Bowles, K. J.↗

The chemical effects of the Martian environment on power system component materials: A theoretical approach

In the foreseeable future, an expedition may be undertaken to explore the planet Mars. Some of the power source options being considered for such a mission are photovoltaics, regenerative fuel cells and nuclear reactors. In addition to electrical power requirements, environmental conditions en route to Mars, in the planetary orbit and on the Martian surface must be simulated and studied in order to anticipate and solve potential problems. Space power systems components such as photovoltaic arrays, radiators, and solar concentrators may be vulnerable to degradation in the Martian environment. Natural characteristics of Mars which may pose a threat to surface power systems include high velocity winds, dust, ultraviolet radiation, large daily variation in temperature, reaction to components of the soil, atmosphere and atmospheric condensates as well as synergistic combinations. Most of the current knowledge of the characteristics of the Martian atmosphere and soil composition was obtained from the Viking 1 and 2 missions in 1976. A theoretical study is presented which was used to assess the effects of the Martian atmospheric conditions on the power systems components. A computer program written at NASA-Lewis for combustion research that uses a free energy minimization technique was used to calculate chemical equilibrium for assigned thermodynamic states of temperature and pressure. The power system component materials selected for this study include: silicon dioxide, silicon, carbon, copper, and titanium. Combinations of environments and materials considered include: (1) Mars atmosphere with power surface material, (2) Mars atmosphere and dust component with power surface material, and (3) Mars atmosphere and hydrogen peroxide or superoxide or superoxide with power system material. The chemical equilibrium calculations were performed at a composition ratio (oxidant to reactant) of 100. The temperature for the silicon dioxide material and silicon, which simulate photovoltaic cells, were 300 and 400 K; for carbon, copper and titanium, which simulate radiator surfaces, 300, 500, and 1000 K. All of the systems were evaluated at pressures of 700, 800, and 900 Pa, which stimulate the Martian atmosphere.

Perez-Davis, Marla E.↗

Nuclear modules for space electric propulsion

Analysis of interplanetary cargo and piloted missions requires calculations of the performances and masses of subsystems to be integrated in a final design. In a preliminary and scoping stage the designer needs to evaluate options iteratively by using fast computer simulations. The Oak Ridge National Laboratory (ORNL) has been involved in the development of models and calculational procedures for the analysis (neutronic and thermal hydraulic) of power sources for nuclear electric propulsion. The nuclear modules will be integrated into the whole simulation of the nuclear electric propulsion system. The vehicles use either a Brayton direct-conversion cycle, using the heated helium from a NERVA-type reactor, or a potassium Rankine cycle, with the working fluid heated on the secondary side of a heat exchanger and lithium on the primary side coming from a fast reactor. Given a set of input conditions, the codes calculate composition. dimensions, volumes, and masses of the core, reflector, control system, pressure vessel, neutron and gamma shields, as well as the thermal hydraulic conditions of the coolant, clad and fuel. Input conditions are power, core life, pressure and temperature of the coolant at the inlet of the core, either the temperature of the coolant at the outlet of the core or the coolant mass flow and the fluences and integrated doses at the cargo area. Using state-of-the-art neutron cross sections and transport codes, a database was created for the neutronic performance of both reactor designs. The free parameters of the models are the moderator/fuel mass ratio for the NERVA reactor and the enrichment and the pitch of the lattice for the fast reactor. Reactivity and energy balance equations are simultaneously solved to find the reactor design. Thermalhydraulic conditions are calculated by solving the one-dimensional versions of the equations of conservation of mass, energy, and momentum with compressible flow.

Difilippo, F. C.↗

SAFSIM overview

An overview of the systems analysis flow simulator (SAFSIM) computer program is provided. SAFSIM is being developed at Sandia National Laboratories and is currently funded by the Air Force Space Nuclear Thermal Propulsion (SNTP) Program. SAFSIM is a general purpose, Fortran computer program to simulate the integrated performance of complex systems involving fluid mechanics, heat transfer, and reactor dynamics. SAFSIM provides sufficient versatility to allow the engineering simulation of almost any system. SAFSIM is based on a 1-D finite element model and provides the analyst with approximate solutions to complex problems.

Dobranich, Dean↗

Overview of space power electronic's technology under the CSTI High Capacity Power Program

The Civilian Space Technology Initiative (CSTI) is a NASA Program targeted at the development of specific technologies in the areas of transportation, operations and science. Each of these three areas consists of major elements and one of the operation's elements is the High Capacity Power element. The goal of this element is to develop the technology base needed to meet the long duration, high capacity power requirements for future NASA initiatives. The High Capacity Power element is broken down into several subelements that includes energy conversion in the areas of the free piston Stirling power converter and thermoelectrics, thermal management, power management, system diagnostics, and environmental compatibility and system's lifetime. A recent overview of the CSTI High capacity Power element and a description of each of the program's subelements is given by Winter (1989). The goals of the Power Management subelement are twofold. The first is to develop, test, and demonstrate high temperature, radiation-resistant power and control components and circuits that will be needed in the Power Conditioning, Control and Transmission (PCCT) subsystem of a space nuclear power system. The results obtained under this goal will also be applicable to the instrumentation and control subsystem of a space nuclear reactor. These components and circuits must perform reliably for lifetimes of 7-10 years. The second goal is to develop analytical models for use in computer simulations of candidate PCCT subsystems. Circuits which will be required for a specific PCCT subsystem will be designed and built to demonstrate their performance and, also, to validate the analytical models and simulations. The tasks under the Power Management subelement will now be described in terms of objectives, approach and present status of work.

Schwarze, Gene E.↗

Arc-Heater Facility for Hot Hydrogen Exposure of Nuclear Thermal Rocket Materials

A hyper-thermal environment simulator is described for hot hydrogen exposure of nuclear thermal rocket material specimens and component development. This newly established testing capability uses a high-power, multi-gas, segmented arc-heater to produce high-temperature pressurized hydrogen flows representative of practical reactor core environments and is intended to serve. as a low cost test facility for the purpose of investigating and characterizing candidate fueUstructura1 materials and improving associated processing/fabrication techniques. Design and development efforts are thoroughly summarized, including thermal hydraulics analysis and simulation results, and facility operating characteristics are reported, as determined from a series of baseline performance mapping tests.

Litchford, Ron J.↗

A Computational Fluid Dynamic and Heat Transfer Model for Gaseous Core and Gas Cooled Space Power and Propulsion Reactors

A computational model based on the axisymmetric, thin-layer Navier-Stokes equations is developed to predict the convective, radiation and conductive heat transfer in high temperature space nuclear reactors. An implicit-explicit, finite volume, MacCormack method in conjunction with the Gauss-Seidel line iteration procedure is utilized to solve the thermal and fluid governing equations. Simulation of coolant and propellant flows in these reactors involves the subsonic and supersonic flows of hydrogen, helium and uranium tetrafluoride under variable boundary conditions. An enthalpy-rebalancing scheme is developed and implemented to enhance and accelerate the rate of convergence when a wall heat flux boundary condition is used. The model also incorporated the Baldwin and Lomax two-layer algebraic turbulence scheme for the calculation of the turbulent kinetic energy and eddy diffusivity of energy. The Rosseland diffusion approximation is used to simulate the radiative energy transfer in the optically thick environment of gas core reactors. The computational model is benchmarked with experimental data on flow separation angle and drag force acting on a suspended sphere in a cylindrical tube. The heat transfer is validated by comparing the computed results with the standard heat transfer correlations predictions. The model is used to simulate flow and heat transfer under a variety of design conditions. The effect of internal heat generation on the heat transfer in the gas core reactors is examined for a variety of power densities, 100 W/cc, 500 W/cc and 1000 W/cc. The maximum temperature, corresponding with the heat generation rates, are 2150 K, 2750 K and 3550 K, respectively. This analysis shows that the maximum temperature is strongly dependent on the value of heat generation rate. It also indicates that a heat generation rate higher than 1000 W/cc is necessary to maintain the gas temperature at about 3500 K, which is typical design temperature required to achieve high efficiency in the gas core reactors. The model is also used to predict the convective and radiation heat fluxes for the gas core reactors. The maximum value of heat flux occurs at the exit of the reactor core. Radiation heat flux increases with higher wall temperature. This behavior is due to the fact that the radiative heat flux is strongly dependent on wall temperature. This study also found that at temperature close to 3500 K the radiative heat flux is comparable with the convective heat flux in a uranium fluoride failed gas core reactor.

Anghaie, S.↗

A 640 foot per second impact test of a two foot diameter model nuclear reactor containment system without fracture

An impact test was conducted on an 1142 pound 2 foot diameter sphere model. The purpose of this test was to determine the feasibility of containing the fission products of a mobile reactor in an impact. 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. The model was significantly deformed and the concrete block demolished. No leaks were detected nor cracks observed in the model after impact.

Puthoff, R. L.↗