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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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NASA NTRS2015

Source Contaminant Control for the Heat Melt Compactor

The Logistics Reduction and Repurposing project includes the heat melt compactor (HMC), a device that compacts waste containing plastic into a tile that will minimize volume, and may be used as materials for radiation shielding. During the process, a small purge gas stream is directed through the HMC chamber to transport out gasses and humidity released from the process. NASA Marshall Space Flight Center is tasked with developing and delivering a contamination control system to clean the purge gas prior to exhausting it back into the cabin for crew inhalation.

Roman, Monsi↗

NASA NTRS2020

Development of an Adsorption System for the Trash Compaction Processing System designed for operation in the International Space Station Express Rack

A water recovery system that utilizes adsorption to work with the Trash Compaction Processing System, formerly known as the Heat Melt Compactor, is being designed at NASA Ames Research Center as an option to current state of the art micro-gravity water management systems and contaminant control systems used in space. The adsorption system will be used in conjunction with the International Space Station Vacuum Exhaust system to avoid both the complexities of gas liquid phase separation in micro-gravity and venting of Trash Compaction Processing System effluents to the spacecraft cabin. The adsorption system will allow the water and gaseous effluents generated during the Trash Compaction System operation to be removed in a matter that meets the Vacuum Exhaust System venting rate requirements. The Trash Compaction Processing System is planned to fly as a Technology Demonstration on the International Space Station in the space station EXPRESS Rack facility. This paper describes the trade space that the adsorption system must operate in using the EXPRESS Rack facilities resources including the use of the Space Station Vacuum Exhaust System. Also described in this paper are design solutions to allow the adsorption system to function within the Express Rack and Vacuum Exhaust System Parameters.

Heat Melt Compactor↗

NASA NTRS1983

The study of integrated coal-gasifier molten carbonate fuel cell systems

A novel integration concept for a coal-fueled coal gasifier-molten carbonate fuel cell power plant was studied. Effort focused on determining the efficiency potential of the concept, design, and development requirements of the processes in order to achieve the efficiency. The concept incorporates a methane producing catalytic gasifier of the type previously under development by Exxon Research and Development Corp., a reforming molten carbonate fuel cell power section of the type currently under development by United Technologies Corp., and a gasifier-fuel cell recycle loop. The concept utilizes the fuel cell waste heat, in the form of hydrogen and carbon monoxide, to generate additional fuel in the coal gasifier, thereby eliminating the use of both an O2 plant and a stream bottoming cycle from the power plant. The concept has the potential for achieving coal-pile-to-busbar efficiencies of 50-59%, depending on the process configuration and degree of process configuration and degree of process development requirements. This is significantly higher than any previously reported gasifier-molten carbonate fuel cell system.

Source record↗

NASA NTRS1973

Domestic wash-water reclamation using an aerospace-developed water recovery subsystem

A prototype aerospace distillation water recovery subsystem was tested to determine its capability to recover potable water from domestic wash water. A total of 0.0994 cu m (26.25 gallons) of domestic wash water was processed over a 7-day period at an average process rate of 0.0146 cu m per day (3.85 gallons per day). The subsystem produced water that met all United States Public Health Standards for drinking water with the exception of two standards which could not be analyzed at the required sensitivity levels. Average energy consumption for this evaluation to maintain both the recovery process and microbial control in the recovered water was approximately 3366 kilowatt-hours per cubic meter (12.74 kilowatt-hours per gallon) of water recovered. This condition represents a worst case energy consumption since no attempt was made to recover heat energy in the subsystem. An ultraviolet radiation cell installed in the effluent line of the subsystem was effective in controlling coliform micro-organisms within acceptable levels for drinking water. The subsystem recovered virtually 100 percent of the available water in the waste-water process. In addition, the subsystem removed 99.6 percent and 98.3 percent of the surfactants and phosphate, respectively, from the wash water.

Hall, J. B., Jr.↗

NASA NTRS1983

Detailed performance analysis of the A.A.D. - concept B

New concepts for engine performance improvement are seen through the adoption of heat regeneration techniques; advanced methods to enhance the combustion; and higher efficiency air handling machinery, such as the positive displacement helical screw expander and compressor. Each of these concepts plays a particular role in engine performance improvement. First regeneration has a great potential for achieving higher engine thermal efficiency through the recovery of waste energy. Although the concept itself is not new (this technique is used in the gas turbine), the application to reciprocating internal combustion engines is quite unusual and presents conceptual difficulties. The second important area is better control of the combustion process in terms of heat transfer characteristics, combustion products, and heat release rate. The third area for performance improvement is in the adoption of high efficiency air handling machinery. In particular, positive displacement helical expander and compressor exhibit an extremely high efficiency over a wide range of operating conditions.

Sekar, R.↗

NASA NTRSDate not supplied

Voxel Based Three-Dimensional Topology Optimization of Heat Exchanger Fins

Increasing interest in novel aircraft propulsion systems and potential for unwanted heat generation, or capture and reuse of waste heat, may require increasingly lightweight and high performing heat exchangers. Advances in manufacturing technologies have shown potential to create complex designs, but design tools need more flexibility. This study utilizes genetic algorithm-driven topology optimization to develop high performance heat exchanger fins for critical applications such as aerospace. The solid domain is generated using voxel representation where a voxel value of 1 indicates the solid domain and a voxel value of 0 refers to the fluid domain. The use of voxel representation somewhat matches the digitization of a model that is required to fabricate using additive manufacturing, and also allows for a highly unconstrained geometry. To test the topology optimization approach, a three-dimensional(3D)baseline offset strip fin geometry in steady laminar flow(Reynolds number = 215)with conjugate heat transfer(simultaneous solution of solid and fluid temperature fields)is optimized. New designs are generated using the genetic algorithm (GA) and sent to evaluation by the CFD software OpenFOAM; then the GA sorts and selects the reproduction pool for the following generation. This process is repeated for 60 generations. The study also investigates the effect off in material on the performance of the GA and the resulting designs. The results show that the optimal designs have overall performance improvement of 18% relative to the baseline. Additionally, a fin constructed of a lower conductivity material (such as an Inconel super alloy that might be necessary for waste heat recovery applications)results in lower overall performance improvement (11%)and optimal designs with higher pressure drop relative to their baseline, and relative to optimal designs produced using higher conductivity materials.

3D Optimization↗

NASA NTRS1980

Analysis of nuclear waste disposal in space, phase 3. Volume 2: Technical report

The options, reference definitions and/or requirements currently envisioned for the total nuclear waste disposal in space mission are summarized. The waste form evaluation and selection process is documented along with the physical characteristics of the iron nickel-base cermet matrix chosen for disposal of commercial and defense wastes. Safety aspects of radioisotope thermal generators, the general purpose heat source, and the Lewis Research Center concept for space disposal are assessed as well as the on-pad catastrophic accident environments for the uprated space shuttle and the heavy lift launch vehicle. The radionuclides that contribute most to long-term risk of terrestrial disposal were determined and the effects of resuspension of fallout particles from an accidental release of waste material were studied. Health effects are considered. Payload breakup and rescue technology are discussed as well as expected requirements for licensing, supporting research and technology, and safety testing.

Rice, E. E.↗

NASA NTRS1996

Advanced waste management technology evaluation

The purpose of this program is to evaluate the feasibility of steam reforming spacecraft wastes into simple recyclable inorganic salts, carbon dioxide and water. Model waste compounds included cellulose, urea, methionine, Igapon TC-42, and high density polyethylenes. These are compounds found in urine, feces, hygiene water, etc. The gasification and steam reforming process used the addition of heat and low quantities of oxygen to oxidize and reduce the model compounds.The studied reactions were aimed at recovery of inorganic residues that can be recycled into a closed biologic system. Results indicate that even at very low concentrations of oxygen (less than 3%) the formation of a carbonaceous residue was suppressed. The use of a nickel/cobalt reforming catalyst at reaction temperature of 1600 degrees yielded an efficient destruction of the organic effluents, including methane and ammonia. Additionally, the reforming process with nickel/cobalt catalyst diminished the noxious odors associated with butyric acid, methionine and plastics.

Couch, H.↗

NASA NTRS2018

Climate Change Impacts on Agriculture: Challenges, Opportunities, and AgMIP Frameworks for Foresight

Agricultural systems are currently undergoing rapid shifts owing to socioeconomic development, technological change, population growth, economic opportunity, evolving demand for commodities, and the need for sustainability amid global environmental change. It is not sufficient to maintain current harvest levels; rather, there is a need to rapidly increase production in light of a population growing to nearly 10 billion by mid-century and to more than 11 billion by 2100 (FAO, 2016; UN, 2016; Popkin et al., 2012). Current and future agricultural systems are additionally burdened by human-caused climate change, the result of accumulating greenhouse gas and aerosol emissions, ecological destruction, and land use changes that have altered the chemical composition of Earth’s atmosphere and trapped energy in the Earth system (IPCC, 2013; Porter et al., 2014). This increased energy has already raised average surface temperatures by approximately 1 degree Centigrade (GISTEMP Team, 2017; Hansen et al., 2010), leading early on to the term “global warming,” but this phenomenon is now more accurately referred to as “climate change” because it also modifies atmospheric circulation, adjusts regional and seasonal precipitation patterns, and shifts the distribution and characteristics of extreme events (Bindoff et al., 2013; Collins et al., 2013). Food and health systems face increasing risk owing to progressive climate change now manifesting itself as more frequent, severe extreme weather events—heat waves, droughts, and floods (IPCC, 2013). Often without warning, weather-related shocks can have catastrophic and reverberating impacts on the increasingly exposed global food system—through production, processing, distribution, retail, disposal, and waste. Simultaneously, malnutrition and ill health are arising from lack of access to nutritious food, exacerbated in crises such as food price spikes or shortages. For some countries, particularly import-dependent low-income countries, weather shocks and price spikes can lead to social unrest, famine, and migration.

Ruane, Alex C.↗

NASA NTRS2014

Central Africa Energy: Utilizing NASA Earth Observations to Explore Flared Gas as an Energy Source Alternative to Biomass in Central Africa

Much of Central Africa's economy is centered on oil production. Oil deposits lie below vast amounts of compressed natural gas. The latter is often flared off during oil extraction due to a lack of the infrastructure needed to utilize it for productive energy generation. Though gas flaring is discouraged by many due to its contributions to greenhouse emissions, it represents a waste process and is rarely tracked or recorded in this region. In contrast to this energy waste, roughly 80% of Africa's population lacks access to electricity and in turn uses biomass such as wood for heat and light. In addition to the dangers incurred from collecting and using biomass, the practice commonly leads to ecological change through the acquisition of wood from forests surrounding urban areas. The objective of this project was to gain insight on domestic energy usage in Central Africa, specifically Angola, Gabon, and the Republic of Congo. This was done through an analysis of deforestation, an estimation of gas flared, and a suitability study for the infrastructure needed to realize the natural gas resources. The energy from potential natural gas production was compared to the energy equivalent of the biomass being harvested. A site suitability study for natural gas pipeline routes from flare sites to populous locations was conducted to assess the feasibility of utilizing natural gas for domestic energy needs. Analyses and results were shared with project partners, as well as this project's open source approach to assessing the energy sector. Ultimately, Africa's growth demands energy for its people, and natural gas is already being produced by the flourishing petroleum industry in numerous African countries. By utilizing this gas, Africa could reduce flaring, recuperate the financial and environmental loss that flaring accounts for, and unlock a plentiful domestic energy source for its people. II. Introduction Background Africa is home to numerous burgeoning economies; a significant number rely on oil production as their primary source of revenue. Relative to its size and population density, the continent has a wealth of natural resources, including oil and natural gas deposits. The exploration of these resources is not a new endeavor, but rather one that spans decades, up to a century in some places. Their resources, if realized, could provide a great means of economic and social mobility for the people of Africa. Currently, Africa represents about 12 % of the energy market, yet at the same time, consumes only 3 % of the world's energy (Kasekende 2009). The higher

Jones, Amber↗

NASA NTRS2021

Aqua Factorem: Ultra Low Energy Lunar Water Extraction

We propose a new method we call Aqua Factorem to extract lunar water. It will drastically reduce energy and complexity of lunar mining operations helping to establish this industry. Other methods to extract water from the regolith are based on phase change, pumping energy into the regolith to sublimate the ice into vapor, then capturing the vapor, re-freezing it, and hauling the solid ice to a chemical processor where it is converted again into vapor for purification then electrolysis. This requires transporting high power into the permanently shadowed regions (PSRs) not only to vaporize the ice in situ in the soil but to heat the surrounding soil itself, which is wasted energy. Still other methods are based on strip mining and hauling the resource along with slag (the unwanted silicates, which constitutes about 95% of the mass), to a processing unit that is located outside the PSRs. That may be a simpler architecture but is generally not favored because hauling 49,000 t of regolith over many kilometers yearly to produce the projected demand of 2,450 t of propellant would be terribly difficult and expensive with high risk that the vehicles will get stuck driving with such loads across the unprepared regolith. We propose an alternative to both of these approaches, taking advantage of the processing that the unique lunar geology has already performed. Micrometeoroid bombardment has already broken most solid material in the upper part of the regolith into fine grains. This includes solid material of all compositions, including the ice, which is as hard as granite at PSR temperatures and is therefore essentially another type of rock. These ice grains are intermixed with all the other minerals, so a simple, ultra-low-energy grain-sorting process can extract the ice without phase change. As another benefit it can extract the 1 wt% free metal known to be in lunar soil, again with very little energy. The ice can then be hauled to the chemical processing unit in solid phase and converted into rocket propellant. We estimate the 800 kW power needed for thermal extraction can be reduced to less than 100 watts using the new method. This affects the entire architecture of the mining operation producing extensive economic benefit, which we will quantify in this study. We will study it in the context of a mission to mine propellants commercially for space tugs that boost commercial communication satellites from Geosynchronous Transfer Orbit (GTO) to Geostationary Orbit (GEO) then return to the lunar surface for refueling. This simple architecture requires the minimum number of in-space elements, and notably does not require an in-space propellant depot, so it provides the lowest cost and lowest risk startup for a commercial operation. The study will also test the innovative Aqua Factorem process through laboratory experiments, and this will produce basic insights into the handling of lunar resources.

lunar↗

NASA NTRS2000

Near-Net-Shape Processing of Sintered Fibrous Ceramics Achieved

A variety of sintered fibrous ceramic (SFC) materials have been developed over the last 50 years as thermal barrier materials for reentry applications. SFC materials typically exhibit very low thermal conductivities combined with low densities and good thermal stability up to 2500 F. These materials have flown successfully on the space shuttle orbiters since the 1960's. More recently, the McDonnell Douglas Corporation successfully used SFC tiles as a heat shield on the underside of its DC X test vehicle. For both of these applications, tiles are machined from blocks of a specific type of SFC called an alumina-enhanced thermal barrier (AETB). The sizes of these blocks have been limited by the manufacturing process. In addition, as much as 80 to 90 percent of the material can be lost during the machining of tiles with significant amounts of curvature. To address these problems, the NASA Glenn Research Center at Lewis Field entered a cooperative contract with the Boeing Company to develop a vacuum-assisted forming process that can produce large (approximately 4 square feet), severely contoured panels of AETB while saving costs in comparison to the conventional cast-and-machine billet process. For shuttle use, AETB is slurry cast, drained, and fired to form square billets conforming to the shape of the filtration box. The billets are then cut into tiles of the appropriate size for thermally protecting the space shuttle. Processing techniques have limited the maximum size of AETB billets to 21.5 square inches by 6.5-in. thick, but the space shuttles use discrete heat shield tiles no more than 8 to 12 square inches. However, in other applications, large, complex shapes are needed, and the tiling approach is undesirable. For such applications, vacuum-assisted forming can produce large parts with complex shapes while reducing machining waste and eliminating cemented joints between bonded billets. Because it allows contoured shapes to be formed, material utilization is inherently high. Initial estimates show that the amount of material lost during machining can be reduced by 50 percent or more. In addition, a fiber alignment favorable for minimum heat transfer is maintained for all panel shapes since the fibers are aligned parallel to the contoured surface of the forming tool or mold. The vacuum-assisted forming process can complete the entire forming operation in a matter of minutes and can produce multiple parts whose size is limited only by the size of the forming tool. To date, panels as large as 2 square feet have been demonstrated The vacuum-assisted forming process starts with the fabrication of a permeable forming tool, or mold, with the proper part contour. This reusable tool is mounted over an internal rib support structure, as depicted in the diagram, such that a vacuum can be pulled on the bottom portion of the tool. AETB slurry is then poured over and around the tool, liquid is drawn from the slurry, and the part forms over the tool surface. The part is then dried, fired, and finished machined. Future plans include an evaluation of the need for additional coatings and surface-toughness treatments to extend the durability and performance of this material.

Angel, Paul W.↗

NASA NTRS2006

Modeling of Heat and Mass Transfer in a TEC-Driven Lyophilizer

Dewatering of wet waste during space exploration missions is important for crew safety as it stabilizes the waste. It may also be used to recover water and serve as a preconditioning step for waste compaction. A thermoelectric cooler (TEC)-driven lyophilizer is under development at NASA Ames Research Center for this purpose. It has three major components: (i) an evaporator section where water vapor sublimes from the frozen waste, (ii) a condenser section where this water vapor deposits as ice, and (iii) a TEC section which serves as a heat pump to transfer heat from the condenser to the evaporator. This paper analyses the heat and mass transfer processes in the lyophilizer in an effort to understand the ice formation behavior in the condenser. The analysis is supported by experimental observations of ice formation patterns in two different condenser units.

Yuan, Zeng-Guang↗

NASA NTRS2008

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗

NASA NTRS1986

Supercritical waste oxidation of aqueous wastes

For aqueous wastes containing 1 to 20 wt% organics, supercritical water oxidation is less costly than controlled incineration or activated carbon treatment and far more efficient than wet oxidation. Above the critical temperature (374 C) and pressure (218 atm) of water, organic materials and gases are completely miscible with water. In supercritical water oxidation, organics, air and water are brought together in a mixture at 250 atm and temperatures above 400 C. Organic oxidation is initiated spontaneously at these conditions. The heat of combustion is released within the fluid and results in a rise in temperature 600 to 650 C. Under these conditions, organics are destroyed rapidly with efficiencies in excess of 99.999%. Heteroatoms are oxidized to acids, which can be precipitated out as salts by adding a base to the feed. Examples are given for process configurations to treat aqueous wastes with 10 and 2 wt% organics.

Modell, M.↗

NASA NTRS2011

Advanced Life Support Technologies and Scenarios

As NASA looks beyond the International Space Station toward long-duration, deep space missions away from Earth, the current practice of supplying consumables and spares will not be practical nor affordable. New approaches are sought for life support and habitation systems that will reduce dependency on Earth and increase mission sustainability. To reduce launch mass, further closure of Environmental Control and Life Support Systems (ECLSS) beyond the current capability of the ISS will be required. Areas of particular interest include achieving higher degrees of recycling within Atmosphere Revitalization, Water Recovery and Waste Management Systems. NASA is currently investigating advanced carbon dioxide reduction processes that surpass the level of oxygen recovery available from the Sabatier Carbon Dioxide Reduction Assembly (CRA) on the ISS. Improving the efficiency of the recovery of water from spacecraft solid and liquid wastes is possible through use of emerging technologies such as the heat melt compactor and brine dewatering systems. Another significant consumable is that of food. Food production systems based on higher plants may not only contribute significantly to the diet, but also contribute to atmosphere revitalization, water purification and waste utilization. Bioreactors may be potentially utilized for wastewater and solid waste management. The level at which bioregenerative technologies are utilized will depend on their comparative requirements for spacecraft resources including mass, power, volume, heat rejection, crew time and reliability. Planetary protection requirements will need to be considered for missions to other solar system bodies.

Barta, Daniel J.↗

NASA NTRS1975

Development of an advanced spacecraft water and waste materials processing system

An Integrated Waste Management-Water System (WM-WS) which uses radioisotopes for thermal energy is described and results of its trial in a 4-man, 180 day simulated space mission are presented. It collects urine, feces, trash, and wash water in zero gravity, processes the wastes to a common evaporator, distills and catalytically purifies the water, and separates and incinerates the solid residues using little oxygen and no chemical additives or expendable filters. Technical details on all subsystems are given along with performance specifications. Data on recovered water and heat loss obtained in test trials are presented. The closed loop incinerator and other projects underway to increase system efficiency and capacity are discussed.

Murray, R. W.↗

NASA NTRS2015

Simulation Apps Bring Us Closer to Mars

My work with mathematical modeling and computer simulations began in earnest in 1987 when I signed on with the National Aeronautics and Space Administration, better known as NASA. At the time I was developing computer simulations to support the design of carbon dioxide (CO2) removal systems for the International Space Station (ISS) life support system. CO2 is a human metabolic waste, produced at a rate of a kilogram per day per crewmember. CO2 must be removed from the crew cabin, as it will quickly become detrimental to crew health. The systems used to remove CO2 are typically based on sorption processes, which include complex interactions of heat transfer, mass transfer, and gas flow through porous media. At this time, there were no commercial options for solving a set of coupled mathematical models such as partial differential equations (PDEs); you either force-fit the physics into a thermal analysis package or wrote your own code, complete with discretization, meshing, and solution algorithms. Unfortunately, coding CO2 removal processes from scratch did not allow an appropriate focus on the challenging yet crucial task of understanding and capturing the underlying physics via appropriate mathematical models. Configuration control was often simply ignored due to tight schedules, resulting in a code that would be quicker for a second party to rewrite than modify. In the early 2000s, I decided to move CO2 removal simulations to a platform with built-in meshing, solvers, and postprocessing capabilities, and that could solve user-defined multiphysics PDEs. The program chosen to meet these needs was COMSOL Multiphysics®. Along with freeing the engineer to focus on the underlying physics, a degree of configuration control was automatically achieved via a consistent user interface, thus allowing COMSOL users to share computer models. My team has developed simulations that are already providing a valuable debugging capability for the ISS CO2 removal system, and will provide guidance in upgrades to that system.

Knox, Jim↗