Liquefied Natural Gas (LNG) as Propellant Fuels; Storage and Transfer Effects: Background, Testing, Data, & Analysis
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Adam Swanger↗
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O2 reduction at the IFC orbiter fuel cell O2 electrode
O2 reduction Tafel data were obtained for the IFC Orbiter fuel cell O2 electrode (Au-10 percent Pt catalyst) at temperatures between 24 and 81 C. BET measurements gave an electrode surface area of about 2040 sq cm per sq cm of geometric area. The Tafel data could be fitted to three straight line regions. For current densities less than 0.001 A/sq cm, the slope was essentially independent of temperature with a value of about 0.032 V/decade. Above 0.001 A/sq cm, the two regions, designated in the present study as the 0.04 and 0.12 V/decate regions, were temperature dependent. The apparent energies of activation for these two regions were about 9.3 and 6.5 kcal/mol, respectively. Tafel data (1 atmosphere O2) were extrapolated to 120 C for predicting changes in overpotential with increasing temperature. A mechanism is presented for O2 reduction.
Fielder, William L.↗
Rotary balance data for an F-15 model with conformal fuel tanks for an angle-of-attack range of 8 deg to 90 deg
Aerodynamic characteristics obtained in a rotational flow environment, utilizing a rotary balance, are presented in plotted form for a 1/12 scale conformal fuel tank equipped F-15 airplane model. The configurations tested included in the buildup of airplane components and the basic airplane with various control deflections. Data are presented for all configurations without analysis for an angle of attack range of 8 to 90 deg, and clockwise and counterclockwise rotations covering an omega b/2V range from 0 to 0.4. Selected configurations are presented over an extended omega b/2V range from 0 to 0.9.
Barnhart, B.↗
Liquid Oxygen/Liquid Methane Integrated Power and Propulsion
The proposed paper will cover ongoing work at the National Aeronautics and Space Administration (NASA) Johnson Space Center (JSC) on integrated power and propulsion for advanced human exploration. Specifically, it will present findings of the integrated design, testing, and operational challenges of a liquid oxygen / liquid methane (LOx/LCH4) propulsion brassboard and Solid Oxide Fuel Cell (SOFC) system. Human-Mars architectures point to an oxygen-methane economy utilizing common commodities, scavenged from the planetary atmosphere and soil via In-Situ Resource Utilization (ISRU), and common commodities across sub-systems. Due to the enormous mass gear-ratio required for human exploration beyond low-earth orbit, (for every 1 kg of payload landed on Mars, 226 kg will be required on Earth) increasing commonality between spacecraft subsystems such as power and propulsion can result in tremendous launch mass and volume savings. Historically, propulsion and fuel cell power subsystems have had little interaction outside of the generation (fuel cell) and consumption (propulsion) of electrical power. This was largely due to a mismatch in preferred commodities (hypergolics for propulsion; oxygen & hydrogen for fuel cells). Although this stove-piped approach benefits from simplicity in the design process, it means each subsystem has its own tanks, pressurization system, fluid feed system, etc. increasing overall spacecraft mass and volume. A liquid oxygen / liquid methane commodities architecture across propulsion and power subsystems would enable the use of common tankage and associated pressurization and commodity delivery hardware for both. Furthermore, a spacecraft utilizing integrated power and propulsion could use propellant residuals - propellant which could not be expelled from the tank near depletion due to hydrodynamic considerations caused by large flow demands of a rocket engine - to generate power after all propulsive maneuvers are complete thus utilizing previously wasted mass. Such is the case for human and robotic planetary landers. Although many potential benefits through integrated power & propulsion exist, integrated operations have yet to be successfully demonstrated and many challenges have already been identified the most obvious of which is the large temperature gradient. SOFC chemistry is exothermic with operating temperatures in excess of 1,000 K; however, any shared commodities will be undoubtedly stored at cryogenic temperatures (90-112 K) for mass efficiency reasons. Spacecraft packaging will drive these two subsystems in close proximity thus heat leak into the commodity tankage must be minimized and/or mitigated. Furthermore, commodities must be gasified prior to consumption by the SOFC. Excess heat generated by the SOFC could be used to perform this phase change; however, this has yet to be demonstrated. A further identified challenge is the ability of the SOFC to handle the sudden power spikes created by the propulsion system. A power accumulator (battery) will likely be necessary to handle these sudden demands while the SOFC thermally adjusts. JSC's current SOFC test system consists of a 1 kW fuel cell designed by Delphi. The fuel cell is currently undergoing characterization testing at the NASA JSC Energy Systems Test Area (ESTA) after which a Steam Methane Reformer (SMR) will be integrated and the combined system tested in closed-loop. The propulsion brassboard is approximately the size of what could be flown on a sounding rocket. It consists of one 100 lbf thrust "main" engine developed for NASA by Aerojet and two 10 lbf thrusters to simulate a reaction control system developed at NASA JSC. This system is also under development and initial testing at ESTA. After initial testing, combined testing will occur which will provide data on the fuel cell's ability to sufficiently handle the power spikes created by the propulsion system. These two systems will also be modeled using General-Use Nodal Network Solver (GUNNS) software. Once anchored with test data, this model will be used to extrapolate onto other firing profiles and used to size the power accumulator.
Banker, Brian↗
Durability, Performance, and Emission of Diesel Engines Using Carbon Fiber Piston and Liner
This report summarizes the research conducted by NC State University in investigating the durability, performance and emission of a carbon fiber piston and liner in our single cylinder research Diesel engine. Both the piston and liner were supplied to NC State University by NASA LaRC and manufactured by C-CAT under a separate contract to NASA LaRC. The carbon-carbon material used to manufacture the piston and liner has significantly lower thermal conductivity, coefficient of thermal expansion, and superior strength characteristics at elevated temperatures when compared to conventional piston materials such as aluminum. The results of the carbon-carbon fiber piston testing were compared to a baseline configuration, which used a conventional aluminum piston in a steel liner. The parameters measured were the brake specific fuel consumption, ignition delay, frictional horsepower, volumetric efficiency, and durability characteristics of the two pistons. Testing was performed using a naturally aspirated Labeco Direct Injection single cylinder diesel engine. Two test cases were performed over a range of loads and speeds. The fixed test condition between the aluminum and carbon-carbon piston configurations was the brake mean effective pressure. The measured data was the fuel consumption rate, volumetric efficiency, load, speed, cylinder pressure, needle lift, and exhaust gas temperature. The cylinder pressure, and fuel consumption, exhaust gas temperature, and needle lift were recorded using a National Instruments DAQ board and a PC. All test cases used Diesel no. 2 for fuel.
Afify, E. M.↗
Effect of the Reservoir Volume on the Discharge Pressures in the Injection System of the N.A.C.A. Spray Photography Equipment
Tests were made to determine the effect of the reservoir volume on the discharge pressures in the injection system of the N.A.C.A. spray photography equipment. The data obtained are applicable to the design of a common rail fuel-injection system. The data show that an injection system of the type described can be designed so that not more than full load fuel quantity can be injected into the engine cylinders, and so that the fuel spray characteristics remain constant over a large range of engine speeds. Formulas are presented for computing the volume of the reservoir and the diameter of the discharge orifice.
Rothrock, A M↗
"We Burn to Learn" About Fuel-Air Mixing Within Aircraft Powerplants
I am working with my branch s advanced diagnostics team to investigate fuel-air mixing in jet-fueled gas turbine combustors and jet-fuel reformers. Our data acquisition begins with bench-top experiments which will help with calibration of equipment for facility testing. While conducting the bench-top experiments I learned to align laser and optical equipment to collect data, to use the data acquisition software, and to process the data into graphs and images. which jet he1 is to be reformed into hydrogen. Testing will commence shortly, after which we will obtain and analyze data and meet a critical milestone for the end of September. I am also designing the layout for a Schlieren system that will be used during that time frame. A Schlieren instrument records changes in the refractive index distribution of transparent media like air flows. The refractive index distribution can then be related to density, temperature, or pressure distributions within the flow. I am working on a scheme to quantify this information and add to the knowledge of the fuel-air mixing process.
Robinson, Heidi N.↗
Effects of fuel-injector design on ultra-lean combustion performance
Emissions data were obtained for six fuel injector configurations tested with ultra lean combustion. Fuel injectors included three multiple source designs and three configurations using a single air assist injector. Only the multiple source fuel injectors provided acceptable emissions. Values of 16g CO/kg fuel, 1.9g HC/kg fuel, and 19.g NO2/kg fuel were obtained for the combustion temperature range of 1450 to 1700 K for both a high blockage 19 source injector and a low blockage 41 source injector. It was shown that high fuel injector pressure drop may not be required to achieve low emissions performance at high inlet air temperature when the fuel is well dispersed in the airstream.
Anderson, D. N.↗
Airborne Observations of Aerosol Emissions from F-16 Aircraft
We presented results from the SASS Near-Field Interactions Flight (SNIF-III) Experiment which was conducted during May and June 1997 in collaboration with the Vermont and New Jersey Air National Guard Units. The project objectives were to quantify the fraction of fuel sulfur converted to S(VI) species by jet engines and to gain a better understanding of particle formation and growth processes within aircraft wakes. Size and volatility segregated aerosol measurements along with sulfur species measurements were recorded in the exhaust of F-16 aircraft equipped with F-100 engines burning fuels with a range of fuel S concentrations at different altitudes and engine power settings. A total of 10 missions were flown in which F-16 exhaust plumes were sampled by an instrumented T-39 Sabreliner aircraft. On six of the flights, measurements were obtained behind the same two aircraft, one burning standard JP-8 fuel and the other either approximately 28 ppm or 1100 ppm S fuel or an equal mixture of the two (approximately 560 ppm S). A pair of flights was conducted for each fuel mixture, one at 30,000 ft altitude and the other starting at 35,000 ft and climbing to higher altitudes if contrail conditions were not encountered at the initial flight level. In each flight, the F-16s were operated at two power settings, approx. 80% and full military power. Exhaust emissions were sampled behind both aircraft at each flight level, power setting, and fuel S concentration at an initial aircraft separation of 30 m, gradually widening to about 3 km. Analyses of the aerosol data in the cases where fuel S was varied suggest results were consistent with observations from project SUCCESS, i.e., a significant fraction of the fuel S was oxidized to form S(VI) species and volatile particle emission indices (EIs) in comparably aged plumes exhibited a nonlinear dependence upon the fuel S concentration. For the high sulfur fuel, volatile particle EIs in 10-second-old-plumes were 2 to 3 x 10 (exp 17) / kg of fuel burned and exhibited no obvious trend with engine power setting or flight altitude. In contrast, about 8-fold fewer particles were observed in similarly aged plumes from the same aircraft burning fuel with 560 ppm S content and EIs of 1 x 10(exp 15)/ kg of fuel burned were observed in the 28 ppm S fuel case. Moreover, data recorded as a function of plume age indicates that formation and growth of the volatile particles proceeds more slowly as the fuel S level is reduced. For example, ultrafine particle concentrations appear to stabilize within 5 seconds after emission in the 1100 ppm S cases but are still increasing in 20-second old plumes produced from burning the 560 ppm S fuel.
Anderson, B. E.↗
Effect of long-term exposure to Low Earth Orbit (LEO) space environment
Data obtained from components and materials from the Solar Maximum Mission satellite are presented and compared to data for similar materials obtained from the Advanced Composite Materials Exposure to Space Experiment (ACOMEX) flown on Shuttle mission STS-41G. In addition to evaluation of surface erosion and mass loss that may be of importance to very long-term missions, comparisons of solar absorptance and thermal emittance measurements for both long and short term exposures were made. Although the ratio of absorptance over emittance can be altered by proper choice of materials to ensure a proper operating environment for the spacecraft, once the thermal design is established, it is important that the material properties not change in order to maintain the operating environment for many payload and bus items such as electronics, batteries, fuel, etc. However, data presented show significant changes after short exposure in low Earth environment. Moreover, the measured changes are shown to differ according to the manner of exposure, i.e., normal or oblique, which also affects the resultant eroded surface morphology. These results identify constraints to be considered in development of flight experiments or laboratory testing.
Zimcik, D. G.↗
Comparison Between Predicted and Experimentally Measured Flow Fields at the Exit of the SSME HPFTP Impeller
Validation of CFD codes is a critical first step in the process of developing CFD design capability. The MSFC Pump Technology Team has recognized the importance of validation and has thus funded several experimental programs designed to obtain CFD quality validation data. The first data set to become available is for the SSME High Pressure Fuel Turbopump Impeller. LDV Data was taken at the impeller inlet (to obtain a reliable inlet boundary condition) and three radial positions at the impeller discharge. Our CFD code, TASCflow, is used within the Propulsion and Commercial Pump industry as a tool for pump design. The objective of this work, therefore, is to further validate TASCflow for application in pump design. TASCflow was used to predict flow at the impeller discharge for flowrates of 80, 100 and 115 percent of design flow. Comparison to data has been made with encouraging results.
Bache, George↗
Metallized Gelled Propellants: Oxygen/RP-1/aluminum Rocket Combustion Experiments
A series of combustion experiments were conducted to measure the specific impulse, Cstar-, and specific-impulse efficiencies of a rocket engine using metallized gelled liquid propellants. These experiments used a small 20- to 40-1bf (89- to 178-N) thrust, modular engine consisting of an injector, igniter, chamber and nozzle. The fuels used were traditional liquid RP-1 and gelled RP-1 with 0-, 5-, and 55-wt% loadings of aluminum and gaseous oxygen was the oxidizer. Ten different injectors were used during the testing: 6 for the baseline 02/RP-1 tests and 4 for the gelled fuel tests which covered a wide range of mixture ratios. At the peak of the Isp versus oxidizer-to-fuel ratio (O/F) data, a range of 93 to 99% Cstar efficiency was reached with ungelled 02/RP-1. A Cstar efficiency range of 75 to 99% was obtained with gelled RP-l (0-wt% RP-1/Al) while the metallized 5-wt% RP-1/Al delivered a Cstar efficiency of 94 to 99% at the peak Isp in the O/F range tested. An 88 to 99% Cstar efficiency was obtained at the peak Isp of the gelled RP1/Al with 55-wt% Al. Specific impulse efficiencies for the 55-wt% RP-1/Al of 67%-83% were obtained at a 2.4:1 expansion ratio. Injector erosion was evident with the 55-wt% testing, while there was little or no erosion seen with the gelled RP-1 with 0- and 5-wt% Al. A protective layer of gelled fuel formed in the firings that minimized the damage to the rocket injector face. This effect may provide a useful technique for engine cooling. These experiments represent a first step in characterizing the performance of and operational issues with gelled RP-1 fuels.
Palaszewski, Bryan↗
Data Mining Methods Applied to Flight Operations Quality Assurance Data: A Comparison to Standard Statistical Methods
In a previous study, multiple regression techniques were applied to Flight Operations Quality Assurance-derived data to develop parsimonious model(s) for fuel consumption on the Boeing 757 airplane. The present study examined several data mining algorithms, including neural networks, on the fuel consumption problem and compared them to the multiple regression results obtained earlier. Using regression methods, parsimonious models were obtained that explained approximately 85% of the variation in fuel flow. In general data mining methods were more effective in predicting fuel consumption. Classification and Regression Tree methods reported correlation coefficients of .91 to .92, and General Linear Models and Multilayer Perceptron neural networks reported correlation coefficients of about .99. These data mining models show great promise for use in further examining large FOQA databases for operational and safety improvements.
Stolzer, Alan J.↗
Hydrogen-fueled postal vehicle performance evaluation
Fuel consumption, range, and emissions data were obtained while operating a hydrogen-fueled postal delivery vehicle over a defined Postal Service Driving Cycle and the 1975 Urban Driving Cycle. The vehicle's fuel consumption was 0.366 pounds of hydrogen per mile over the postal driving cycle and 0.22 pounds of hydrogen per mile over the urban driving cycle. These data correspond to 6.2 and 10.6 mpg equivalent gasoline mileage for the two driving cycles, respectively. The vehicle's range was 24.2 miles while being operated on the postal driving cycle. Vehicle emissions were measured over the urban driving cycle. HC and CO emissions were quite low, as would be expected. The oxides of nitrogen were found to be 4.86 gm/mi, a value which is well above the current Federal and California standards. Vehicle limitations discussed include excessive engine flashbacks, inadequate acceleration capability the engine air/fuel ratio, the water injection systems, and the cab temperature. Other concerns are safety considerations, iron-titanium hydride observed in the fuel system, evidence of water in the engine rocker cover, and the vehicle maintenance required during the evaluation.
Hall, R. A.↗
Preignition-limited performance of several fuels
Preignition-limited performance data were obtained on a supercharged CFR engine at two sets of operating conditions over a wide range of fuel-air ratios to determine the preignition characteristics for the following five fuels: s-3 reference fuel, s-3 plus 4 ml. tel per gallon, afd-33(140-p), benzene, and diisobutylene. Maximum thermal-plug temperatures at constant intake-air pressures were also determined to correlate the preignition characteristics of each fuel with its ability to increase general engine-temperature levels. Additional runs were made to compare the preignition-limited performance of triptane, triptane plus 4 ml. tel per gallon, and an-f-28r fuel.
Male, Donald W↗
Results from Symposium on Future Orbital Power Systems Technology Requirements
Technology deficiencies, adequacy of current programs, and recommendations for reducing the testing and risks involved in future orbital energy systems made at the NASA Symposium are summarized. Photovoltaic space power system problems, including structural dynamics and attitude control problems due to solar array flexing; solar cell radiation resistance, manufacturing capability, and cost reduction; solar arrays including inflatable arrays, spectrum selection to increase efficiency, and polymer coatings for cells; battery technology; the endurance data base for fuel cell and electrolysis technology, and power management were discussed. Other topics considered were laser/microwave power transmission, thermal management, nuclear power systems, and environmental interactions. It was concluded that a 'front end' system study is needed in each area and current programs for multi-hundred-kW power systems are underscoped.
Gorland, S.↗
Premixing quality and flame stability: A theoretical and experimental study
Models for predicting flame ignition and blowout in a combustor primary zone are presented. A correlation for the blowoff velocity of premixed turbulent flames is developed using the basic quantities of turbulent flow, and the laminar flame speed. A statistical model employing a Monte Carlo calculation procedure is developed to account for nonuniformities in a combustor primary zone. An overall kinetic rate equation is used to describe the fuel oxidation process. The model is used to predict the lean ignition and blow out limits of premixed turbulent flames; the effects of mixture nonuniformity on the lean ignition limit are explored using an assumed distribution of fuel-air ratios. Data on the effects of variations in inlet temperature, reference velocity and mixture uniformity on the lean ignition and blowout limits of gaseous propane-air flames are presented.
Radhakrishnan, K.↗
Evaluation of catalytic combustion of actual coal-derived gas
The combustion characteristics of a Pt-Pl catalytic reactor burning coal-derived, low-Btu gas were investigated. A large matrix of test conditions was explored involving variations in fuel/air inlet temperature and velocity, reactor pressure, and combustor exit temperature. Other data recorded included fuel gas composition, reactor temperatures, and exhaust emissions. Operating experience with the reactor was satisfactory. Combustion efficiencies were quite high (over 95 percent) over most of the operating range. Emissions of NOx were quite high (up to 500 ppm V and greater), owing to the high ammonia content of the fuel gas.
Blanton, J. C.↗