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153 records · Page 9

FEED Study of Carbon Capture Inc. DAC and CarbonCure Utilization Using United States Steel's Gary Works Waste Plant

Direct Air Capture (DAC) has been proposed as a means of reducing atmospheric concentrations of CO2. While DAC has been evaluated through lab-scale, bench-scale, and small-scale pilot units, large-scale deployment has not been achieved. Feasibility studies are one tool to understand the potential design, operation, performance, and impact of commercial-scale DAC. This paper presents the results of a feasibility study for a passive DAC system deployed at >100,000 tpy scale in three different regions across the U.S. and awarded to Carbon Collect by the U.S. Department of Energy National Energy Technology Laboratory (DOE NETL). The MechanicalTree™technology has been designed and engineered by Carbon Collect based on the concept initially developed at Arizona State University Center for Negative Carbon Emissions. It uses a tower of stacked, sorbentcontaining disks supported by a lifting mechanism, exposed to the air to capture CO2 during the adsorption phase. The disks are then lowered into a regeneration chamber for vacuum and steam regeneration to produce CO2 product during the desorption step. The modular tree design allows large installations with repeatable, mass-manufactured units connected to common utilities such as steam supply, vacuum, and CO2 processing for compression and geologic storage. The passive DAC system eliminates the equipment and energy of forced air fans by using natural air circulation to contact the sorbent with the CO2 in the air. Because of this, the performance is dependent on the wind speed in addition to the temperature and relative humidity. Performance and flow rate fluctuations were incorporated into equipment and facility design with considerations for turndown to 10% of maximum rated flow to allow operation in all seasons. The feasibility study was undertaken to evaluate the technology in different regions and climates. Three locations were selected for this study representing different climates: Alabama (hot and humid), California (hot and arid), and Wyoming (continental). For each region, the adsorption/desorption cycle was optimized including tuning the heat integration and cycle timings. The performance of individual trees was then scaled to the full facility with the same design of more than 20,000 trees common between all regions. The installations had expected average CO2 capture rates of between 330,000 and 485,000 tonnes of CO2 per year depending on the climate. The initial engineering design for the facility at each location was performed with cost and performance estimates for the trees, carbon purification and compression, and the balance of plant. To supply thermal and electrical energy for the facility, carbon-free or low-carbon power must be considered. Options for low-carbon, continuous thermal and electrical energy were considered. The best-performing option from those considered was identified to be an electrically-heated molten salt energy storage system, powered by an on-site photovoltaic field. During molten salt thermal discharge, steam is produced from heat exchange with the molten salt and used to generate power in a steam turbine as well as steam for regenerating the DAC carbon trees. The thermal and electrical supply and analysis is presented in the context of low-carbon power for carbon removal. Modelling and economics of transportation and geologic storage of the CO2 is considered and presented for each location. The results of the feasibility study are incorporated into the presented techno-economic and life-cycle assessments. This work is intended to provide an understanding of the performance, cost, and impact of capturing CO2 at the commercial scale and the impact of climate and regional siting on the considered passive DAC system.

42 ENGINEERING↗

Lithium-Ion Batteries Being Evaluated for Low-Earth-Orbit Applications

The performance characteristics and long-term cycle life of aerospace lithium-ion (Li-ion) batteries in low-Earth-orbit applications are being investigated. A statistically designed test using Li-ion cells from various manufacturers began in September 2004 to study the effects of temperature, end-of-charge voltage, and depth-of-discharge operating conditions on the cycle life and performance of these cells. Performance degradation with cycling is being evaluated, and performance characteristics and failure modes are being modeled statistically. As technology improvements are incorporated into aerospace Li-ion cells, these new designs can be added to the test to evaluate the effect of the design changes on performance and life. Cells from Lithion and Saft have achieved over 2000 cycles under 10 different test condition combinations and are being evaluated. Cells from Mine Safety Appliances (MSA) and modules made up of commercial-off-the-shelf 18650 Li-ion cells connected in series/parallel combinations are scheduled to be added in the summer of 2005. The test conditions include temperatures of 10, 20, and 30 C, end-of-charge voltages of 3.85, 3.95, and 4.05 V, and depth-of-discharges from 20 to 40 percent. The low-Earth-orbit regime consists of a 55 min charge, at a constant-current rate that is 110 percent of the current required to fully recharge the cells in 55 min until the charge voltage limit is reached, and then at a constant voltage for the remaining charge time. Cells are discharged for 35 min at the current required for their particular depth-of-discharge condition. Cells are being evaluated in four-cell series strings with charge voltage limits being applied to individual cells by the use of charge-control units designed and produced at the NASA Glenn Research Center. These charge-control units clamp the individual cell voltages as each cell reaches its end-of-charge voltage limit, and they bypass the excess current from that cell, while allowing the full current flow to the remaining cells in the pack. The goal of this evaluation is to identify conditions and cell designs for Li-ion technology that can achieve more than 30,000 low-Earth-orbit cycles. Testing is being performed at the Naval Surface Warfare Center, Crane Division, in Crane, Indiana.

McKissock, Barbara I.↗

Synergistic Development, Test, and Qualification Approaches for the Ares I and V Launch Vehicles

The U.S. National Aeronautics and Space Administration is designing and developing the Ares I and Ares V launch vehicles for access to the International Space Station (ISS) and human exploration of the Moon. The Ares I consists of a first stage reusable five-segment solid rocket booster, a upper stage using a J-2X engine derived from heritage experience (Saturn and Space Shuttle External Tank programs), and the Orion crew exploration vehicle (CEV). The Ares V is designed to minimize the development and overall life-cycle costs by leveraging off of the Ares I design. The Ares V consists of two boosters, a core stage, an earth departure stage (EDS), and a shroud. The core stage and EDS use LH2/LO2 propellants, metallic propellant tanks, and composite dry structures. The core stage has six RS-68B upgraded Delta IV engines while the EDS uses a J-2X engine for second stage ascent and trans-lunar injection (TLI) burn. System and propulsion tests and qualification approaches for Ares V elements are being considered as follow-on extensions of the Ares I development program. Following Ares I IOC, testing will be conducted to verify the J-2X engine's orbital restart and TLI burn capability. The Ares I upper stage operation will be demonstrated through integrated stage development and acceptance testing. The EDS will undergo similar development and acceptance testing with additional testing to verify aspects of cryogenic propellant management, operation of sub-systems in a space simulation environment, and orbital re-start of the main propulsion system. RS-68B certification testing will be conducted along with integrated core stage development and acceptance testing. Structural testing of the Ares V EDS and core stage propellant tanks will be conducted similar to the Ares I upper stage. The structural qualification testing may be accomplished with separate propellant tank test articles. Structural development and qualification testing of the dry structure will be pursued as part of the design and development process. Especially critical is the development test program for the composite structures. The Ares V payload shroud will undergo acoustic, vibration, structural qualification, and deployment testing in a space simulation environment. Similar to Ares I, requirements for full-scale structural dynamic testing are being studied. Both Ares I and Ares V include validation flight testing as part of the qualification programs.

Cockrell, Charles E.↗

Heart Rate Responses to Unaided Orion Side Hatch Egress in the Neutral Buoyancy Laboratory

NASA is developing the Orion capsule as a vehicle for transporting crewmembers to and from the International Space Station (ISS) and for future human space exploration missions. Orion and other commercial vehicles are designed to splash down in the ocean where nominally support personnel will assist crewmembers in egressing the vehicle. However, off-nominal scenarios will require crewmembers to egress the vehicle unaided, deploy survival equipment, and ingress a life raft. PURPOSE: To determine the heart rate (HR) responses to unaided Orion side hatch egress and raft ingress as a part of the NASA Crew Survival Engineering Team's evaluation of the PORT Orion mockup in the Neutral Buoyancy Laboratory (NBL). METHODS: Nineteen test subjects, including four astronauts (N=19, 14 males/5 females, 38.6+/-8.4 y, 174.4+/-9.6 cm, 75.7+/-13.1 kg), completed a graded maximal test on a cycle ergometer to determine VO2peak and HRpeak and were divided into five crews of four members each; one subject served on two crews. Each crew was required to deploy a life raft, egress the Orion vehicle from the side hatch, and ingress the life raft with two 8 kg emergency packs per crew. Each crew performed this activity one to three times; a total of ten full egresses were completed. Subjects wore a suit that was similar in form, mass, and function to the Modified Advanced Crew Escape Suit (MACES) including helmet, gloves, boots, supplemental O2 bottles, and a CO2-inflated life preserver (approx.18 kg); subjects began each trial seated supine in the PORT Orion mockup with seat belts and mockup O2 and communication connections and ended each trial with all four crewmembers inside the life raft. RESULTS: VO2peak was 40.8+/-6.8 mL/kg/min (3.1+/-0.7 L/min); HRpeak was 181+/-10 bpm. Total egress time across trials was 5.0+/-1.6 min (range: 2.8-8.0 min); all subjects were able to successfully complete all trials. Average maximum HR at activity start, at the hatch opening, in the water, and in the raft, was 108, 137, 147, and 153 bpm, respectively; these values corresponded to 59+/-10%, 73+/-8%, 82+/-3%, and 84+/-6% of HRpeak, respectively. The highest HRs were seen after raft ingress and ranged from 72-99% HRpeak. Across all trials, cumulative averages of 5.4, 3.0, 1.1, and 0.2 min were spent at HRs >60%, >70%, >80%, and >90% HRpeak, respectively. CONCLUSION: Unaided Orion side hatch egress in the NBL is a relatively short-duration activity that elicits a high HR response for several min. Although all crewmembers successfully completed this activity, additional factors such as high seas, poor visibility, an incapacitated crewmember, neurovestibular perturbation, and neuromuscular deconditioning characteristic of a true operational environment may increase the physiologic demand (or decrease crewmembers' physiologic capacity) of unaided Orion side hatch egress. Additionally, landing conditions may require the crewmembers to egress from the top hatch, which is expected to be even more physiologically demanding; this condition will be evaluated in subsequent collaborative testing with the NASA Crew Survival Engineering Team.

English, Kirk L.↗

The Pascal Discovery Mission: A Mars Climate Network Mission

The climate of Mars is a major focus of Mars exploration. With the loss of MCO, however, it remains uncertain how it will be achieved. We argue that a truly dedicated climate mission to Mars should have both orbital and landed components, and that these should operate simultaneously for at least 1 Mars year if not longer. Pascal is a Discovery mission that emphasizes the landed component. Its principal goal is to establish a network of 24 small weather stations on the surface of Mars that will operate for 2 Mars years, with an extended mission option for an additional 8 Mars years bringing the total mission lifetime up to 10 Mars years. The stations will collect hourly measurements of pressure, temperature, and optical depth. After delivering the probes to Mars, Pascal's carrier spacecraft will go into an elliptical orbit which will serve as a relay for the landers, and a platform for synoptic imaging. These simultaneous measurements from the surface and from orbit will allow us to characterize the planet's general circulation and its interaction with the dust, water, and CO2 cycles. During entry, descent, and landing, each of Pascal's 24 probes will also measure the temperature structure of the atmosphere and acquire images of the surface. These data will allow us to determine the global structure of the atmosphere between 15 and 130 km, and characterize the local terrain to help interpret the landed data. The descent images are part of Pascal's outreach program, as the probe camera system will be developed by faculty-supervised student project. The intent is to generate enthusiasm for the Pascal mission by directly involving students. Pascal will be launched on a Delta II-7925 in August of 2005. A type I trajectory will deliver Pascal to Mars in January of 2006. On approach, the three-axis stabilized carrier spacecraft will spring deploy the Pascal probes in 4 separate salvo's of 6 each. Global coverage is achieved with small time-of-arrival adjustments in between each salvo. Pascal's probes utilize an aeroshell, parachute, and crushable material for entry, descent and landing. On the surface, their long life and global coverage is enabled by a Micro Thermal Power Source with demonstrated heritage. After all probes are released, the carrier spacecraft will execute a small burn for insertion into an elliptical orbit. The long lifetime of the Pascal network was chosen in part to maximize the chances that orbital sounding, like that planned with MCO, would occur at some point during the mission. If Pascal is selected for launch in '05, this could occur if MCO-like science is reflown in the '05 opportunity or, if it is reflown in '03, the mission is extended to overlap with Pascal. The combination of temperature sounding from orbit, and surface pressure mapping from the surface will allow a direct determination of the full 3-D wind field for the first time.

Haberle, R. M.↗

The Pascal Discovery Mission: A Mars Climate Network Mission

The climate of Mars is a major focus of Mars exploration. With the loss of MCO, however, it remains uncertain how it will be achieved. We argue that a truly dedicated climate mission to Mars should have both orbital and landed components, and that these should operate simultaneously for at least I Mars year if not longer. Pascal is Discovery mission that emphasizes the landed component. Its principal goal is to establish a network of 24 small weather stations on the surface of Mars that will operate for 2 Mars years, with an extended mission option for an additional 8 Mars years bringing the total mission lifetime up to 10 Mars years. The stations will collect hourly measurements of pressure, temperature, and optical depth. After delivering the probes to Mars, Pascal's carrier spacecraft will go into an elliptical orbit which will serve as a relay for the landers, and a platform for synoptic imaging. These simultaneous measurements from the surface and from orbit will allow us to characterize the planet's general circulation and its interaction with the dust, water, and CO2 cycles. During entry, descent, and landing, each of Pascal's 24 probes will also measure the temperature structure of the atmosphere and acquire images of the surface. These data will allow us to determine the global structure of the atmosphere between 15 and 130 km, and characterize the local terrain to help interpret the landed data. The descent images are part of Pascal's outreach program, as the probe camera system will be developed by faculty-supervised student project. The intent is to generate enthusiasm for the Pascal mission by directly involving students. Pascal will be launched on a Delta 11-7925 in August of 2005. A type I trajectory will deliver Pascal to Mars in January of 2006. On approach, the three-axis stabilized carrier spacecraft will spring deploy the Pascal probes in 4 separate salvo's of 6 each. Global coverage is achieved with small time-of-arrival adjustments in between each salvo. Pascal's probes utilize an aeroshell, parachute, and crushable material for entry, descent and landing. On the surface, their long life and global coverage is enabled by a Micro Thermal Power Source with demonstrated heritage. After all probes are released, the carrier spacecraft will execute a small bum for insertion into an elliptical orbit. The long lifetime of the Pascal network was chosen in part to maximize the chances that orbital sounding, like that planned with MCO, would occur at some point during the mission. If Pascal is selected for launch in -05, this could occur if MCO-like science is reflown in the '05 opportunity or, if it is reflown in '03, the mission is extended to overlap with Pascal. The combination of temperature sounding from orbit, and surface pressure mapping from the surface will allow a direct determination of the full 3-D wind field for the first time.

Haberle, Robert M.↗

Experimental system for studying temperature gradient-driven fracture of oxide nuclear fuel out of reactor

Temperature gradients in ceramic light water reactor (LWR) uranium dioxide (UO 2 ) nuclear fuel pellets generate thermal stresses that cause fractures in the fuel beginning early in the life of fresh fuel. The combination of heating due to fission and forced convective cooling on the exterior of LWR fuel rods generates a temperature profile that is difficult to replicate outside the reactor environment. In the present study, a state-of-the-art experimental set-up using electrical heating to replicate fission heating was built and surrogate fuel materials such as ceria (CeO 2 ) were used to validate the system. Cracking experiments were conducted on these surrogates by inducing reactivity-initiated-accident (RIA) like temperature gradients in the pellets via induction and direct resistance heating. Induction heating was done using copper coils and molybdenum susceptors which heated the surrogates to a threshold temperature that is sufficiently high for the fuel material to conduct current. Thereafter, direct resistance heating was used by a D.C. power supply to introduce volumetric heating to replicate LWR operating conditions analogous to fission heating. The pellets were held against nickel electrodes and mounted on a boron nitride test-stand. All the tests were carried out in a stainless-steel vacuum chamber. Simultaneous real-time dual imaging of the surrogate pellet surface has been implemented using an optical and infrared camera system which will be mounted along axial and perpendicular directions to the pellet surface respectively. A beam-splitter was used to split the incoming radiation from the sample into two halves. While one of the beams is transmitted from the splitter through a bandpass filter to obtain optical images, the other beam is reflected from the splitter to the thermal camera to capture full field temperature gradients of the as fabricated pellet surface during crack initiation and propagation. In the current series of tests, a 2-color pyrometer was used for recording and comparing the surface and centerline temperatures of the surrogate pellets in lieu of the thermal camera. A LabVIEW data acquisition system has been set up for collecting useful data during experiments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

IACMI Project 4.2: Thermoplastic Composite Development for Wind Turbine Blades

(Section 5.1) Composites made from Arkema’s Elium® thermoplastic resin and Johns Manville fiberglass were researched during this project for applications in wind blade manufacturing. A techno-economic model was developed to model this wind blade manufacturing process using these materials in place of traditional composites made with thermoset resin. This model was based on manufacturing a 61.5-meter wind blade, which showed a 4.7% reduction in wind blade cost as compared traditional thermoset materials. These cost savings were not from the thermoplastic material costing less than traditional thermoset materials, but rather from decreased capital costs, faster cycle times and reduced energy requirements and labor costs. (Section 5.2) An infusion and curing model was developed for thermoplastic composite wind blades using PAM-RTM. The primary goal was to demonstrate the infusion simulation for the Elium® resin system on a 13-meter wind blade. Additionally, the exotherm temperature was predicted and compared to measurements, which showed model results within 10% of actual measurements. (Section 5.3) Composite laminate panels and composite sandwich panels with a balsa core were produced; specimens were cut and characterized. Similar composite specimens were made with Elium® thermoplastic resin and Hexion thermoset epoxy (RIMR135/RIMH1366) to enable comparisons between these resin systems. The static test methods included: tensile, compression, in-plane shear, interlaminar shear, flexural, sandwich core shear flexure, and single cantilever beam tests for sandwich beams. Fatigue testing at room temperature was completed to composite laminate panels at a stress ratio of R=0.1 and R=10. In addition, fatigue testing to laminate panels was completed at -30°C, and at room temperature after conditioning specimens at 70°C and 90% relative humidity. Overall, mechanical test results from Elium® composites are similar to epoxy composites. (Section 5.4) Elium composite panels were produced with intentional defects such as voids and nonwetting of fibers to begin to understand performance sensitivity to defects. A thermal digital image correlation (TDIC) method provides high spatial resolution strain field at elevated temperatures and can be used to identify defective regions within composite panels. Flexural modulus differences of 21% were seen between defect and non-defect panels. Other Elium® composite panels were forced to be defective by boiling the resin after infusion, which created voids throughout the composite laminate. X-ray computed tomography scanning was used to view the internal structure of the defect panels. Defect panels had a significant reduction in fatigue life as compared to baseline panels produced without intentional defects. (Section 5.5) Lap shear specimens were fabricated to compare the lap shear strength of an off-the-shelf adhesive (Plexus MA590) and two new adhesives developed by Arkema (Bostik SAF30 90 and Bostik SAF30 120). ISO standard 4587:2003 was used to standardize the testing method and sample fabrication. Lap shear specimens were made at 1mm, 3mm, and 10mm thicknesses. The Bostik adhesive lap shear test results were similar to Plexus for all thicknesses. (Section 5.6) Fiber-reinforced polymer (FRP) composites are typically used in high-performance applications (e.g., aerospace), and their expansion into high-volume industries (e.g. consumer automotive and wind turbine blade manufacturer or similar) is hindered by their cost and a lack of efficient manufacturing techniques. Monitoring the curing process of these composites during manufacturing can improve the efficiency of the process, and therefore reduce the manufacturing cost. Cure monitoring techniques were developed that use probabilistic estimation methods and surface temperature measurements made using infrared cameras. These techniques enable real-time monitoring of the infusion process to locate manufacturing flaws, and they can, potentially, estimate residual stresses in the part. Their commercialization will help facilitate expansion of FRP composites in high-volume industries. (Section 5.7) A 13-meter composite wind blade was produced with Elium® resin and Johns Manville fiberglass; this blade was made with VARTM processing similar to how megawatt-scale wind blades are currently manufactured, but no post-mold heating was used for this thermoplastic composite blade. The wind blade underwent full-scale validation for static loading (4-different load orientations) and flapwise fatigue loading to simulate 20-years of operational loads. The thermoplastic composite wind blade withstood the loading without any noted issues and performed similar to results from a previous full-scale validation to an equivalent epoxy composite wind blade produced with the same blade molds. (Section 5.8) A study was conducted to determine the feasibility of recycling composite wind turbine blade components fabricated with glass fiber reinforced Elium® thermoplastic resin. Dissolution, which is a process unique to thermoplastic matrices, allows recovery of both the polymer matrix and full-length glass fibers, while maintaining their stiffness and strength throughout the recovery process. The economics of recycling is favorable if 50% of the glass fiber is recovered and resold for a process of $\$$ 0.28/kg, and 90% of the resin is recovered and resold at a price of $\$$ 2.50/kg.(Section 10) Recommendations are outlined for commercializing thermoplastic resin for composite wind blade production, in addition to recommended areas for future research.

17 WIND ENERGY↗

Unmanned Aircraft Systems (UAS) Integration in the National Airspace System (NAS) Project KDP-C Review

The topics discussed are the UAS-NAS project life-cycle and ARMD thrust flow down, as well as the UAS environments and how we operate in those environments. NASA's Armstrong Flight Research Center at Edwards, CA, is leading a project designed to help integrate unmanned air vehicles into the world around us. The Unmanned Aircraft Systems Integration in the National Airspace System project, or UAS in the NAS, will contribute capabilities designed to reduce technical barriers related to safety and operational challenges associated with enabling routine UAS access to the NAS. The project falls under the Integrated Systems Research Program office managed at NASA Headquarters by the agency's Aeronautics Research Mission Directorate. NASA's four aeronautics research centers - Armstrong, Ames Research Center, Langley Research Center, and Glenn Research Center - are part of the technology development project. With the use and diversity of unmanned aircraft growing rapidly, new uses for these vehicles are constantly being considered. Unmanned aircraft promise new ways of increasing efficiency, reducing costs, enhancing safety and saving lives 460265main_ED10-0132-16_full.jpg Unmanned aircraft systems such as NASA's Global Hawks (above) and Predator B named Ikhana (below), along with numerous other unmanned aircraft systems large and small, are the prime focus of the UAS in the NAS effort to integrate them into the national airspace. Credits: NASA Photos 710580main_ED07-0243-37_full.jpg The UAS in the NAS project envisions performance-based routine access to all segments of the national airspace for all unmanned aircraft system classes, once all safety-related and technical barriers are overcome. The project will provide critical data to such key stakeholders and customers as the Federal Aviation Administration and RTCA Special Committee 203 (formerly the Radio Technical Commission for Aeronautics) by conducting integrated, relevant system-level tests to adequately address safety and operational challenges of national airspace access by unmanned aircraft systems, or UAS. In the process, the project will work with other key stakeholders to define necessary deliverables and products to help enable such access. Within the project, NASA is focusing on five sub-projects. These five focus areas include assurance of safe separation of unmanned aircraft from manned aircraft when flying in the national airspace; safety-critical command and control systems and radio frequencies to enable safe operation of UAS; human factors issues for ground control stations; airworthiness certification standards for UAS avionics and integrated tests and evaluation designed to determine the viability of emerging UAS technology. Five Focus Areas of the UAS Integration in the NAS Project Separation Assurance Provide an assessment of how planned Next Generation Air Transportation System (NextGen) separation assurance systems, with different functional allocations, perform for UAS in mixed operations with manned aircraft Assess the applicability to UAS and the performance of NASA NextGen separation assurance systems in flight tests with realistic latencies and uncertain trajectories Assess functional allocations ranging from today's ground-based, controller-provided aircraft separation to fully autonomous airborne self-separation Communications Develop data and rationale to obtain appropriate frequency spectrum allocations to enable safe and efficient operation of UAS in the NAS Develop and validate candidate secure safety-critical command and control system/subsystem test equipment for UAS that complies with UAS international/national frequency regulations, standards and recommended practices and minimum operational and aviation system performance standards for UAS Perform analysis to support recommendations for integration of safety-critical command and control systems and air traffic control communications to ensure safe and efficient operation of UAS in the NAS Human Systems Integration Develop a research test bed and database to provide data and proof of concept for GCS - ground control station - operations in the NAS Coordinate with standards organizations to develop human-factors guidelines for GCS operation in the NAS Certification Define a UAS classification scheme and approach to determining Federal Aviation Regulation airworthiness requirements applicable to all UAS digital avionics Provide hazard and risk-related data to support development of type design criteria and best development practices Integrated Tests and Evaluation Integrate and test mature concepts from technical elements to demonstrate and test viability Evaluate the performance of technology development in a relevant environment (full-mission, human-in-the-loop simulations and flight tests)

outreach↗