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NASA NTRS2020

KRUSTY Reactor Design

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a reactor design, development, and test program to demonstrate the nuclear operation of a Kilopower reactor. Kilopower systems are intended to provide between 1 and 10 kW(electric) in space, or on the surface of planets or moons, with a clear evolution to substantially higher power systems. KRUSTY was a prototype of a 1-kW(electric) highly enriched uranium–fueled Kilopower system. In March of 2018, KRUSTY successfully operated as a fission power system and was the first nuclear-powered operation of any truly new reactor concept in the United States in over 40 years. This paper discusses the design of the KRUSTY reactor along with the philosophy, goals, and engineering work that ultimately led to KRUSTY’s success.

Kilopower↗

NASA NTRS2017

Electrically Heated Testing of the Kilowatt Reactor Using Stirling Technology (KRUSTY) Experiment Using a Depleted Uranium Core

The Kilopower project aims to develop and demonstrate scalable fission-based power technology for systems capable of delivering 110 kW of electric power with a specific power ranging from 2.5 - 6.5 Wkg. This technology could enable high power science missions or could be used to provide surface power for manned missions to the Moon or Mars. NASA has partnered with the Department of Energys National Nuclear Security Administration, Los Alamos National Labs, and Y-12 National Security Complex to develop and test a prototypic reactor and power system using existing facilities and infrastructure. This technology demonstration, referred to as the Kilowatt Reactor Using Stirling TechnologY (KRUSTY), will undergo nuclear ground testing in the summer of 2017 at the Nevada Test Site. The 1 kWe variation of the Kilopower system was chosen for the KRUSTY demonstration. The concept for the 1 kWe flight system consist of a 4 kWt highly enriched Uranium-Molybdenum reactor operating at 800 degrees Celsius coupled to sodium heat pipes. The heat pipes deliver heat to the hot ends of eight 125 W Stirling convertors producing a net electrical output of 1 kW. Waste heat is rejected using titanium-water heat pipes coupled to carbon composite radiator panels. The KRUSTY test, based on this design, uses a prototypic highly enriched uranium-molybdenum core coupled to prototypic sodium heat pipes. The heat pipes transfer heat to two Advanced Stirling Convertors (ASC-E2s) and six thermal simulators, which simulate the thermal draw of full scale power conversion units. Thermal simulators and Stirling engines are gas cooled. The most recent project milestone was the completion of non-nuclear system level testing using an electrically heated depleted uranium (non-fissioning) reactor core simulator. System level testing at the Glenn Research Center (GRC) has validated performance predictions and has demonstrated system level operation and control in a test configuration that replicates the one to be used at the Device Assembly Facility (DAF) at the Nevada National Security Site. Fabrication, assembly, and testing of the depleted uranium core has allowed for higher fidelity system level testing at GRC, and has validated the fabrication methods to be used on the highly enriched uranium core that will supply heat for the DAF KRUSTY demonstration.

Briggs, Maxwell H.↗

NASA NTRS2018

Electrically Heated Testing of the Kilowatt Reactor Using Stirling TechnologY (KRUSTY) Experiment Using a Depleted Uranium Core

The Kilopower project aims to develop and demonstrate scalable fission-based power technology for systems capable of delivering 1 to 10 kW of electric power with a specific power ranging from 2.5 to 6.5 W/kg. This technology could enable high-power science missions or could be used to provide surface power for manned missions to the Moon or Mars. NASA has partnered with the U.S. Department of Energy's National Nuclear Security Administration, Los Alamos National Laboratory, Nevada National Security Site (NNSS), and Y−12 National Security Complex to develop and test a prototypic reactor and power system using existing facilities and infrastructure. This technology demonstration, referred to as the "Kilowatt Reactor Using Stirling TechnologY (KRUSTY)," will undergo nuclear ground testing by the end of calendar year (CY) 2017 at the NNSS. The 1-kWe variation of the Kilopower system was chosen for the KRUSTY demonstration. The concept for the 1-kWe flight system consists of a 4 kWt highly enriched uranium-molybdenum reactor operating at 800 degC coupled to sodium heat pipes. The heat pipes deliver heat to the hot ends of eight 125-W Stirling convertors producing a net electrical output of 1 kW. Waste heat is rejected using titanium-water heat pipes coupled to carbon composite radiator panels. The KRUSTY test, based on this design, uses a prototypic highly enriched uranium-molybdenum core coupled to prototypic sodium heat pipes. The heat pipes transfer heat to two Advanced Stirling Convertors (ASC−E2s) and six thermal simulators, which simulate the thermal draw of full-scale power conversion units. Thermal simulators and Stirling engines are gas cooled. The most recent project milestone was the completion of nonnuclear system-level testing using an electrically heated depleted uranium (DU) (nonfissioning) reactor core simulator at the NASA Glenn Research Center. System-level testing has validated performance predictions and has demonstrated system-level operation and control in a test configuration that replicates the one to be used at the Device Assembly Facility (DAF) at the NNSS. Fabrication, assembly, and testing of the DU core has allowed for higher fidelity system-level testing at Glenn, and has validated the fabrication methods to be used on the highly enriched uranium core that will supply heat for the DAF KRUSTY demonstration.

Briggs, Maxwell H.↗

NASA NTRS2020

Kilopower Project: The KRUSTY Fission Power Experiment and Potential Missions

The Kilopower Project was initiated by NASA’s Space Technology Mission Directorate/Game Changing Development Program in fiscal year 2015 to demonstrate subsystem-level technology readiness of small space fission power in a relevant environment (Technology Readiness Level 5) for space science and human exploration power needs. The Kilopower Project centerpiece is the Kilowatt Reactor Using Stirling TechnologY (KRUSTY) test, which consists of the development and testing of a ground technology demonstrator of a 1-kW(electric)–class fission power system (FPS). The technologies to be developed and validated by KRUSTY are extensible to space FPSs from 1 to 10 kW(electric), which can enable modular surface FPSs for human exploration as well as higher-power future potential deep space science missions. The KRUSTY demonstration is cofunded by NASA and the U.S. Department of Energy National Nuclear Security Administration. The KRUSTY demonstration in the National Critical Experiment Research Center’s Device Assembly Facility was completed in the first quarter of 2018.

Space nuclear reactor↗

NASA NTRS2020

Results of the KRUSTY Warm Critical Experiments

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a prototypic nuclear-powered test of a 5-kW(thermal) Kilopower space reactor. This paper presents results from the KRUSTY warm critical experiments, which were completed prior to the final system test. The first set of criticals comprised cold or zero-power criticals; i.e., the core was not heated by fission power. These were followed by three warm criticals, where fission power heated the core to 200°C, 300°C, and 450°C, respectively. These criticals provided the data, confidence, and regulatory framework that were needed to proceed with the KRUSTY nuclear system test. The criticals also provided valuable data for the benchmarking of codes applicable to all nuclear systems. Finally, a comparison of KRUSTY results to pretest predictions is provided, and overall, the models matched the experimental results very closely.

David I. Poston↗

NASA NTRS2018

The Kilopower Reactor Using Stirling TechnologY (KRUSTY) Nuclear Ground Test Results and Lessons Learned

The Kilopower nuclear ground testing nicknamed KRUSTY (Kilopower Reactor Using Stirling TechnologY) was completed at the Nevada Nuclear Security Site (NNSS) on March 21, 2018. This full scale nuclear demonstration verified the Kilopower reactor neutronics during startup, steady state, and transient operations in a space simulated environment. This was the first space reactor test completed for fission power systems in over 50 years and marked a turning point in NASA's nuclear program. The completed reactor power system design incorporated flight prototypic materials and full scale components in an effort to study the reactor dynamics at full power and significantly reduce follow on risk of a future flight demonstration. This design provided a unique opportunity for the power system to simulate several expected and unexpected mission scenarios that allowed the designers to verify that the reactor dynamics could tolerate many worst case conditions regarding reactor stability and control. The dynamic changes imposed on the reactor validated the ability of the reactor to load follow the power conversion system and passively control the fuel temperature and overall system stability. With successful completion of the KRUSTY experiment, the NASA/DOE team will evaluate the lessons learned throughout the project and apply them towards a flight demonstration of a Kilopower reactor.

Gibson, Marc A.↗

NASA NTRS2018

Kilopower Reactor Using Stirling TechnologY (KRUSTY) Nuclear Ground Test Results and Lessons Learned

The Kilopower nuclear ground testing nicknamed KRUSTY (Kilopower Reactor Using Stirling TechnologY) was completed at the Nevada Nuclear Security Site (NNSS) on March 21, 2018. This full scale nuclear demonstration verified the Kilopower reactor neutronics during startup, steady state, and transient operations in a space simulated environment. This was the first space reactor test completed for fission power systems in over 50 years and marked a turning point in NASA's nuclear program. The completed reactor power system design incorporated flight prototypic materials and full-scale components in an effort to study the reactor dynamics at full power and significantly reduce follow on risk of a future flight demonstration. This design provided a unique opportunity for the power system to simulate several nominal and off-nominal mission scenarios that allowed the designers to verify that the reactor dynamics could tolerate many worst case conditions regarding reactor stability and control. The dynamic changes imposed on the reactor validated the ability of the reactor to load follow the power conversion system and passively control the fuel temperature and overall system stability. With successful completion of the KRUSTY experiment, the NASA/DOE team will evaluate the lessons learned throughout the project and apply them towards a flight demonstration of a Kilopower reactor.

Gibson, Marc A.↗

NASA NTRS2018

Kilopower Reactor Using Stirling Technology (KRUSTY) Nuclear Ground Test Results and Lessons Learned

Gibson, Marc↗

NASA NTRS2020

Results of the KRUSTY Nuclear System Test

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a prototypic nuclear-powered test of a 5-kW(thermal) Kilopower space reactor. This paper presents results from the KRUSTY nuclear system test, which operated the power system at various temperatures and power levels for 28 consecutive hours. The testing showed that the system operated as expected and that the reactor is highly tolerant of possible failure conditions and transients. The key feature demonstrated was the ability of the reactor to load-follow the demand of the power conversion system. The thermal power of the test ranged from 1.5 to 5.0 kW(thermal), with a fuel temperature up to 880°C. Each 80-W(electric)–rated Stirling converter produced ~90 W(electric) at a component efficiency of ~35% and an overall system efficiency of ~25%.

David I. Poston↗

NASA NTRS2017

Kilopower: Small and Affordable Fission Power Systems for Space

The Nuclear Systems Kilopower Project was initiated by NASA's Space Technology Mission Directorate Game Changing Development Program in fiscal year 2015 to demonstrate subsystem-level technology readiness of small space fission power in a relevant environment (Technology Readiness Level 5) for space science and human exploration power needs. The Nuclear Systems Kilopower Project centerpiece is the Kilopower Reactor Using Stirling Technology (KRUSTY) test, which consists of the development and testing of a fission ground technology demonstrator of a 1 kWe-class fission power system. The technologies to be developed and validated by KRUSTY are extensible to space fission power systems from 1 to 10 kWe, which can enable higher power future potential deep space science missions, as well as modular surface fission power systems for exploration. The Kilopower Project is cofounded by NASA and the Department of Energy National Nuclear Security Administration (NNSA).KRUSTY include the reactor core, heat pipes to transfer the heat from the core to the power conversion system, and the power conversion system. Los Alamos National Laboratory leads the design of the reactor, and the Y-12 National Security Complex is fabricating it. NASA Glenn Research Center (GRC) has designed, built, and demonstrated the balance of plant heat transfer and power conversion portions of the KRUSTY experiment. NASA MSFC developed an electrical reactor simulator for non-nuclear testing, and the design of the reflector and shielding for nuclear testing. In 2016, an electrically heated non-fissionable Depleted Uranium (DU) core was tested at GRC in a configuration identical to the planned nuclear test. Once the reactor core has been fabricated and shipped to the Device Assembly Facility at the NNSAs Nevada National Security Site, the KRUSTY nuclear experiment will be assembled and tested. Completion of the KRUSTY experiment will validate the readiness of 1 to 10 kWe space fission technology for NASAs future requirements for sunlight-independent space power. An early opportunity for demonstration of In-Situ Resource Utilization (ISRU) capability on the surface of Mars is currently being considered for 2026 launch. Since a space fission system is the leading option for power generation for the first Mars human outpost, a smaller version of a planetary surface fission power system could be built to power the ISRU demonstration and ensure its end-to-end validity. Planning is underway to start the hardware development of this subscale flight demonstrator in 2018.

Space nuclear power↗

NASA NTRS2019

The Kilopower Space Nuclear Fission Power Reactor

Nuclear fission power offers an attractive alternative to solar electric or radioisotope power systems for certain applications on the Moon, Mars, and deep space science missions. The advantages of independence from solar irradiance, high energy density, and abundance of fuel allow fission power systems to enable novel, high power mission architectures. While NASA has had numerous fission power programs throughout its history, few have gone far beyond the design phase. The recent test campaign called the Kilopower Reactor Using Stirling Technology project (KRUSTY) focused on a low power, kilowatt-scale design for simplicity and reduced cost, with the driving motivation to perform a full nuclear hardware prototype test. Following the successful completion of the KRUSTY nuclear hardware test in March of 2018, NASA has begun the formulation process for a Technology Demonstration Mission (TDM) using the Kilopower reactor technology. In support of NASA's lunar surface initiatives, the Kilopower TDM will target a 1-3 kW fission electric power system that can survive the lunar night and operate for one year. The system will be heavily influenced by the KRUSTY reactor design, using a solid Uranium metal core with high temperature heat pipes and Stirling engine power conversion. During this formulation phase, continued engineering efforts are ongoing to improve heat transfer efficiency in the system, examine fission radiation damage effects, and begin to address the thermal and structural requirements of a Kilopower flight system.

Chaiken, Max↗

NASA NTRS2016

Nuclear Systems Kilopower Overview

The Nuclear Systems Kilopower Project was initiated by NASAs Space Technology Mission Directorate Game Changing Development Program in fiscal year 2015 to demonstrate subsystem-level technology readiness of small space fission power in a relevant environment (Technology Readiness Level 5) for space science and human exploration power needs. The Nuclear Systems Kilopower Project consists of two elements. The primary element is the Kilopower Prototype Test, also called the Kilopower Reactor Using Stirling Technology(KRUSTY) Test. This element consists of the development and testing of a fission ground technology demonstrator of a 1 kWe fission power system. A 1 kWe system matches requirements for some robotic precursor exploration systems and future potential deep space science missions, and also allows a nuclear ground technology demonstration in existing nuclear test facilities at low cost. The second element, the Mars Kilopower Scalability Study, consists of the analysis and design of a scaled-up version of the 1 kWe reference concept to 10 kWe for Mars surface power projected requirements, and validation of the applicability of the KRUSTY experiment to key technology challenges for a 10 kWe system. If successful, these two elements will lead to initiation of planning for a technology demonstration of a 10 kWe fission power capability for Mars surface outpost power.

Space Nuclear Power↗

NASA NTRSDate not supplied

Vacuum Operation of Consolidated Heat Pipe (CHP) for Fission Surface Power

Consolidated Heat Pipe (CHP) is a new technology that enables direct thermal power delivery to the hot-end of a Stirling engine using a heat pipe--a two phase passive heat transfer device. CHP was developed after the efforts of the Kilopower Using Stirling TechnologY (KRUSTY) test where a heat pipe was used to deliver thermal power from a fission-basedreactor to a Stirling engine to produce 1 kWe of useable electrical power in 2018. Large thermal losses were noted during the KRUSTY test where a temperature drop of 145 °C was measured between the heat pipe’s condenser and the engine’s hot-end. The Consolidated Heat Pipe was designed to address and mitigate this temperature loss. CHP was designed, built and tested at the Glenn Research Center (GRC). The initial test was performed in ambient air conditions, and the results were presented in “Consolidation of a Sodium Heat Pipe and Stirling Engine for Fission Surface Power” at the Thermal Fluids Analysis Workshop in 2023. Researchers at GRC have tested this technology again in a vacuum environment in 2024. Results show that the heat pipe and the hot-end of the Stirling engine are isothermal with a minimal temperature differential of approximately 2.5 °C in varying operational states. The Consolidated Heat Pipe technology has proven to be an efficient way of delivering thermal power directly to Stirling engines.

Greeta J Thaikattil↗

NASA NTRS2018

Kilopower Reactor Development and Testing

The Kilopower Reactor Using Stirling Technology (KRUSTY) was the first nuclear-powered operation of a truly new fission reactor concept in the US in over 40 years. It provided valuable experience and data, demonstrated the passive reactor operation of the Kilopower reactor class, showed that developing a small reactor is not inherently expensive, and demonstrated a space reactor concept that can be used for near-term space science and exploration. KRUSTY/Kilopower is the first step towards truly astounding space fission capabilities

Gibson, Marc↗

NASA NTRS2018

Special Topic for Nuclear CLT: Kilopower Project

NASA needs nuclear power to achieve a sustainable human presence on Lunar and Mars surfaces. Kilopower II addresses a gap in the NASA Technology Roadmaps (TA-03) for robust, sun-independent power generation in the 1 to 10 kWe range. NASA needs a long-life, low-cost power option for missions where solar is not practical. Future Exploratory Missions require a reliable source of power Lunar/Mars explorations including ISRU propellant production and crew life support and operations, for which there is no off-the-shelf solution. KRUSTY serves as a baseline for on follow-on human missions with multiple stand-alone units that provide redundancy/fault tolerance and flexibility for re-use at multiple sites with power needs of 1 to 10 kWe throughout the solar system (e.g. permanently-shaded lunar craters, subsurface Europa science, deep space electric propulsion, others.)

Hernandez-Lugo, Dionne Marie↗

NASA NTRS2020

Higher Power Design Concepts for NASA's Kilopower Reactor

The successful testing of the Kilopower reactor during the KRUSTY (Kilopower Reactor Using Stirling TechnologY) experiment significantly reduced the risk to fly fission power systems by demonstrating stable reactor operation through nominal and severe simulated mission scenarios. The experiment validated the neutronics, heat transfer, and power conversion systems needed for 1 kilowatt of electrical power production from the Kilopower reactor. The need for higher power reactors to support human exploration missions to the moon and Mars has become increasingly important due to the urgency to put boots on the moon by 2024 and have a sustainable presence in the following years. This desire has prompted NASA to continue the development of the Kilopower reactor to extend the power up to 10 kilowatts of electricity in support of a lunar base. These 10 kilowatt units are expected to be used as standalone units or be ganged together to create a modular power grid for propellent production, human habitats, and robotic exploration to name a few. The Kilopower reactor was originally designed to produce electrical power from 1 to 10 kilowatts using the same highly enriched uranium fuel, sodium heat pipes, and Stirling convertors at the proper scale. Consideration has also been given to the use of low enriched uranium fuel for these missions and will be studied along with the other aspects of the reactor. This paper will focus on the design concepts and trades associated with the scale up of the Kilopower power conversion system and heat transfer system to support human exploration of the moon and Mars.

Gibson, Marc↗

NASA NTRS2019

Space fission power: NASA's best bet to continue to explore the outer solar system

Implementation of balanced, cost-efficient programs to develop power technologies would enable future Voyager- and Cassini-class missions at the outermost planets; open up subsurface missions at Europa, Enceladus, and Titan; and facilitate orbiter and lander missions at Neptune and Triton. A rebalancing of the NASA power technology portfolio could establish the option of using fission power in space. The timing is right for the development of a small nuclear reactor design (such as KRUSTY) that can provide power for multi-year robotic missions and serve as a pathfinder and risk reduction strategy for the larger needs of future human exploration space power systems.

Cassini, John↗

NASA NTRSDate not supplied

Design Study of a Nuclear-Electric Transport Vehicle for Ice Giant Missions

Nuclear-electric propulsion, in which a nuclear reactor is used to power high specific-impulse ion thrusters for propulsion, is a promising method for such applications as missions to the ice giants Uranus and Neptune, identified as targets of high science value in the most recent NASA Decadal Survey of Planetary Science. Until recently, however, this has required a lightweight space nuclear power system that has yet to be designed. NASA has recently been developing the “Kilopower” nuclear reactor as a power source for future exploration missions, with a 1-kW prototype recently tested under the KRUSTY program. We utilized a next-generation Kilopower reactor to design a transportation system for missions to the ice giant planets. The mission objectives were to carry a payload of 1164 kg, comprising a lander/hopper vehicle to be delivered to explore the moon or moons of the target ice giant, along with atmospheric probes to drop into the atmosphere, plus 188 kg of science instrumentation on the spacecraft itself.

nuclear electric propulsion↗