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Design, development, and performance of 35 to 150 kilowatt Brayton power conversion module and application to nuclear reactor powered system
Preliminary results from a spacecraft system study show that an optimum hot junction temperature is in the range of 1500 K for advanced nuclear reactor technology combined with thermoelectric conversion. Advanced silicon germanium thermoelectric conversion is feasible if hot junction temperatures can be raised roughly 100 C or if gallium phosphide can be used to improve the figure of merit, but the performance is marginal. Two new classes of refractory materials, rare earth sulfides and boron-carbon alloys, are being investigated to improve the specific weight of the generator system. Preliminary data on the sulfides have shown very high figures of merit over short temperature ranges. Both n- and p-type doping have been obtained. Pure boron-carbide may extrapolate to high figure of merit at temperatures well above 1500 K but not lower temperature; n-type conduction has been reported by others, but not yet observed in the JPL program. Inadvertant impurity doping may explain the divergence of results reported.
Nuclear-electric propulsion can significantly reduce the launch mass for manned Mars missions. By using high-specific-impulse (lsp) electric propulsion systems with advanced nuclear reactors, the total mass-to-orbit for a series of manned Mars flight is reduced. Propulsion technologies required for the manned Mars mission are described. Multi-megawatt Ion and Magneto-Plasma-Dynamic (MPD) propulsion thrusters, Power-Processing Units and nuclear power source are needed. Xenon (Xe)-Ion and MPD thruster performance are detailed. Mission analyses for several Mars mission options are addressed. Both MPD and Ion propulsion were investigated. A four-megawatt propulsion system power level was assumed. Mass comparisons for all-chemical oxygen/hydrogen propulsion missions and combined chemical and nuclear-electric propulsion Mars fleets are included. With fleets of small nuclear-electric vehicles, short trip times to Mars are also enabled.
Over the past five decades, NASA Glenn Research Center had been advancing the development of single crystal silicon carbide growth, sensors and electronics device technologies, culminating in the recent demonstration of Micro-Electro-Mechanical Systems scale batch fabricated pressure sensors operating at 800 °C and integrated circuit electronics with demonstrated durability of over 1000 hours at 500 °C. As a result of the progress made in demonstrating the high temperature capability of the technology, insertion into actual operational environments, such as in jet engines and planet Venus, are in progress. The high temperature, near inert surface chemistry, and radiation hardness attributes of SiC, coupled with the relative maturation of the device batch microfabrication, contact metallization, and packaging technologies, make the material a prime candidate for use as part of future advanced nuclear reactor instrumentation and control strategy. Hence the current research efforts at NASA Glenn are aimed toward harnessing these attributes in developing SiC sensors and electronics for nuclear reactor applications, potentially for future Lunar/Martian nuclear power and the emerging terrestrial micro nuclear power plants.
Nuclear thermal propulsion (NTP) is a candidate in-space propulsion technology for crewed missions to Mars. An NTP engine relies on the use of a reactor as a heat exchanger to directly heat a hydrogen propellant which is expanded through a nozzle for high specific impulse (> 850s), high thrust (>15 klbf) propulsion. NTP reactor and engine technologies are currently being developed to enable a future NTP engine prototype demonstration. Technology readiness level (TRL) definitions are a useful tool to plan necessary technology advancement tasks as they provide guidance on expected development activities and necessary level of fidelity of test article or testing conditions for demonstration tasks. However, technology readiness definitions for an NTP reactor and related demonstration tasks have not yet been defined. This paper identifies relevant TRL definitions by the National Aeronautics and Space Administration (NASA) and Department of Energy (DOE). Based on these definitions, preliminary recommendations on testing conditions and important parameters to consider for NTP reactor technology development planning are provided for TRL 1 - 6. As a part of this effort, functional characteristics and important performance parameters for the reactor are identified, as well as a summary of relevant literature which was considered when assessing development tasks capable of meeting TRL definition criteria.
Nuclear thermal propulsion (NTP) is a candidate in-space propulsion technology for crewed missions to Mars. An NTP engine relies on the use of a reactor as a heat exchanger to directly heat a hydrogen propellant which is expanded through a nozzle for high specific impulse (> 850s), high thrust (>15 klbf) propulsion. NTP reactor and engine technologies are currently being developed to enable a future NTP engine prototype demonstration. Technology readiness level (TRL) definitions are a useful tool to plan necessary technology advancement tasks as they provide guidance on expected development activities and necessary level of fidelity of test article or testing conditions for demonstration tasks. However, technology readiness definitions for an NTP reactor and related demonstration tasks have not yet been defined. This paper identifies relevant TRL definitions by the National Aeronautics and Space Administration (NASA) and Department of Energy (DOE). Based on these definitions, preliminary recommendations on testing conditions and important parameters to consider for NTP reactor technology development planning are provided for TRL 1 - 6. As a part of this effort, functional characteristics and important performance parameters for the reactor are identified, as well as a summary of relevant literature which was considered when assessing development tasks capable of meeting TRL definition criteria.
The results of a materials technology program for a long-life (50,000 hr), high-temperature (950 C coolant outlet), lithium-cooled, nuclear space power reactor concept are reviewed and discussed. Fabrication methods and compatibility and property data were developed for candidate materials for fuel pins and, to a lesser extent, for potential control systems, reflectors, reactor vessel and piping, and other reactor structural materials. The effects of selected materials variables on fuel pin irradiation performance were determined. The most promising materials for fuel pins were found to be 85 percent dense uranium mononitride (UN) fuel clad with tungsten-lined T-111 (Ta-8W-2Hf).
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Deep Space Exploration missions, both for scientific and Human Exploration and Development (HEDS), appear to be as weight limited today as they would have been 35 years ago. Right behind the weight constraints is the nearly equally important mission limitation of cost. Launch vehicles, upper stages and in-space propulsion systems also cost about the same today with the same efficiency as they have had for many years (excluding impact of inflation). Both these dual mission constraints combine to force either very expensive, mega systems missions or very light weight, but high risk/low margin planetary spacecraft designs, such as the recent unsuccessful attempts for an extremely low cost mission to Mars during the 1998-99 opportunity (i.e., Mars Climate Orbiter and the Mars Polar Lander). When one considers spacecraft missions to the outer heliopause or even the outer planets, the enormous weight and cost constraints will impose even more daunting concerns for mission cost, risk and the ability to establish adequate mission margins for success. This paper will discuss the benefits of using a safe in-space nuclear reactor as the basis for providing both sufficient electric power and high performance space propulsion that will greatly reduce mission risk and significantly increase weight (IMLEO) and cost margins. Weight and cost margins are increased by enabling much higher payload fractions and redundant design features for a given launch vehicle (higher payload fraction of IMLEO). The paper will also discuss and summarize the recent advances in nuclear reactor technology and safety of modern reactor designs and operating practice and experience, as well as advances in reactor coupled power generation and high performance nuclear thermal and electric propulsion technologies. It will be shown that these nuclear power and propulsion technologies are major enabling capabilities for higher reliability, higher margin and lower cost deep space missions design to reliably reach the outer planets for scientific exploration.
An exploratory out-of-reactor investigation was made of the effects of short-time temperature excursions above the nominal operating temperature of 990 C on the compatibility of advanced nuclear space-power reactor fuel pin materials. This information is required for formulating a reliable reactor safety analysis and designing an emergency core cooling system. Simulated uranium mononitride (UN) fuel pins, clad with tungsten-lined T-111 (Ta-8W-2Hf) showed no compatibility problems after heating for 8 hours at 2400 C. At 2520 C and above, reactions occurred in 1 hour or less. Under these conditions free uranium formed, redistributed, and attacked the cladding.
In view of the difficult times the US and global economies are experiencing today, funds for the development of advanced fission reactors nuclear power systems for space propulsion and planetary surface applications are currently not available. However, according to the Energy Policy Act of 2005 the U.S. needs to invest in developing fission reactor technology for ground based terrestrial power plants. Such plants would make a significant contribution toward drastic reduction of worldwide greenhouse gas emissions and associated global warming. To accomplish this goal the Next Generation Nuclear Plant Project (NGNP) has been established by DOE under the Generation IV Nuclear Systems Initiative. Idaho National Laboratory (INL) was designated as the lead in the development of VHTR (Very High Temperature Reactor) and HTGR (High Temperature Gas Reactor) technology to be integrated with MMW (multi-megawatt) helium gas turbine driven electric power AC generators. However, the advantages of transmitting power in high voltage DC form over large distances are also explored in the seminar lecture series. As an attractive alternate heat source the Liquid Fluoride Reactor (LFR), pioneered at ORNL (Oak Ridge National Laboratory) in the mid 1960's, would offer much higher energy yields than current nuclear plants by using an inherently safe energy conversion scheme based on the Thorium --> U233 fuel cycle and a fission process with a negative temperature coefficient of reactivity. The power plants are to be sized to meet electric power demand during peak periods and also for providing thermal energy for hydrogen (H2) production during "off peak" periods. This approach will both supply electric power by using environmentally clean nuclear heat which does not generate green house gases, and also provide a clean fuel H2 for the future, when, due to increased global demand and the decline in discovering new deposits, our supply of liquid fossil fuels will have been used up. This is expected within the next 30 to 50 years, as predicted by the Hubbert model and confirmed by other global energy consumption prognoses. Having invested national resources into the development of NGNP, the technology and experience accumulated during the project needs to be documented clearly and in sufficient detail for young engineers coming on-board at both DOE and NASA to acquire it. Hands on training on reactor operation, test rigs of turbomachinery, and heat exchanger components, as well as computational tools will be needed. Senior scientist/engineers involved with the development of NGNP should also be encouraged to participate as lecturers, instructors, or adjunct professors at local universities having engineering (mechanical, electrical, nuclear/chemical, and/or materials) as one of their fields of study.
The development of plasma-core nuclear reactors for advanced terrestrial and space-power sources is researched. Experimental measurements of the intensity and the spectral distribution of radiation from a nonfissioning uranium plasma are reported.
Viewgraphs on the nuclear gas core propulsion research program are presented. The objectives of this research are to develop models and experiments, systems, and fuel elements for advanced nuclear thermal propulsion rockets. The fuel elements under investigation are suitable for gas/vapor and multiphase fuel reactors. Topics covered include advanced nuclear propulsion studies, nuclear vapor thermal rocket (NVTR) studies, and ultrahigh temperature nuclear fuels and materials studies.
Nuclear rockets, kiwi nuclear reactor tests, electric propulsion and gaseous reactor systems for manned exploration of mars
Solid core nuclear reactor engine variables, considering specific impulse, engine weight, operating life and engine thrust
Fissioning uranium plasmas are the nuclear fuel in conceptual high-temperature gaseous-core reactors for advanced rocket propulsion in space. A gaseous-core nuclear rocket would be a thermal reactor in which an enriched uranium plasma at about 10,000 K is confined in a reflector-moderator cavity where it is nuclear critical and transfers its fission power to a confining propellant flow for the production of thrust at a specific impulse up to 5000 sec. With a thrust-to-engine weight ratio approaching unity, the gaseous-core nuclear rocket could provide for propulsion capabilities needed for manned missions to the nearby planets and for economical cislunar ferry services. Fueled with enriched uranium hexafluoride and operated at temperatures lower than needed for propulsion, the gaseous-core reactor scheme also offers significant benefits in applications for space and terrestrial power. They include high-efficiency power generation at low specific mass, the burnup of certain fission products and actinides, the breeding of U-233 from thorium with short doubling times, and improved convenience of fuel handling and processing in the gaseous phase.
Advancement of U.S. scientific, security, and economic interests through a robust space exploration program requires high performance propulsion systems to support a variety of robotic and crewed missions beyond low Earth orbit. Past studies, in particular those in support of the Space Exploration Initiative (SEI), have shown nuclear thermal propulsion systems provide superior performance for high mass high propulsive delta-V missions. The recent NASA Design Reference Architecture (DRA) 5.0 Study re-examined mission, payload, and transportation system requirements for a human Mars landing mission in the post-2030 timeframe. Nuclear thermal propulsion was again identified as the preferred in-space transportation system. A common nuclear thermal propulsion stage with three 25,000-lbf thrust engines was used for all primary mission maneuvers. Moderately lower thrust engines may also have important roles. In particular, lower thrust engine designs demonstrating the critical technologies that are directly extensible to other thrust levels are attractive from a ground testing perspective. An extensive nuclear thermal rocket technology development effort was conducted from 1955-1973 under the Rover/NERVA Program. Both graphite and refractory metal alloy fuel types were pursued. Reactors and engines employing graphite based fuels were designed, built and ground tested. A number of fast spectrum reactor and engine designs employing refractory metal alloy fuel types were proposed and designed, but none were built. The Small Nuclear Rocket Engine (SNRE) was the last engine design studied by the Los Alamos National Laboratory during the program. At the time, this engine was a state-of-the-art graphite based fuel design incorporating lessons learned from the very successful technology development program. The SNRE was a nominal 16,000-lbf thrust engine originally intended for unmanned applications with relatively short engine operations and the engine and stage design were constrained to fit within the payload volume of the then planned space shuttle. The SNRE core design utilized hexagonal fuel elements and hexagonal structural support elements. The total number of elements can be varied to achieve engine designs of higher or lower thrust levels. Some variation in the ratio of fuel elements to structural elements is also possible. Options for SNRE-based engine designs in the 25,000-lbf thrust range were described in a recent (2010) Joint Propulsion Conference paper. The reported designs met or exceeded the performance characteristics baselined in the DRA 5.0 Study. Lower thrust SNRE-based designs were also described in a recent (2011) Joint Propulsion Conference paper. Recent activities have included parallel evaluation and design efforts on fast spectrum engines employing refractory metal alloy fuels. These efforts include evaluation of both heritage designs from the Argonne National Laboratory (ANL) and General Electric Company GE-710 Programs as well as more recent designs. Results are presented for a number of not-yet optimized fast spectrum engine options.
An overall system analysis approach is used to propose potential conceptual designs of advanced terrestrial nuclear power plants based on Oak Ridge National Laboratory (ORNL) Molten Salt Reactor (MSR) experience and utilizing Closed Cycle Gas Turbine (CCGT) thermal-to-electric energy conversion technology. In particular conceptual designs for an advanced 1 GWe power plant with turbine reheat and compressor intercooling at a 950 K turbine inlet temperature (TIT), as well as near term 100 MWe demonstration plants with TITS of 950 K and 1200 K are presented. Power plant performance data were obtained for TITS ranging from 650 to 1300 K by use of a Closed Brayton Cycle (CBC) systems code which considered the interaction between major sub-systems, including the Liquid Fluoride Thorium Reactor (LFTR), heat source and heat sink heat exchangers, turbo -generator machinery, and an electric power generation and transmission system. Optional off-shore submarine installation of the power plant is a major consideration.