High-Temperature Pump
Heat exchanger in water-cooled pumps allows high-temperature operation.
Hale, R. R.↗
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Hybrid Electric Aircraft Thermal Management: Now, New Visions and Future Concepts and Formulation
The global fuel consumption by commercial airlines has increased each year since 2009 and is predicted to reach an all-time high of 97 billion gallons in 2019. There is also an environmental impact from this: CO2 emissions from commercial passenger and freight operations totaled 918 Mt in 2018 (ICCT, 2019), or around 2.5% of global energy-related CO2 emissions. Passenger transport accounted for 81% of the total. Emissions from aviation have grown 32% over the past five years. Coupled with this aspect, there is a continuous and growing need to satisfy ever-growing electrical power needs on commercial and military aircraft. All the armed services (Army, Navy, and Air Force) are continuously trying to enhance UAV (unmanned aerial vehicle) endurance and range across a broad fleet of different aircraft. The commercial Boeing 787 requires about 1.2MWe and that is expected to grow. Current technologies used to supply increased on-board electrical power are generally: 1) “burn more fuel and convert through on-board generators” and 2) use additional heavy (i.e., weight-inefficient) and sometimes unsafe battery systems on-board the aircraft. The aircraft industry is seeking new, innovative ways to satisfy this increasing power demand. One as-yet-untapped power source is the enormous amount of “waste” thermal energy flowing out the jet engine exhaust; some estimates in smaller “by-pass” flow jet engines is several hundreds of kilowatts (e.g., Pratt & Whitney Canada PW545B turbofan). This quantity is much higher in large jet engines associated with commercial aircraft. This large waste thermal energy manifests itself in large temperature differences within the by-pass-flow engine exhaust system relative to outside ambient conditions, because of the actual by-pass engine design configuration. There is strong need to develop thermal technologies and systems that could harness and convert at least a portion of this thermal energy into useful electrical energy to satisfy growing on-board electrical needs. In addition, there is a strong desire within the aircraft and engine manufacturing community to reduce the “carbon footprint” of the industry though reduced fuel usage worldwide. NASA has a robust aircraft electrification program to meet these desires and support industry in its aircraft electrification objectives. This program is integrating thermoacoustic systems, advanced lightweight heat exchanger technology, and advanced heat pipe technology to capture and transport large amounts of engine waste thermal energy for on-board power conversion, advanced heat-pump cooling, and exergy enhancement (i.e., temperature lift). Advanced lightweight heat exchangers are envisioned to capture engine exhaust thermal energy at approximately 673 K and deliver it to efficient thermoacoustic power conversion systems operating at temperature ratios (Thot/Tcold) > 1.6. Advanced heat pipe systems are envisioned to transport thermal energy from low temperature sources, through thermoacoustic heat pumps, to high temperature needs such as wing anti-icing, fuel pre-heating, and combustion air pre-heating. The paper will discuss the current state-of-the-art, objectives, system design architecture, and remaining technical challenges in system formulation within the NASA aircraft electrification program.
Dyson, Rodger↗
Lunar base heat pump, phase 1
This report describes the Phase 1 process and analysis used to select a refrigerant and thermodynamic cycle as the basis of a vapor compression heat pump requiring a high temperature lift, then to perform a preliminary design to implement the selected concept, including major component selection. Use of a vapor compression heat pump versus other types was based on prior work performed for the Electric Power Research Institute. A high lift heat pump is needed to enable a thermal control system to remove heat down to 275 K from a habitable volume when the external thermal environment is severe. For example, a long-term lunar base habitat will reject heat from a space radiator to a 325 K environment. The first step in the selection process was to perform an optimization trade study, quantifying the effect of radiator operating temperature and heat pump efficiency on total system mass; then, select the radiator operating temperature corresponding to the lowest system mass. Total system mass included radiators, all heat pump components, and the power supply system. The study showed that lunar night operation, with no temperature lift, dictated the radiator size. To operate otherwise would require a high mass penalty to store power. With the defined radiation surface, and heat pump performances assumed to be from 40 percent to 60 percent of the Carnot ideal, the optimum heat rejection temperature ranged from 387 K to 377 K, as a function of heat pump performance. Refrigerant and thermodynamic cycles were then selected to best meet the previously determined design conditions. The system was then adapted as a ground-based prototype lifting temperature to 360 K (versus 385 K for flight unit) and using readily available commercial-grade components. Over 40 refrigerants, separated into wet and dry compression behavioral types, were considered in the selection process. Refrigerants were initially screened for acceptable critical temperature. The acceptable refrigerants were analyzed in ideal single and two-stage thermodynamic cycles. Top candidates were analyzed assuming realistic component limits and system pressure drops, and were evaluated for other considerations such as safety, environmental impact, and commercial availability. A maximum coefficient of performance (COP) of 56 percent of the Carnot ideal was achievable for a three-stage CFC-11 cycle operating under the flight conditions above. The program was completed by defining a control scheme and by researching and selecting the major components, compressor and heat exchangers, that could be used to implement the thermodynamic cycle selected. Special attention was paid to using similar technologies for the SIRF and flight heat pumps resulting in the commercially available equivalent of the flight unit. A package concept was generated for the components selected and mass and volume estimated.
Goldman, Jeffrey H.↗
High Temperature mechanically pumped fluid loop for space applications - working fluid selection
Mechanically pumped single-phase fluid loops are increasingly being used for heat rejection purposes in space applications. Examples of Earth orbiting missions using this technology include NSTS Shuttles (water and Freon-based loops) and the International Space Station (water and ammonia-based loops). For deep space missions, both the Mars Pathfinder (1996) and Mars Exploration Rover (2003) missions used mechanically pumped Freon-I 1 loops for their primary Heat Rejection Systems (HRS.) Mechanically pumped loops are particularly well suited for rejecting large amounts of waste heat from spacecraft and future missions incorporating components with extremely high thermal energy dissipation (e.g. radar instruments, Radioisotope-based power sources) are ideal candidates for their use. However, previous implementations of mechanically pumped loops were designed for moderate temperatures (below 6OOC) and, thus, would require relatively large radiators to reject high heat loads to space. Loops designed for a higher operating temperature would allow large amounts of heat to be rejected within the constraints of a mass efficient thermal control system.
high temperature↗
The Design and Testing of the LSSIF Advanced Thermal Control System
The Life Support Systems Integration Facility (LSSIF) provides a platform to design and evaluate advanced manned space systems at NASA Johnson Space Center (JSC). The LSSIF Early Human Testing Initiative requires the integration of such subsystems to enable human occupancy of the 6 meter chamber for a 90 day closed volume test. The Advanced Thermal Control System (TCS) is an important component of the integrated system by supplying coolant to the subsystems within the chamber, such as the Air Revitalization System. The TCS incorporates an advanced high efficiency, heat pump to reject waste heat from the chamber to an external sink or 'lift' temperature that emulates a Lunar environment. The heat pump is the High Lift Heat Pump, developed by Foster-Miller, Inc., and is the main test article of the TCS. The heat pump prototype utilizes a non-CFC refrigerant in a design where the thermal requirements exceed existing terrestrial technology. These operating requirements provide a unique opportunity to design and test an advanced integrated thermal system and the associated controls. The design, control, and systems integration of the heat pump and the TCS also have terrestrial technology application. This paper addresses the design of the TCS and the heat pump, along with the control scheme to fully test the heat pump. Design approaches utilized in the LSSIF TCS are promoted for implementation in terrestrial thermal systems. The results of the preliminary thermal and fluid analyses used to develop the control of the thermal systems will also be discussed. The paper includes objectives for the 90 day human test and the test setup. Finally, conclusions will be drawn and recommendations for Earth design application are submitted.
Henson, Robert A.↗
NASA Goddard Space Flight Center Cooperative Enterprise
The viability of a Capillary Heat Pump (CHP) concept using a Loop Heat Pipe evaporator and an eductor in a closed loop to reject heat at a higher temperature than it is acquired at with the goal of reducing spacecraft radiator area is examined. Eductor inefficiency resulting from the mixing of high velocity motive flow with low velocity suction flow may preclude spacecraft radiator area savings. The utility of a CHP for thermal management may be limited to those missions where system mass is of secondary concern compared to system reliability, or where a heat pump is required to accommodate relatively high thermal rejection temperatures. Shearography techniques for nondestructive inspection and evaluation were examined for two unique applications. Shearography is shown to give good results in evaluating the quality of bonds holding lead tiles to the SWIFT spacecraft BAT gamma ray mask. Also, a novel technique was developed allowing specular objects to be inspected using shearography to evaluate bonding between the skin and core of a specular surface honeycomb structure. Large-scale bond failures are readily identified.
Fredley, Joseph E.↗
Conceptual design of a lunar base thermal control system
Space station and alternate thermal control technologies were evaluated for lunar base applications. The space station technologies consisted of single-phase, pumped water loops for sensible and latent heat removal from the cabin internal environment and two-phase ammonia loops for the transportation and rejection of these heat loads to the external environment. Alternate technologies were identified for those areas where space station technologies proved to be incompatible with the lunar environment. Areas were also identified where lunar resources could enhance the thermal control system. The internal acquisition subsystem essentially remained the same, while modifications were needed for the transport and rejection subsystems because of the extreme temperature variations on the lunar surface. The alternate technologies examined to accommodate the high daytime temperatures incorporated lunar surface insulating blankets, heat pump system, shading, and lunar soil. Other heat management techniques, such as louvers, were examined to prevent the radiators from freezing. The impact of the geographic location of the lunar base and the orientation of the radiators was also examined. A baseline design was generated that included weight, power, and volume estimates.
Simonsen, Lisa C.↗
High temperature mechanically pumped fluid loop for space applications : working fluid selection
Mechanically pumped single-phase fluid loops are well suited for transporting and rejecting large amounts of waste heat from spacecraft electronics and power supplies. While past implementations of these loops on spacecraft have used moderate operating temperatures (less than 6OoC), higher operating temperatures would allow equivalent heat loads to be rejected by smaller and less massive radiators. A high temperature (100 to 15OOC) mechanically pumped fluid loop is currently being investigated at the Jet Propulsion Laboratory for use on future Mars missions. This paper details the trade study used to select the high temperature working fluid for the system and the initial development testing of loop components.
thermal control↗
Advanced radiator concepts
Two radiator systems to reject heat from future space nuclear power systems were conceptually designed. One design would dissipate 1.7 MWt of heat at 600 K, and the other would reject 2.4 MWt at 875 K. The low-temperature radiator utilized a pumped loop system constructed of titanium, and achieved a specific mass of 5.8 kg/sq m, including pumps and structure. The high-temperature radiator system utilized potassium heat pipes constructed of SiC-reinforced titanium, and achieved a specific mass of 5.5 kg/sq m. Both radiators took advantage of light, high-thermal-conductivity carbon/graphite composite fins to distribute and radiate the rejected heat.
Begg, L. L.↗
Performance Evaluation of a Vapor-compression-cycle Based Heat Pump System for a Lunar Habitat under the Impact of Dust Deposits on the Coupled Radiators
Space exploration gains new momentum. A near goal is set by NASA to return humans to the Moon andestablish a sustainable presence on the lunar surface for more repeatable and affordable expeditions.The lunar dust is one of the dangerous environment hazard causing serious problems for explorationactivities. In this paper, in order to study the impact of lunar dust on the performance of a thermalmanagement system for a lunar habitat, a dynamical model of an active thermal control system that iscomprised of a vapor-compression cycle heat pump and a radiator loop is developed. A heat pump to liftthe heat rejection temperature is required due to high lunar daytime surface temperature. Parametricstudies on radiator size, percentage of dust coverage on the radiator, and lunar habitat location arecarried out. The results show that lunar deposits can significantly increase the power consumption ofthe thermal management system. A dust covered radiator panel results in net heat input to the heattransfer fluid during the period of strong solar irradiance, causing deteriorated performance of theradiator loop. The lunar dust contamination problem raises the requirement of redundancy design of asystem for fault tolerance. A synergetic design of a thermal management system, a power generationsystem and robotic maintenance system is proposed to achieve maximal mass cut for a whole lunarhabitat system.
Chunjian Pan↗
Potential of a New Lunar Surface Radiator Concept for Hot Lunar Thermal Environments
The optimum radiator configuration in hot lunar thermal environments is one in which the radiator is parallel to the ground and has no view to the hot lunar surface. However, typical spacecraft configurations have limited real estate available for top-mounted radiators, resulting in a desire to use the spacecraft s vertically oriented sides. Vertically oriented, flat panel radiators will have a large view factor to the lunar surface, and thus will be subjected to significant incident lunar infrared heat. Consequently, radiator fluid temperatures will need to exceed approx.325 K (assuming standard spacecraft radiator optical properties) in order to provide positive heat rejection at lunar noon. Such temperatures are too high for crewed spacecraft applications in which a heat pump is to be avoided. A recent study of vertically oriented radiator configurations subjected to lunar noon thermal environments led to the discovery of a novel radiator concept that yielded positive heat rejection at lower fluid temperatures. This radiator configuration, called the Upright Lunar Terrain Radiator Assembly (ULTRA), has exhibited superior performance to all previously analyzed concepts in terms of heat rejection in the lunar noon thermal environment. A key benefit of the ULTRA is the absence of louvers or other moving parts and its simple geometry. Analysis of the ULTRA for a lunar extravehicular activity (EVA) portable life support system (PLSS) is shown to provide moderate heat rejection, on average, at all solar incident angles assuming an average radiator temperature of 294 K, whereas prior concepts exhibited insignificant heat rejection or heat absorption at higher incident angles. The performance of the ULTRA for a lunar lander is also discussed and compared to the performance of a vertically oriented, flat panel radiator at various lunar latitudes.
Ochoa, Dustin A.↗
Optimized Radiator Geometries for Hot Lunar Thermal Environments
The optimum radiator configuration in hot lunar thermal environments is one in which the radiator is parallel to the ground and has no view to the hot lunar surface. However, typical spacecraft configurations have limited real estate available for top-mounted radiators, resulting in a desire to use the spacecraft's vertically oriented sides. Vertically oriented, flat panel radiators will have a large view factor to the lunar surface, and thus will be subjected to significant incident lunar infrared heat. Consequently, radiator fluid temperatures will need to exceed approximately 325 K (assuming standard spacecraft radiator optical properties) in order to provide positive heat rejection at lunar noon. Such temperatures are too high for crewed spacecraft applications in which a heat pump is to be avoided. A recent study of vertically oriented radiator configurations subjected to lunar noon thermal environments led to the discovery of a novel radiator concept that yielded positive heat rejection at lower fluid temperatures. This radiator configuration, called the Intense Thermal Infrared Reflector (ITIR), has exhibited superior performance to all previously analyzed concepts in terms of heat rejection in the lunar noon thermal environment. A key benefit of ITIR is the absence of louvers or other moving parts and its simple geometry (no parabolic shapes). ITIR consists of a specularly reflective shielding surface and a diffuse radiating surface joined to form a horizontally oriented V-shape (shielding surface on top). The point of intersection of these surfaces is defined by two angles, those which define the tilt of each surface with respect to the local horizontal. The optimum set of these angles is determined on a case-by-case basis. The idea assumes minimal conductive heat transfer between shielding and radiating surfaces, and a practical design would likely stack sets of these surfaces on top of one another to reduce radiator thickness.
Ochoa, Dustin↗
Compact, Lightweight Electromagnetic Pump for Liquid Metal
A proposed direct-current electromagnetic pump for circulating a molten alkali metal alloy would be smaller and lighter and would demand less input power, relative to currently available pumps of this type. (Molten alkali metals are used as heat-transfer fluids in high-temperature stages of some nuclear reactors.) The principle of operation of this or any such pump involves exploitation of the electrical conductivity of the molten metal: An electric current is made to pass through the liquid metal along an axis perpendicular to the longitudinal axis of the flow channel, and a magnetic field perpendicular to both the longitudinal axis and the electric current is superimposed on the flowchannel region containing the electric current. The interaction between the electric current and the magnetic field produces the pumping force along the longitudinal axis. The advantages of the proposed pump over other such pumps would accrue from design features that address overlapping thermal and magnetic issues.
Godfroy, Thomas↗
Ceramic Wick For Capillary-Pumped Heat Pipe
Fibrous ceramic wick allows choice of working fluid and high-temperature fabrication and/or operation. Wick material resists degradation at temperatures from -195 to +1,500 degrees C. Liquid refrigerant fills bore of silica/alumina wick. After flowing by capillary action through pores of wick, refrigerant evaporates from finned outer surface of wick and enters heat pipe, flowing toward condenser section.
Seidenberg, Benjamin↗
A Comparison of Coolant Options for Brayton Power Conversion Heat Rejection Systems
This paper describes potential heat rejection design concepts for Brayton power conversion systems. Brayton conversion systems are currently under study by NASA for Nuclear Electric Propulsion (NEP) and surface power applications. The Brayton Heat Rejection Subsystem (HRS) must dissipate waste heat generated by the power conversion system due to inefficiencies in the thermal-to-electric conversion process. Sodium potassium (NaK) and H2O are two coolant working fluids that have been investigated in the design of a pumped loop and heat pipe space HRS. In general NaK systems are high temperature (300 to 1000 K) low pressure systems, and H2O systems are low temperature (300 to 600 K) high pressure systems. NaK is an alkali metal with health and safety hazards that require special handling procedures. On the other hand, H2O is a common fluid, with no health hazards and no special handling procedures. This paper compares NaK and H20 for the HRS pumped loop coolant working fluid. A detailed Microsoft Excel (Microsoft Corporation, Redmond, WA) analytical model, HRS_Opt, was developed to evaluate the various HRS design parameters. It is capable of analyzing NaK or H2O coolant, parallel or series flow configurations, and numerous combinations of other key parameters (heat pipe spacing, diameter and radial flux, radiator facesheet thickness, fluid duct system pressure drop, system rejected power, etc.) of the HRS. This paper compares NaK against water for the HRS coolant working fluid with respect to the relative mass, performance, design and implementation issues between the two fluids.
Mason, Lee S.↗
A Comparison of Coolant Options for Brayton Power Conversion Heat Rejection Systems
This paper describes potential heat rejection design concepts for Brayton power conversion systems. Brayton conversion systems are currently under study by NASA for Nuclear Electric Propulsion (NEP) and surface power applications. The Brayton Heat Rejection Subsystem (HRS) must dissipate waste heat generated by the power conversion system due to inefficiencies in the thermal-to-electric conversion process. Sodium potassium (NaK) and H2O are two coolant working fluids that have been investigated in the design of a pumped loop and heat pipe space HRS. In general NaK systems are high temperature (300 to 1000 K) low pressure systems, and H2O systems are low temperature (300 to 600 K) high pressure systems. NaK is an alkali metal with health and safety hazards that require special handling procedures. On the other hand, H2O is a common fluid, with no health hazards and no special handling procedures. This paper compares NaK and H2O for the HRS pumped loop coolant working fluid. A detailed Microsoft Excel (Microsoft Corporation, Redmond, WA) analytical model, HRS_Opt, was developed to evaluate the various HRS design parameters. It is capable of analyzing NaK or H2O coolant, parallel or series flow configurations, and numerous combinations of other key parameters (heat pipe spacing, diameter and radial flux, radiator facesheet thickness, fluid duct system pressure drop, system rejected power, etc.) of the HRS. This paper compares NaK against water for the HRS coolant working fluid with respect to the relative mass, performance, design and implementation issues between the two fluids.
Siamidis, John↗
Solar energy
The book opens with a review of the patterns of energy use and resources in the United States, and an exploration of the potential of solar energy to supply some of this energy in the future. This is followed by background material on solar geometry, solar intensities, flat plate collectors, and economics. Detailed attention is then given to a variety of solar units and systems, including domestic hot water systems, space heating systems, solar-assisted heat pumps, intermediate temperature collectors, space heating/cooling systems, concentrating collectors for high temperatures, storage systems, and solar total energy systems. Finally, rights to solar access are discussed.
Rapp, D.↗
Space Evaporator Absorber Radiator (SEAR) for Thermal Storage on Manned Spacecraft
Future manned exploration spacecraft will need to operate in challenging thermal environments. State-of the- art technology for active thermal control relies on sublimating water ice and venting the vapor overboard in very hot environments. This approach can lead to large loss of water and a significant mass penalty for the spacecraft. This paper describes an innovative thermal control system that uses a Space Evaporator Absorber Radiator (SEAR) to control spacecraft temperatures in highly variable environments without venting water. SEAR uses heat pumping and energy storage by LiCl/water absorption to enable effective cooling during hot periods and regeneration during cool periods. The LiCl absorber technology has the potential to absorb over 800 kJ per kg of system mass, compared to phase change heat sink systems that typically achieve approx. 50 kJ/kg. The optimal system is based on a trade-off between the mass of water saved and extra power needed to regenerate the LiCl absorber. This paper describes analysis models and the predicted performance and optimize the size of the SEAR system, estimated size and mass of key components, and power requirements for regeneration. We also present a concept design for an ISS test package to demonstrate operation of a subscale system in zero gravity.
Izenson, Michael G.↗