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All sources NASA NTRS DOE OSTI

DOE OSTI2015

Design and Testing of a Liquid Nitrous Oxide and Ethanol Fueled Rocket Engine

A small-scale, bi-propellant, liquid fueled rocket engine and supporting test infrastructure were designed and constructed at the Energetic Materials Research and Testing Center (EMRTC). This facility was used to evaluate liquid nitrous oxide and ethanol as potential rocket propellants. Thrust and pressure measurements along with high-speed digital imaging of the rocket exhaust plume were made. This experimental data was used for validation of a computational model developed of the rocket engine tested. The developed computational model was utilized to analyze rocket engine performance across a range of operating pressures, fuel-oxidizer mixture ratios, and outlet nozzle configurations. A comparative study of the modeling of a liquid rocket engine was performed using NASA CEA and Cantera, an opensource equilibrium code capable of being interfaced with MATLAB. One goal of this modeling was to demonstrate the ability of Cantera to accurately model the basic chemical equilibrium, thermodynamics, and transport properties for varied fuel and oxidizer operating conditions. Once validated for basic equilibrium, an expanded MATLAB code, referencing Cantera, was advanced beyond CEAs capabilities to predict rocket engine performance as a function of supplied propellant flow rate and rocket engine nozzle dimensions. Cantera was found to comparable favorably to CEA for making equilibrium calculations, supporting its use as an alternative to CEA. The developed rocket engine performs as predicted, demonstrating the developedMATLAB rocket engine model was successful in predicting real world rocket engine performance. Finally, nitrous oxide and ethanol were shown to perform well as rocket propellants, with specific impulses experimentally recorded in the range of 250 to 260 seconds.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2019

Study of the Effects of Materials Selection for the Closeout Structure on the Service Life of a Liquid Rocket Engine Thrust Chamber

The external structure of rocket engines thrust chambers for aerospace applications should be designed in order to provide adequate stiffness to the thrust chamber; however, it affects in a significant way the engine service life since it acts as a structural bound for the internal structure which is subjected to very high temperature values. The adoption of thin closeout structures allows to have lighter structures and to significantly increase the service life of the thrust chamber. The aim of the present work is to perform numerical investigations on the influence of the closeout geometry and materials on the number of cycles to failure of the thrust chamber. Furthermore, a study on the impact of creep phenomenon on the service life is illustrated. In particular, the present paper is focused on the thermomechanical study of the closeout structure, in terms of material choice, thickness, joining process with the inner liner, etc. Transient thermal and static structural nonlinear analyses are conducted by means of a commercial finite element code (ANSYS), in order to evaluate the number of cycles to failure for the investigated configurations. Viscoplastic models are adopted in order to simulate the highly nonlinear and rate-dependent phenomena occurring in the inner liner structure.

36 MATERIALS SCIENCE↗

DOE OSTI2018

The Rocket Test Case Study.

Suppose Tom is working to develop a rocket. Susan is very interested in knowing what Tom is doing but cannot directly observe his testing of the rocket propulsion system. Specifically, she would like to know if Tom has the ability to launch a heavy rocket or a light rocket. She thinks she can learn about Tom’s capability by learning about what type of rocket engine Tom is using, and the number of rockets in the design. She is considering buying a special sensor that can observe flashes from the rocket firing up during the tests and indicate if the rockets fire in a sufficiently narrow window of time such that they would successfully lift a heavy rocket.

42 ENGINEERING↗

DOE OSTI2019

Design and Test of a Pintle Injector for Oxy-Coal Combustion

This paper presents the design and fluid spray profile of a modular pintle injector for pressurized oxy-coal combustion systems. Although pintle injectors have been traditionally used in rocket engines, it presents a promising approach in clean coal combustion technology due to effectiveness and enhanced performance. Thus, a detailed design of a pintle injection developed for pressurized oxy-coal combustion has been presented in this work. Additionally, the fluid injection and spray angles have been characterized through shadowgraph imaging. Furthermore, droplet size, Reynolds number, Weber number and Ohnesorge number have also been characterize through shadowgraphy. At the highest mass flow of gaseous propellant, the spray presents the smallest droplet size. Comparisons between different concentrations of weight are achieved. Ohnesorge and Reynolds are compared to determine atomization mechanisms

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2018

Nuclear Rocket Motors: Development Status and Application Prospects

The possibility and expediency of using nuclear rocket motors at the present stage of development of rocketspace technology as part of conventional and advanced space means, including the upper stages of carrier rockets and acceleration blocks, reusable interorbital tugs, and a motor assembly of the piloted Martian expedition complex are discussed. It is shown that because of high cost it is not expedient to use NRM in single-use booster blocks and multi-use tugs for transport operations in near-Earth space, since the specific cost of delivering a useful load into high working orbits increases by a factor of 1.5 or more as compared with transport means based on oxygen-hydrogen rocket motors. At the same time, their use for the Martian expedition complex makes it possible to improve considerably the design characteristics of the complex (starting mass and expedition duration) as compared with non-nuclear motor systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2019

Oxy-Combustion Modeling for Direct-Fired Supercritical CO 2 Power Cycles

We report that supercritical CO 2 power cycles for fossil energy power generation will likely employ oxy-combustion at very high pressures, possibly exceeding 300 bar. At these high pressures, a direct fired oxy-combustor is more likely to behave like a rocket engine than any type of conventional gas turbine combustor. Issues such as injector design, wall heat transfer, and combustion dynamics may play a challenging role in combustor design. Computational fluid dynamics modeling will not only be useful, but may be a necessity in the combustor design process. To accurately model turbulent reacting flows, combustion submodels appropriate for the conditions of interest as defined by the turbulent time and length scales as well as chemical kinetic time scales are necessary. Here, this paper presents a comparison of various turbulence–chemistry interaction (TCI) modeling approaches on a canonical, single injector, direct-fired sCO 2 combustor. Large eddy simulation is used to model the turbulent combustion process with varying levels of injector oxygen concentration while comparing the effect of the combustion submodel on CO emissions and flame shape. While experimental data are not yet available to validate the simulations, the sensitivity of CO production and flame shape can be studied as a function of combustion modeling approach and oxygen concentration in an effort to better understand how to approach combustion modeling at these unique conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Space Nuclear Power Autonomous Control Algorithm and Control Element Test Bed

Nuclear thermal rockets are currently NASA’s preferred option for use in a manned mission to Mars in the 2040s. The communication delay between an Earth ground station and a spacecraft heading toward Mars can be up to 20 min. Therefore, controlling the nuclear rocket engine would require either a full-time reactor operator on the mission or an autonomous control system for the reactor. The latter idea of making space nuclear reactors fully autonomous has drawn more interest from stakeholders, but such an autonomous control system must be rigorously tested and validated before it is certified for human use. The cost of a full ground test for a space nuclear reactor is tremendous, so a nonnuclear mock reactor test bed was created to test and validate control elements and control algorithms for space nuclear reactors. The test bed consists of control element hardware that inputs physical measurement data into a reactor emulator to produce the reactor’s performance under steady-state, transient, and fault conditions. The control element hardware consists of six full-sized control drums equipped with servo drives and motors and is instrumented with optical encoders, resolvers, and torque sensors for drum movement characterization. In addition to the drums, a two-phase flow loop was designed and built to mimic the valves and turbomachinery associated with the propellant flow through a nuclear thermal rocket engine; components such as pressure sensors, flow meters, thermocouples, and tachometers are instrumented throughout the loop to characterize the fluid flow, valve, and turbomachinery behavior of the system. The data from the physical hardware (e.g., drum position, propellant flow rates) are input to a nuclear reactor simulator to determine the actual nuclear reactor parameters, and the data are sent back to a control algorithm to complete the control loop. The ability to conduct numerous tests of the control systems and autonomous algorithms can help validate the instrumentation and control aspects for a space nuclear reactor for every possible fault situation.

Wilson, Brandon↗

DOE OSTI2016

Design and qualification of an UHV system for operation on sounding rockets

The sounding rocket mission MAIUS-1 has the objective to create the first Bose–Einstein condensate in space; therefore, its scientific payload is a complete cold atom experiment built to be launched on a VSB-30 sounding rocket. An essential part of the setup is an ultrahigh vacuum system needed in order to sufficiently suppress interactions of the cooled atoms with the residual background gas. Contrary to vacuum systems on missions aboard satellites or the international space station, the required vacuum environment has to be reached within 47 s after motor burn-out. This paper contains a detailed description of the MAIUS-1 vacuum system, as well as a description of its qualification process for the operation under vibrational loads of up to 8.1 g{sub RMS} (where RMS is root mean square). Even though a pressure rise dependent on the level of vibration was observed, the design presented herein is capable of regaining a pressure of below 5 × 10{sup −10} mbar in less than 40 s when tested at 5.4 g{sub RMS}. To the authors' best knowledge, it is the first UHV system qualified for operation on a sounding rocket.

42 ENGINEERING↗

DOE OSTI2019

Rocket Engine Test System for Development of Novel Propulsion Technologies

A 150 lb f thrust class, modular, bi-propellant, rocket engine/gas-generator and supporting test infrastructure has been developed in a cooperative effort between Sandia National Laboratories and the New Mexico Institute of Mining and Technology’s (NMIMT’s) Energetic Materials Research and Testing Center (EMRTC). This modular test engine design consists of a head end fuel-oxidizer injector, a spark ignition gaseous H 2 /O 2 torch igniter, combustion chamber and nozzle module. This robust design allows for rapid configuration changes as well as economical repair should hardware become damaged in testing. The engine interfaces with a permanently installed pressurizing system capable of delivering liquid nitrous oxide and a variety of liquid fuels for both rocket engine development and propellant performance evaluation. The regulated high pressure systems allow for delivery of liquefied gases above their saturation pressure as well as allowing for high pressure rocket engine/gas-generator operation. The facility test cell houses a 1 ton thrust capacity test stand leaving room for larger scale engine development.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Space Nuclear Thermal Propulsion Critical Assembly Boron Worth Experiments

The Space Nuclear Thermal Propulsion (SNTP) project was an attempt to create a more powerful and more efficient rocket engine utilizing nuclear technologies. As part of this project a zero-power critical assembly referred to as SNTPCX was designed and installed at Sandia National Laboratories. The SNTP-CX was a light water moderated particle bed reactor utilizing highly enriched uranium fuel in the form of UC particles. The SNTP-CX performed 142 runs covering numerous experiments from the year 1989 to 1992. The program was canceled in 1994 as the nation’s priorities shifted. Now these experiments are being evaluated for use as criticality safety benchmarks. Nineteen of the 142 reactor runs were dedicated to a series of experiments to calculate the worth of the boron used in the light water moderator. This series of experiments has been selected for further evaluation as a critical benchmark for the International Criticality Safety Benchmark Evaluation Project (ICSBEP).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Technology Demonstration of a High-Pressure Swirl Oxy-Coal Combustor

This technical report presents the exploration of the design and prototyping of a High-Pressure Swirl Oxy-coal Combustor. Pressurized oxy-coal combustion systems have the potential to improve efficiency along with an increased carbon capture rate. Reduction of flue gas at higher pressure, smaller system size, and capital cost reductions render high-pressure oxy-coal systems particularly attractive as next-generation energy-producing systems. High-pressure oxy-coal combustion systems are a recent concept, and thus operability issues of combustor designs for such systems are not fully understood. Significant challenges exist to maintain oxy-coal combustion stability at elevated pressure and a high CO 2 diluent environment. Although a body of knowledge exists for high-pressure oxygen combustion in rocket engines (or similar applications), it is yet to be strategized how these fundamental concepts can be translated to low-temperature CO 2 diluent combustion regimes. The realization of the pressurized oxy-coal based systems requires combustor components to be designed and demonstrated for an operating pressure over 10 bar. However, pressurized oxy-coal combustor design information at this pressure range and scale relevant to validate those proposed systems is currently limited. Experimental data from MWth scale oxy-coal combustors are needed to identify the optimal trade-off between net efficiency and systems size. The proposed effort is aimed at demonstrating a 1 MWth down-fired swirl Oxy-Coal combustor and investigate the interrelation between combustor operating conditions (pressure; flame stability; flue gas recirculation ratio) and conversion efficiencies to minimize oxygen requirements. One of the key challenges is to configure burner design (i.e., swirl number and injector) and operating conditions for high-pressure oxy-coal combustion systems. These experiments differ from current systems partly due to the high theoretical flame temperature and related burner operability issues associated with oxy-combustion. An ASPEN PLUS® model study for 550 MWe TIPS and ENEL pressurized oxy-coal systems with CO 2 recirculation was performed to evaluate system design, subsystems sizing, and operating condition determination. The system analysis effort included TRL and technology gap determination of subsystems and critical components. This information was scaled to develop design requirements (design pressure and flue gas recirculation: RR Flue Gas = $\frac{m_{flue}}{m_{total}}$) for the 1 MWth combustor. The effects of a wide range of carbon dioxide recirculation ratios on the thermal efficiency of ENEL and TIPS cycles are studied. The pressure of 10 bar and 80 bar are used for ENEL and TIPS cycles, respectively. The thermal efficiency of ENEL is significantly higher than the efficiency of TIPS at a pressure of less than 10 bar. The insights from system analysis were then used to design a 1 MWth swirl oxy-coal combustor. Flame temperature analysis and material strength analysis was performed to determine the combustor thickness. The structural integrity of the combustor was validated by finite element analysis using Abacus® and Hypermesh®. Feasibility of igniters and secondary burners are investigated in successful high-pressure oxy-methane combustion. The secondary burners are designed in such a way that it can operate between 100 to 500 kW firing input. Three generations of the pintle injector were designed based on swirl numbers (S=0, 0.9, and 1.2). Key pintle injector parameters such as pintle size, pintle orifice size, spray pattern were investigated by cold flow tests. Information from these tests was used to modify injector design for smooth and successful operation. A 5 mm pintle orifice size was decided upon as the optimum size for oxy-coal operation for the combustor. Shadow sizing experiments were performed to identify the atomization rate of each injector. Different coal water slurry mixtures (30 – 50% coal by wt% in the mixture) at various total momentum ratios (TMR) were investigated for this purpose. These experiments provided decisive information to choose the best design of the injector. The injector with 1.2 swirl provided higher atomization in all cases than other designs. The mean equivalent droplet size of the jet was similar at different TMR and mixture ratios using this injector, thus making it suitable for use in most cases. Therefore, the 1.2 swirl-pintle injector was chosen for the shakedown test. The combustor and other sub-systems, including feed systems and control and data acquisition, have been manufactured, assembled, and integrated. The total system integration and installation began on July 1, 2020. The shake-down tests and initial operational capability demonstration are expected to be completed by September 30, 2020.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Implementation of Surface Tension on a Reacting Flow Solver, PeleLM: Preprint

In liquid rocket engines, the fuel is supplied to the combustion chamber in the liquid state though injectors. Such fuel undergoes atomization, vaporization, and combustion processes. To design reliable and efficient injectors, it is required to understand the full processes. This research is part of an effort to develop a full atomization-vaporization-combustion solver from first principles. As an initial step to tackle the atomization process, a multiphase flow solver is under development. For the development, a library of the volume of fluid scheme for multiphase, IRL is coupled with a reacting Navier-Stokes equation solver, PeleLM. Furthermore, as the surface tension has considerable effects on spray breakup. surface tension is implemented in the momentum equation using the continuum surface force model and the improved height function technique.

height function↗

DOE OSTI2015

Center for Space Nuclear Research (CSNR) NTP Design Team Report

The CSNR NTR Design Team has developed a history of collaboration with NASA Marshall Spaceflight Center (MSFC). First assembled in the summer of 2013 to explore the concept of the Low-Enriched Uranium Nuclear Thermal Rocket (LEU-NTR), the team continued research to find solutions with guiding Nuclear Thermal Propulsion (NTP) technological development and provide design and analysis support for the Space Capable Cryogenic Thermal Engine (SCCTE) Project. The work presented in this report provides a background on the cermet LEU-NTR, summarizes work complete to explore a new design space for NTRs, and describes the SCCTE core that was developed.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Characterization of Oxy-Coal Swirl Injector

The article presents the design and testing of a coal-slurry swirl-pintle injector for high pressure oxy-coal combustion systems. Pressurized oxy-coal combustion-based systems have the potential to improve efficiency by recovering latent heat of the steam in flue gas and achieve 90% CO2 capture. In oxy-coal combustion, coal is burned in the presence of pure oxygen, which results in higher efficiency and less greenhouse gas in the exhaust. With the advancement of pressurized oxy-coal combustor research, there is a need to investigate injector technology suitable for this unique combustion approach. Effective atomization and mixing of coal-slurry and oxidizer pose a challenge for the efficient burning of coal particles. A swirl-pintle type injector was designed and tested to enhance the atomization of the coal-water slurry spray by adding a swirl to the oxygen flow path. Although pintle type injectors are traditionally used in rocket engines, they present a promising approach in clean coal combustion technology due to higher mixing effectiveness and enhanced performance. The mixing behavior of three pintle injectors with different swirl numbers (S = 0, 0.9, and 1.2) was tested using a high-speed shadow sizing technique. Mixture ratios of 30% (by mass) coal-water slurry were studied. The droplet diameter and dispersion characteristics were determined from shadow images of coal-water spray. The jet breakup length, droplet number, total moment ratio (TMR), and Ohnesorge number were then calculated to compare the performance of different injectors. The paper presents an empirical correlation of the TMR with droplet size and spray regimes. For a pintle injector with S = 1.2 swirler, the droplets diameter was found to be in the range of 1 mm to 12 mm. The jet breakup length was also shorter in comparison to S= 0 and 0.9 injectors. A second atomization zone was also observed at 2 and 5 diameters downstream of injector exist at spray edge and jet core respectively

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2016

SPOC Benchmark Case: SNRE Model

The Small Nuclear Rocket Engine (SNRE) was modeled in the Center for Space Nuclear Research’s (CSNR) Space Propulsion Optimization Code (SPOC). SPOC aims to create nuclear thermal propulsion (NTP) geometries quickly to perform parametric studies on design spaces of historic and new NTP designs. The SNRE geometry was modeled in SPOC and a critical core with a reasonable amount of criticality margin was found. The fuel, tie-tubes, reflector, and control drum masses were predicted rather well. These are all very important for neutronics calculations so the active reactor geometries created with SPOC can continue to be trusted. Thermal calculations of the average and hot fuel channels agreed very well. The specific impulse calculations used historically and in SPOC disagree so mass flow rates and impulses differed. Modeling peripheral and power balance components that do not affect nuclear characteristics of the core is not a feature of SPOC and as such, these components should continue to be designed using other tools. A full paper detailing the available SNRE data and comparisons with SPOC outputs will be submitted as a follow-up to this abstract.

MCNP↗

DOE OSTI2014

Optimal Shielding for Minimum Materials Cost of Mass

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2014

Optimal Shielding Design For Minimum Materials Cost or Mass - Paper 128

Material costs dominate some shielding design problems. This is certainly the case for manned nuclear power space applications for which shielding is essential and the cost of launching by rocket from Earth is high. In such situations or in those where shielding volume or mass is constrained, it is important to optimize the design. Although trial and error synthesis methods may succeed, a more systematic approach is warranted. Design automation may also potentially reduce engineering costs. The objective is to automate the design of optimal radiation shielding to meet specified attenuation requirements given a menu of allowed shielding materials, their properties and their delivered costs per unit volume. The cost-optimal design is one which, at each location in the shield, chooses the menu material minimizing a particular functional of forward and adjoint angular fluxes plus material cost. Thus a Boltzmann forward and adjoint angular flux solver with additional calculations can evaluate whether a shield design is optimal or whether improvements are possible. An iterative algorithm based on approximated optimality is proposed to solve for the optimal shield design and numerical experiments with it are discussed. The future use of 3D Boltzmann solvers will allow extending results to shaped shield designs in which material is not wasted to maintain unneeded spherical symmetry. The largest cost savings of automated optimal design of shielding is expected to be for applications involving nuclear powered manned space missions where the required shielding attenuation of radiation and costs are both large. However, less exotic applications such as the shielding of radiation facilities on Earth could also benefit from optimal shielding design, and automation of the design process may reduce engineering costs. (author)

61 RADIATION PROTECTION AND DOSIMETRY↗

DOE OSTI2019

Solid Rocket Motor Design using a Low-Dimensional Fluid Model

This document is a summary of the mathematical models that are used in the DARPA TRADES project for the solid rocket motor design challenge. It is hoped that this brief description of these models will be of use to those that are working on the project.

42 ENGINEERING↗