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The thermal design work completed for the Thermal Protection System (TPS) of the Space Shuttle System (TPS) of the space shuttle vehicle was documented. This work was divided into three phases, the first two of which reported in previous documents. About 22 separate tasks were completed in phase III, such as: hot gas facility (HGF) support, guarded tank support, shuttle external tank (ET) thermal design handbook support, etc.
The process of steel production is energy and carbon intensive with global average energy consumption of 5.5 MWh/tonne of steel and CO2 emission intensity of 1.83 tonne CO2/tonne of steel. The steel making process has inherent CO2 emissions from mineral conversion and is considered major contributors to the global carbon emissions. The steel industry is responsible for 8% of global carbon emissions. The main objective of this research project is to execute and complete a front-end engineering and design (FEED) study for a commercial-scale, carbon capture project that separates 95% of the total CO2 emissions at the ArcelorMittal’s Hot Briquetted Iron (HBI) plant in Portland, TX (Figure 1). The HBI is an ore-based metallic that is used as high-grade feedstock for high-quality steel via an Electric Arc Furnace (EAF) route. The HBI plant produces 2.0 million metric tonnes of high-quality HBI and emits approximately 1 million tonnes CO2/yr. The capture system is a Pressure Swing Adsorption (PSA) system assisted Cryocap™ FG technology (Figure 2). The captured CO2 will be pipeline grade and will be geologically stored in a facility within 10 miles of the CO2 source. The Host Site location in Corpus Christi, TX, is near hydrocarbon processing facilities and near Environmental Justice (EJ) and Qualified Opportunity Zone (QOZ) communities. Due to the location of the Host Site, the retrofit project offers the ability to demonstrate how a workforce focused on the fossil energy sector can be redirected to the clean- energy sector. The Air Liquide Cryocap™ capture technology is a proven technology and has been extensively examined for large industrial applications. It has been shown to be applicable to a variety of industrial applications including the steel industry. Cryocap™ FG (specific setup for Flue Gas application) consists of a Pressure Swing Adsorption (PSA) unit coupled with a Cryogenic System. The PSA pre-concentrates the CO2 from the flue gas, while the cryogenic unit enables the CO2 purity to be increased to the desired level. The scope of this study incorporates completing FEED study of the CO2 capture system which includes point-source CO2 capture and balance-of-plant; Business Case Analysis (BCA) outlining the current and projected volumes of the steel plant’s point sources of CO2 and the potential utilization of tax credits, including its projected revenue and duration; Life Cycle Analysis (LCA); Environmental Justice Analysis; Economic Revitalization and Job Creation Outcomes Analysis; and Workforce Readiness Plan. The plant design work was divided into two components: Inside Battery Limits (ISBL) and Outside Battery Limits (OSBL). The ISBL focuses on the capture system, while the OSBL focuses on the utility feeds and ducting from the plant to the capture system. Various design and engineering deliverables will be developed to define commodity quantities, equipment specifications, and labour effort required to execute the project. These FEED study deliverables will be prepared with the intent to develop an overall project capital cost estimate consistent with an AACE Class 3 estimate. The modular approach for the Cryocap™ FG that is being designed for this study integrates compression, PSA, and cryogenic “bricks” to achieve the desired CO2 capture rates. This carbon capture system integrates easily with the existing plant, thus reducing project costs and risks. It is also capable of managing impurities such as nitrogen oxides (NOx), sulfur oxides (SOx), mercury, hydrocarbons, and particulate matter. The capture system has a smaller footprint than amine-based systems. The two-step process uses PSA to preconcentrate the CO2 in the feedstream and then uses the cryogenic portion to purify and compress the resulting high purity CO2 product. This combination of purification and compression (i.e., process intensification) significantly reduces the CAPEX associated with use of a separate compressor commonly utilized for amine solvent-based systems. Successful completion of the FEED study will provide DOE with a detailed understanding of the costs for scaling up this proven capture technology for commercial applications at industrial facilities.
Four space projects' activities are summarized. Design work on the Mars Penetrator Project, in cooperation with the NASA Ames Research Center, is being continued. Efforts are focused on the drilling mechanism which must penetrate the martian subsurface soil to collect and retrieve an uncontaminated sample. The new design consists of a rotary-percussive drill mechanism. This mechanism is optimum for dry drilling, necessary to avoid contamination of the soil sample, in many different soil types. The need for a small, relatively inexpensive device to study the chemical structure of this martian soil was also established. The egg design was chosen for its low cost compared to other systems and potential for a large number of eggs to be deployed on the martian surface. The design process included analysis of the dynamics of reentry, dissipation of heat during reentry, impact with the surface, access to undisturbed soil samples, and ability to gather samples from the soil at three depths. The egg consists of the reentry systems, soil probe lifting system, soil probe package, gas chromatograph, transmitter, and battery power supply. The egg must function only once, but is designed to withstand one martian year. The Mars Mole is designed as a rover-based device which penetrates the martian soil to a depth of up to 10 m, obtains a sample of soil, and returns it to the surface for analysis. The mole was designed to meet the following specifications: (1) weight less than 10 kg; (2) size less than 20 x 20 x 30 cm; (3) power less than 100 W; (4) ability to obtain a sample of at least 5 cc; (5) ability to penetrate fine, loose sand; and (6) need to obtain at least one sample. The space station umbilical connector project is a device which provides the translational motion of the connectors on the Space Station Freedom to allow engagement for power and data transfer. The design is capable of delivering a 20 lb force within the necessary tolerances and will operate reliably in the space environment.
The National Aeronautics and Space Administration (NASA)'s Constellation Program is depending on the Ares Projects Office (APO) to deliver the crew and cargo launch capabilities needed to send human explorers to the Moon, Mars, and beyond. The APO continues to make progress toward design, component testing, and early flight testing of the Ares I crew launch vehicle, as well as early design work for the Ares V cargo launch vehicle. Ares I and Ares V will form the core space launch capabilities that the United States needs to continue its pioneering tradition as a spacefaring nation (Figure 1). This paper will discuss design, fabrication, and testing progress toward building these new launch vehicles.
Circulating Moving Bed (CMB) combustion technology has its roots in traditional circulating fluidized bed technology and involves a novel method of solid fuel combustion and heat transfer. CMB technology represents a step change in improved performance and cost relative to conventional PC and FBC boilers. The CMB heat exchanger preheats the energy cycle working fluid, steam or air, to the high temperature levels required in systems for advanced power generation. Unique features of the CMB are the reduction of the heat transfer surfaces by about 60% as a result of the enhanced heat transfer rates, flexibility of operation, and about 30% lower cost over existing technology. The CMB Phase I project ran from July 2001 through March 2003. Its objective was to continue development of the CMB technology with a series of proof of concept tests. The tests were conducted at a scale that provided design data for scale up to a demonstration plant. These objectives were met by conducting a series of experiments in ALSTOM Power’s Multi-use Test Facility (MTF). The MTF was modified to operate under CMB conditions of commercial interest. The objective of the tests were to evaluate gas-to-solids heat transfer in the upper furnace, assess agglomeration in the high temperature CMB bubbling bed, and evaluate solids-to-tube heat transfer in the moving bed heat exchanger. The Phase I program results showed that there are still some significant technical uncertainties that needed to be resolved before the technology can be confidently scaled up for a successful demonstration plant design. Work remained in three primary areas: • scale up of gas to solid heat transfer • high temperature finned surface design • the overall requirements of mechanical and process design. The CMB Phase II workscope built upon the results of Phase I and specifically addressed the remaining technical uncertainties. It included a scaled MTF heat transfer test to provide the necessary data to scale up gas-to-solids heat transfer. A stress test rig was built and tested to provide validation data for a stress model needed to support high temperature finned surface design. Additional cold flow model tests and MTF tests were conducted to address mechanical and process design issues. This information was then used to design and cost a commercial CMB design concept. Finally, the MBHE was reconfigured into a slice arrangement and tested for an extended duration at a commercial CFB plant.
Multi-MW proton driver capability remains a challenging, critical technology for many core HEP programs, particularly the neutrino ones such as the Muon Collider and Neutrino factory, and for high-profile energy applications such as Accelerator Driven Subcritical Reactors (ADS) and Accelerator Transmutation of Waste for nuclear power and waste management. Work is focused almost exclusively on an SRF linac, as, to date, no re-circulating accelerator can attain the 10-20 MW capability necessary for the nuclear applications. Recently, the concept of isochronous orbits has been explored and developed for nonscaling FFAGs using powerful new methodologies in FFAG accelerator design. Work is progressing on a stable, high-intensity, 1 GeV isochronous FFAG. Initial specifications of novel magnets with the nonlinear radial fields required to support isochronous operation are also reported here.
We report on the design and development of an all-dielectric laser-driven accelerator to be used in the GALAXIE (GV-per-meter Acce Lerator And X-ray-source Integrated Experiment) project's compact free-electron laser. The approach of our working design is to construct eigenmodes, borrowing from the field of photonics, which yield the appropriate, highly demanding dynamics in a high-field, short wavelength accelerator. Topics discussed include transverse focusing, power coupling, bunching, and fabrication.
The design work for 2nd harmonic 95 GHz, 50 kW gyrotron based on continuous operation copper solenoid is presented. Thermionic magnetron injection gun specifications were calculated according to the linear trade off equation, and simulated with CST program. Numerical code is used for cavity design using the non-uniform string equation as well as particle motion in the “cold” cavity field. The mode TE02 with low Ohmic losses in the cavity walls was chosen as the operating mode. The Solenoid is designed to induce magnetic field of 1.8 T over a length of 40 mm in the interaction region with homogeneity of ±0.34%. The solenoid has six concentric cylindrical segments (and two correction segments) of copper foil windings separated by water channels for cooling. The predicted temperature in continuous operation is below 93 °C. The parameters of the design together with simulation results of the electromagnetic cavity field, magnetic field, electron trajectories, and thermal analyses are presented.
Inertial confinement fusion (ICF) experiments rely on complex multi-physics simulation codes such as the Lawrence Livermore National Laboratory-developed HYDRA to guide design work. However, these simulations have several dozen tunable parameters and can be computationally expensive. This makes searching the parameter space challenging and time-consuming. Recently developed automated tools utilize Bayesian optimization to search these high-dimensional parameter spaces for optimal designs. The optimization tools run 2D integrated simulations in HYDRA to converge on a design that produces specified scalar or vector outputs. In this paper, we apply the Bayesian optimization tools to two common tuning scenarios. First, we tune simulation inputs to match measurements of a well-characterized experiment at the National Ignition Facility. This type of tuning is commonly performed to compensate for the use of simplified simulation settings (e.g. reduced resolution) or to account for missing physics in the simulations. Second, we search for an ICF simulation design that has a particular radiation drive profile. These optimizations replicate the kinds of tuning researchers routinely perform, but do so with significantly reduced manual effort. This approach demonstrates a powerful and efficient pathway toward autonomous, high-fidelity design optimization for future ICF experiments.
With the downturn of the world economy, the priority of unmanned exploration of the solar system has been lowered. Instead of foregoing all missions to our neighbors in the solar system, a new philosophy of exploration mission design has evolved to insure the continued exploration of the solar system. The 'Discovery-class' design philosophy uses a low cost, limited mission, available technology spacecraft instead of the previous 'Voyager-class' design philosophy that uses a 'do-everything at any cost' spacecraft. The Percival Mission to Mars was proposed by Ares Industries as one of the new 'Discovery-class' of exploration missions. The spacecraft will be christened Percival in honor of American astronomer Percival Lowell who proposed the existence of life on Mars in the early twentieth century. The main purpose of the Percival mission to Mars is to collect and relay scientific data to Earth suitable for designing future manned and unmanned missions to Mars. The measurements and observations made by Percival will help future mission designers to choose among landing sites based on the feasibility and scientific interest of the sites. The primary measurements conducted by the Percival mission include gravity field determination, surface and atmospheric composition, sub-surface soil composition, sub-surface seismic activity, surface weather patterns, and surface imaging. These measurements will be taken from the orbiting Percival spacecraft and from surface penetrators deployed from Mars orbit. The design work for the Percival Mission to Mars was divided among four technical areas: Orbits and Propulsion System, Surface Penetrators, Gravity and Science Instruments, and Spacecraft Structure and Systems. The results for each of the technical areas is summarized and followed by a design cost analysis and recommendations for future analyses.
Analysis and concept design work completed in Phase 1 have identified a low heat rejection engine configuration with the potential to meet the Heavy Duty Transport Technology program specific fuel consumption goal of 152 g/kW-hr. The proposed engine configuration incorporates low heat rejection, in-cylinder components designed for operation at 24 MPa peak cylinder pressure. Water cooling is eliminated by selective oil cooling of the components. A high temperature lubricant will be required due to increased in-cylinder operating temperatures. A two-stage turbocharger air system with intercooling and aftercooling was selected to meet engine boost and BMEP requirements. A turbocompound turbine stage is incorporated for exhaust energy recovery. The concept engine cost was estimated to be 43 percent higher compared to a Caterpillar 3176 engine. The higher initial engine cost is predicted to be offset by reduced operating costs due the lower fuel consumption.
We are currently creating protective garments to be worn during the duration of SPE (solar particle events). Several garment prototypes have been created to protect the body, but nothing has been created for head protection. My focus during this internship was creating headgear designs. Some of the big requirements of an effective headgear design is that the hood design needs to cover the forehead and not have any gaps between the hood and neckline, and the areal density of radiation shielding needs to be at least 1.5 g/cm2. My designs were inspired by many different brands and designers including Nike’s outerwear selection, Moncler’s Fall 20 Genius collaborations with Simone Rocha, Craig Green, and Alyx, Marine Serre F/W 20, and A-Cold-Wall S/S 19. All of these had great examples of hood and vest designs. Many sketches were created from these and many other inspirations. Pattern development began by taking several measurements of the head and neck. I drafted the hood to cover the forehead and cover the neck. After the initial draft, the pattern was modified to accommodate a center panel to contour and shape the hood further. I also created a shoulder drape based on a kimono sleeve to add extra coverage over the neckline of the garment from a basic sloper’s neckline and shoulders. Radiation shielding was a special consideration in my design work. I did extensive research on different materials and ways to incorporate them into garments and found that I was not limited to polypropylene or polyethylene. Many common textiles are hydrogen rich, such as cotton, polyester, and silk, and could be incorporated into designs as radiation shielding. From this research, I am in the process of creating a prototype that uses these materials as shielding. I will be returning for the summer and hope to put more of the ideas I have into production.
The building-block approach is a method for building confidence in designs, working from lower-level components to more complex assemblies, using knowledge gained at each step to inform higher fidelity representations. The goals of this paper are to revisit the basic techniques of the building-block approach as it applies to structural design and analysis and illustrate some best practices that should be considered when developing structural analysis models. The paper demonstrates the process of leveraging existing information to build confidence in the design/development of analysis models, followed by examples of how the building-block approach for analysis was used in NASA hardware and spacecraft development efforts. The paper will also discuss virtual testing and hybrid simulation techniques, which are showing promise for more efficient/cost-effective verification of aerospace structures.
PERLE (Powerful Energy Recovery LINAC for Experiment) is a high-power Energy Recovery LINAC (ERL) facility with 20 mA beam current and beam energy from 250 MeV to 500 MeV featuring three passes through two cryomodules. It is a hub for validation of the ERL technology development towards future energy and intensity frontier machines. Design challenges of PERLE and its beam parameters make it a test-bed to validate multi-turn high current ERL operation for the LHeC. It will be the first ERL for some pioneering experiment of the eN interaction with radioactive nuclei. In this work, design and optimization of the commutational magnet (B-com) used to spread/combine the three beams and one series of the quadrupole magnet is discussed. It gives the design parameters including: yoke geometry, pole profile, and material, and calculation of the excitation current needed to drive the magnet, the coil parameters and the number of turns. The B-com magnet is optimized for a 30° bending angle with magnetic field of 0.88 T along the magnet length and a harmonic content of 0.036%. The quadrupole magnet is designed for a gradient field of 34.15 T/m and experiences saturation above this value. Further studies to avoid saturation and achieve the maximum gradient of 44.1 T/m required by the beam dynamics is undergoing.
Future millimeter-wave radio astronomy instruments will use arrays of many SIS receivers, either as focal plane arrays on individual radio telescopes, or as individual receivers on the many antennas of radio interferometers. Such applications will require broadband integrated mixers without mechanical tuners. To produce such mixers, it will be necessary to improve present mixer design techniques, most of which use the three-frequency approximation to Tucker's quantum mixer theory. This paper examines the adequacy of three approximations to Tucker's theory: (1) the usual three-frequency approximation which assumes a sinusoidal LO voltage at the junction, and a short-circuit at all frequencies above the upper sideband; (2) a five-frequency approximation which allows two LO voltage harmonics and five small-signal sidebands; and (3) a quasi five-frequency approximation in which five small-signal sidebands are allowed, but the LO voltage is assumed sinusoidal. These are compared with a full harmonic-Newton solution of Tucker's equations, including eight LO harmonics and their corresponding sidebands, for realistic SIS mixer circuits. It is shown that the accuracy of the three approximations depends strongly on the value of omega R(sub N)C for the SIS junctions used. For large omega R(sub N)C, all three approximations approach the eight-harmonic solution. For omega R(sub N)C values in the range 0.5 to 10, the range of most practical interest, the quasi five-frequency approximation is a considerable improvement over the three-frequency approximation, and should be suitable for much design work. For the realistic SIS mixers considered here, the five-frequency approximation gives results very close to those of the eight-harmonic solution. Use of these approximations, where appropriate, considerably reduces the computational effort needed to analyze an SIS mixer, and allows the design and optimization of mixers using a personal computer.
PERLE (Powerful Energy Recovery LINAC for Experiment) is a high-power Energy Recovery LINAC (ERL) facility with 20 mA beam current and beam energy from 250 MeV to 500 MeV featuring three passes through two cryomodules. It is a hub for validation of the ERL technology development towards future energy and intensity frontier machines. Design challenges of PERLE and its beam parameters make it a test-bed to validate multi-turn high current ERL operation for the LHeC. It will be the first ERL for some pioneering experiment of the eN interaction with radioactive nuclei. In this work, design and optimization of the commutational magnet (B-com) used to spread/combine the three beams and one series of the quadrupole magnet is discussed. It gives the design parameters including: yoke geometry, pole profile, and material, and calculation of the excitation current needed to drive the magnet, the coil parameters and the number of turns. The B-com magnet is optimized for a 30° bending angle with magnetic field of 0.88 T along the magnet length and a harmonic content of 0.036%. The quadrupole magnet is designed for a gradient field of 34.15 T/m and experiences saturation above this value. Further studies to avoid saturation and achieve the maximum gradient of 44.1 T/m required by the beam dynamics is undergoing.
The detailed outer mold line shaping of a Mach 1.6, demonstrator-sized low-boom concept is presented. Cruise trim is incorporated a priori as part of the shaping objective, using an equivalent-area-based approach. Design work is performed using a gradient-driven optimization framework that incorporates a three-dimensional, nonlinear flow solver, a parametric geometry modeler, and sensitivities derived using the adjoint method. The shaping effort is focused on reducing the under-track sonic boom level using an inverse design approach, while simultaneously satisfying the trim requirement. Conceptual-level geometric constraints are incorporated in the optimization process, including the internal layout of fuel tanks, landing gear, engine, and crew station. Details of the model parameterization and design process are documented for both flow-through and powered states, and the performance of these optimized vehicles presented in terms of inviscid L/D, trim state, pressures in the near-field and at the ground, and predicted sonic boom loudness.
This thesis starts from the analytical mechanical analysis of a superconducting solenoid, loaded by self generated Lorentz forces. Also, a finite element model is proposed and verified with the analytical results. To study the anisotropic behavior of a coil made by layers of superconductor and insulation, a finite element meso-mechanic model is proposed and designed. The resulting material properties are then used in the main solenoid analysis. In parallel, design work is performed as well: an existing Insert Test Facility (ITF) is adapted and structurally verified to support a coil made of YBa{sub 2}Cu{sub 3}O{sub 7}, a High Temperature Superconductor (HTS). Finally, a technological winding process was proposed and the required tooling is designed.