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All sources NASA NTRS DOE OSTI

NASA NTRS1984

Active cooling requirements for propellant storage

Recent NASA and DOD mission models have indicated future needs for orbital cryogenic storage and supply systems. Two thermal control systems which show the greatest promise for improving propellant storage life were evaluated. One system was an open cycle thermodynamic vent type with a refrigeration system for partial hydrogen reliquefaction located at the LH2 tank and a vapor cooled shield for integrated and non-integrated tank designs to reduce boiloff. The other was a closed system with direct refrigeration at the LH2 tank. A reversed Brayton cycle unit was baselined for the propellant processor. It is concluded that: (1) reliquefaction systems are not attractive for minimizing propellant boiloff; (2) open cycle systems may not be economically attractive for long term storage; (3) a number of refrigeration systems are available to assist in the long term storage of cryogenic propellants; and (4) shields can significantly improve the performance of mechanical coolers.

Klein, G. A.↗

NASA NTRS1985

Recent cryocooler progress in Japan

The progress of cryocoolers and related devices in Japan is reviewed. The Japanese National Railways has developed the light weight 4 K on-board refrigerators since 1977 as part of the MAGLEV train program. Superconducting and cryogenic fundamental technology was examined which included high performance cryocooler, magnetic refrigerator and superfluid refrigeration. Space cryogenics such as the cooling systems of IR-detectors was studied. Cryocooler for special applications such as cryopump, NMR-CT and JJ devices was investigated. Compact heat exchangers, high performance regenerators and reliable compressors are investigated as a critical component technology.

Matsubara, Y.↗

NASA NTRS1985

Dynamics insulation systems

Advanced dynamic insulation systems were analyzed from a thermodynamic point of view. A particular performance measure is proposed in order to characterize various insulations in a unique manner. This measure is related to a base quantity, the refrigeration power ratio. The latter is the minimum refrigeration power, for a particular dynamic insulation limit, to the actual reliquefaction power associated with cryoliquid boiloff. This ratio serves as reference quantity which is approximately constant for a specific ductless insulation at a chosen normal boiling point. Each real container with support structure, vent tube, and other transverse components requires a larger refrigeration power. The ratio of the actual experimental power to the theoretical value of the support-less system is a suitable measure of the entire insulation performance as far as parasitic heat leakage is concerned. The present characterization is illustrated using simple thermodynamic system examples including experiments with liquid nitrogen. Numerical values are presented and a comparison with liquid helium is given.

Chen, W. E. W.↗

NASA NTRS1989

Magnetic-Flux-Compression Cooling Using Superconductors

Proposed magnetic-flux-compression refrigeration system produces final-stage temperatures below 4.2 K. More efficient than mechanical and sorption refrigerators at temperatures in this range. Weighs less than comparable liquid-helium-cooled superconducting magnetic refrigeration systems operating below 4.2 K. Magnetic-flux-compression cooling stage combines advantages of newly discovered superconductors with those of cooling by magnetization and demagnetization of paramagnetic salts.

Strayer, Donald M.↗

NASA NTRS1991

Report of the sensor cooler technology panel

The Sensor Cooler Technology Panel identified three major areas in which technology development must be supported in order to meet the system performance requirements for the Astrotech 21 mission set science objectives. They are: long life vibration free refrigerators; mechanical refrigeration for 2 K to 5 K; and flight testing of emerging prototype refrigerators. A development strategy and schedule were recommended for each of the three areas.

Ross, Ronald↗

NASA NTRS1991

Advances in cryogenic engineering. Vols. 37A & 37B - Proceedings of the 1991 Cryogenic Engineering Conference, Univ. of Alabama, Huntsville, June 11-14, 1991

The present volume on advances in cryogenic engineering discusses heat and mass transfer in helium, heat transfer in cryogenic fluids, thermoacoustic oscillations, and insulation. Attention is given to applications of superconductivity with reference to magnetic stability and coil protection, cryogenic techniques, and refrigeration for electronics and superconducting systems. Topics addressed include compressors, expanders, and pumps for liquid helium, magnetic refrigerators, pulse tube refrigerators, and cryocoolers. Also examined are properties of cryogenic fluids, cryogenic applications in transportion and space science and technology, and cryogenic instrumentation.

Fast, Ronald W.↗

NASA NTRS1998

Modeling of a Two-Phase Jet Pump with Phase Change, Shocks and Temperature-Dependent Properties

One of the primary motivations behind this work is the attempt to understand the physics of a two-phase jet pump which constitutes part of a flow boiling test facility at NASA-Marshall. The flow boiling apparatus is intended to provide data necessary to design highly efficient two-phase thermal control systems for aerospace applications. The facility will also be capable of testing alternative refrigerants and evaluate their performance using various heat exchangers with enhanced surfaces. The test facility is also intended for use in evaluating single-phase performance of systems currently using CFC refrigerants. Literature dealing with jet pumps is abundant and covers a very wide array of application areas. Example application areas include vacuum pumps which are used in the food industry, power station work, and the chemical industry; ejector systems which have applications in the aircraft industry as cabin ventilators and for purposes of jet thrust augmentation; jet pumps which are used in the oil industry for oil well pumping; and steam-jet ejector refrigeration, to just name a few. Examples of work relevant to this investigation includes those of Fairuzov and Bredikhin (1995). While past researchers have been able to model the two-phase flow jet pump using the one-dimensional assumption with no shock waves and no phase change, there is no research known to the author apart from that of Anand (1992) who was able to account for condensation shocks. Thus, one of the objectives of this work is to model the dynamics of fluid interaction between a two-phase primary fluid and a subcooled liquid secondary fluid which is being injected employing atomizing spray injectors. The model developed accounts for phase transformations due to expansion, compression, and mixing. It also accounts for shock waves developing in the different parts of the jet pump as well as temperature and pressure dependencies of the fluid properties for both the primary two-phase mixture and the secondary subcooled liquid. The research effort on which this document partly reports described a relatively simple model capable of describing the performance of a two-phase flow jet pump. The model is based on the isentropic homogeneous expansion/compression hypothesis and is capable of fully incorporating the effects of shocks in both the mixing chamber and the throat/diffuser parts of the pump. The physical system chosen is identical to that experimentally tested by Fairuzov and Bredikhin (1995) and should therefore be relatively easy to validate.

Sherif, S. A.↗

NASA NTRS2000

Design and Testing of Demonstration Unit for Maintaining Zero Cryogenic Propellant Boiloff

Launching of cryogenic propellants into earth orbit and beyond is very expensive. Each additional pound of payload delivered to low earth orbit requires approximately 35 pounds of additional weight at liftoff. There is therefore a critical need to minimize boiloff in spacecraft long term missions/systems. Various methods have been used to date, including superinsulation and thermodynamic vents to reduce boiloff. A system was designed and tested as described herein that will totally eliminate boiloff. This system is based on a closed-loop, two-stage pulse tube refrigerator with a net refrigeration of four watts at 15k for the recovery of hydrogen propellant. It is designed to operate at 30 Hz which is an order of magnitude higher than other typical pulse tube refrigerators. This high frequency allows the use of a much smaller, lighter weight compressor, This paper describes the system design, fabrication and test results.

Dean, W. G.↗

NASA NTRS1995

Staged regenerative sorption heat pump

A regenerative adsorbent heat pump process and system for cooling and heating a space. A sorbent is confined in a plurality of compressors of which at least four are first stage and at least four are second stage. The first stage operates over a first pressure region and the second stage over a second pressure region which is higher than the first. Sorbate from the first stage enters the second stage. The sorbate loop includes a condenser, expansion valve, evaporator and the compressors. A single sorbate loop can be employed for single-temperature-control such as air conditioning and heating. Two sorbate loops can be used for two-temperature-control as in a refrigerator and freezer. The evaporator temperatures control the freezer and refrigerator temperatures. Alternatively the refrigerator temperature can be cooled by the freezer with one sorbate loop. A heat transfer fluid is circulated in a closed loop which includes a radiator and the compressors. Low temperature heat is exhausted by the radiator. High temperature heat is added to the heat transfer fluid entering the compressors which are desorbing vapor. Heat is transferred from compressors which are sorbing vapor to the heat transfer fluid, and from the heat transfer fluid to the compressors which are desorbing vapor. Each compressor is subjected to the following phases, heating to its highest temperature, cooling down from its highest temperature, cooling to its lowest temperature, and warming up from its lowest temperature. The phases are repeated to complete a cycle and regenerate heat.

Jones, Jack A.↗

NASA NTRS2011

Lightweight Magnetic Cooler With a Reversible Circulator

A design of a highly efficient and lightweight space magnetic cooler has been developed that can continuously provide remote/distributed cooling at temperatures in the range of 2 K with a heat sink at about 15 K. The innovative design uses a cryogenic circulator that enables the cooler to operate at a high cycle frequency to achieve a large cooling capacity. The ability to provide remote/distributed cooling not only allows flexible integration with a payload and spacecraft, but also reduces the mass of the magnetic shields needed. The active magnetic regenerative refrigerator (AMRR) system is shown in the figure. This design mainly consists of two identical magnetic regenerators surrounded by their superconducting magnets and a reversible circulator. Each regenerator also has a heat exchanger at its warm end to reject the magnetization heat to the heat sink, and the two regenerators share a cold-end heat exchanger to absorb heat from a cooling target. The circulator controls the flow direction, which cycles in concert with the magnetic fields, to facilitate heat transfer. Helium enters the hot end of the demagnetized column, is cooled by the refrigerant, and passes into the cold-end heat exchanger to absorb heat. The helium then enters the cold end of the magnetized column, absorbing heat from the refrigerant, and enters the hot-end heat exchanger to reject the magnetization heat. The efficient heat transfer in the AMRR allows the system to operate at a relatively short cycle period to achieve a large cooling power. The key mechanical components in the magnetic cooler are the reversible circulator and the magnetic regenerators. The circulator uses non-contacting, self-acting gas bearings and clearance seals to achieve long life and vibration- free operation. There are no valves or mechanical wear in this circulator, so the reliability is predicted to be very high. The magnetic regenerator employs a structured bed configuration. The core consists of a stack of thin GGG disks alternating with thin polymer insulating films. The structured bed reduces flow resistance in the regenerator and therefore the pumping work by the cryogenic circulator. This magnetic cooler will enable cryogenic detectors for sensing infrared, x-ray, gamma-ray, and submillimeter radiation in future science satellites, as well as the detector systems in the Constellation-X (Con-X) and the Single Aperture Far-Infrared observatory (SAFIR). Scientific ap p - lica tions for this innovation include cooling for x-ray micro calorimeter spectrometers used for microanalysis, cryogenic particle detectors, and superconducting tunnel junction de tectors for biomolecule mass spectrometry. The cooler can be scaled to provide very large cooling capacities at very low temperatures, ideal for liquid helium and liquid hydrogen productions.

Chen, Weibo↗

NASA NTRS2011

Improved Design and Fabrication of Hydrated-Salt Pills

A high-performance design, and fabrication and growth processes to implement the design, have been devised for encapsulating a hydrated salt in a container that both protects the salt and provides thermal conductance between the salt and the environment surrounding the container. The unitary salt/container structure is known in the art as a salt pill. In the original application of the present design and processes, the salt is, more specifically, a hydrated paramagnetic salt, for use as a refrigerant in a very-low-temperature adiabatic demagnetization refrigerator (ADR). The design and process can also be applied, with modifications, to other hydrated salts. Hydrated paramagnetic salts have long been used in ADRs because they have the desired magnetic properties at low temperatures. They also have some properties, disadvantageous for ADRs, that dictate the kind of enclosures in which they must be housed: Being hydrated, they lose water if exposed to less than 100-percent relative humidity. Because any dehydration compromises their magnetic properties, salts used in ADRs must be sealed in hermetic containers. Because they have relatively poor thermal conductivities in the temperature range of interest (<0.1 K), integral thermal buses are needed as means of efficiently transferring heat to and from the salts during refrigeration cycles. A thermal bus is typically made from a high-thermal-conductivity met al (such as copper or gold), and the salt is configured to make intimate thermal contact with the metal. Commonly in current practice (and in the present design), the thermal bus includes a matrix of wires or rods, and the salt is grown onto this matrix. The density and spacing of the conductors depend on the heat fluxes that must be accommodated during operation.

Shirron, Peter J.↗

NASA NTRS2013

Micromachined Active Magnetic Regenerator for Low-Temperature Magnetic Coolers

A design of an Active Magnetic Regenerative Refrigeration (AMRR) system has been developed for space applications. It uses an innovative 3He cryogenic circulator to provide continuous remote/distributed cooling at temperatures in the range of 2 K with a heat sink at about 15 K. A critical component technology for this cooling system is a highly efficient active magnetic regenerator, which is a regenerative heat exchanger with its matrix material made of magnetic refrigerant gadolinium gallium garnet (GGG). Creare Inc. is developing a microchannel GGG regenerator with an anisotropic structured bed for high system thermal efficiency. The regenerator core consists of a stack of thin, single-crystal GGG disks alternating with thin polymer insulating layers. The insulating layers help minimize the axial conduction heat leak, since GGG has a very high thermal conductivity in the regenerator s operating temperature range. The GGG disks contain micro channels with width near 100 micrometers, which enhance the heat transfer between the circulating flow and the refrigerant bed. The unique flow configuration of the GGG plates ensures a uniform flow distribution across the plates. The main fabrication challenges for the regenerator are the machining of high-aspect-ratio microchannels in fragile, single-crystal GGG disks and fabrication and assembly of the GGG insulation layers. Feasibility demonstrations to date include use of an ultrashort- pulse laser to machine microchannels without producing unacceptable microcracking or deposition of recast material, as shown in the figure, and attachment of a thin insulation layer to a GGG disk without obstructing the flow paths. At the time of this reporting, efforts were focused on improving the laser machining process to increase machining speed and further reduce microcracking.

Chen, Weibo↗

NASA NTRS2013

Passivation of Flexible YBCO Superconducting Current Lead With Amorphous SiO2 Layer

Adiabatic demagnetization refrigerators (ADR) are operated in space to cool detectors of cosmic radiation to a few 10s of mK. A key element of the ADR is a superconducting magnet operating at about 0.3 K that is continually energized and de-energized in synchronism with a thermal switch, such that a piece of paramagnetic salt is alternately warm in a high magnetic field and cold in zero magnetic field. This causes the salt pill or refrigerant to cool, and it is able to suck heat from an object, e.g., the sensor, to be cooled. Current has to be fed into and out of the magnets from a dissipative power supply at the ambient temperature of the spacecraft. The current leads that link the magnets to the power supply inevitably conduct a significant amount of heat into the colder regions of the supporting cryostat, resulting in the need for larger, heavier, and more powerful supporting refrigerators. The aim of this project was to design and construct high-temperature superconductor (HTS) leads from YBCO (yttrium barium copper oxide) composite conductors to reduce the heat load significantly in the temperature regime below the critical temperature of YBCO. The magnet lead does not have to support current in the event that the YBCO ceases to be superconducting. Cus - tomarily, a normal metal conductor in parallel with the YBCO is a necessary part of the lead structure to allow for this upset condition; however, for this application, the normal metal can be dispensed with. Amorphous silicon dioxide is deposited directly onto the surface of YBCO, which resides on a flexible substrate. The silicon dioxide protects the YBCO from chemically reacting with atmospheric water and carbon dioxide, thus preserving the superconducting properties of the YBCO. The customary protective coating for flexible YBCO conductors is silver or a silver/gold alloy, which conducts heat many orders of magnitude better than SiO2 and so limits the use of such a composite conductor for passing current across a thermal gradient with as little flow of heat as possible to make an efficient current lead. By protecting YBCO on a flexible substrate of low thermal conductivity with SiO2, a thermally efficient and flexible current lead can be fabricated. The technology is also applicable to current leads for 4 K superconducting electronics current biasing. A commercially available thin-film YBCO composite tape conductor is first stripped of its protective silver coating. It is then mounted on a jig that holds the sample flat and acts as a heat sink. Silicon dioxide is then deposited onto the YBCO to a thickness of about 1 micron using PECVD (plasma-enhanced chemical vapor deposition), without heating the YBCO to the point where degradation occurs. Since SiO2 can have good high-frequency electrical properties, it can be used to coat YBCO cable structures used to feed RF signals across temperature gradients. The prime embodiment concerns the conduction of DC current across the cryogenic temperature gradient. The coating is hard and electrically insulating, but flexible.

Johannes, Daniel↗

NASA NTRSDate not supplied

Scaling of Liquefaction Systems and the Effects of Gravity

Recent exploration initiatives both by NASA and others have produced interest in the liquefaction of fluids produced through in-situ processes on the surfaces of the Moon and Mars. Liquefaction of fluids in cryogenic temperatures is routinely done at large scale for terrestrial uses, but these processes do not necessarily scale down in an economical or technologically feasible manner for the anticipated rates of initial Lunar or Martian production plants. To understand appropriate processes and scaling parameters, various options should be considered. A multi-center team at NASA considered multiple different refrigeration cycles and refrigeration integration methodologies as well as how these might fit into early liquefaction plants. These studies resulted in the conclusion that integrating the tubing on the storage tank wall (for both structural and heat spreading reasons), preferably the tank which will actually use the fluid, is the nearest path forward. Given that assumption on the general framework of the liquefaction system, there are several different heat transfer mechanisms to consider from a scaling perspective. These include forced convection heat removal to the refrigeration system (or cryocooler), conduction through the tank wall heat exchanger, and condensation (with some natural convection) on the inner tank wall. Analysis of these mechanisms shows that while there is some sensitivity to gravitational level, that within the bounds of current interest (Lunar and Martian applications), this sensitivity does not dominate the liquefaction application. While there will be some effect, perhaps in a limiting manner as the tanks approach some high fill level, system level testing on the Earth should suffice for the performance prediction and demonstration of liquefaction operations as applicable to Lunar and Martian applications. However, as one approaches orbital conditions, this general approach to liquefaction will not be appropriate as the scaling of the heat transfer mechanisms is not appropriate. At this point, other approaches will need to be developed and demonstrated in the micro-gravity environment.

Cryogenics↗

NASA NTRSDate not supplied

Energy Efficient Large-Scale Storage of Liquid Hydrogen

The world’s largest liquid hydrogen storage tanks were constructed in the mid-1960sat the NASA Kennedy Space Center. These two vacuum-jacketed, perlite powder insulated tanks, still in service today, have 3,200 m3 of useable capacity. In 2018, construction began on an additional storage tank at Launch Complex 39B. This new tank will give an additional storage capacity of 4,700 m3 for a total on-site storage capacity of roughly 8,000 m3. NASA’s new Space Launch System (SLS) heavy lift rocket for the Artemis program includes an LH2tank that makes up the bulk of the vehicle, holding 2,033 m3 of LH2 in its 8.4-m diameter by40-m height. The new storage tank includes two new energy-efficient technologies: a glass bubbles insulation system in lieu of perlite, and an Integrated Refrigeration and Storage (IRAS)heat exchanger for controlled storage capability. The evacuated glass bubbles insulation system is based on the prior two decades of research to prove the thermal performance benefits as well as the mechanical and vacuum integrity; and has been shown to reduce LH2 boiloff by 46%versus perlite in field demonstrations. The IRAS capability is centered on a heat exchanger system that is built within the inner vessel to reject heat from the bulk liquid through the future implementation of an external helium refrigerator. Controlled storage via IRAS, when fully implemented, will provide full control of the ullage pressure, zero boiloff, and even production of densified LH2 pending its adoption on future launch vehicles. The design basics are described along with main construction and testing processes involved. The key features of the new technology items and implications on simplified operations and long-term energy savings are addressed

cryogenics↗

NASA NTRS1972

EC/LSS thermal control system study for the space shuttle

The results of a parametric weight analysis of heat rejection systems for the space shuttle orbiter are presented. Integrating the suborbital heat rejection system with the overall heat rejection system design and the possible use of a common system for both on-orbit and suborbital operations require an overall system and parametric analyses applicable to all mission phases. The concept of equivalent weights, with weight penalties assigned for power, induced aircraft drag and radiator area is used to determine weight estimates for the following candidate systems: vapor cycle refrigeration, gas cycle refrigeration, radiators (space and atmospheric convectors), expendable heat sinks, and ram air. The orbiter power penalty, ram air penalty, and radiator weight penalty are analyzed. The vapor compression system and an expendable fluid system utilizing a multifluid spraying flash evaporator are selected as the two most promising systems. These are used for maximum on-orbit heat rejection in combination with or as a supplement to a space radiator.

Howell, H. R.↗

NASA NTRS1975

The thermal system for an environmental chamber

The design of a cooling and heating system for obtaining temperatures in the range of -60 C to +120 C on a thermal shroud is described. The proposed temperature control uses mechanical refrigeration with Freon-22 as the primary refrigerant, methanol as the secondary coolant for low temperatures, and electrically heated ethylene glycol for high temperatures. The system is designed to give the following time-temperature characteristics: lowering the temperature from +30 C to -60 C in 1.5 hours; maintaining the temperature at -60 C for a period of 6 hours; heating from -60 C to +120 C in 3 hours; maintaining the temperature at +120 C for a period of 6 hours; and cooling from +120 C in 1.5 hours. A description of the system and its operation are given.

Srinivasan, K.↗

NASA NTRS1975

Shuttle freezer conceptual design

A conceptual design for a kit freezer for operation onboard shuttle was developed. The freezer features a self-contained unit which can be mounted in the orbiter crew compartment and is capable of storing food at launch and returning with medical samples. Packaging schemes were investigated to provide the optimum storage capacity with a minimum weight and volume penalty. Several types of refrigeration systems were evaluated to select one which would offer the most efficient performance and lowest hazard of safety to the crew. Detailed performance data on the selected, Stirling cycle principled refrigeration unit were developed to validate the feasibility of its application to this freezer. Thermal analyses were performed to determine the adequacy of the thermal insulation to maintain the desired storage temperature with the design cooling capacity. Stress analyses were made to insure the design structure integrity could be maintained over the shuttle flight regime. A proposed prototype freezer development plan is presented.

Proctor, B. W.↗