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NASA NTRS2011

Fission Surface Power Technology Development Update

Power is a critical consideration in planning exploration of the surfaces of the Moon, Mars, and places beyond. Nuclear power is an important option, especially for locations in the solar system where sunlight is limited or environmental conditions are challenging (e.g., extreme cold, dust storms). NASA and the Department of Energy are maintaining the option for fission surface power for the Moon and Mars by developing and demonstrating technology for a fission surface power system. The Fission Surface Power Systems project has focused on subscale component and subsystem demonstrations to address the feasibility of a low-risk, low-cost approach to space nuclear power for surface missions. Laboratory demonstrations of the liquid metal pump, reactor control drum drive, power conversion, heat rejection, and power management and distribution technologies have validated that the fundamental characteristics and performance of these components and subsystems are consistent with a Fission Surface Power preliminary reference concept. In addition, subscale versions of a non-nuclear reactor simulator, using electric resistance heating in place of the reactor fuel, have been built and operated with liquid metal sodium-potassium and helium/xenon gas heat transfer loops, demonstrating the viability of establishing system-level performance and characteristics of fission surface power technologies without requiring a nuclear reactor. While some component and subsystem testing will continue through 2011 and beyond, the results to date provide sufficient confidence to proceed with system level technology readiness demonstration. To demonstrate the system level readiness of fission surface power in an operationally relevant environment (the primary goal of the Fission Surface Power Systems project), a full scale, 1/4 power Technology Demonstration Unit (TDU) is under development. The TDU will consist of a non-nuclear reactor simulator, a sodium-potassium heat transfer loop, a power conversion unit with electrical controls, and a heat rejection system with a multi-panel radiator assembly. Testing is planned at the Glenn Research Center Vacuum Facility 6 starting in 2012, with vacuum and liquid-nitrogen cold walls to provide simulation of operationally relevant environments. A nominal two-year test campaign is planned including a Phase 1 reactor simulator and power conversion test followed by a Phase 2 integrated system test with radiator panel heat rejection. The testing is expected to demonstrate the readiness and availability of fission surface power as a viable power system option for NASA's exploration needs. In addition to surface power, technology development work within this project is also directly applicable to in-space fission power and propulsion systems.

Palac, Donald T.↗

NASA NTRS1994

Optimal control of thermally coupled Navier Stokes equations

The optimal boundary temperature control of the stationary thermally coupled incompressible Navier-Stokes equation is considered. Well-posedness and existence of the optimal control and a necessary optimality condition are obtained. Optimization algorithms based on the augmented Lagrangian method with second order update are discussed. A test example motivated by control of transport process in the high pressure vapor transport (HVPT) reactor is presented to demonstrate the applicability of our theoretical results and proposed algorithm.

Ito, Kazufumi↗

NASA NTRS2012

Development Status of the Fission Power System Technology Demonstration Unit

This paper summarizes the progress that has been made in the development of the Fission Power System Technology Demonstration Unit (TDU). The reactor simulator core and Annular Linear Induction Pump have been fabricated and assembled into a test loop at the NASA Marshall Space Flight Center. A 12 kWe Power Conversion Unit (PCU) is being developed consisting of two 6 kWe free-piston Stirling engines. The two 6 kWe engines have been fabricated by Sunpower Inc. and are currently being tested separately prior to integration into the PCU. The Facility Cooling System (FCS) used to reject convertor waste heat has been assembled and tested at the NASA Glenn Research Center (GRC). The structural elements, including a Buildup Assembly Platform (BAP) and Upper Truss Structure (UTS) have been fabricated, and will be used to test cold-end components in thermal vacuum prior to TDU testing. Once all components have been fully tested at the subsystem level, they will be assembled into an end-to-end system and tested in thermal vacuum at GRC.

Briggs, Maxwell H.↗

NASA NTRS2012

Large-Scale Weibull Analysis of H-451 Nuclear- Grade Graphite Specimen Rupture Data

A Weibull analysis was performed of the strength distribution and size effects for 2000 specimens of H-451 nuclear-grade graphite. The data, generated elsewhere, measured the tensile and four-point-flexure room-temperature rupture strength of specimens excised from a single extruded graphite log. Strength variation was compared with specimen location, size, and orientation relative to the parent body. In our study, data were progressively and extensively pooled into larger data sets to discriminate overall trends from local variations and to investigate the strength distribution. The CARES/Life and WeibPar codes were used to investigate issues regarding the size effect, Weibull parameter consistency, and nonlinear stress-strain response. Overall, the Weibull distribution described the behavior of the pooled data very well. However, the issue regarding the smaller-than-expected size effect remained. This exercise illustrated that a conservative approach using a two-parameter Weibull distribution is best for designing graphite components with low probability of failure for the in-core structures in the proposed Generation IV (Gen IV) high-temperature gas-cooled nuclear reactors. This exercise also demonstrated the continuing need to better understand the mechanisms driving stochastic strength response. Extensive appendixes are provided with this report to show all aspects of the rupture data and analytical results.

Nemeth, Noel N.↗

NASA NTRS2012

Development Status of the Fission Power System Technology Demonstration Unit

Briggs, Maxwell H.↗

NASA NTRSDate not supplied

Status of ISS Water Management and Recovery

Water management on ISS is responsible for the provision of water to the crew for drinking water, food preparation, and hygiene, to the Oxygen Generation System (OGS) for oxygen production via electrolysis, to the Waste & Hygiene Compartment (WHC) for flush water, and for experiments on ISS. This paper summarizes water management activities on the ISS US Segment as of March 2022 and provides a status of the performance and issues related to the operation of the Water Processor Assembly (WPA) and Urine Processor Assembly (UPA).

Water Recovery System↗

NASA NTRS2020

Results of the KRUSTY Nuclear System Test

The Kilowatt Reactor Using Stirling TechnologY (KRUSTY) was a prototypic nuclear-powered test of a 5-kW(thermal) Kilopower space reactor. This paper presents results from the KRUSTY nuclear system test, which operated the power system at various temperatures and power levels for 28 consecutive hours. The testing showed that the system operated as expected and that the reactor is highly tolerant of possible failure conditions and transients. The key feature demonstrated was the ability of the reactor to load-follow the demand of the power conversion system. The thermal power of the test ranged from 1.5 to 5.0 kW(thermal), with a fuel temperature up to 880°C. Each 80-W(electric)–rated Stirling converter produced ~90 W(electric) at a component efficiency of ~35% and an overall system efficiency of ~25%.

David I. Poston↗

NASA NTRS1972

Thermionic reactor program - An overview.

An overview of the AEC/NASA thermionic reactor program is presented with emphasis on the latest progress in this technology. The possible applications for utilization of thermionic reactors are reviewed and the joint AEC/NASA program approach to demonstrate thermionic technology is outlined. The thermionic reactor technology programs of France, West Germany, and the Soviet Union are highlighted.

Beard, D. S.↗

NASA NTRS2007

Catalytic Ignition and Upstream Reaction Propagation in Monolith Reactors

Using numerical simulations, this work demonstrates a concept called back-end ignition for lighting-off and pre-heating a catalytic monolith in a power generation system. In this concept, a downstream heat source (e.g. a flame) or resistive heating in the downstream portion of the monolith initiates a localized catalytic reaction which subsequently propagates upstream and heats the entire monolith. The simulations used a transient numerical model of a single catalytic channel which characterizes the behavior of the entire monolith. The model treats both the gas and solid phases and includes detailed homogeneous and heterogeneous reactions. An important parameter in the model for back-end ignition is upstream heat conduction along the solid. The simulations used both dry and wet CO chemistry as a model fuel for the proof-of-concept calculations; the presence of water vapor can trigger homogenous reactions, provided that gas-phase temperatures are adequately high and there is sufficient fuel remaining after surface reactions. With sufficiently high inlet equivalence ratio, back-end ignition occurs using the thermophysical properties of both a ceramic and metal monolith (coated with platinum in both cases), with the heat-up times significantly faster for the metal monolith. For lower equivalence ratios, back-end ignition occurs without upstream propagation. Once light-off and propagation occur, the inlet equivalence ratio could be reduced significantly while still maintaining an ignited monolith as demonstrated by calculations using complete monolith heating.

Struk, Peter M.↗

NASA NTRS2006

Dynamic Response Testing in an Electrically Heated Reactor Test Facility

Non-nuclear testing can be a valuable tool in development of a space nuclear power or propulsion system. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Standard testing allows one to fully assess thermal, heat transfer, and stress related attributes of a given system, but fails to demonstrate the dynamic response that would be present in an integrated, fueled reactor system. The integration of thermal hydraulic hardware tests with simulated neutronic response provides a bridge between electrically heated testing and full nuclear testing. By implementing a neutronic response model to simulate the dynamic response that would be expected in a fueled reactor system, one can better understand system integration issues, characterize integrated system response times and response characteristics, and assess potential design improvements at a relatively small fiscal investment. Initial system dynamic response testing was demonstrated on the integrated SAFE-100a heat pipe cooled, electrically heated reactor and heat exchanger hardware, utilizing a one-group solution to the point kinetics equations to simulate the expected neutronic response of the system (Bragg-Sitton, 2005). The current paper applies the same testing methodology to a direct drive gas cooled reactor system, demonstrating the applicability of the testing methodology to any reactor type and demonstrating the variation in system response characteristics in different reactor concepts. In each testing application, core power transients were controlled by a point kinetics model with reactivity feedback based on core average temperature; the neutron generation time and the temperature feedback coefficient are provided as model inputs. Although both system designs utilize a fast spectrum reactor, the method of cooling the reactor differs significantly, leading to a variable system response that can be demonstrated and assessed in a non-nuclear test facility.

Bragg-Sitton, Shannon M.↗

NASA NTRS2014

Series-Bosch Technology for Oxygen Recovery During Lunar or Martian Surface Missions

Long‐duration surface missions to the Moon or Mars will require life support systems that maximize resource recovery to minimize resupply from Earth. To address this need, NASA previously proposed a Series‐Bosch (S‐Bosch) oxygen recovery system, based on the Bosch process, which can theoretically recover 100% of the oxygen from metabolic carbon dioxide. Bosch processes have the added benefits of the potential to recover oxygen from atmospheric carbon dioxide and the use of regolith materials as catalysts, thereby eliminating the need for catalyst resupply from Earth. In 2012, NASA completed an initial design for an S‐Bosch development test stand that incorporates two catalytic reactors in series including a Reverse Water‐Gas Shift (RWGS) Reactor and a Carbon Formation Reactor (CFR). In 2013, fabrication of system components, with the exception of a CFR, and assembly of the test stand was initiated. Stand‐alone testing of the RWGS reactor was completed to compare performance with design models. Continued testing of Lunar and Martian regolith simulants provided sufficient data to design a CFR intended to utilize these materials as catalysts. Finally, a study was conducted to explore the possibility of producing bricks from spend regolith catalysts. The results of initial demonstration testing of the RWGS reactor, results of continued catalyst performance testing of regolith simulants, and results of brick material properties testing are reported. Additionally, design considerations for a regolith‐based CFR are discussed.

Abney, Morgan B.↗

NASA NTRS2014

Series-Bosch Technology for Oxygen Recovery During Lunar or Martian Surface Missions

Long-duration surface missions to the Moon or Mars will require life support systems that maximize resource recovery to minimize resupply from Earth. To address this need, NASA previously proposed a Series-Bosch (S-Bosch) oxygen recovery system, based on the Bosch process, which can theoretically recover 100% of the oxygen from metabolic carbon dioxide. Bosch processes have the added benefits of the potential to recover oxygen from atmospheric carbon dioxide and the use of regolith materials as catalysts, thereby eliminating the need for catalyst resupply from Earth. In 2012, NASA completed an initial design for an S-Bosch development test stand that incorporates two catalytic reactors in series including a Reverse Water-Gas Shift (RWGS) Reactor and a Carbon Formation Reactor (CFR). In 2013, fabrication of system components, with the exception of a CFR, and assembly of the test stand was initiated. Stand-alone testing of the RWGS reactor was completed to compare performance with design models. Continued testing of Lunar and Martian regolith simulants provided sufficient data to design a CFR intended to utilize these materials as catalysts. Finally, a study was conducted to explore the possibility of producing bricks from spent regolith catalysts. The results of initial demonstration testing of the RWGS reactor, results of continued catalyst performance testing of regolith simulants, and results of brick material properties testing are reported. Additionally, design considerations for a regolith-based CFR are discussed.

Abney, Morgan B.↗

NASA NTRS1981

Development of a high-temperature durable catalyst for use in catalytic combustors for advanced automotive gas turbine engines

Durable catalytic reactors for advanced gas turbine engines were developed. Objectives were: to evaluate furnace aging as a cost effective catalytic reactor screening test, measure reactor degradation as a function of furnace aging, demonstrate 1,000 hours of combustion durability, and define a catalytic reactor system with a high probability of successful integration into an automotive gas turbine engine. Fourteen different catalytic reactor concepts were evaluated, leading to the selection of one for a durability combustion test with diesel fuel for combustion conditions. Eight additional catalytic reactors were evaluated and one of these was successfully combustion tested on propane fuel. This durability reactor used graded cell honeycombs and a combination of noble metal and metal oxide catalysts. The reactor was catalytically active and structurally sound at the end of the durability test.

Tong, H.↗

NASA NTRSDate not supplied

Lunar Polar Exploration with Beamed Powered Rovers

Use of a laser to transmit power to a photovoltaic array has been proposed many times, including significant work done at NASA Glenn during the 1990s, but until recently the technology has lagged behind the ambitious requirements. The current NASA objective of lunar polar exploration provides the need, and evolution of higher-power and more efficient lasers provides the opportunity. Exploration of the ice-bearing craters near the lunar poles, where complete absence of sunlight precludes solar power, have been identified as a significant technology challenge for NASA’s future exploration. An approach to solve this is to use a laser to send power from the illuminated crater rim to a photovoltaic receiver on a rover inside the permanently dark region. A conceptual design was done of a prototype laser power system to be included on a proposed flight demonstration of the Kilopower space reactor. For the design, the laser transmitter is mounted on a small rover capable of moving to a location in line of sight of the receiving rover, e.g., on a crater rim with a view into the permanently dark region to be explored. A 250-watt laser diode bar transmits power at 808 nm, using a 10.5 cm optical beam director. The beam is received by a GaAs solar array mounted on the exploring rover, where it is converted into electrical power at ~50% optical to electrical efficiency. For the flight demonstration, 50 meters of laser transmission was required. The design showed a total laser mass of 7.8 kg is capable of producing the beam needed, not including the thermal control system. The demonstration design demonstrates 50-m transmission, but it would be valuable to have longer point-to-point beaming on the moon. Long beam paths require higher coherence than the diode laser bars of the demonstration system. The development of high-efficiency diode-pumped fiber lasers meets this technology need: and diode-pumped fiber lasers using the Er/Yb system can be purchased commercially with overall conversion efficiency of greater than 50% at wavelength 1.06 micrometers. Two technologies for a photovoltaic converter for this wavelength are the InGaAs photovoltaic cell, using technology developed for multi-junction space solar cells, or newly-developed high-quantum efficiency silicon cells. The next step to mature the technology would be a lunar flight demonstration. In the future, this has the potential to enhance and enable future human exploration of the moon, harvesting and utilizing the ice resources of these permanently-shadowed craters.

Geoffrey A Landis↗

NASA NTRS1955

Spatial Burnout in Water Reactors with Nonuniform Startup Distributions of Uranium and Boron

Spatial burnout calculations have been made of two types of water moderated cylindrical reactor using boron as a burnable poison to increase reactor life. Specific reactors studied were a version of the Submarine Advanced Reactor (sAR) and a supercritical water reactor (SCW) . Burnout characteristics such as reactivity excursion, neutron-flux and heat-generation distributions, and uranium and boron distributions have been determined for core lives corresponding to a burnup of approximately 7 kilograms of fully enriched uranium. All reactivity calculations have been based on the actual nonuniform distribution of absorbers existing during intervals of core life. Spatial burnout of uranium and boron and spatial build-up of fission products and equilibrium xenon have been- considered. Calculations were performed on the NACA nuclear reactor simulator using two-group diff'usion theory. The following reactor burnout characteristics have been demonstrated: 1. A significantly lower excursion in reactivity during core life may be obtained by nonuniform rather than uniform startup distribution of uranium. Results for SCW with uranium distributed to provide constant radial heat generation and a core life corresponding to a uranium burnup of 7 kilograms indicated a maximum excursion in reactivity of 2.5 percent. This compared to a maximum excursion of 4.2 percent obtained for the same core life when w'anium was uniformly distributed at startup. Boron was incorporated uniformly in these cores at startup. 2. It is possible to approach constant radial heat generation during the life of a cylindrical core by means of startup nonuniform radial and axial distributions of uranium and boron. Results for SCW with nonuniform radial distribution of uranium to provide constant radial heat generation at startup and with boron for longevity indicate relatively small departures from the initially constant radial heat generation distribution during core life. Results for SAR with a sinusoidal distribution rather than uniform axial distributions of boron indicate significant improvements in axial heat generation distribution during the greater part of core life. 3. Uranium investments for cylindrical reactors with nonuniform radial uranium distributions which provide constant radial heat generation per unit core volume are somewhat higher than for reactors with uniform uranium concentration at startup. On the other hand, uranium investments for reactors with axial boron distributions which approach constant axial heat generation are somewhat smaller than for reactors with uniform boron distributions at startup.

Fox, Thomas A.↗

NASA NTRS2003

Thermally Simulated Testing of a Direct-Drive Gas-Cooled Nuclear Reactor

This paper describes the concept and preliminary component testing of a gas-cooled, UN-fueled, pin-type reactor which uses He/Xe gas that goes directly into a recuperated Brayton system to produce electricity for nuclear electric propulsion. This Direct-Drive Gas-Cooled Reactor (DDG) is designed to be subcritical under water or wet-sand immersion in case of a launch accident. Because the gas-cooled reactor can directly drive the Brayton turbomachinery, it is possible to configure the system such that there are no external surfaces or pressure boundaries that are refractory metal, even though the gas delivered to the turbine is 1144 K. The He/Xe gas mixture is a good heat transport medium when flowing, and a good insulator when stagnant. Judicious use of stagnant cavities as insulating regions allows transport of the 1144-K gas while keeping all external surfaces below 900 K. At this temperature super-alloys (Hastelloy or Inconel) can be used instead of refractory metals. Super-alloys reduce the technology risk because they are easier to fabricate than refractory metals, we have a much more extensive knowledge base on their characteristics, and, because they have a greater resistance to oxidation, system testing is eased. The system is also relatively simple in its design: no additional coolant pumps, heat exchanger, or freeze-thaw systems are required. Key to success of this concept is a good knowledge of the heat transfer between the fuel pins and the gas, as well as the pressure drop through the system. This paper describes preliminary testing to obtain this key information, as well as experience in demonstrating electrical thermal simulation of reactor components and concepts.

Godfroy, Thomas↗

NASA NTRS1978

Gaseous fuel reactors for power systems

The Los Alamos Scientific Laboratory is participating in a NASA-sponsored program to demonstrate the feasibility of a gaseous uranium fueled reactor. The work is aimed at acquiring experimental and theoretical information for the design of a prototype plasma core reactor which will test heat removal by optical radiation. The basic goal of this work is for space applications, however, other NASA-sponsored work suggests several attractive applications to help meet earth-bound energy needs. Such potential benefits are: small critical mass, on-site fuel processing, high fuel burnup, low fission fragment inventory in reactor core, high temperature for process heat, optical radiation for photochemistry and space power transmission, and high temperature for advanced propulsion systems.

Helmick, H. H.↗

NASA NTRS1979

Silicon halide-alkali metal flames as a source of solar grade silicon

The feasibility of using alkali metal-silicon halide diffusion flames to produce solar-grade silicon in large quantities and at low cost is demonstrated. Prior work shows that these flames are stable and that relatively high purity silicon can be produced using Na + SiCl4 flames. Silicon of similar purity is obtained from Na + SiF4 flames although yields are lower and product separation and collection are less thermochemically favored. Continuous separation of silicon from the byproduct alkali salt was demonstrated in a heated graphite reactor. The process was scaled up to reduce heat losses and to produce larger samples of silicon. Reagent delivery systems, scaled by a factor of 25, were built and operated at a production rate of 0.5 kg Si/h. Very rapid reactor heating rates are observed with wall temperatures reaching greater than 2000 K. Heat release parameters were measured using a cooled stainless steel reactor tube. A new reactor was designed.

Olsen, D. B.↗