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Inspection, proof pressure, and functional testing of check valve used in tank vent line of liquid hydrogen fuel system
New fuel cell components for use in liquid feed fuel cell systems are provided. The components include biplates and endplates, having a hydrophilic surface and allow high efficiency operation. Conductive elements and a wicking device also form a part of the fuel cell components of the invention.
New fuel cell elements for use in liquid feed fuel cells are provided. The elements including biplates and endplates are low in cost, light in weight, and allow high efficiency operation. Electrically conductive elements are also a part of the fuel cell elements.
NASA has successfully fired several configurations of a dual regenerative 10K lbf class Rotating Detonation Rocket Engines using cryogenic liquid methane, liquid hydrogen, and RP-1 as fuel and liquid or gaseous oxygen as the oxidizer. In addition, 3 hot fire test phases were conducted to evaluate parametrically varying combustor geometries using a subscale 500-1K lbf class thruster RDRE. Several studies were successfully completed to evaluate the impacts of contraction ratio, annulus L’, heat transfer through calorimetry, and varying injector designs. Laser powder bed fusion GRCop-42, GRX-810, and C-103 alloys were used for the outer bodies, inner bodies, nozzles, and injector variations. The development of RDRE technology is only now possible with additive manufacturing techniques and these specialized alloys. Critical design parameters, design rules of thumb, and operability limitations have been identified. Major lessons learned in the development of critical components have also been documented. All critical technology gaps have been demonstrated at one scale or another and closed. A major finding of this work is that the combustion efficiency of the RDRE is far superior to that of the traditional liquid rocket engine requiring an order of magnitude lower chamber volume and residence time to react. Because of this, the design trade space opens up significantly. More compact chamber geometries are now possible with potential mass savings and significant length savings possible to flight geometries. In addition, the ceiling for the technology, in terms of Isp, has not yet been reached. It is likely that an additional ~10% better Isp over equivalent state-of-the-art combustion devices may be achieved over the next decade should the technology continue to be developed. This technology has been shown to be viable for near term infusion (2-5 years) into space missions and enable cost effective space access for US industry. This final report documents all major findings from this early career initiative (ECI) project and lays out what is needed post ECI.
Underutilized wet waste is a promising feedstock for production of carbon-neutral or carbon-negative liquid transportation fuels. Arrested methanogenesis of wet wastes by microbes, which produces mixtures of C2-C8 carboxylic acids (volatile fatty acids, VFAs), is practiced industrially at a pilot scale and the VFA products can be catalytically upgraded to molecules suitable for use as transportation fuels (alcohols and alkanes) via sequential ketonization and hydrogenation, both steps of which have been demonstrated with high (>90%) yield at the lab scale. We present in this work a simulation-based decision-making framework which evaluates upgrading strategies of VFAs to alcohol- and hydrocarbon-based neat and blended diesel, jet, and gasoline fuels. The processes utilize sequential upgrading steps (ketonization and hydrogenation) accompanied by one distillation step (either separating VFAs before ketonization or alcohols after ketone hydrogenation) to form two liquid streams: a light alcohol stream best suited as a light-duty fuel and a heavy alcohol or hydrocarbon stream best suited as a diesel or jet fuel. Suitability of the liquid products as transportation fuels and maximum blending levels with petrofuels comes from simulation of critical fuel properties (boiling point, flash point, lower heating value, viscosity, melting point, water solubility, and cetane/octane number). Catalytic upgrading steps and fuel property mixing models used by the simulation are experimentally validated. We demonstrate the flexibility of the decision-making algorithm by evaluating processing scenarios for experimentally-observed VFA profiles with varied carbon chain length distributions. Processing scenarios are optimized for either maximum total renewable carbon utilization or production of heavy-duty (jet or diesel) fuels. We evaluate the economic viability and CO2 emissions of each proposed upgrading scenario using techno-economic and life cycle analyses. The decision-making framework developed in this work can also be used to down-select promising strategies for upgrading of other bio-based feedstocks to sustainable fuels and chemicals.
A series of trade studies are presented on a complementary architecture of launch vehicles as a part of a study often referred to as Shuttle-2. The results of the trade studies performed on the vehicles of a reference Shuttle-2 mixed fleet architecture have provided an increased understanding of the relative importance of each of the major vehicle parameters. As a result of trades on the reference booster-orbiter configuration with a methane booster, the study showed that 60 percent of the total liftoff thrust should be on the booster and 40 percent on the orbiter. It was also found that the liftoff thrust to weight ratio (T/W) on the booster-orbiter should be 1.3. This leads to a low dry weight and still provides enough thrust to allow the design of a heavy lift architecture. As a result of another trade study, the dry weight of the reference booster-orbiter was chosen for a variety of operational considerations. Other trade studies on the booster-orbiter demonstrate that the cross feeding of propellant during boost phase is desirable and that engine-out capability from launch to orbit is worth the performance penalty. Technology assumptions made during the Shuttle-2 design were shown to be approx. equivalent to a 25 percent across the board weight reduction over the Space Shuttle technology. The vehicles of the Shuttle-2 architecture were also sized for a wide variety of payloads and missions to different orbits. Many of these same parametric trades were also performed on completely liquid hydrogen fueled fully reusable concepts. If a booster-orbiter is designed using liquid hydrogen engines on both the booster and orbiter, the total vehicle dry weight is only 3.0 percent higher than the reference dual-fuel booster-orbiter, and the gross weight is 3.8 percent less. For this booster-orbiter vehicle, a liftoff T/W of 1.3, a thrust of about 60 percent on the booster, and a Mach staging number of 3 all proved to be desirable. This modest dry weight increase for a liquid hydrogen fueled Shuttle-2 system should be more than offset by the elimination of the entire hydrocarbon engine development program and the savings in operation cost realized by the elimination of an entire fuel type.
With the growing concerns of global warming, the need for pollution-free vehicles is ever increasing. Pollution-free flight is one of NASA's goals for the 21" Century. , One method of approaching that goal is hydrogen-fueled aircraft that use fuel cells or turbo- generators to develop electric power that can drive electric motors that turn the aircraft's propulsive fans or propellers. Hydrogen fuel would likely be carried as a liquid, stored in tanks at its boiling point of 20.5 K (-422.5 F). Conventional electric motors, however, are far too heavy (for a given horsepower) to use on aircraft. Fortunately the liquid hydrogen fuel can provide essentially free refrigeration that can be used to cool the windings of motors before the hydrogen is used for fuel. Either High Temperature Superconductors (HTS) or high purity metals such as copper or aluminum may be used in the motor windings. Superconductors have essentially zero electrical resistance to steady current. The electrical resistance of high purity aluminum or copper near liquid hydrogen temperature can be l/lOO* or less of the room temperature resistance. These conductors could provide higher motor efficiency than normal room-temperature motors achieve. But much more importantly, these conductors can carry ten to a hundred times more current than copper conductors do in normal motors operating at room temperature. This is a consequence of the low electrical resistance and of good heat transfer coefficients in boiling LH2. Thus the conductors can produce higher magnetic field strengths and consequently higher motor torque and power. Designs, analysis and actual cryogenic motor tests show that such cryogenic motors could produce three or more times as much power per unit weight as turbine engines can, whereas conventional motors produce only 1/5 as much power per weight as turbine engines. This summer work has been done with Litz wire to maximize the current density. The current is limited by the amount of heat it generates. By increasing the heat transfer out of the wire, the wires can carry a larger current and therefore produce more force. This was done by increasing the surface area of the wire to allow more coolant to flow over it. Litz wire was used because it can carry high frequency current. It also can be deformed into configurations that would increase the surface area. The best configuration was determined by heat transfer and force plots that were generated using Maxwell 2D. Future work will be done by testing and measuring the thrust force produced by the wires in a magnetic field.
Studies dealing with the use of liquid hydrogen for fuel in subsonic air transport systems are reviewed. Topics of the studies include the possibility for economical production of hydrogen, the problems associated with the efficient liquefaction of the gas, the development of insulation materials and materials for long-lasting liquid hydrogen fuel tanks, the difficulties related to fueling processes and the installation of liquid hydrogen fuel stations at major air terminals, an assessment of the hazards connected with liquid hydrogen fuels, and the engineering and design problems involved in incorporating liquid hydrogen fuel systems into large subsonic passenger aircraft.
Fueled bipropellant liquid propulsion system exposed to ethylene oxide and heat sterilization
Increasing fuel efficiency has been a goal for chemists for several decades. Particularly, a more efficient fuel can increase the range of liquid-hydrocarbon-fueled ram-jets and cruise missiles. A storable high-energy fuel that spontaneously ignites upon addition of an oxidizer is defined as a hypergolic fuel. Hypergolic storable fuels provide an increase in energy per unit volume of fuel and eliminate the need for an external ignition system. Several classes of functionalized hydrocarbons such as amines, boranes, and phosphines are known to be hypergolic with nitric acid oxidizers, but only hydrazine and its simple derivatives5 have been found to exhibit true hypergolic behavior with H2O2. Hydrogen peroxide is a good candidate for an oxidizer due to its reduced toxicity and improved storage capability. Hydrazine-based fuels are expensive, highly corrosive, and toxic, thus providing the need for investigation of other fuels that may be hypergolic with H2O2. Strained hydrocarbons have been studied as high-density fuels. Some examples including benzvalene and cubane, exhibit an increase in heat of combustion as the density of the fuel increases. Many conventional hydrocarbon fuels, such as JP-5 and JP-10, show a decrease in heat of combustion as density of the fuel increases. Strained hydrocarbons can therefore increase the range of the missile by increasing the combustion efficiency per volume of fuel. The goal of this research is to investigate hypergolic behavior of strained hydrocarbons by adding an amine functional group which has been found to hypergolic with nitric acid oxidizers. N,N-Dimethyl-[3]-triangulane-7-methylamine (l), cyclopropylamines (2), cyclobutylamines (3), propylamines (4), and butylamines (5) were synthesized and investigated. The amino group should react with oxygen, providing the initiation step for ring decomposition. The highly exothermic reactions will accumulate energy and potentially lead to spontaneous ignition of the fuel. Triangulanes possess high strain energy, while the less strained cyclopropane and cyclobutanes are more volatile and may show shorter ignition times.
A historical review is presented on the research and development of liquid hydrogen for use as a propulsion fuel. The document is divided into three parts: Part 1 (1945-1950); Part 2 (1950-1957); and Part 3 (1957-1958), encompassing eleven topics. Two appendixes are included. Hydrogen Technology Through World War 2; and Propulsion Primer, Performance Parameters and Units.
There is a growing interest in the use of fuel cells as a power source for all-electric aircraft propulsion as a means to substantially reduce or eliminate environmentally harmful emissions. Among the technologies under consideration for these concepts are advanced proton exchange membrane and solid oxide fuel cells, alternative fuels and fuel processing, and fuel storage. This paper summarizes the results of a first-order feasibility study for an all-electric personal air vehicle utilizing a fuel cell-powered propulsion system. A representative aircraft with an internal combustion engine was chosen as a baseline to provide key parameters to the study, including engine power and subsystem mass, fuel storage volume and mass, and aircraft range. The engine, fuel tank, and associated ancillaries were then replaced with a fuel cell subsystem. Various configurations were considered including: a proton exchange membrane (PEM) fuel cell with liquid hydrogen storage; a direct methanol PEM fuel cell; and a direct internal reforming solid oxide fuel cell (SOFC)/turbine hybrid system using liquid methane fuel. Each configuration was compared to the baseline case on a mass and range basis.
There is a growing interest in the use of fuel cells as a power source for all-electric aircraft propulsion as a means to substantially reduce or eliminate environmentally harmful emissions. Among the technologies under consideration for these concepts are advanced proton exchange membrane and solid oxide fuel cells, alternative fuels and fuel processing, and fuel storage. This paper summarizes the results of a first-order feasibility study for an all-electric personal air vehicle utilizing a fuel cell-powered propulsion system. A representative aircraft with an internal combustion engine was chosen as a baseline to provide key parameters to the study, including engine power and subsystem mass, fuel storage volume and mass, and aircraft range. The engine, fuel tank, and associated ancillaries were then replaced with a fuel cell subsystem. Various configurations were considered including: a proton exchange membrane (PEM) fuel cell with liquid hydrogen storage; a direct methanol PEM fuel cell; and a direct internal reforming solid oxide fuel cell (SOFC)/turbine hybrid system using liquid methane fuel. Each configuration was compared to the baseline case on a mass and range basis.
The performance of jet fuel with an oxidant mixture containing 70 percent liquid fluorine and 30 percent liquid oxygen by weight was investigated in a 500-pound-thrust engine operating at a chamber pressure of 300 pounds per square inch absolute. A one-oxidant-on-one-fuel skewed-hole impinging-jet injector was evaluated in a chamber of characteristic length equal to 50 inches. A maximum experimental specific impulse of 268 pound-seconds per pound was obtained at 25 percent fuel, which corresponds to 96 percent of the maximum theoretical specific impulse based on frozen composition expansion. The maximum characteristic velocity obtained was 6050 feet per second at 23 percent fuel, or 94 percent of the theoretical maximum. The average thrust coefficient was 1.38 for the 500-pound thrust combustion-chamber nozzle used, which was 99 percent of the theoretical (frozen) maximum. Mixtures of fluorine and oxygen were found to be self-igniting with jet fuel with fluorine concentrations as low as 4 percent, when low starting propellant flow rated were used.
For NASA's Apollo program, McDonnell Douglas Astronautics Company, Huntington Beach, California, developed and built the S-IVB, uppermost stage of the three-stage Saturn V moonbooster. An important part of the development task was fabrication of a tank to contain liquid hydrogen fuel for the stage's rocket engine. The liquid hydrogen had to be contained at the supercold temperature of 423 degrees below zero Fahrenheit. The tank had to be perfectly insulated to keep engine or solar heat from reaching the fuel; if the hydrogen were permitted to warm up, it would have boiled off, or converted to gaseous form, reducing the amount of fuel available to the engine. McDonnell Douglas' answer was a supereffective insulation called 3D, which consisted of a one-inch thickness of polyurethane foam reinforced in three dimensions with fiberglass threads. Over a 13-year development and construction period, the company built 30 tanks and never experienced a failure. Now, after years of additional development, an advanced version of 3D is finding application as part of a containment system for transporting Liquefied Natural Gas (LNG) by ship.
Photothermal CO 2 hydrogenation is a promising route to produce methanol as a sustainable liquid solar fuel. However, most existing catalysts require a combination of solar irradiation and additional heat input to achieve a satisfactory reaction rate. For the few that can be driven solely by light, their reaction rates are one order of magnitude lower. We develop a photothermal catalyst with multilevel interfaces that achieves improved methanol production from photothermal CO 2 hydrogenation without external heat. The catalyst features a layered structure comprising Cu/ZnO/Al 2 O 3 (CZA) covered by oxidized carbon black (oCB), where the oCB/CZA interface promotes efficient heat generation and transfer, and the Cu/oxide interface contributes to high catalytic activity. Under a mild pressure of 8 bar, our oCB/CZA catalyst shows a methanol selectivity of 64.7% with a superior production rate of 4.91 mmol·g cza −1 ·h −1 , at least one order of magnitude higher than other photothermal catalysts solely driven by light. This work demonstrates a photothermal catalyst design strategy for liquid solar fuel production.
Experimental investigation of the validity of Zuber and Finlay's (1965) gas flow-rate formula for a two-phase flow in a rotating cylinder under high centrifugal acceleration. This formula was originally derived from tests in a 1-g environment in pipes. In the light of the investigation results obtained, the formula is valid also for a high-g environment in the rotating chamber tested.
McDonnell Douglas Aerospace, as part of its Independent R&D, has initiated development of a clean burning, high performance hybrid fuel for consideration as an alternative to the solid rocket thrust augmentation currently utilized by American space launch systems including Atlas, Delta, Pegasus, Space Shuttle, and Titan. It could also be used in single stage to orbit or as the only propulsion system in a new launch vehicle. Compared to solid propellants based on aluminum and ammonium perchlorate, this fuel is more environmentally benign in that it totally eliminates hydrogen chloride and aluminum oxide by products, producing only water, hydrogen, nitrogen, carbon oxides, and trace amounts of nitrogen oxides. Compared to other hybrid fuel formulations under development, this fuel is cheaper, denser, and faster burning. The specific impulse of this fuel is comparable to other hybrid fuels and is between that of solids and liquids. The fuel also requires less oxygen than similar hybrid fuels to produce maximum specific impulse, thus reducing oxygen delivery system requirements.