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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Gateway at the Crossroads of Sustainable Lunar Exploration

The Gateway Program has made substantial design and development progress toward delivering a small, human-tended lunar space station purposefully designed to enable sustainable human exploration. The Program integrates partners and providers organizationally and physically as part of the spacecraft. The Power and Propulsion Element (PPE) and the Habitation and Logistics Outpost (HALO) with the European System Providing Refueling, Infrastructure and Telecommunications (ESPRIT) HALO Lunar Communications System (HLCS) have begun manufacturing the long lead components and will be launched first as a Co-Manifested Vehicle (CMV). The International Habitat (I-Hab) and ESPRIT Refueling Module (ERM) are passing life cycle milestones and include capabilities key for human crewmembers, such as windows, private sleeping quarters, and galley functions. The Logistics Module (LM) may provide a variety of services to Gateway depending on each mission. Requirements for the airlock have been developed, including requests that it support the integrated spacecraft with functions like augmenting heat rejection capabilities, and interfaces with new spacesuits will soon be developed in more detail. As a critical element of the architecture for solar system exploration, Gateway implements key tenets and features of international interoperability standards necessary to operate with multiple visiting vehicles and lunar assets, especially avionics, communications, and docking. Specific choices such as software architecture and standards, power standards, and robotics standards make it possible to utilize heritage or proprietary technology, yet still operate as one spacecraft. Engineering teams are evaluating many possible future missions to be executed at or utilizing the Gateway. The system architecture protects for an evolvable, extensible, and flexible capability. Designing systems robust enough to serve as a cornerstone of exploration activities for decades while remaining adaptable is not without its challenges. The detailed integration activities have revealed challenges and the need to mature key technologies. Refueling is a key component of achieving long life for Gateway, with unique operations to plan, safety concerns to mitigate, and risk reduction activities to conduct to better understand the system. The constraints and impacts of the design of visiting vehicles is also an important concern, with orientation constraints, control of attitude and orbit of the Gateway with docked visiting vehicles. Tradeoffs between robust maintainable systems and lightweight, compact systems must be balanced. Opportunities still exist for adding additional advanced capabilities to increase and extend Gateway’s benefits, such as intravehicular robotics, autonomous Guidance Navigation and Control (GN&C), and augmented control propulsion, heat rejection, or other services.

Molly S Anderson↗
DOE OSTI2021

Hydrogen Component Leak Rate Quantification for System Risk and Reliability Assessment through QRA and PHM Frameworks: Preprint

The National Renewable Energy Laboratory's (NREL) Hydrogen Safety Research and Development (HSR&D) program in collaboration with the University of Maryland's Systems Risk and Reliability Analysis Laboratory (SyRRA) are working to improve reliability and reduce risk in hydrogen systems. This approach strives to use quantitative data on component leaks and failures, together with Prognosis and Health Management (PHM), and Quantitative Risk Assessment (QRA) to identify at-risk components, reduce component failures and downtime, and predict when components require maintenance. Hydrogen component failures increase facility maintenance cost, facility downtime, and reduce public acceptance of hydrogen technologies, ultimately increasing facility size and cost because of potentially overly conservative requirements. Leaks are a predominant failure mode for hydrogen components. However, uncertainties in the amount of hydrogen emitted from leaking components and the frequency of those failure events limit the understanding of the risks that they present under real-world operational conditions. NREL has deployed a test fixture, the Leak Rate Quantification Apparatus (LRQA), to quantify the mass flow rate of leaking gases from medium and high-pressure components that have failed while in service. Quantitative hydrogen leak rate data from this system could ultimately be used to better inform risk assessment and Regulation Codes and Standards (RCS). Parallel activity explores the use of PHM and QRA techniques to assess and reduce risk, thereby improving safety and reliability of hydrogen systems. The results of QRAs could further provide a systematic and science-based foundation for the design and implementation of RCS, as in the latest versions of the NFPA 2 code for gaseous hydrogen stations. Alternatively, data-driven techniques of PHM could provide new damage diagnosis and health-state prognosis tools. This research will help end users, station owners and operators, and regulatory bodies move towards risk-informed preventative maintenance versus emergency corrective maintenance, reducing cost and improving reliability. Predictive modelling of failures could improve safety and affect RCS requirements such as setback distances at liquid refuelling sites. The combination of leak rate quantification research, PHM, and QRA can lead to better informed models enabling data-based decision to be made for hydrogen system safety improvements.

codes and standards↗
DOE OSTI2025

Assessing fuel cycle design options for advanced microreactors

Microreactor (MR) technology have recently gained traction due to their reduced construction cost compared to traditional large reactors. Their small physical geometry results in increased neutron leakage and deteriorated neutron economy which limits the achievable burnup of MR fuel. Refueling strategy currently discussed in MR design community is the battery-like refueling which is involve replacing the entire reactor core at the end of their operational cycle. Here, this paper investigates partial core refueling as means to increase MR fuel burnup and improve fuel cycle economy as a result. Two fuel cycle design strategies have been successful. These are the partial core refueling and partial core refueling combined with assembly rotation. Both strategies have been tested to operate a heatpipe-cooled MR referred to as the eVinci-like core for 72 Effective Full Power Months (EFPMs). The partial core refueling showed to reduce the refueling requirements by 18% compared to the battery-like refueling strategy. This corresponds to 10.5% reduction in the Net Present Value (NPV) of fuel cost over the 72 EFPMs of operation. The partial core refueling combined with rotation case reduces the refueling requirements by 29% (corresponding to 14.5% reduction in NPV of fuel cost) compared to the battery-like refueling strategy.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1990

Final design of a space debris removal system

The objective is the removal of medium sized orbital debris in low Earth orbits. The design incorporates a transfer vehicle and a netting vehicle to capture the medium size debris. The system is based near an operational space station located at 28.5 degrees inclination and 400 km altitude. The system uses ground based tracking to determine the location of a satellite breakup or debris cloud. This data is unloaded to the transfer vehicle, and the transfer vehicle proceeds to rendezvous with the debris at a lower altitude parking orbit. Next, the netting vehicle is deployed, tracks the targeted debris, and captures it. After expending the available nets, the netting vehicle returns to the transfer vehicle for a new netting module and continues to capture more debris in the target area. Once all the netting modules are expended, the transfer vehicle returns to the space station's orbit, where it is resupplied with new netting modules from a space shuttle load. The new modules are launched by the shuttle from the ground, and the expended modules are taken back to Earth for removal of the captured debris, refueling, and repacking of the nets. Once the netting modules are refurbished, they are taken back into orbit for reuse. In a typical mission, the system has the ability to capture 50 pieces of orbital debris. One mission will take about six months. The system is designed to allow for a 30 degree inclination change on the outgoing and incoming trips of the transfer vehicle.

Carlson, Erika↗
NASA NTRS1991

SPECS: Orbital debris removal

The debris problem has reached a stage at which the risk to satellites and spacecraft has become substantial in low Earth orbit (LEO). This research discovered that small particles posed little threat to spacecraft because shielding can effectively prevent these particles from damaging the spacecraft. The research also showed that, even though collision with a large piece of debris could destroy the spacecraft, the large pieces of debris pose little danger because they can be tracked and the spacecraft can be maneuvered away from these pieces. Additionally, there are many current designs to capture and remove large debris particles from the space environment. From this analysis, it was decided to concentrate on the removal of medium-sized orbital debris, that is, those pieces ranging from 1 cm to 50 cm in size. The current design incorporates a transfer vehicle and a netting vehicle to capture the medium-sized debris. The system is based near an operational space station located at 28.5 deg inclination and 400 km altitude. The system uses ground-based tracking to determine the location of a satellite breakup or debris cloud. These data are uploaded to the transfer vehicle, which proceeds to rendezvous with the debris at a lower altitude parking orbit. Next, the netting vehicle is deployed, tracks the targeted debris, and captures it. After expending the available nets, the netting vehicle returns to the transfer vehicle for a new netting module and continues to capture more debris in the target area. Once all the netting modules are expended, the transfer vehicle returns to the space station's orbit where it is resupplied with new netting modules from a space shuttle load. The new modules are launched by the shuttle from the ground and the expended modules are taken back to Earth for removal of the captured debris, refueling, and repacking of the nets. Once the netting modules are refurbished, they are taken back into orbit for reuse. In a typical mission, the system has the ability to capture 50 pieces of orbital debris. One mission will take approximately six months and the system is designed to allow for a 30 deg inclination change on the outgoing and incoming trips of the transfer vehicle.

Source record↗
DOE OSTI2024

Levelized cost of charging of extreme fast charging with stationary LMO/LTO batteries

Extreme DC fast charging for electric vehicles (EVs) could be competitive with the internal combustion engine refueling experience and enable longer-distance travel, which could help with EV adoption and decarbonization, but these systems have high capital costs and extremely variable high-power demands. Behind-the-meter systems (BTMS) could support extreme-fast-charging (XFC) stations to increase nationwide adoption of EVs. Here, this study examines the optimal break-even levelized cost of charging (LCOC) across 96 BTMS scenarios to enable low-wait XFC stations providing 200 miles of charge in 10 min. This research simulates LCOC via synthetic XFC-capable EV loads, machine-learned battery life models from testing data, and nonlinear optimal controls, co-minimizing complex utility costs and battery replacements. An aggregate optimal BTMS design treating each EV load as equal likely gives an optimal LCOC per utility rate, the average of which is $\$$0.59/kWh. In addition, the sensitivity of optimal and off-optimal design factors, the long-life LMO/LTO chemistry, and optimized controls are analyzed. The battery control model, based on battery stressors to compare chemistries, optimizes LMO/LTO resting state of charge and cycle depth without compromising cost reduction, which enables greater flexibility in operation. The LCOC savings due to replacement reduction are small, up to $\$$0.035/kWh (6%), with an average of $\$$0.02/kWh (3.5%). Compared with gasoline stations, the aggregate XFC station design achieves comparable speed, experience of service, and cost at $\$$3.81/gal gasoline, showing that EVs can replace gasoline vehicles even for longer-distance travel.

25 ENERGY STORAGE↗
NASA NTRS1987

Space Station flight telerobotic servicer functional requirements development

The Space Station flight telerobotic servicer (FTS), a flight robotic system for use on the first Space Station launch, is described. The objectives of the FTS program include: (1) the provision of an alternative crew EVA by supporting the crew in assembly, maintenance, and servicing activities, and (2) the improvement of crew safety by performing hazardous tasks such as spacecraft refueling or thermal and power system maintenance. The NASA/NBS Standard Reference Model provides the generic, hierarchical, structured functional control definition for the system. It is capable of accommodating additional degrees of machine intelligence in the future.

Oberright, John↗
NASA NTRS1987

Servicing of spacecraft in the geostationary arc

The possibility of servicing geosynchronous spacecraft in connection with the development of the Space Station and its associated infrastructure is discussed. The proposed servicing infrastructure is presented as well as the design of a serviceable spacecraft, and a servicing scenario for a geostationary earth observation platform. The scenario employs the space based OTV, OMV, remote servicer and remote refueling system. It is shown that servicing geostationary spacecraft provides the largest economic benefit when performed on a scheduled basis.

Russell, Paul K.↗
NASA NTRS2013

A Mission Concept: Re-Entry Hopper-Aero-Space-Craft System on-Mars (REARM-Mars)

Future missions to Mars that would need a sophisticated lander, hopper, or rover could benefit from the REARM Architecture. The mission concept REARM Architecture is designed to provide unprecedented capabilities for future Mars exploration missions, including human exploration and possible sample-return missions, as a reusable lander, ascend/descend vehicle, refuelable hopper, multiple-location sample-return collector, laboratory, and a cargo system for assets and humans. These could all be possible by adding just a single customized Re-Entry-Hopper-Aero-Space-Craft System, called REARM-spacecraft, and a docking station at the Martian orbit, called REARM-dock. REARM could dramatically decrease the time and the expense required to launch new exploratory missions on Mars by making them less dependent on Earth and by reusing the assets already designed, built, and sent to Mars. REARM would introduce a new class of Mars exploration missions, which could explore much larger expanses of Mars in a much faster fashion and with much more sophisticated lab instruments. The proposed REARM architecture consists of the following subsystems: REARM-dock, REARM-spacecraft, sky-crane, secure-attached-compartment, sample-return container, agile rover, scalable orbital lab, and on-the-road robotic handymen.

Davoodi, Faranak↗
DOE OSTI2024

Hydrogen Detection Strategies to Support H2@SCALE - The NREL Sensor Laboratory

Hydrogen represents a major pathway to decarbonize and stabilize the national and international energy industry and select manufacturing markets. To facilitate the development of hydrogen markets, the US Department of Energy initiated H2@Scale to bring together stakeholders to advance affordable hydrogen production, transport, storage, and utilization to increase revenue opportunities in multiple energy sectors. One major impediment to hydrogen implementation is cost. To expedite the use of hydrogen in energy and other markets, the United States announced in 2021 the Hydrogen Shot, which seeks to reduce the cost of clean hydrogen by 80% to $1 per 1 kilogram in 1 decade ("1 1 1"). As the cost of hydrogen drops, new applications will emerge that will require unique configurations of existing equipment and infrastructure, and eventually lead to advances in the generation and utilization of hydrogen. As the hydrogen economy expands, sensors and detection methods will need to adapt to changing infrastructure demands to address the primary targets of health & safety, emissions monitoring, and process control. The NREL Sensor Laboratory is playing a pivotal role in advancing the use of hydrogen sensors and detection methodologies in each of these categories to support DOE's mission for safe and efficient utilization in emerging markets. Health & safety monitors are required to ensure that operators and facilities can react to unintended hydrogen releases, either as GH2, LH2, or as a constituent of blends (e.g., natural gas or ammonia). Current detection methodologies focus on safety applications to detect near its lower flammable limit (4 vol %), and typically include point sensors in applications such as fixed or mobile detectors (e.g., personal gas monitors). Methodologies amenable for area detection include acoustic, emerging optical imaging methods, and flame detectors. Comparable detection strategies can be utilized for emissions monitoring and quantization, however few methods can simultaneously cover both low (emissions) and high (health & safety) levels. Deployment of emission level detectors will be required to 1) reduce product loss through small but potentially significant leaks from an environmental or cost perspective, 2) reduce downtime of high demand systems by early identification of eminent system failures (leaks through pump or compressor seals indicative of impending failure), and 3) address potential emission monitoring requirements that may be set by regulating bodies. The first two points should be adopted by industry to reduce the cost-of-goods-sold. The third main category for hydrogen detection relates to process control and may be advantageous for many existing applications. Two main applications are emerging. For example, the purity requirements for hydrogen that is dispensed from refueling systems for hydrogen fuel cell electric vehicles (FCEV) is rigorously regulated by the Standard SAE J2719, which prescribes maximum allowable levels of multiple impurities in the hydrogen fuel and must be verified by a regulatory body. Hydrogen contaminant detectors (HCD) integrated to the fueling station can assure this compliance. HCDs must be able operate in 100% H2 backgrounds and be able to distinguish between multiple contaminants at low ppm to low ppb levels. Secondly, as a strategy to decarbonize the natural gas grid, there are proposals to blend hydrogen with natural gas. This blending will affect transport applications (pipeline infrastructure), stationary combustion systems (turbines), and consumer and commercial appliances. In the short-term, hydrogen levels up to 20% are proposed. Variations in the hydrogen level can have dramatic impact on the combustion process and on the potential response of safety sensors. These mixtures may be regulated so that the concentration at a delivery point must be monitored with high precision. However, routine maintenance may introduce background gases such as ambient air (with water) or maintenance gases (introduced with welding processes or adhesive outgassing.) Therefore, the detection methodology must be robust enough to recover or respond to various contaminants. Several reviews can be found in literature addressing sensing and detection technologies, including their limitations and applications. However, for most applications, limitations can be alleviated by combining various detection techniques either through system integration or implementation of machine learning methods (artificial intelligence). In this presentation, we will discuss several applications, highlight their current approach for hydrogen detection, and suggest detection strategies to supplement their limitations.

ENERGY STORAGE,HYDROGEN↗
DOE OSTI2021

History of Ethanol Fuel Adoption in the United States: Policy, Economics, and Logistics

Ethanol has the achieved the greatest market share of all the alternative transportation fuels that have been researched, developed, and deployed in the US. There are multiple lessons to be learned from the history of ethanol adoption that can be applied to future fuels and products. Ethanol has replaced portions of gasoline in three main blend levels, with corresponding vehicles, equipment, benefits, and policies. The first is E10, which has replaced nearly all pure gasoline (E0) sold in the United States today (U.S. Energy Information Administration 2015). This was brought about through generations of policies that were motivated by multiple factors related to engine performance, energy security, health, air quality, and climate protection. Ethanol's high octane has been a consistent driver of the fuel because this enables higher performance engines. Early policies (1973-1979) were largely motivated by the desire to reduce dependence on petroleum sourced from members of the Organization of the Petroleum Exporting Countries, or OPEC. Fuel policy in the 1980s was largely in pursuit of promoting octane number enhancers that could replace lead. Criteria pollutant reduction was the overarching goal of actions taken from 1990 to 2005. From 2005 to the present, fuel policy has been largely motivated by energy security and climate protection goals. These policies were usually technology-agnostic and promoted multiple fuels and additives during each period. However, ethanol is the only fuel identified that is cost effective with qualities that enabled it to prosper in the policy environments of all four of these periods.The second market for ethanol is via 85% ethanol (E85). This fuel has the advantage of a greater concentration of ethanol but the disadvantage of not being compatible with regular gasoline vehicles. Instead, it can only be used in flexible-fuel vehicle (FFVs), which can use every blend level from E0 to E85. Therefore, much of the effort to increase E85 consumption has been aimed at incentivizing automakers to manufacture FFVs, drivers to purchase FFVs, and fueling stations to equip themselves to sell E85.The third, and newest, market through which ethanol is consumed is 15% ethanol (E15), which builds upon the E10 market to increase ethanol consumption by common gasoline vehicles. Efforts to create the E15 market consisted largely of testing vehicles and refueling equipment for compatibility, creating waivers to allow the use of E15, placing requirements on E15 retailers, and incentivizing retailers to equip themselves to purchase E15.

09 BIOMASS FUELS↗
NASA NTRS1987

Shuttle bay telerobotics demonstration

A demonstration of NASA's robotics capabilities should be a balanced agenda of servicing and assembly tasks combined with selected key technical experiments. The servicing tasks include refueling and module replacement. Refueling involves the mating of special fluid connectors while module replacement requires an array of robotic technologies such as special tools, the arm of a logistics tool, and the precision mating of orbital replacement units to guides. The assembly task involves the construction of a space station node and truss structure. The technological experiments will focus on a few important issues: the precision manipulation of the arms by a teleoperator, the additional use of several mono camera views in conjunction with the stereo system, the use of a general purpose end effector versus a caddy of tools, and the dynamics involved with using a robot with a stabilizer.

Chun, W.↗
DOE OSTI2020

Advanced Electrochemical Hydrogen Compressor

U.S. automakers have invested significant resources in the research and development of hydrogen fuel cell electric vehicles (FCEVs). However, to enable the widespread deployment of FCEVs, an additional major investment is required to achieve an infrastructure for compressing hydrogen in hydrogen fueling stations. In order to dispense hydrogen to FCEV tanks quickly, the hydrogen must be compressed above a pressure of 875 bar (12,687 psi) at the fueling station. Mechanical compressors currently in use have high maintenance costs, poor reliability, and are noisy. To eliminate the need for mechanical compressors, Plug Power is extending its extensive experience in high-pressure proton-exchange-membrane (PEM), to develop an electrochemical hydrogen compressor (EHC) system for refueling applications that can deliver hydrogen at pressures greater than 875 bar. The work performed during this project was a collaboration between the Nation Renewable Energy Laboratory (NREL), Rensselaer Polytechnic Institute (RPI), and Gaia Energy Research Institute LLC (GAIA).

08 HYDROGEN↗
NASA NTRS1984

Propellant transfer: Tethered depot

Spacebasing of orbital transfer vehicles at a space station requires a depot that safely and efficiently stores and transfers the resupply propellants. In order to transfer propellants, a method effectively acquire only liquid and vent only gas must exist. A method that produces a low gravity to settle propellants would bypass these weaknesses, while allowing ground-like operations. This low gravity can be passively produced using gravity gradient techniques. A satellite with a large length to diameter ratio, such as a depot attached to a space station with a tether, stabilizes along on Earth radial because of an outward acceleration proportional to the distance from the satellite's center of gravity. Analysis indicates that liquid can be setteled with relatively short tether lengths. The feasibility, design requirements, and operational limitations of a tethered refueling depot were investigated with special emphasis on slosh control.

Kroll, K.↗
DOE OSTI2022

Modeling Freight Traffic Demand and Highway Networks for Hydrogen Fueling Station Planning: A Case Study of U.S. Interstate 75 Corridor

The use of hydrogen as an alternative transportation fuel has gained much interest in recent years. Hydrogen can be utilized in electric vehicles equipped with hydrogen powertrains (including hydrogen internal combustion engines or fuel cells). Given that most of the freight in the U.S. is transported via diesel trucks, transition to hydrogen fuel would help achieve significant environmental benefits as well as accelerate the decarbonization of the freight transportation sector. This paper presents the methodology and results of a case study on modeling freight traffic demand and highway networks based on publicly available data for the Interstate 75 freight corridor. The purpose of this study is to prepare input traffic and network data that can support the planning of a hydrogen fueling station infrastructure. In particular, the data can be used for siting and characterizing an optimized framework of hydrogen fueling stations from candidate diesel stations along the Interstate 75 corridor. The methodologies developed and presented in this paper may be readily expanded and applied to any transport corridor given the data availability. This paper is the first in a series that will build out a comprehensive model to optimize a consolidated national hydrogen refueling infrastructure eco-system targeted at commercial vehicles.

Uddin, Majbah↗
NASA NTRS1990

Engineering test results for the Moog Single Line Disconnect

New and innovative types of disconnects will be required to service, resupply, and maintain future spacecraft subsystems. Efficiently maintaining orbiting scientific instruments, spacecraft support systems, and a manned space station over a long period of time will require the periodic replenishment of consumables and the replacement of components. To accomplish these tasks, the fluid disconnect must be designed to allow the connection and separation of fluid lines and components with minimal hazard to crew and equipment. The capability to simply connect a refueling line or to easily replace a failed component greatly extends the life of a space based fluid system. A test program was initiated to evaluate the Moog Single Line Disconnect. The objective of the test program was to demonstrate the operational characteristics of the disconnect and to verify compliance with current safety regulations. The results of the program are summarized in the referenced document.

Glubke, Scott E.↗
NASA NTRS2004

Cargo Assured Access to International Space Station

Boeing's Cargo Assured Access logistics delivery system will provide a means to transport cargo to/from the International Space Station, Low Earth Orbit and the moon using Expendable Launch Vehicles. For Space Station, this capability will reduce cargo resupply backlog during nominal operations (e.g., supplement Shuttle, Progress, ATV and HTV) and augment cargo resupply capability during contingency operations (e.g., Shuttle delay and/or unavailability of International Partner launch or transfer vehicles). This capability can also provide an autonomous means to deliver cargo to lunar orbit, a lunar orbit refueling and work platform, and a contingency crew safe haven in support of NASA's new Exploration Initiative.

Smith, David A.↗