Thermodynamic modeling of the no-vent fill methodology for transferring cryogens in low gravity

The filling of tanks with cryogens in the low-gravity environment of space poses many technical challenges. Chief among these is the inability to vent only vapor from the tank as the filling proceeds. As a potential solution to this problem, the NASA Lewis Research Center is researching a technique known as No-Vent Fill. This technology potentially has broad application. The focus is the fueling of space based Orbital Transfer Vehicles. The fundamental thermodynamics of the No-Vent Fill process to develop an analytical model of No-Vent Fill is described. The model is then used to conduct a parametric investigation of the key parameters: initial tank wall temperature, liquid-vapor interface heat transfer rate, liquid inflow rate, and inflowing liquid temperatures. Liquid inflowing temperature and the liquid-vapor interface heat transfer rate seem to be the most significant since they influence the entire fill process. The initial tank wall temperature must be sufficiently low to prevent a rapid pressure rise during the initial liquid flashing stage, but then becomes less significant

Cryogenic transfer options for exploration missions

The literature of in-space cryogenic transfer is reviewed in order to propose transportation concepts to support the Space Exploration Initiative (SEI). Forty-nine references are listed and key findings are synopsized. An assessment of the current maturity of cryogenic transfer system technology is made. Although the settled transfer technique is the most mature technology, the No-Vent Fill technology is maturing rapidly. Future options for development of cryogenic transfer technology are also discussed

Probabilistic Flow Regime Map Modeling of Two-Phase Flow

The purpose of this investigation is to develop models for two-phase heat transfer, void fraction, and pressure drop, three key design parameters, in single, smooth, horizontal tubes using a common probabilistic two-phase flow regime basis. Probabilistic two-phase flow maps are experimentally developed for R134a at 25 ??C, 35 ??C, and 50 ??C, R410A at 25 ??C, mass fluxes from 100 to 600 kg/m2-s, qualities from 0 to 1 in 8.00 mm, 5.43 mm, 3.90 mm, and 1.74 mm I.D. horizontal, smooth, adiabatic tubes in order to extend probabilistic two-phase flow map modeling to single tubes. An automated flow visualization technique, utilizing image recognition software and a new optical method, is developed to classify the flow regimes present in approximately one million captured images. The probabilistic two-phase flow maps developed are represented as continuous functions and generalized based on physical parameters. Condensation heat transfer, void fraction, and pressure drop models are developed for single tubes utilizing the generalized flow regime map developed. The condensation heat transfer model is compared to experimentally obtained condensation data of R134a at 25 ??C in 8.915 mm diameter smooth copper tube with mass fluxes ranging from 100 to 300 kg/m2-s and a full quality range. The condensation heat transfer, void fraction, and pressure drop models developed are also compared to data found in the literature for a wide range of tube sizes, refrigerants, and flow conditions.Air Conditioning and Refrigeration Project 18

Investigation of Adiabatic Refrigerant Pressure Drop and Flow Visualization in Flat Plate Evaporators

Adiabatic pressure drop and flow visualization in chevron plate, 1:1 aspect ratio bumpy plate, and 2:1 aspect ratio bumpy plate heat exchangers were investigated for vertical upward flow with R134a. Qualities ranging from subcooled liquid to superheated vapor were investigated. Mass fluxes ranged from 16 kg/m2-s (for superheated vapor) to approximately 300 kg/m2-s (for sub-cooled liquid). The pressure drop experiments were conducted for 10o C and 20o C inlet temperatures. The flow visualization experiments were conducted at a 10o C inlet temperature. The following is the order of highest to lowest pressure drop geometries on both a mass flux and mass flow bases: chevron plate, 1:1 aspect ratio bumpy plate, and 2:1 aspect ratio bumpy plate. These trends are more pronounced on a mass flow basis. Four flow regimes were observed for the flat plate geometries investigated and are mapped out on a mass flux versus quality basis for each geometry. The chevron geometry was seen to undergo flow transitions at lower qualities and mass fluxes than the bumpy plate geometries. The kinetic energy per unit volume of the flow was found to have a strong linear relationship with pressure drop for both single-phase and two-phase flow, suggesting that inertial effects are the dominant mode of pressure drop in flat plate heat exchangers. Vapor pressure drop prediction models based on the kinetic energy of the flow are presented, which predict pressure drop within 20%. A two-phase pressure drop model is developed, also based on kinetic energy per unit volume of the flow. A pseudo void fraction is defined in order to correlate the two-phase pressure drop to the single-phase pressure drop. The two-phase pressure drop model predicts two-phase pressure drop to within 15% of experimental measurements. A description of and modifications to the experimental test facilities are provided. In addition, the geometries and construction of the plates are provided.Air Conditioning and Refrigeration Project 12

Numerical calculation of the parameters of the efflux from a helium dewar used for cooling of heat shields in a satellite

The parameters of the efflux from a helium dewar in space were numerically calculated. The flow was modeled as a one dimensional compressible ideal gas with variable properties. The primary boundary conditions are flow with friction and flow with heat transfer and friction. Two PASCAL programs were developed to calculate the efflux parameters: EFFLUZD and EFFLUXM. EFFLUXD calculates the minimum mass flow for the given shield temperatures and shield heat inputs. It then calculates the pipe lengths, diameter, and fluid parameters which satisfy all boundary conditions. Since the diameter returned by EFFLUXD is only rarely of nominal size, EFFLUXM calculates the mass flow and shield heat exchange for given pipe lengths, diameter, and shield temperatures

Review and test of chilldown methods for space-based cryogenic tanks

The literature for tank chilldown methods applicable to cryogenic tankage in the zero gravity environment of earth orbit is reviewed. One method is selected for demonstration in a ground based test. The method selected for investigation was the charge-hold-vent method which uses repeated injection of liquid slugs, followed by a hold to allow complete vaporization of the liquid and a vent of the tank to space vacuum to cool tankage to the desired temperature. The test was conducted on a 175 cubic foot, 2219 aluminum walled tank weighing 329 pounds, which was previously outfitted with spray systems to test nonvented fill technologies. To minimize hardware changes, a simple control-by-pressure scheme was implemented to control injected liquid quantities. The tank cooled from 440 R sufficiently in six charge-hold-vent cycles to allow a complete nonvented fill of the test tank. Liquid hydrogen consumed in the process is estimated at 32 pounds

Small experiments for the maturation of orbital cryogenic transfer technologies

The no-vent method is a promising approach to handling the problems of low-g venting during propellant transfer. A receiver tank is first cooled to remove thermal energy from the tank wall and the resultant vapor vented overboard. The nozzles mix the incoming liquid and residual vapor in the tank maintaining a thermodynamic state which allows the tank to fill with liquid without venting. Ground based testing at NASA Lewis Research Center (LeRC) has demonstrated the no-vent fill process and attempted to bound its low-gravity performance. But, low-gravity testing is required to validate the method. As an alternative to using a dedicated spacecraft for validation, several small scale experiments to study no-vent fill in low-g were formulated. Cost goals quickly limited the search to two possibilities: a secondary payload on the space shuttle, or a small scale sounding rocket experiment. The key issues of small scale experimentation are discussed, and a conceptual design of a sounding rocket experiment with liquid hydrogen for studying the fill process is presented

Improved thermodynamic modeling of the no-vent fill process and correlation with experimental data

The United States' plans to establish a permanent manned presence in space and to explore the Solar System created the need to efficiently handle large quantities of subcritical cryogenic fluids, particularly propellants such as liquid hydrogen and liquid oxygen, in low- to zero-gravity environments. One of the key technologies to be developed for fluid handling is the ability to transfer the cryogens between storage and spacecraft tanks. The no-vent fill method was identified as one way to perform this transfer. In order to understand how to apply this method, a model of the no-vent fill process is being developed and correlated with experimental data. The verified models then can be used to design and analyze configurations for tankage and subcritical fluid depots. The development of an improved macroscopic thermodynamic model is discussed of the no-vent fill process and the analytical results from the computer program implementation of the model are correlated with experimental results for two different test tanks

Comparing the results of an analytical model of the no-vent fill process with no-vent fill test results for a 4.96 cubic meters (175 cubic feet) tank

The NASA Lewis Research Center (NASA/LeRC) have been investigating a no-vent fill method for refilling cryogenic storage tanks in low gravity. Analytical modeling based on analyzing the heat transfer of a droplet has successfully represented the process in 0.034 m and 0.142 cubic m commercial dewars using liquid nitrogen and hydrogen. Recently a large tank (4.96 cubic m) was tested with hydrogen. This lightweight tank is representative of spacecraft construction. This paper presents efforts to model the large tank test data. The droplet heat transfer model is found to over predict the tank pressure level when compared to the large tank data. A new model based on equilibrium thermodynamics has been formulated. This new model is compared to the published large scale tank's test results as well as some additional test runs with the same equipment. The results are shown to match the test results within the measurement uncertainty of the test data except for the initial transient wall cooldown where it is conservative (i.e., overpredicts the initial pressure spike found in this time frame)

Investigation of an R134A Refrigerant/Iso 32 Polyol Ester Oil Mixture in Condensation

Air Conditioning and Refrigeration Project 12