Cryogenic Propellant Storage and Distribution System

1
Cryogenic Propellant Storage and Distribution
System

• Detailed Design Review
• Cornell University
• Odysseus Team

Presenters Bryan Rivard Ben Canilang
Paul Germain Shahriar Samad
2
Overview

• Introduction
• System Overview
• Storage Tank Design
• Thermal Systems
• Refrigeration and Densification System
• Operational Timeline
• Sensors and Controls
• Outreach
• Questions

3
Introduction

• Objectives Space Launch Initiative (SLI)
• Reduce cost to space
• Increase safety of space flight
• Increase rate of travel to space
• Requirements to meet objectives
• Fully reusable launch vehicle (RLV)
• Reduced mass to orbit
• Highly efficient supporting infrastructure
• Our focus
• Cryogenic Propellant Storage Distribution
  (CPSDS)
• Densified Propellants ? Reduced mass to orbit

4
System Overview

• Detailed Design Review
• Cornell University
• Odysseus Team

Presenter Bryan Rivard
5
System Overview Site Layout

• Objectives
• Maximize Safety
• Operate Efficiently and Reliably
• Easy Access
• System Components
• Tanker Ingress/Egress Routes
• Escape Routes
• Drainage Areas
• H2 and O2 Main Storage Tanks
• Transport Pipes
• RLV Launch Pad Onboard Storage Tanks

6
System Overview Site Layout
7
System Overview Transport Storage

• Single Launch Requirement
• Accommodate gt 80 H2 Tankers
• Accommodate gt 30 O2 Tankers
• Transport System Design
• Accommodate 5 Tankers of H2 and O2 at once
• Offload 20-30 tankers each day
• Acts as reverse fueling station into Main Tanks
• Main Tanks Accommodate Enough Fuel For Launch

8
System Overview Transport and Storage
9
System Overview System Purging
10
Structural Design

• Detailed Design Review
• Cornell University
• Odysseus Team

Presenter Bryan Rivard
11
Structural Design Main Tanks

• Spherical and Vacuum Jacketed
• Reduced Heat Transfer
• Stainless Steel
• Robust Material and specified in project
• Inner Diameters LH2 19.1m, LO2 14m
• Fixed based on Densified Propellant Storage
  Requirement 2 Ullage
• Outer Wall Thickness LH2 .04cm, LO2 .04cm
• Fixed based on Annulus Pressure Differential
• Inner Wall Thickness LH2 3cm, LO2 3cm
• Fixed by ASME boiler/Pressure Vessel Calculations

12
Structural Design Main Tanks

• Annulus Design
• 20cm Annulus
• Increasing gap-size beyond this point provides
  little benefit
• Multi-Layer Mylar Insulation
• Reduced Internal Radiative Heat Transfer
• Internal Support Design
• Glass/Epoxy Composite
• Meets required compressive strength while
  reducing heat transfer
• Vertical Cylinder Geometry
• Decreased contact area as compared to pin-type
• Minimum Thicknesses LH2 .037cm, LO2 .4cm

13
Structural Design Pipes

• Design to
• Eliminate Icing
• Reduce Heating
• Reduce Temperature Increase
• Meet Mass Flow and Pumping Requirements
• Inner Diameters
• 16cm for Main Pipes
• 12cm for Others

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Storage Tank Design RLV Tanks

• Main Considerations
• Minimize Mass to Orbit
• Eliminate External Icing
• Primary Source of Propellant Heating
• Determines Densification Requirement

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Storage Tank Design RLV Tanks

• Material Definition
• Structural Carbon/Epoxy Composite
• Insulation Urethane Based Spray on Foaming

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Storage Tank Design RLV Tanks
17
Storage Tank Design RLV Tanks

• Final Design

18
Thermal Systems

• Detailed Design Review
• Cornell University
• Odysseus Team

Presenter Ben Canilang
19
Thermal Systems Stages

• 4 Stages of operation
• Stage 1 Filling of main tanks
• Stage 2 Main tank steady-state storage
• Stage 3 RLV Fueling
• Stage 4 RLV steady-state storage

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Thermal Systems Stage 1

• Main Tanks Cool-Down
• Pumping LH2 and LO2 at low flow rates
• Cooling via Vaporization
• Vented lost to atmosphere

21
Thermal Systems Stage 2

• Main Tanks Steady State Storage Heating
• Internal Radiation
• Conduction through Supports
• Free Convection negligible
• Total Steady State Heating Rate
• LH2 11.7 kW
• LO2 5.9 kW

22
Thermal Systems Stage 3

• RLV Tanks Transient Filling Pipes Cool-Down

23
Thermal Systems Stage 3

• RLV Tanks Transient Filling
• Fluid Energy Structural Insulation Cooling
  Energy
• Pumping LH2 and LO2 at low flow rates
• Cooling via Vaporization
• Vented lost to atmosphere

24
Thermal Systems Stage 4

• RLV Tanks Steady State Storage Heating

• LH2 RLV Tank
• q 125 kW
• LO2 RLV Tank
• q 51 kW

25
Refrigeration and Densification Systems

• Detailed Design Review
• Cornell University
• Odysseus Team

Presenter Paul Germain
26
Densification System Requirements

• Store propellants with minimal losses
• Deliver propellants to RLV in densified state
• LO2 _at_ 68.5K
• LH2 _at_ 16.5K
• Store propellants in RLV for 6 hours
• RLV refrigeration

27
Cryogenic System Design

• RLV heat loss is main design driver
• Continuous Densification/Refrigeration

28
Hydrogen Densification System
29
Oxygen Densification System
30
Refrigeration Methods

• Regenerative cycles
• Pulse Tube Coolers
• Recuperative cycles
• Reverse Brayton cycle
• Sub-atmospheric cyrogen baths
• Cryogenic consumables

31
Sub-Atmospheric Cryogen Baths

• Cold Compressors _at_ 14K and 8kPa
• Boiling hydrogen bath
• 10 tankers of H2 required

32
Regenerative Cycles

• Ideal Reversed Brayton Cycle
• Helium working fluid
• Isentropic compression, constant pressure heat
  removal, isentropic expansion, and constant
  pressure heat addition

33

• Reverse Brayton cycle
• Three Stage Compressors with inter-stage cooling
• Recuperators
• Two Bypass loops
• LO2/GHe HX
• LH2/GHe HX

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Ideal Reverse Brayton Cycle
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Ideal Reverse Brayton Cycle
LO2 HX
LH2 HX
36
Non-Ideal Reverse Brayton Cycle

• Efficiencies of the compressors
• Effectiveness of heat exchangers
• Pressure drops in heat exchangers and pipes

37
System Optimization

• Vary the flow through the bypass loop
• Vary the pressure ratio
• Vary mass flow rate through compressors

38
Non-Ideal Modified Reverse Brayton Cycle
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Non-Ideal Modified Reverse Brayton Cycle
LH2 HX
LO2 HX
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Final Specifications

• Max Operating Pressure 6 MPa
• Max Operating Temperature 600K
• Mass flow through compressors 3.65kg/s

41
Densification System Conclusions

• No cryogenic consumables
• Allows for liquefaction of hydrogen and oxygen on
  site
• Operates above atmospheric pressure
• Compressors are not in the cold region

42
Operational Timeline

• Detailed Design Review
• Cornell University
• Odysseus Team

Presenter
43
Operational Timeline

• 10 days for routine maintenance/cryogen
  liquefaction
• Tanker operations begin at T-10 days
• Two stage hydrogen densification
• Turn-down ratio hydrogen loop

44
Sensors and Controls

• Detailed Design Review
• Cornell University
• Odysseus Team

Presenter Shahriar Samad
45
Sensors Selection

• Final list of sensors
• - Temperature Silicon Diode (Cryotracker)
• - Pressure Capacitive
• - Fluid velocity Ultrasonic
• - Liquid level Silicon Diode (Cryotracker)
• - Structural Integrity Bonded Resistance
  Strain Gage
• - Leakage Detection Ultrasonic

46
Application Specific Controllers

• Only connected to the specific sensors that
  supply information needed to perform
  pre-programmed functions
• Decentralized network of system controllers
• Allows for easier maintenance and flexible
  control
• Does not affect the functionality of
• the other system components if
• one fails

47
Valve Specifications and Actuation

• Flow control and pressure relief
• valves are of the globe type
• Check valves are of the horizontal
• swing-check type
• Electrical actuation will be used for both type
  of valves. Reasons (1) consistent torque (2)
  fast response

48
Process and Instrumentation Diagram

• PID is a schematic of CPSDS
• sensor and control mechanisms
• Shows quantity of component
• and relative location to each
• other

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PID LO2 System
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PID LH2 System
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PID Densification System
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Mass Gauging Storage and RLV
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Leakage Monitoring

• Essential note LH2 and LO2 CANNOT mix!
• Location (e.g. joints) and quantity of sensors
  critical to
• successful detection
• Combination of monitoring methods (1) Point
  Source Method (2) Systematic Leak Detection
• Pressure variations are the key to leak
  detection especially
• large pressure drops
• Valves before and after leak will close upon
  detection

54
System Monitoring Data Collection

• Extra sensors relay information to central
  controller
• Data stored for analysis at a later time
• - used to improve the overall process
• - creating a more robust design
• - eliminate the need for unnecessary sensors
  and controllers

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Outreach

• Detailed Design Review
• Cornell University
• Odysseus Team

Presenter
56
Outreach

• Completed Projects
• Brochure
• Middle School Question and Answer
• High School Mentoring
• Cornell U. Presentation
• Webpage Development
• Radio Public Service Announcements
• Current Projects
• Partnership with YMCA
• Newsletter

57
Outreach
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Outreach
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Questions?

• Detailed Design Review
• Cornell University
• The Odysseus Team
• Thanks you!