Members Login
Username 
 
Password 
    Remember Me  
Post Info TOPIC: LOX Augmented NTR for SSTO applications


Guru

Status: Offline
Posts: 606
Date:
LOX Augmented NTR for SSTO applications


I did some rough calculations for a Nuclear Thermal Rocket Engine of the Phoebis-2 class, which was a 5,000 MWt class engine capable of generating nearly 250,000 lbf of thrust with greater than 860 sec of specific impulse. Had Project NERVA continued, this engine could have flown as Saturn upper stage as part of an Expanded Advanced Apollo Program...but alas it was not to be. NERVA was cancelled and soon so was Apollo...

Anyways the question asked was: if a nuclear thermal rocket engine of 250,000 lbf were augmented by injecting liquid oxygen downstream of the nozzle, could such a hybrid engine be used for a practical SSTO?

Without doing the detailed nozzle calculations (which are needed for a responsible and thorough analysis!) some tentative indications are that: yes, a 250 Klbf NTR, augmented with LO2 to bring its thrust up to nearly 1 million lbf, could infact be used to create a single stage to orbit vehicle given quite a few conditions.

I can't seem to attach a file (I was going to upload a PDF) so I guess I'll just dump the whole thing in here. My apologies for any formatting errors, and I apologize for the length, but here goes:


Estimation of some important parameters for a Reusable SSTO utilizing a 250 Klbf-class NTR in a
LANTR boost-mode


LEO Orbital Velocity: 7700 m/s
Total mission delta-V requirements accounting for Gravity and Aerodynamic Losses: 10,000 m/s

Base engine performance:
Isp, vacuum operation, not augmented: 960 sec
equivalent exhaust velocity: 9,414 m/s
Isp, vacuum operation, augmented: 880 sec
equivalent exhaust velocity: 8,630 m/s
Isp, boost phase, augmented, sea level: 700 sec
equivalent exhaust velocity: 6,864 m/s

Thrust, vacuum, non-augmented: 250,000 lbf (1112 KN)
liquid hydrogen consumption rate: 118.1 kg/s

kinetic power of exhaust jet: 5,235 MW
assume 98% nozzle efficiency to estimate total reactor power: 5,340 MWt


Liquid Oxygen Augmentation of Thrust:

O/F = 4.0:1
Liquid oxygen consumption rate: 472.5 kg/s
Lower (non condensing) heat of combustion of hydrogen: -286 KJ/mole (141.9 MJ/kg)
Pcombustion = 118.1 kg/s * 141.9 MJ/kg
= 16,758 MWt (total combustion power)

Ptotal jet power = 5,235 MW + 16,758 MW
= 21,993 MW
total propellant consumption rate: 118.1 kg/s + 472.5 kg/s
: 590.6 kg/s

from K=1/2*m*v^2, differentiating with respect to time, keeping v constant:
P=1/2*mdot*v^2
solving for v gives:

v=sqrt(2*P/mdot)

Let P=21,993 MW, mdot=590.6 kg/s

v=8630 m/s (Isp = 880 sec)


Without doing detailed nozzle calculations (required for a thorough analysis), experience suggests that a sea level performance reduction of 20% from vacuum Isp can be expected:

Isp, sea level, augmented = 880 sec * 0.8
= 700 sec
v sea level = 6,865 m/s

This suggests we can expect a sea level thrust to be near:

F = g*Isp*mdot

= (9.80665 m/s^2) * (700 s) * (590.6 kg/s)
= 4,054 kN (911,440 lbf)

This suggests a GLOW (gross lift off weight) of about F/1.2 = 750,000 lb (340,000 kg)

Assume a boost phase, augmented thrust, burn time: t = 139 sec

"1st Stage" boost phase LO2 consumed, 100% throttle: 65,680 kg
assume +5% for ullage: 69,000 kg.

boost phase LH2 consumed, 100% throttle: 16,416 kg
total boost phase propellants consumed: 82,093 kg.

Average Isp, boost phase, augmented thrust:
60 % sea level to 40% vacuum level: 0.6*700 s + 0.4 * 880 s = 772 s
average equivalent exhaust velocity: 7570.6 m/s

mission delta-V achieved to t=139 s:

deltaV=c*ln(mi/mf)

let c=7,570.6 m/s; mi=340,000 kg; mf = mi - 82,093 kg
deltaV=2,092 m/s (note: this is not the actual velocity achieved at t=139 s, since there are gravity and drag losses...)

mission deltaV remaining: 10,000 m/s - 2,092 m/s =7,908 m/s

"2nd Stage"
assume principly vacuum operation, no augmentation:
Isp, vac, no augmentation: 960 s

total vehicle mass at "2nd Stage": 257,907 kg

V=c*ln(mi/mf) solve for mf:

mf = mi*EXP(-V/c)

Let mi = 257,907 kg; c = 960 s * 9.80665 m/s^2, V=7,908 m/s:
mf = 111,342 kg.

This is the total mass delivered to orbit: this includes the mass of the structure, the engine, remaining propellants (residuals,) and payload.

Total mass of propellants consumed during this phase: mi-mf = 146,565 kg of which this is entirely liquid hydrogen.

Total Hydrogen consumed in flight: 146,565 kg + 16,416 kg
: 162,981 kg
density of liquid hydrogen at 20K boil point: 70.7 kg/m^3

Volume of Liquid Hydrogen tank: 2,305 m^3.
assume 5% ullage space: 2,420 m^3 (actual tank volume)

total liquid oxygen consumed in flight: 65,680 kg
assume +5% ullage mass: 68,960 kg
density of liquid oxygen at 90 K boil point: 1,140 kg/m^3
volume of liquid oxygen: 60.5 m^3
assume +5% volume: 63.5 m^3 actual tank volume

Total mass of Propellants consumed: 231,941 kg

Back GLOW = 231,941 kg + 111,342 kg = 343,283 kg, very close to our original estimate of 340,000 kg.

At this point I would point out that by shifting the boost-burn time back, burning more oxygen, we would end up with a more compact vehicle. The optimal result occurs when the total tankage mass is minimized while simultaneously maximizing total delta-V. This is more complex than it sounds, because you pay a slight performance penalty in Isp by burning longer with oxygen, but you save tankage volume (and hence tankage weight) by burning less hydrogen. Also a more compact vehicle will naturally have less atmospheric drag, and hence drag losses will also be less. Now since the hydrogen tank is so big, making it smaller will save you More mass than by making the oxygen tank bigger (because oxygen is denser than hydrogen by a factor 16 to 1, and since tankage mass scales approximately with volume.) The complexity of these interelated factors makes a detailed analysis exceedingly difficult--which is why such an optimization is usually done iteratively on a computer (requiring detailed mathematical models of the various configurations.)

If one wants to get an idea of how much liquid hydrogen 163,000 kg represents look at the Sace Shuttle ET. The LH2 section carries 226,000 lb of liquid hydrogen (102,500 kg.) This RSSTO carries 60% more hydrogen than that...that starts to give us an idea of how big this machine would be...

Estimating the mass of the tankage, which if the vehicle is like a large right frustrum cone, will also be very difficult because of the non-standard geometry and the fact the the tankage must be intregral with the vehicle structure (to save weight.)

I tend to use something I am familiar with for comparison: The Space Shuttle ET.

The Super-Light Weight ET has a mass of about 26,560 kg and contains about 735,550 kg of propellants for a containment ratio of: 27.7 : 1, that is for every 27.7 kg of propellant, you only have 1 kg of tank.

Assuming we can do no better than 15:1 (which incidently is very close to the Apollo Saturn 5 1st stage) because of the complexity of the vehicle tankage geometry, we may expect to have a tankage mass in the range of: 231,941 kg/15 = 15,462 kg. Actually this sounds a bit too light to me...

This may, or may not be accurate. Only a detailed analysis of an actual tankage structural design will give a really meaningful answer.





__________________


Senior Member

Status: Offline
Posts: 366
Date:

Good work.  Youve certainly taken this to much more detail than I have.  If I read this right youre calculation show that this concept is close to SSTO.    Of course there are a lot of details but its at least good enough for use in a hard sci-fi story! My thought is that any such program is a way off and so there will be time for some NTP technology improvements before this would be seriously considered.  There will be a lot of tweaking both good and bad before a final answer. We also have to face the political problems of using nuclear energy this way.  China might not be so fastidious when their program can reach this technology for example.



__________________


Guru

Status: Offline
Posts: 606
Date:

I have to admit that, preliminarily, the idea looks good. A 110,000 kg orbital mass would suggest to me a delivered payload in the 10,000-12,000 kg range--respectable especially if the vehicle is a single engined SSTO and reusable! Interestingly enough, again without doing the nozzle calculations, it occurs to me that such an engine would benefit from variable geometry provided by a deployed-in-flight, radiation cooled, carbon composite nozzle extension which would slide down over the fully regeneratively cooled nozzle section. Such nozzle extensions have been used for years on many solid and liquid propelled upper stages. Using it on a boost vehicle would be a first though--since boost engines rarely get the chance to participate in upperstage burns. Once the vehicle was past the boost phase and oxygen injection was shut down, the nozzle extension would deply and actually increase the available Isp by perhaps another 10-12%.

Another thing that occurs to me is the idea of using a tungsten-zirconium pebble bed reactor: using tunsten-zirconium alloyed with highly enriched uranium (92-96% U-235) has been used safely for years in US nuclear submarines. It hasn't yet been applied to pebble beds--but the thermal conductivity of the metals is far superior to the oxides--so heat is more efficiently and quickly transfered from the fuel to the reaction mass--a little fact that Jaro has pointed out to me on a few occasions! I don't have the numbers in front of me, but this is starting to sound like an exciting design--and I have to admit, it is pretty much right up my alley. So I will keep everyone posted!

Ty Moore


__________________


Guru

Status: Offline
Posts: 606
Date:

I've been looking into this a little more. The original Project Rover and Project NERVA engines utilized carbon based cores--usually a (U,Zr)C fuel monolith matrix with NbC lined coolant channels. However this matrix is brittle and susceptable to thermal fracture--this is the origin of the erosion seen in those engines. This core technology is susceptible to 'carbon leaching' from the hot hydrogen--presumably from the formation of -CH2- free radicals...

Using an all metal (W,Zr,U) more homogenous tungsten, zirconium, uranium alloy technology may increase the thermal conductivity of the core, reduce leaching by hydrogen, and simplify core nucleonics by using an already establiblished fuel technology albeit one that the US Navy has a history with in their naval reactors. Moving away from heterogenous cermets (where fuel materials are chemically altered to be ceramics--usually as a uranium carbide or as an uranium dioxide) may increase reactor operating temperatures because there will be much less differential thermal expansion--which is the primary killer of carbon/carbide cores.

I've been trying to locate more info on the tungsten, zirconium, uranium (93-96% enriched U-235) alloys--but commen sense suggests that the enriched uranium fuel is probably diluted with zirconium so that the volume loading of fissile materials is reduced to give acceptable control over a range of specific powers (volumetric power density.) In this way, possibly heterogenous fuel loadings can be accomplished in the core with the ability to tailor the concentration of fissile fuels to even out the power distribution throughout the volume of the core.

Any helpful suggestions on where I can find some more (unclassified) info on these alloys? I can't seem to find any info on leaching, or corrosion of tungsten by hydrogen at 3000+ K and 80-200 atm of pressure--the primary mechanism I would expect would be volatilization of tungsten hydride from the surface of cooling channels--even a simple test of passing hydrogen through a pressure tube made of tungsten heated with an rf-induction furnace in an atmosphere of helium ought to give good results on this...just in case anybody has a gas analyzer just 'laying around!'

Ty Moore

__________________


Veteran Member

Status: Offline
Posts: 62
Date:

Long time coming back to look at this again, and I second the congrats on the good work. Lots of tricky numbers to crunch in there!

To toss a monkey wrench into it, if you or anybody gets back to crunching these numbers:

How about improving the payload or performance by staging it? At least tankage for the O2 can be dumped. The bottom of the cone, forming a "donut/skirt" around the extendable nozzle?
I wouldn't particularly object (even in the 21st C) if it's expendable. I note nothing was said in the OP about re-usability and it's effect on mass -not to mention man-rating the beast, or equipping it for re-entry.
 Maybe best to just make it unmanned, and only partially re-usable (if the nuke engine could be re-built for future flights. Even that would probably turn out like the SSME: not at all worth the trouble/cost of re-using it as opposed to scrapping/recycling.
The K.I.S.S. rule and Truax's truism about making it only just as reliable as it needs, would seem to apply.

And, maybe tripropellant? I know, there's not any work to look at, to figure out how such a beast might work... I know of NTRs having been designed to run with NH3 (ammonia), and there's been work on using water in a steam rocket for putt-putting around the Jovian moons / trojans and such.
How about tossing a few minutes of CH4 into the first stage numbers? Lower isp but even denser fuel, for a smaller vehicle.

When I had access to numbers for this kind of thing, and a calculator to handle the job, I toyed with a chemical rocket version of this (something like the old SS-X concept ship). After almost making it worthwhile with SSTO H2/O2, I tipped the scale by adopting tri-propellant and expendable tankage. (for a "realistic" S.F. RPG concept)
Remember the B.I.S. MUSTARD concept, too: cross-feeding fuels so the upper stage is fully fueled at staging. (maybe applicable, since any expendable tankage would make it resemble a parallel-burning multi-stage).


-- Edited by john fraz at 04:49, 2008-11-04

__________________
"A devotee of Truth may not do anything in deference to convention. He must always hold himself open to correction, and whenever he discovers himself to be wrong he must confess it at all costs and atone for it." Monhandas K. Gandhi


Guru

Status: Offline
Posts: 606
Date:

I am currently working on a project for the NSTI which involves a rather enormous vehicle: 12m core stage, cluster of atleast 6 RS-68's on the core stage, surrounded by 8 (or 4 depending upon specific configuration) strapon boosters each with a single RD-170 engine, (or in the case of 4 strapon flybacks) 2 RD-170's per booster. One feature of the vehicle is the core stage has equal volume liquid hydrogen and liquid oxygen tanks; the extra liquid oxygen is burned in the 'fuel only' strapon boosters; and the core stage is designed to be dissassembled on orbit.

One of the 'cute features' of this Launch Vehicle design, is that it is also designed from the start to be easily mated to and use a very large LANTR engine--which I have tentatively called "Goliath." This engine would also be designed, from the start, to have the capability to be "upgraded" to a ground start capabilty and used as a primary propulsion system, once things like internal erosion were identified and eliminated. The added specific impulse available might give significant enhancements to payload, mission capability, or both. The components of core stage tankage and Goliath LANTR engines could then be assembled, on orbit, into a rather large deep space vehicle--a true 'spaceship' in the grandest sense of the word, I suppose.

Detailed analysis and design of this architecture is in the works--currently my progress is slow...

Incidently, I have yet to come up with a tentative name for this Launch Vehicle...

I'm open to suggestions...  :)


__________________


Veteran Member

Status: Offline
Posts: 62
Date:

GoogleNaut wrote:
>I am currently working on... a rather enormous vehicle: 12m core stage, cluster of atleast 6 RS-68's on the core stage, surrounded by 8 (or 4 depending upon specific configuration) strapon boosters each with a single RD-170 engine, (or in the case of 4 strapon flybacks) 2 RD-170's per booster. One feature of the vehicle is the core stage has equal volume liquid hydrogen and liquid oxygen tanks; the extra liquid oxygen is burned in the 'fuel only' strapon boosters; and the core stage is designed to be dissassembled on orbit
>... it is also designed from the start to be easily mated to and use a very large LANTR engine

Again, considering things like reusability entails a lot of complexity & weight. Are those engines really economically salvageable? Is it worth keeping them for later? Even if you only parachute them into the ocean downrange instead of flying them back to a wheels-down runway landing you eat up a lot of payload mass fraction and add significant cost.

OTOH, I well understand the temptation to save the first stage. Of any of the stages, that's the easiest to re-use (aside from the upper/circularization/OMS stage)Picture the DC-X as one of your strap-ons... Lots of mass fraction devoted to landing gear and the VTOL capability.
There's also the possibility to use a turbojet for fly-back and approach, if not VL. Possibly burning some fuel on lift-off and for a while into the flight (handy air-breathing first stage cheat, there). If it's not too much complexity for a first stage, make it tri-propellant: H2/RPX/O2, and save some of the RPX for the jet flyback.

As tempting as it is to use an NTR for lift-off & as much as possible of the total boost requirements, I think there's a lot to be said for saving it for upper stage & space-use. (part of my design philosophy quirk to not mix stage uses between the first 6 minutes and the following months/years of use in space.)
Don't use the rocket that lifts it off the ground and through the air and the first few km/sec speed gain, for anything above circularization/OMS in LEO, if even that amount of cross-regime utility. Two radically different flight regimes with different requirements.

I could see a NTR used clustered for upper stages (for large payloads), used clustered for interplanetary travel or singly around the asteroids or small moons.
 Better yet, tri-modal NTR. Used as auxilliary/maneuvering thrusters for the NPR interplanetary ship, and dis-mountable for use as asteroid/small moon hoppers. The power plant function is auxilliary/emergency power for the interplanetary ship, or possibly for an NEP in the outer solar system or interplanetary trajectories (if NPR is not used), and as remote power when grounded or for an ISRU fuel processor.
A tri-mode NTR is everything that a VASIMR is, and if not prototyped, then it's ready to come off the production lines at any time now. Since it's kept around as a power plant, why not carry 4-6 of them all identical.
Possibly built well enough to be used for a planetary/transorbital Mars hopper.
I'm making a S-WAG about the numbers here, but if 4 or 6 of them is an upper stage/circularization cluster, then would 1 of them lift a 20 ton vehicle around Mars? (more than enough for a larger vehicle around an asteroid or -say- Enceladus).
 Produce a good deal of electricity to power a ground station or an emergency power plant for the ship, or the interplanetary electric rocket stage?

 Since I don't at present have the numbers to show that it's roughly feasible that it's economical if the design costs can be kept down, I'll just toss it out there. Maintenance of a re-startable NTR might be a killer. I tried figuring it for a G.U.R.P.S. RPG campaign, and that was the big unknown. The one place I might have to introduce some interesting things into the game, like tele-robotic repair 'droids and modular design.

>Incidently, I have yet to come up with a tentative name for this Launch Vehicle...

>I'm open to suggestions...  :)
You couldn't do worse/better than to come up with a handy acronym name. "MUSTARD" is unforgettable, as a name for a rocket...
doh


-- Edited by john fraz at 04:50, 2008-11-15

__________________
"A devotee of Truth may not do anything in deference to convention. He must always hold himself open to correction, and whenever he discovers himself to be wrong he must confess it at all costs and atone for it." Monhandas K. Gandhi


Guru

Status: Offline
Posts: 606
Date:

---Payload mass fractions aren't as sensitive to booster weight than upper stage weight. This vehicle that I am designing also uses a 'backward' philosophy which isn't used at all--as far as I know. The reason being, the core stage actually constitutes part of the delivered payload. As such, there will be tradeoffs that would normally not be made in a conventional vehicle. For instance, I am working on the problem of providing for 'hatch knockouts'--specially designed panels that can be removed from the tank structure so that berthing mechanisms can be easily installed--this is a non-trivial task. Normally this would be insane--because it adds weight an unnecessary complexity--but in this design where the core stage is part of the payload it becomes necessary.

--Reuseability of booster engines: the basic RD-170 engine is designed for use about 20 times. It could be modified to use liquid hydrogen coolant for the chamber and nozzle--which reduces and eliminates hydrocarbon coking in the channel walls (this makes the engine tripropellant--kind of.) Further since the boosters are fuel-only (liquid oxygen is provided from the core stage LOX tank) this eliminates one whole set of tankage on the boosters. With only a single, non-cryogenic tank to deal with, it becomes much easier to design an aerodynamic/structural shape that solves simultaneously the problems of boost load force distributions and airworthiness--thus a flyback booster is a real possibility. It could even be made small enough--I think--to use General Electric F101-GE-102 turbofans (the same engine as the B1B bomber) for propulsion. There should be plenty of reserve propellant for fuel for these engines. With a domestic manufacturing license to produce RD-170 engines, and a good solid parts base, refurbishing the engines shouldn't be a problem.

--The nuclear engine component of this architecture: I haven't figured out where electrical cogeneration may fit in yet...I've done some initial calculations which suggests that the burnup from power generation may actually exceed burnup from main engine burns. For a large vehicle it may infact make more sense to have a dedicated nuclear auxiliary power unit. However, electrical cogeneration with the main engines during full power burns, and subsequent shut down decay heat removal may be desirable and necessary. The burnup issue will likely go right to the heart of engine life: how many hours of full power operation can we get from it. Currently, I don't know.

--Reaction Control: again, another critical design issue. If chemical, this is going to be a large mass penalty: probably approaching 25% total vehicle mass. A combination of large Reaction Wheels and VASIMR style thrusters could probably be used for vernier controls, but gross translations will probably have to be handled by a combination of RCS thrusters. For a vehicle this size, those thrusters might look a lot like an RL-10A2 LH2/LO2 engine. Nuclear RCS is a possibility, but this really challenges us for shielding requirements--we really don't want to fry the crew!

--MUSTARD has already been used in the past. I was thinking of raiding something from Greek Mythology--surely there is something worthy that could be used there...I just haven't had the time to go look yet. :)

Cheers!
Ty Moore



-- Edited by GoogleNaut at 18:14, 2008-11-15

__________________
Page 1 of 1  sorted by
 
Quick Reply

Please log in to post quick replies.

Tweet this page Post to Digg Post to Del.icio.us


Create your own FREE Forum
Report Abuse
Powered by ActiveBoard