prototype sabtier co2 reduction system
TRANSCRIPT
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DEVELOPMENT OF A PREPROTOTYPE
SABAT I ER
cot REDUCTION SUBSYSTEM
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GILBERP N. KLEINER
AND
DR. PHILIP BIRBARA
PREPARED UNDER (:ONTRACT NO. NAS 9-15470
BY
HAMILTON STANDARDDIVISION OF UNITED TECHNOLOGIES CORPORATION
WINDSOR LOCKS, CONNECTICUT
FOR
NATIONAL AERONAUTICS AND SPACE ADMINISTRATIONLYNDON B. JOHNSON SPACE CENTER
HOUSTON, TEXAS
AUGUST, 1980
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1 ^ U DEVELOPMENT OF A PREPROTOTYPE
SABATIER
CO2 REDUCTION SUBSYSTEM
BY
GILBERT N. KLEINER
AND
DR. PHILIP BIRBARA
PREPARED UNDER CONTRACT NO. NAS 9-15470
BY
HAMILTON STANDARDDIVISION OF UNITED TECHNOLOGIES CORPORATION
WINDSOR LOCKS, CONNECTICUT
FOR
NATIONAL AERONAUTICS AND SPACE ADMINISTRATIONLYNDON B. JOHNSON SPACE CENTER
HOUSTON, TEXAS
AUGUST, 1980
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ABSTRACT
A preprototype Sabatier CO Reduction Subsystem was successfullydesigned, fabricated and tisted. The lightweight, quick starting(<5 minutes) reactor utilizes a highly active and physicallydurable methanation catalyst composed of ruthenium on alumina.The use of this improved catalyst developed and fabricated byHamilton Standard permits a single straight through plug flowdesign with an average lean component H /CO conversion efficiencyof over 99% over a range of H /CO molai ratios of 1.8 to 5 whileoperating with flows equivalent t8 a crew size of one personsteadystate to 3 persons cyclical (equivalent to 5 persons steady-state). The reactor requires no heater operation after start-upeven during simulated 55 minute lightside/39 minute darksideorbital operation over the above ranee of molar ratios and crewloadings.
Subsystem performance was proven by parametric testing andendurance testing over a wide range of crew sizes and metabolicloadings. The subsystem's operation and performance i^ con-trolled by a microprocessor and displayed on a nineteen inchmulti-colored cathode ray tube.
ii
NAMIL4^ON STANDARD Ommund
SVHSER 7221
FOREWORD
This report has been prepared by the Hamilton Standard Division'^. of United Technologies Corporation for the National Aeronautics
and Space Administration's Lyndon B. Johnson Space Center inaccordance with Contract NAS 9-13624, "Development of a Preproto-type Sabatier CO 2 Reduction Subsystem."
Appreciation is expressed to the NASA Technical Monitor, Mr.Robert J. Cusick of the NASA, Johnson Space Center, for hisguidance and advice.
Hamilton Standard personnel responsible for the conduct of thisprogram were Messrs. Harlan F. Brose, Program Manager, and GilbertN. Kleiner, Program Engineering Manager. Appreciation is expressedto Dr. Philip Birbara, Technical Consultant, Messrs. Robert Moserand Edward O'Connor, Analysis, and Messrs. William Perkins andWilliam Walters, Electrical Encineering.
iii
HAMILTON STANDiARD °""'0^.
Table of Contents
TITLE
PAGE,i•
SUMMARYINTRODUCTION
Program ObjectiveProgram Duration
CONCLUSIONSRECOMMENDATIONSRESULTSDISCUSSION
SUBSYSTEM DESIGNGeneral Design PhilosophySubsystem Analysis
Maximum Reactor TemperatureWater AccumulatorCooling Gas Flow RequirementsCharcoal BedCondenser/Separator SizingSabatier Reactor CatalystComputer Program
Hardware DescriptionController and DisplaySabatier Package AssemblyWeight and VolumeComponent Descriptions
MaintenanceSUBSYSTEM FABRICATIONSUBSYSTEM TESTING AND RESULTS
AccuracySubsystem ChangesCalibration CurvesTest TimeCooling FlowsPower ConsumptionEffects of PressureEffect of Reactant DewpointEffect of H /CO 2 Molar RatiosCO Conversion EfficienciesEffect of Air Addition to theSabatier Cyclic OperationWater ProductionWater QualitySubsystem MalfunctionsAnalysis and Correlation of Test Data
SUBSYSTEM DELIVERYCOORDINATION WITH RLSEDOCUMENTATIONSUPPORT REQUIREMENTSQUALITY ASSURANCERELIABILITYSAFETY
- Steadystate
Sabatier Reactants
1222345
1415171919202020202122222631343443434348575758566666677171717478787879
123124125127128129130
iv
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MAMl 3M STANOiARD Dmmd .•
List of Tables
Title Page
Table 1 Conversion Efficiency During Steadystate Testing 11Table 2 Conversion Efficiency During Cyclic Testing 12Table 3 Desgin Specification 18Table 4 Control Logic 33Table 5 Preprototype Sabatier Subsystem Weight 35Table 6 Design Definition 36Table 7 Preprototype Sabatier Subsystem Make/Buy List 47Table 8 Data Record Method 54Table 9 Test Data Tolerances 56Table 10 Temperature Sensor 62Table 11 Sabatier Test Log 64
Table 12 Calculated Effort Of Total Pressure And Dewpoint 67On Conversion EfficiencyTable 13 Effect of Pressure on H Conversion 69Table 14 Effect of Reactant Dewp8int 70Table 15 Steadystate Conversion Efficiency Test Results 73Table 16 Conversion Efficiency During Cyclic Testing 76Table 17 Cycle Operating Range Without Heater Assistance 77
Table 18 Steadystate Test and Simulation Conversion 80EfficienciesTable 19 Average Conversion Efficiency For Cyclic Tests 103Table 20 Data Submittals 126
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MAMIL7^OM STANOiARD ^_°i'°^•
List of Figures
Figure 1 Preprototype Sabatier Subsystem Schematic 6Figure 2 Preprototype Sabatier Package Assembly 7Figure 3 Sabatier Driver Box 8Figure 4 Package Assembly With Driver Box And Controller 9Figure 5 Display And Keyboard 10Figure 6 Preprototype Sabatier Subsystem 23Figure 7 TIMES Controller 24Figure 8 Controls And Displays Block Diagram 25Figure 9 Sabatier CRT Display Format 27Figure 10 Sabatier Mode Selection Table 28Figure 11 Sabatier Operation Diagram 29Figure 12 Sabatier Performance Diagram 30Figure 13 Keyboard 32Figure 14 Sabatier Reactor--Cross Section 38Figure 15 Reactor Before Insulation Installed 39Figure 16 Reactor Assembly (Instrumentation) 41Figure 17 Condenser/Separator 42Figure 18 Reactor Installation 44Figure 19 Gas Monitor Installation 45Figure 20 Heater Installation 46Figure 21 Test Rig--Front 49Figure 22 Test Rig--Rear 50Figure 23 Gas Chromatograph 51Figure 24 Data Aquisition Unit 52Figure 25 Sample Raw Data Test Summary Sheet 53Figure 26 Accumulator Calibration Curve 59Fiq ure 27 Sabatier I 902-1 Pressure Transducer Calibration 60Figure 28 Sabatier I 902-2 Pressure Transducer 61
Figure 29 Comparison of Reactor Performance With 72and Without Air Addition
Figure 30 Pressure VS. Elapsed Time During Off Cycle 75Figure 31 Sabatier Steadystate Bed Temperatures 82Figure 32 Sabatier Steadystate Bed Temperatures 83Figure 33 Sabatier Steadystate Bed Temperatures 84Figure 34 Sabatier Steadystate Bed Temperatures 85Figure 35 Sabatier Steadystate Bed Temperatures 86Figure 36 Sabatier Steadystate Bed Temperature 87Figure 37 Sabatier Steadystate Bed Temperatures 88Figure 38 Sabatier Steadystate Bed Temperatures 89Figure 39 Sabatier Steadystate Bed Temperatures 90Figure 40 Sabatier Steadystate Bed Temperatures 91Figure 41 Sabatier Steadystate Bed Temperatures 92Figure 42 Sabatier Steadystate Bed Temperatures 93Figure 43 Sabatier Steadystate Bed Temperatures 94Fiqure 44 Sabatier Steadystate Bed Temperatures 95Figure 45 Sabatier Steadystate Bed Temperatures 96Figure 46 Sabatier Steadystate Bed Temperatures 97Fiqure 47 Sabatier Steadystate Bed Temperatures 98Figure 48 Sabatier Steadystate Bed Temperatures 99
vi
100101102105106
History 10710`3109
History 110111112
History 113114115
History 116History 117History 118History 119
120
121
122
Figure 49 Sabatier Steadystate Bed TemperaturesFigure 50 Sabatier Steadystate Bed TemperaturesFigure 51 Sabatier Steadystate Bed TemperaturesFigure 52 Sabatier Transient Bed TemperaturesFigure 53 Sabatier Transient Bed TemperaturesFigure 54 Sabatier Warm-up Conversion EfficiencyFigure 55 Sabatier Transient Bed TemperaturesFigure 56 Sabatier Transient Bed TemperaturesFigure 57 Sabatier Warm-up Conversion EfficiencyFigure 58 Sabtaier Transient Bed TemperaturesFigure 59 Sabatier Transient Bed TemperaturesFigure 60 Sabatier Warm-up Conversion EfficiencyFigure 61 Sabatier Transient Bed TemperaturesFigure 62 Sabatier Transient Bed Temperature3Figure 63 Sabatier Warm-up Conversion EfficiencyFigure 64 Sabatier Warm-up Conversion EfficiencyFigure 65 Sabatier Warm-up Conversion EfficiencyFigure 66 Sabatier Warm-up Conversion EfficiencyFigure 67 Sabatier Comparison Of Steadystate And
Transient Bed Temperatures
Figure 68 Sabatier Comparison Of Steadystate AndTransient Bed Temperatures
Figure 69 Sabatier Comparison Of Steadystate AndTransient Bed Temperatures
vii
SVHSER 7221
SUMMARY
A development program of a Preprototype Sabatier CO ReductionSubsystem was successfully completed at Hamilton Standard. Thesubsystem converts hydrogen and carbon dioxide to water and meth-ane with an average demonstrated lean component efficiency of over99% for a range of H /CO 2 molar ratios of 1.8 to 5.0 for a crewsize range of one peison steadystate to 3 persons cyclical opera-ting with a simulated 55 minute light side/39 minute dark sideorbital operation. The reactor starts up in less than five min-utes, requires no heater operation after start-up and requires noactive controls. Over 700 hours of on-line reactor test time overa wide range of operating conditions were accomplished during thisprogram.
The primary feature of the reactor is the high activity catalystdeveloped and fabricated by Hamilton Standard and designated asUASC-151G. This catalyst, ruthenium on a 14-18 mesh granularalumina substrate, permitted a simple straight-through plug flowreactor design without complicated heat exchangers.
The subsystem was successfully integrated with a microprocessorbased controller which permitted complete automatic control and aCRT di-play which provided a colored display of subsystem flow andkey operating and performance parameters. All possible controland emergency shutdown provisions were demonstrated.
The test data obtained during this program was examined and suc-cessfully used as a basis for correlation of a Sabatier ThermalComputer Model. Steadystate conversion efficiencies agreementwith test data were within 0.1% for most test cases.
1^AM^1 °`"`° SVHSER 7221
INTRODUCTION
Future extended mission manned spacecrafts will require regenera-tion of all possible to reduce the amount of expendables requiredfor resupply. One of the most promising methods is to catalyti-cally convert carbon dioxide and hydrogen in a Sabatier reactorto water and methane. The water would be used for crew consump-tion or electrolyzed to produce oxygen. The methane would bedumped to space.
A program to develop a preprototype Sabatier subsystem was under-taken by Hamilton Standard to demonstrate the performance andlife characteristics of an efficient (>99%), simple lightweightdesign. This program is an outgrowth of Hamilton S`andard's sixprevious Sabatier programs which included the Space StationPrototype (SSP) Sabatier program. Compared to the 98% efficientSSP reactor, the preprototype subsystem developed in this programis 1/5 the weight, 2/3 the size, uses 1/4 the catalyst, starts upin 1/20 the time and requires no heater operation after start-up.Operation of the subsystem is completely automatic by utilizing amicroprocessor based controller.
Program Objective
The basic objective of this program w,s to develop a SabatierCO Reduction Subsystem to be integrated with other individualtechnologies in the area of regenerative life support and eval-uated as a part of a Regenerative Life Support Evaluation (RLSE)program at the NASA/JSC.
Program Duration
This final report encompasses all work performed during theperiod of April 1978 through June 1980.
The calculations in this report were made in L'S customary unitsand converted to SI metric units.
SVHSER 7221s
CONCLUSIONS
The following conclusions were reached as a result of this programactivity:
1. The preprototype Sabatier subsystem successfully completedthe development program requirements.
2. The reactor starts up in less than five minutes under alldesign conditions.
3. The catalytic Sabatier reaction is inherently self-limitingto a temperature of 593°C (1100°F).
4. Analytical computer techniques were shown to be accurate inpredicting performance.
5. Once started, the reactor requires no active cooling orheating operation during a 55 minute lightside, 39 minutedarkside orbital mission.
6. The subsystem was tested for a total of 720 hours with nodegradation in performance. In Eact performance improved.
7. The inlet dew point reactant from essentially dry to 21°C(70°F) and supply pressure variation from 1.2 to 1.34 atm(17.7 to 19.7 psia) had no detectable effect on the subsystemperformance.
8. The preprototype design is directly applicable to a prototypesystem.
9. The controller and display, which is common to the TIMES (1)subsystem, requires no i,lj u itiaents other than switchingleads from one subsystem to another to provide completeautomatic control with a display which illustrates flowpaths and significant performance parameters.
10. The reactor efficiency is essentially over 99% efficient forH 2/Co 2 molar ratios in the range of 1.8 to 5.0.
11. The subsystem was operated successfully with 5% air (18oxygen) mixed with the inlet gases. No adverse effects onthe catalyst bed resulted as evidenced by subsequent base-line testing.
12. The reactor with adequate cooling can efficiently handlereactant flows equivalent to a crew size of up to 30 persons.
(1)Reference NASA Contract No. NAS9-15471
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MAMI^T^OM STAI^ARO °'"^ SVHSER 7 221
RECOMMENDATIONS
The following recommendations are a result of successful comple-tion of this ;program.
1. Testing of an integrated system consisting of an elec-trolysis unit, a carbon dioxide concentrator and a Sabatiersubsystem should be demonstrated to verify total airrevitalization system operation and performance.
2. Since the reactor is capable, with adequate cooling, tohandle reactant flows equivalent to a crew size of 30persons, it is recommended that parametric testing beconducted to define the cooling required to achieve thisincreased capacity, the resultant reactor efficiencies,and the performance range with fired cooling flows.
3. A prototype flight subsystem should be fabricated inorder to demonstrate performance compliance on a simulatedspace mission and to be available for a possible flightevaluation.
4. If it is desired to operate the subsystem at reactantinlet pressures less than 1.2 atm (3 psig), it is recom-mended that the possibility of redesign of the watercollection section be investigated.
S. In order to operate the Sabatier and TIMES subsystemconcurrently it is recommended that an additional control-ler and display be fabricated or the controller capacitybe increased to permit monitoring or operation of bothsystems concurrently using the same display and keyboard.
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MAMILTOOi STAl10lARD ^ o'•ond" SVHSER 7221
RESULTS
This Preprototype Sabatier Carbon Dioxide Reduction Subsystem^^ Program resulted in the design fabrication, extensive testing and
delivery to the NASA/JSC of a preprototype Sabatier Subsystem.
The preprototype Sabatier subsystem is shown schematically inFigure 1. Figure 2 is a photograph of the front and rear view ofthe subsystem package assembly. Figure 3 is a photograph of theSabatier controller driver box assembly. Figure 4 shows theSabatier subassembly integrated with the "common" TIMES control-ler. Figure 5 shows the "common" TIMES display and keyboardwhich is used to operate and monitor the Sabatier subsystem.
The subsystem was successfully integrated with the controller anddisplay/keyboard from the TIMES program. Either subsystem, TIMESor Sabatier, can be operated by connecting the electrical leadsfrom the subsystem and driver box of the subsystem to be operatedto the controller. The electrical leads are common from thecontroller to the 19 inch, six color display and keyboard.
Over 700 hours of test time including a 120 hour continuousoperation test run was accumulated during the development testprogram on the subsystem packayo! •i-3 . 34! Reactor steadystateperformance was above 998 for all but two cases at a molar ratioof 4.0. The conversion efficiencies were calculated from gaschromatograph readings of outlet gas composition, and from flow-meter measurements. Table 1 shows the resultant performancedata. An off design 10 person case at a molar ratio of 2.6 withthe same cooling flow had a conversion effectiveness of 97.1%.
Cyclic operation of the subsystem to simulate a 55 minute on, 39minute off orbital duty cycle also demonstrated an averageconversion efficiency of 998. Performance data obtained duringthis operation is shown in Table 2. As can be noted, subsequenttesting after a catalyst treatment to remove additional residualchlorides resulted in improved performance for thi cases rerun.During all these tests cooling flow was maintained at all timesand no heater operation was required to initiate the reaction.
The effect of variation in total gas reactant inlet supplypressure of 1.2 atm to 1.34 atm (17.7 to 19.7 psia) showed thatreactor performance 4 s negligibly affected (<0.18). The effectof reactant gas dewpoint from a dry condition to a dewpoint of21.1°C (70°F) also showed that the hydrogen conversion efficiencyis within 0.18.
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FIGURE 2PRE:PROTOTYPE SAUATIER iACKAGE ASSEMBLY
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FIGURE 3SARATIER DRIVER BOX
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FIGURE 4SABATIER PACKAGE ASSEMBLY WITH DRIVER BOX AND CONTROLLER
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FIGURE 5DISPLAY AND KEYBOARD
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TABLE 1
Preprototype Sabatier Subsystem PerformanceConversion Efficiency During Steadystate Testing
H 2/CO2 Molar Ratio
? CO 2 Flow 1.8 2.6 3.5 4.0
1 Man Continuous 99.8 99.8 99.6 99.1
1 Man Cyclic 99.7 99.7 99.2 98.2
2 Man Cyclic ---- 99.7 ---- ----
3 Man Continuous 99.3 99.6 99.3 99.0
3 Man Cyclic 99.4 99.6 99.3 98.4
iMan Continuous ---- 97.2 ---- ----
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5.0
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TABLE 2
Preprototype Sabatier Subsystem PerformanceAverage Conversion Efficiency During Cyclic Testing
(55 Minutes On - 39 Minutes Off)
H 2/CO 2 Molar Ratio
CO 2 Flow 1.8 2.6 3.5 4.0 5.0
1 Man 99.6 99.6 99.4 98.6 100
2 Man ---- 99.6 ---- ---- ----
3 Man 99.6 98.8 98.1 97.4 100(99.4) (98.8)
( ) - Test results after completion of testprogram and catalyst treatment
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HAMILTON STANOiARD Oowwncl . SVHSER 7221
Test results showed that for molar ratios above 4.06 no carbondioxide was detected for the 3-man cyclic flow test condition.As a result, it appears that 1008 conversion of the CO 2 leancomponent occurs at above a molar ratio of about 4.1.
A test conducted with 5.18 air (18 oxygen) ;nixed in with theinlet reactants showed no catalyst damage as a result of oxygenexposure.
During all start-up operations, the reaction was started in fiveminutes or less. Water production rates were usually <2.58 ofthe calculated value and water quality quickly improved duringtesting to a pH of 4.5-6.0, chlorides to bearly detectable by thesensitive silver nitrate test and water conductivity to 10-20A mhos.
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--TMM °i^°^, SVHSER 7221
DISCUSSION
The NASA Statement of Work ( SOW) defined the major tasks for thisprogram. The corresponding Hamilton Standard Work Breakdown
1 ^,' Structure ( WBS) and the detailed presentation of this reportsection is presented below:
Tasks SOW Paragraph WBS No.
Subsystem Design
Subsystem Fabrication
Subsystem Testing
Subsystem Delivery
Coordination with RLSE
')ocumentation
Support Requirements
Quality Assurance
Reliability
Safety
3.2.1 1.0
?.2.2 2.0
3.2.3 3.0
3.2.4 2.0, 3.0
3. 2. 4.0
4.6 5.0
5.0 2.0
6.0 2.0
7.0 3.0
8.0 1.0, 3.0
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1 $T 00MOO"Of^e SVHSER 7221
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SUBSYSTEM DESIGN
The Sabatier subsystem schematic is shown in Figure 1. The carbondioxide and hydrogen mixture enters the subsystem through a char-coal filter which protects the reactor from any trace amount ofcontaminant carryover from the upstream electrochemical carbondioxide concentrator or the electrolysis subsystem. The mixturethen passes to the reactor where it is converted to water vaporand methane. The water vapor, methane and excess reactant (eitherCO or H ) then flow to the air cooled condenser/separator, wherethi watei vapor is condensed, separated from the gas stream andpumped out. The gases (methane and excess reactant and uncon-densed water vapor) are then dumped overboard to space vacuumthrough a pressure regulator which also serves to regulate CO2and H supply pressure. A bypass function for CO and H isprovi^ed for emergency shutdown and to permit maiAtenanci on theSabatier subsystem without interruption of the CO Removal and0, Generation processes. The water is pumped out 2of the waters^parator by the pressure differential between the reactant pres-sure and a spring loaded accumulator which maintains a constantpressure drop across the porous plate separator. A positivedisplacement pump empties the accumulator when full. A fixed aircooling flow is supplied to the Sabatier Reactor and the conden-ser/separator by the fan. A controller is provided to controlsystem operation, to monitor the instrumentation, provide statusinformation to the display, activate bypass operating modes inresponse to out of tolerance conditions, provide warnings andinstructions to the test operator. For all operating conditionsand modes other than failure modes, the controller is not requiredto drive any thermal controls because the Sabatier Reactor requiresno cooling modulation or heater operation (except at start-up) tomeet the full range of performance requirements. The subsystemfunctions, capabilities, interface definition, schematic andoperation are consistent with the RLSE system requirements.
The heart of the subsystem includes the reactor, the water con-denser;separator, the accumulator and the water pump. Theseitems, as further described in later paragraphs of this section,were developed on this program to the standards of space flighthardware, and will not require major modifications for flightuse. The balance of the subsystem components are classified asancillary equipment. Hiqh quality commercial items were employedfor the ancillary items, with modifications as necessary to achievethe hi;lh duality and functional capio ilities required of the prt-prototype unit.
The pump delivers water to the water management system at 2 atm(30 psia) which is the upper pressure limit defined by RLSE. Thepreprototype unit has its own cooling fan, however, the air cooling3a-ket at the reactor is designed to operate at low flow with thepressure drop available from normal Spacelab rack cooling air.
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MANS30H S DWOM01
%OUM, SVHSER 7221
To limit touch temperature to 45 °C (113°F) the front end of thereactor is insulated along the first 12.7 cm (5.0 inches) of lengthwith min K type insulation. This insulation also retains morethan adequate heat during the off period of cyclic operation toeliminate need for heater operation.
The rema'_nder of the reactor has two air cooling jackets thatdirect flow air axially from the reactant exit end of the reactortoward the inlet end. Since jacket temperature can be quitehigh, an outer shield is used to limit temperature of exposedsurfaces to 45°C (113 0F).
The Sabatier reaction is self-limiting (a reverse endothermicreaction takes place) at about 593°C (1100 0 F). Therefore, thereis no danger of the reactor overheating itself to failure underany load or molar flow ratio. For control and normal performancemonitoring, a single thermocouple in the front end of the reactorbed is used. For preprototype performance analysis, the reactorwas instrumented with 8 thermocouples running down the center ofthe bed and 3 thermocouples along the wall of the bed. Since thereactor radius is only 0.3 cm (0.72 in) centerline thermocouplesand wall thermocouples reading were sufficient to map the temper-ature gradient. The reactor is sized to convert more than 99% ofthe lean reactant over a CO2 flow range of from 0.91 kg/day (2.0lb/day) at cyclic and continuous operation to 3.6 kg/day (7.9 avglbs/day) at cyclic and continuous operation over a H 2/CO2 molarratio of from 1.8 to 5.0. This represents the maximum flow rangeconsidering a one to three-man crew and cyclic operation matchedto a 94 minute orbit with 55 minute light side operation. Theminimum flow is for one man, minimum metabolic, continuous opera-tion and the maximum flew is for three men maximum metaboliccyclic operation.
The subsystem controls for normal operation are only the limitranges in the water accumulator. The electric heater is usedfor startup and is turned on automatically when the subsystem isplaced in the standby or process mode if the reactor temperatureis below 177°C (350°F). The cooling air flow remains on at alltimes at a fixed flow condition during all operating modes.Since the reaction itself is self-limiting at 593°C (1100°F), allcomponents are capable of operating while the reactor is at thiscondition. The Sabatier system can also withstand vacuum, orpressures far exceeding those that could be produced by the WVEor EDC. Although the reactor subsystem itself is inherently pro-tected by design, there are some failures which could effect theinterfacing subsystems. A controller and data processing unit isprovided to detect such failures and take the necessary protec-tive action. The control unit includes a multicolor display ofsubsystem flow, perfor • Tacice status and water production rate.
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MAMR1^Olo^ STANDiARD °"°• SVHSER 7221
'*:ie Sabatier subsystem is not dependent on gravity and can bet;perated in any attitude in one G. The only components having.more than a single fluid phase present are the reactor and tl-:eseparator/condenser. Both of these component designs have A,eendemonstrated at + 1 G showing that capillary forces control theliquid gas interlace.
General Design Philosophy
The design of the Sabatier CO l Reduction Subsystem was based onan extensive background of both experimental and analytical datawith the actual catalyst used in the preprototype unit. Onethousand hours of operating time has now been accumulated on thiscatalyst material. The subsystem is designed to meet the require-ments specified in Table 3. These requirements include therequirements of the NASA work statement, RLSE design require-ments, and other regU'rements necessary to ensure that the com-ponents comprising tt.! heart of the subsystem are of flight1esi(3n. The main feature of the concept is simplicity of bothdesign and control. This was obtained by the use of a HamiltonStandard developed catalyst which permited operation over a widerange of temperature, molar ratios and loads with no activecontrol at high efficiency ( 998+).
Due to the high activity catalyst used, the heat generat,!,l in agiven volume is larger than its heat loss and the reaction isself-sustaining. As a result, the reactor "ignites" at und,.r177°C (350°F). Since the higher activity catalyst requires asmaller bed there is less heat loss and less thermal mass to heatand the reactor starts within five minutes.
The ability of the catalyst to operate effectively at lowertemperatures allows reactor operation over a large range atconditions without. active temperature control. Cooling flow isdetermined by performance at the maximum load conditions andremains constant. Although reactor temperatures are lower at lowloads, substantial temperature margin for a self-sustainingreaction still exists. Electric heater or modulation of coolingflow are unnecessary even at minimum load conditions and intermit-tent cyclic o peration, thus saving power, increasing the intrinsicreliability of the system, reducing weight and cost, and reducingthe important parameter of total equivalent weight.
Two temperature measurements are suf f is if,nt-. t-., i n l irate reactorperformance status and provi,le ,-)v -rt. i:)-_2 rature protection.Although eleven thermocouplHS are provided in the preprototype tomap the reactor performance, flight hardware systems will requir-O II Iy two temperature measurements to monitor tl?e ofthe subsystem.
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MAMNIMsTANOiARD OWL, SVHSER 7221
TABLE 3
DESIGN SPECIFICATION
n
CO2 FLOW RATE
NOMINAL
MINIMUM
MAXIMUM
H 2/CO 2 MOLAR RATIO
MINIMUM
MAXIMUM
REACTOR EFFICIENCY
REACTANT SUPPLY PRESSURE
REACTANT SUPPLY TEMPERATURE
REACTANT DEW POINT
TOUCH TEMPFRATURE MAXIMUM
WATER DELIVERY PRESSURE
START-UP TIME MAXIMUM
GRAVITY
SUBSYSTEM DUTY CYCLE
1.8 1.85.0 5.0
99% 99%1.4 A,rm* ( 5 PSIG* )
18-24°C (65-75 °F)
SATURATED SATURATED
45°C (113 °F)
2 ATM (30 PSIA)5 MIN 5 MIN0 TO + 1G 0 TO + 1G
CONTINUOUS OR CYCLIC
3.0 kg/day (6.6 lb/day)0.9 kg/day (2.0 lb/day)3.6 kg/day (7.92 lb/day)
* LATER REVISED TO 1.24 (3.5 PSIG)
7
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MAMaT4M STAl^A1iDAwl,^. SVHSER 7111
Subsystem Analysis
Substantial analysis was conducted on the performance and opera-tion of the Sabatier Subsystem and its subelements. In the case
•' of all the active subelements, the analysis was verified by testdata. In the computerized areas, the models were thoroughlyverified by test data, at conditions squired by the contract.The analysis techniques and computer programs were revised uponcompletion of the testing to reflect the actual performanceobtained.
Maximum Reactor Temperature
The Sabatier reactor process is characterized by an exothermicgas phase reaction, cataly4ed by a supported metal catalyst.
The maximum theoretical temperature which can be achieved in thereactor without external heat input was calculated by applying asuccessive approximation procedure to find the simultaneoussolution of the standard equations of chemical equilibrium,conservation of mass and conservation of energy.
This calculated temperature is 593°C (1)00°F) and was arrived atby the following procedure.
Thermodynamic gas equilibriur,: compositions were calculated in thecomputer program (NAS SP-273) for a wide range of operatingconditions listed below:
Reactant Gas Compositions - H 2/CO molar ratios from 2.0 to 4.0 in0.2 increments
Dew Points - Bone dry, 27 r,ic 38°C (80 0and 100°F)
Temperatures - 149 0 to 816°C in 55°C increments(300 to 1500°F in 100°F increments)
Total Gas Pressures - 1 and 1.4 atm (15 and 20 psia)
Based on the enthalpy of equilibrium gas products (obtained fr !1-ir,31er Tabulations), it wi> ,1 .^termined that at a H !1711) molarratio of 4. 0, the temperature was 5S2°.= J025 ZF) , at aratio of 2.6, the temperature is 593°C (1100°F).
The calculated adiabatic temperatures are in good agreement withthe maximum experimentally measured bed temperatures. No temper-atures in excess of 586°C (1087*F) were noted in the bed regionunder any design or off-desi g n condition run.
19
HAMILTON & as
SVHSER 7221
The reactor's upper temperature level is regulated by a variationin the gas products' enthalpy via the reversible nature of thesteam reforming reaction. Thus temperature greater than 593°C(1100°F) cannot be achieved without external heat input. Thisinherent self-control feature of the reaction is used in thesubsystem to assure a safe system--one that the laws of chemicalthermodynamics prevent from "running away".
Water Accumulator
The water accumulator is sized to hold 45 grams (0.1 lb). For 3-man operation at an H /CO molar ratio of 2.6 it will cycleapproximately every 41 minutes during continuous operation andabout every 24 minutes during the on phase of cyclic operation.
Cooling Gas Flow Requirements
A constant cooling gas flow was selected to meet all requirementsand is never changed during reactor operation. This capabilityincreases system reliabiity by eliminating the need for activecoolant controls. The cooling gas requirement is calculated fromthe change in enthalpy of the process stream ( H - H products - Hreactants), and the inlet and exit coolant temperature require-ments. For the Sabatier reactor, assuming an inlet temperatureof 25°C (77 °F) and an outlet temperature of 121°C (250 0 F); nominalthree man flow conditions with 318 grams/day O (0.7 lVday 0 )leakage. The calculated volumetric flow rate 2 0.52 ^ /min (18.4cfm). During testing fan flow was measured as 0.62 m /min (22 cfm).
Charcoal Bed
There are no specific requirements for a charcoal sorbent bedupstream of the Sabatier reactor. However, there are the possi-bility of contaminants whici may be released by the CO removalsystem to the Sabatier reactor subsystem. Consistent Lth theRLSE baseline, a charcoal filter is provided. If in the future,the development of the CO 2 removal system obviate-s the need, thecharcoal filter may be removed. The filter size at this time isthe minimum required to prevent flow channeling.
Condenser/Separator Sizing
The full range of possible subsystem operation was consideredwhen sizing the condenser/separator. CO 2 flow rates of 1 ratan (atminimum metabolic rates) continuous to 3 man (maximum metabolicrate) cyclic operation and a H 2 to CO 2 molar ratio of 1.8 to 5.0were considered. The sizing case occurred at the maximum CO flowrate of 3 man cyclic and a H to CO molar ratio of 5.0. Thisdesign case has the highest Zater pioduction rate and effluentflow.
20
__r
MAMILTON STANDARD %°"'^• SVHSER 7221
A process gas inlet temperature of 100°C (210 °F) was used in thedesign. This value is used because it is greater or equal to thehighest reactor outlet temperature recorded in our tests andexcept for the off design cases, represents the most severeperformance condition.
The cooling air stream is considered to be 0.71 m 3/in (25 cfm) a^24°C (752F). The condenser/separator was found to r1quire 0.04m(0.41 ft ) of heat transfer area and 0.08 m (.19 ft ) of masstransfer area. The air stream flows over stainless steel fins0.51 cm (0.2 in) high by 5.1 mm (0.002 in) thick, set at 5.5 finper cm (14 fins per in).
The process gas passes over pin fins 25 percent open in fourpasses. The porous plate is the same material and constructionas used in a Shuttle application, series A316 stainless steel 1.6mm (0.0625 in) thick, and has a bubble point of 0.5 atm (7 psi).
Sabatier Reactor Catalyst
The Hamilton Standard catalyst used in the reactor is.
Designation - UASC-151G
Composition - About 208 Ruthenium on alumina
Shape - 14-18 mesh granules
This catalyst is highly active and structually durable. Theactivity of UASC-151G is five times greater than that of UASC-150T, the catalyst supplied for the SSP Sabatier reactor. Theimproved reactor performance obtained is primarily due to thehig h activity of USAC-151G.
The specific surface area for a 3.8 cm (1.5 in) diameter bed ofthe 14-18 mesh granules is 300 percent greater than a bed of 0.3cm X 0.3 cm (1/8 in X 1/8 in) tablets (SSP Sabatier catalyst)while the bed porosity is approximately 10 percent greater. Thedetermination that the active Ruthenium is dispersed to a muchoreater extt•nt on the granular support (4 to 5 times) is borne,),it: by the hydrogen measurements. Microproberesults indicate that Ruthenium deposition is uniform over theouter granular surface and throughout the cross-section of theUASC-151G granules.
21
1'^AM^T'ON'r' TANaARD °^ o.... SVHSER 7221
Computer Program
The Hamilton Standard thermal math model of the Sabatier Reactor.- has been implemented for computer simulation using the H581
thermal analysis program. This program was merged with severalsubroutines which handle the chemical heat generation and chemicalanalysis.
H581 is a generic heat transfer program which solves a nodal heattransfer network. It was used to perform the thermal analysis ofthe Sabatier thermal model. The special chemical analysis routinescalculate the chemical heat generated and provide the calculatedheat as an input to the program. Also, the H581 provides thetemperature distribution of the catalyst bed required by thechemical analysis routines, and so the calculations are iterative.Carbon dioxide and hydrogen flows into the reactor are determinedby the chemical analysis routines from the mass flow heat capacityfor hydrogen and carbon dioxide input to the program. Therefore,any reactant flow case is specified by inputting the appropriatevalues for the mass flow heat capacity and the reactant gas filmcoefficients.
Input for the Sabatier simulation is in four major sections: (1)• list of conductivities, (2) a list of thermal connections, (3)• description of each node, including thermal mass, and (4) datafor the chemical reaction subroutines.
Hardware Description
The Sabatier subsystem, Figure 6, consists of the followingassemblies.
• Sabatier, Package Assembly Figure 2• Sabatier, Driver Box Figure 3• TIMES, Controller Figure 7• TIMES, Display • and Keyboard Figure 5• Interconnectiig harnesses
The TIMES items are used to operate the Sabatier subsystem, toreduce program costs and to demonstrate the common capability ofthese items.
22
115 VAC 60 HZ
115 VAC 400 HZREMOTESIGNALS
115 VAC 60 HZ
MAM^TON sTANOiARp °^° a ^• SVHSER 7221
CRT
a
I CONTROLLER KEYBOARD
I DRIVER I
INST, CONTROLS,PW R , ETC.
WASTE GAS- REACTANT GAS
PRODUCT H2O
N 2 PURGE
VALVE ACCESS - FRONT
CIR BKRSREARSUBSYSTEM INTERFACES
PACKAGE
FIGURE 6
PREPROTOTYFE SABATIER SUBSYSTEM
23
HAMILTON STANDARD 4""
SVHSER 7221
a •fir,
tw
4
^, rW177, W.-sleFroopw
EVA a!F^
I b^
r
AlA i
I l^^ J^'
W , f,(h ell P^ rF
FIGURE 7TIMES CONTROLLER
24
ohmvmo^e SVHSER 7221
qqq Dq q qq qq oO q D
OPERATINGK^ MASSSYSTEM MEMORY
.4 .
DISPLAY
KEYBOARD
a
INSTRUMENTS SUBSYSTEM CONTROLLERCONTROL ELEMENTS(VALVES, PUMPS, ETC.)
BUFFEREDRS232CINSTRUMENTATION
OUTPUT DATA STREAMOUTPUT
FIGURE 8CONTROLS AND DISPLAYS BLOCK DIAGRAM
25
HAMMON STANDAM ^ SVHS E R 7221vwv
The Sabatier package assembly, driver box and TIMES controllerwill be installed in the NASA test racks in close proximity toone another while the TIMES display and keyboard will be locatedremotely in the laboratory control center. A 10 meter transmis-sion line is provided to permit the remote location. A 10 meterline is also provided to permit the NASA to install a remote
` discrete shutdown switch. The Sabatier electrical harness isI
defined by Hamilton Standard drawing SVSK 100140. An 0-5VDCanalog output of all input parameter suitable for interfacingwith the NASA Data Acquisition System is provided. A generalpurpose communication link for remote display, recording, or fortransmitting information to other subsystems is also provided.
Controller and Display
Figure 8 is a block diagram of the control and display layout.This portion of the subsystem utilizes an advanced microprocessor-based controller and display that provides automatic control, 24hour monitoring of subsystem water output, automatic shutdown,subsystem performance and flow monitoring, and maintenance servic-ing and checkout provisions.
A multi-colored Cathode Ray Tube (CRT) display format shown inFigure 9 provides a continuous readout of system mode, any subsys-tem anomolies or advice system status, and operations instruc-tions. Any one of six visual displays of appropriate data can beselected. These are:
- Mode Selection Table (Figure 10)- Operation Diagram (Figure 11)- Performance Diagram (Figure 12)- Performance Table With Limits- Performance Plot of Water Production•° Maintenance Diagram
In addition, an anomaly readout together with an anomaly light,either white, yellow or red is displayed. White for a low levelindication of abnormal occurrence, yellow for a caution and redfor a warning and indicating the fact that the system is automat-ically being shutdown. An audible alarm accompanies the redanomaly light. In addition, the status of the electrical heaters,either on or off, is indicat:-d by having the heater wire in theschematic glow red if on; and if off, blL" ::, The status of theheight of water in the accumulator is also visibly displayed ingreen in real time.
The display provides maximum essential informa l. .t::-,n at a glanceand requires minimum interpretation and training for monitoringor subsystem control. The microprocessor controller providesautomatic sequencing, dynamic control, tailuae detection andisolation, processes instrumentation signals. calculates waterproduction rate and provides ground test instrumentation inter-faces.
26
RA STANDARD avNKTn
SVHSER 7221
Mode: SABATI E14Anomalies: UG
LIGHTAdvice: Display Titl e
SelectedDisplay
I/O.Echo. Computer Feedback Computer Options
FIGURE 9SABATIER CRT DISPLAY FORMAT
w
27 s
I w'
HAMILTON STANDARD /i tbw avrnA
SVIISEI? 7221?Om w
kit
FIGURE 10SABATIER MODE SELECTION TABLE
28
HAMILTON STANDARD <" (". d S V I I S E R 7221
FIGURE 11SABATIFR OPERATION DIAGW%M
29
SVHSER 7221HAMILTO!! STANDARD 1/
p,,•'^
w
FIGURE 12SADA,riER PERFORMANCE DIAGRAM
30
_i
MAMIL7 ON STAND^ARO°"'° ^. SVHSER 7221
Control of the subsystem is straight forward and requires minimalinstruction for operator usage as control is experienced byinputting commands designated on the CRT display using the key-board shown in Figure 13.
Four operating modes, shutdown, purge, standby and process, and amaintenance checkout mode are provided. The logic summary forthese modes is shown in Table 4. Also shown are the malfunctionshutdowns and the modes during which they are initiated. Themaintenance checkout mode can only be entered after the system iscompletely shutdown, purged and by entering "107 DISPLAY" on thekeyboard. This mode permits electrical operation of the elec-trical valves (Item 306) and operation of the pump (Item 545).Operation of the pump, while clean filtered water is fed into thesubsystem upstream of the condenser outlet ( sample point 806)will permit purging of gas from the pump during the initialstart-up of the subsystem. This pump operation will also permitobservation of the accumulator fill and dump cycle diagramaticallyon the screen. Caution--"Operation of the pump e► ithout an externalsupply of water will pump the water subsystem dry and result inthe pump becoming airbound."
Operation of the suvsystem automatically drives the valves to theproper position whether left in the wrong position, the mainten-ance mode, or if manually repositioned when the power was off.
Subsystem operating time is recorded by an elapsed timer mountedin the driver box. The timer is actuated upon subsystem powerapplication and selection of a mode that requires fan operation.This prevents accumulation of "operating time" on a shutdownsystem when only power is supplied.
The Sabatier driver box which interfaces with the TIMES controllerand display uses low voltage logic signals from the controller tocontrol high voltage switches that in turn supply power to thevarious subsystem component motor and heaters. All main controlrelays are high quality military-type relays designed for 400cycle use.
Sabatier Package Assembly
Thl Sabatier package assembly is packaged in a 0.18 m 3 (6.3ft ) volume 61 cm X 63.5 cm X 45.7 cm deep (24" X 25" X 18"deep;. The cooling fan is included within this envelope. Compon-ents were grouped for the best compromise of simple plumbing,manual valve operation, and maintenance accessibilty. Portionsof the reactor are insulated and also thermally isolated from thestructure. All interfaces terminate ^:t the aft surface of thepackage. The structure is built within an aluminum frame withchannel sections bolted together with simple support brackets andpanels as required.
31
.a.-o
HAMILTON STANDARD °i wino S VI I s E R 72 21VEZ"Im.
It ^ll ^: "^ r A c;p Zc
FIGURE 13/ri
!iM ►K iJr'Q ,y^KEYBOARD
32
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F : Er
V M ^ Vq
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y wN Y W
w
^IL
^A pp
^
77
O ^y.V -^ N ^ f a^ y ^
III
s^ ^
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i
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77
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HANWJW i,d SVHSER ?221
This package fits within the RLSE test area specified by theNASP. A flight experiment package of the same subsystem can bemu r-t: smaller since improved packaging efficiency will be achieved,
y the cooling fan and muffler can be eliminated as well as themanual shutoff valves.
Weight and Volume
Total weight and weight breakdown are presented for the preproto-type hardwa t, in Table 5.
The package .ae'.c- t includes:
• Sabatier packaging assembly• Sabatier Driver Box• Ducts, tubes and fittings• Frame and bracketsFastenersWiring and all SataLier electrical harnesses (5) betweenthe subsystem package, driver box and the controller (TIMES)
Table 6 defines the Hamilton Standard part numbers and designco-iments for all component items in the subsystem.
Component Descriptions
The Sabatier subsystem components were selected for their demon-strated ability to meet Sabatier subsystem requirements. Allcomponents are backed by test data and are used here in lessdemanding requirements than they have demonstrated in the past.The main dynamic components--the reactor and the water condenser/separator are new designs based on previous Hamilton Standarddesigns.
Sabatier Reactor: The catalyst bed weighs 460 gms (i.01 lbs) andis contained in a cylindrical tube, 34 cm (13.5 in) long, 3.6 cm(1.43 in) in diameter separated into two zones: the high temper-ature primary reaction zone; and the cooling or secondary reac-tion zone. Two heaters for redundancy are used to initially heatup the catalyst to start the reaction. The heaters are notrequired during normal cyclic operating modes, as there is suf-ficient thermal storage to restart the reaction.
The first or primary reaction zone is insulated to prevent heatloss to the cabin and to retain the heat of reaction during the"down" cycle of operation, eliminating power and time requirementsfor retreating of the catalyst. Two cooling jackets with a fixedrate of cabin air flowing through them surrounds the secondaryzone.
34
HAMMON STANDARD 0'4re SVHSER 7221
TABLE 5
PREPRO'1UME SABATIER SUBSYSTEM WEIGHT
PREPROTOTYP£UNIT TOTAL UNIT TOTALWT. WT. SETT. WT.
DESCRIPTION QTY. kgs. kgs. lbs. lbs.
VALVE, EIECTRICAL SHUT-OFF 5 0.82 4.08 1.8 9.0VALVE, CHECK WATER 2 0.05 0.09 0.1 0.2CANISTER, CHARCOAL 1 0.62 0.62 1.4 1.4SABATIER REACTOR ASSEMBLY (INSTRUMENTED) 1 3.40 3.40 7.5 7.5HEATER, ELECTRIC 2 ( 0.05) (0.10) ( 0.1) (0.2) CONDENSER/SEPARATOR (DRY) 1 1.32 1.32 2.9 2.9SENSOR, TEMP. 2 0.05 0.09 0.1 0.2SENSOR, LIQUID 1 0.09 0.09 0.2 0.2REGULATOR BACK PRESSURE 2 1.13 2.27 2.5 5.0VALVE, MANUAL SHUT-OFF 4 0.23 0.91 0.5 2.0FAN, CCOLING/MUFFLER ASSE13LY 1 1.91 1.91 4.2 4.2ACCUMULATOR ASSEMBLY 1 1.13 1.13 2.5 2.5PL24P i 1.81 1.81 4.0 4.0SENSOR, COMBUSTIBLE GAS SENSING ELEMENT 4 0.14 0.56 0.3 1.2CCeTTROLL.ER, COMBUSTIBLE GAS SIGNAL CCND. 4 1.31 5.24 2.9 11.5DRIVER BOX 1 6.53 6.53 14.4 14.4SENSOR, PRESSURE 2 0.14 0.28 0.3 0.6
CCMPCNENT SUB-TOTAL 30.3 66.8
PACKAGING (INCLUDES HARNESSES)* 19.3 42.6
TCITAL WEIGHT (DRY) 49.6 109.4
* BETWEEN SUBSYSTEM PACKAGE, DRIVER BOX & CCNTROL.LER (TIMES)
35
r ' SVSK 96500
SVSK 96467
-VSK 96471SVSK 99752
S'VSK 96490SVSK 96349
SVSK 96482
SVSK 96470
SVSK 86319
SVSK 9444
SVSK 34411
SVSK 34530
SVSK 84456-100
SVSK 34456-100
&.'SK 9b4b0
S^SK 1011.:4
SVSK 1011::6SVSK %465-1
SVSK 96465-1
^VSK 101113-1
SVSK 10114
w.SK 101129
SVSK 100140
SVSK 10117
',.SK 49'53
SVSK 101130
' SK 1011.,5-1
VSK 101125-2
tiVSK 96499
SVSK 9o48b
'V'tiK %4o5
SV^ K 9049-aV'SK 9o4y1
SV'K 704 179
rrEM 46
ITEM 26
ITEM 61
rI'E1 51
ITEM 91
r LN 31
rrD 4. 545
rrEIM 306
ITEM 310
rrEN 507
ITEM 178
rr£M 178ITEM 41
rrLm 42
"Ev, 31-1
ITEM 81-2
rrEM 90--1
ITEM 902-1
111:1 907
ITEM 3^
rrEM 83
IT'M 85
ITD4 86
r l-%l 159rrEm 87 6
ITUM 37
rrE-M 7J1-705
LTEM 8Ji-809
HAMILTON STANDARD ".. .wwwoM -
SVHSER 7221
TABLE 6DESIGN DEFINITION
PAi71 NO
ITEM NO. PART NAME
SABATIER PACKAGE ASSEMBLY
FAN, SABATIER AIR COOLLWG
SILENCER, FAN
ADUTEER, FAN 40WING
ACCLIMULAMR ASSEMBLY
010ENSER, SABATIER
RFACM, SABATIER
CANISTER, aWCOAL
PUMP
VALVE, ELECTRICAL S.O.
REG AArO t, BACK PRESS.VALVE, MAMMAL S.O.
SEN"-^'DMBUSTIBLE GAS
SENSOR, MON17M ASSEMBLY
VALVE, aiE) :K
VALVE, aiSCK
FILTER, 30NDENSER INLET
SENSOR, TEMPERAT'RE
S-"%OR, TE"SPERAT RE
lmANSWZFR, PRESS RE- AGE
TRANSCUCER, PRESSURE-GAGE
DE'IEL-IDR, L (T I D MATER
HARNESS, ELEI':'RICAL
TUBING, FLEXIBLE
HOUSING, SENSOR
FRAME, SARATIE'R PACKAGE
BRACXET, REAk-MR, A )UTrING
3R1>i:KET, REACIUK, ML)LWl.X;
S£ LSC , TEMPERATURE
HEATER - RFA^`IUR
SENOR, TEMPERA'ly TZ
a'.Ei2I1CA:01?LE, CHFCKEI.-AI;SMEL
AC VA,LA'IROR
5E`]_SOR, a ALITY-AL ,-WLAIUR
THERAX'CUPLE, .lilkMFL-AL:MLL
ORIFICE, Cam[.
&%%IPLE,' PRFS,;URE e')Rr
HAMILTON STANDARD DESIGN,SEE DESCRIPTION IN TEXr
BUY ITEM
:MODIFIED COMMERCIAL ITEM
HAMILTON STANDARD DESIGN
GFE, SHUTTLE ITEM
HAMILTON STANDARD DESIGN
K26MILT0N STANDARD DESIGN
HAMILTON STANDARD DESIGN
GFE, SSP ITEM
GFE, SSP ITEM
GFE, SSP ITEM
GFE, SSP ITEM
GFE, SSP ITEM
GFE, SSP ITEM
, ATALi)G ITEM
CATALOG 17"-
rMILTCN STANDARD DESIGN
.LNMkLA)G ITEM
CATALCOG ITEMGFE, MODIFIED SSP
(7E, MODIFIED SSP
HAMIiTON STANDARD DESIuV
WILTON STANDARD DESIv<1
,ATALOG ITEM
HAMILTON STANDARD DESIGN
HAMILTON STANDARD DESIGN
HAMILTON STANDARD DESI(:Z4
HAMILICXN S"MN IARD DESIGN
HAMILTON STANDARD DESIGN
HAMILTON STANDARD DESIc24
.:NrAIJC; ITEM
HAMIL'IU4 STANDARD DESIGiv
;'E, %UDI.FIED -'4i=LE ITSM
i;FE, SHUTTLE ITEMM
:ATA" I r:'M
HAMI:,lUN STANDARD DESIL'V
u.A'aAL.'X; ITEM
36
HAWLTMumffaa^ *
SVHSER 7221
A platinum resistance temperature (PRT) sensor is located belowthe heater rod to indicate when the catalyst and reaction hasreached a high or low temperature. Another PRT sensor locatedon the outside of the reactor underneath the insulation is usedto monitor the temperature in the event that the bed temperaturebecomes too high due to failure to turn off the heaters.
A multi-point temperature sensor prohe is included to take atemperature profile of the internal bed at 9 different pointsalong the length. Three thermocoup:es are also located in thebed next to the outside wall.
The unit is of all stainless steel construction welded and boltedtogether with an aluminum perforated sheet outside shell forhandling and touch temperature protection.
The catalyst bed is enclosed in a 5-.a-.nless steel tube with awelded cap on the inlet end with an opening for the reactant gasand the heater elements. The heater elements are enclosed inclose fitting sheath for good heat transfer into the primaryzone of the catalyst bed. The heaters can be removed and/orreplaced without disturbing the bed. The exit end is flanged andbolted with provision for preloading the catalyst bed.
The primary zone is insulated with a i:igh Temperature Min F (F182) blanket. The cooling jacket consists of stainless steelserrated fins wrapped around the bed cylinder for good airflowand heat conduction, covered with a shell of stainless steel.
The unit is three-point mounted with the single point at thebottom mount for axial movement. Figure 14, 15 and 16 show thereactor internal configuration, outside configuration, beforeinsulation and heaters are installed and after insulation isinstalled.
Condenser./Separator: The condenser/separator shown in Figure 17is an all stainlesssteel plate and fin heat exchanger. The unitis made up of three adjacent layers. The first layer is a singlepass 0.51 cm (0.200) inch) high plate and fin construction with aheader on one end for avionics or cabin air flow. The watercollection pass is a pin-fin plate that is the cold plate of thesystem and is on one side of the tole air pass. The top layer orhot pass consists of a stainless steel porous plate that is incontact on one side with the pin fin plate and on the other sidewith a 4 pass configuration of stainless steel serrated finsseparated with stainless steel pass separators. The top plate isa solid stainless steel plate that is brazed to the top unit.
37
HANKTON DmomdSVHSER 7221
CC4 41
Co z
u v %-
d. CL 9L
W3
40
z M. c6-
Z 2 7 71.1 Tc • a 0642 Ae c
4c W3
A
X-Zcn CLC E.
0 3 c
c73
CL
0
31
O c aCcc
cac
COE
38
F
HAMILTON STANDARD /%"--"SVHSER 7221
FIGURE 15REACTOR BEFORE INSULATION INSTALLED
39
HAMILTON STANDARD
SVIISER 7221
r '
FIGURE 16REACTOR ASSEMBLY (INSTRUMENTED)
lkI(;
OF' Poo )ft
41
..#
^t
FIGURE 17CON DENSE R/SEPERATOR
HAMILTON STANDARD % ""1e""'w ono e SVliSER 7221
42
HAMMOM STAN 4-"VEAWSMS
SVHSER 7221
Maintenance
Maintenance of the subsystem was considered in the design andlayout of the hardware. No scheduled maintenance is required forany of the items except possibly for the charcoal filter, Item31, depending on the quality of the inlet gases. All componentsitems are considered line replaceable components and are easilyremoved as ample access to all items has been provided. Particularattention was made to facilitate removal of the reactor, Figure18, the combustible gas monitors, Figure 19 and the heaters inthe reactors Figure 20. In addition, a bolted flange in thecharcoal canister and the Sabatier reactor permits replacing thecharcoal or catalyst bed.
A special maintenance checkout mode in the controller logic hasbeen provided which permits the electrical valves to be actuatedindependently to an open or close position, the pump to be oper-ated, and the accumulator to be filled and emptied without result-ing in an automatic system shutdown. The latter permits chargingwith water and purging of air from the system during initial(first time) start-up of the subsystem. A maintenance diagramcan also be displayed which identifies and shows the location ofall component items within the subsystem.
An Operating and Maintenance manual SVHSER 7222 provides moredetails for operating and maintenance of this subsystem.
SUBSYSTEM FABRICATION
Table 7 identifies the principal items in the preprototype Sabatiersubsystem and shows whether they are make, buy or GFE items. TheSabatier subsystem package assembly was assembled using 1/4 inchand 1/2 inch stainless steel tubing, as appropriate, and Swagelokor equivalent stainless steel fittings. Components were locatedto facilitate maintenance, manual positioning and visual monitor-ing of the valves, to minimize line lengths and crossover points,and to provide all interface connectors on the back side of thepackage.
SUBSYSTEM TESTING AND RESULTS
The Sabatier test program was conducted in accordance with theHamilton Standard Test Plan SVHSER 7196 Revision A (Appendix A).
The laboratory test system used for this test program is a HamiltonStandard rig constructed from commercial hardware. This rigpermitted testing on a continuous basis over the full range ofreactant compositions and flows required to determine the effectsof variation in H /CO molar ratios, reactant flow rates, reactanto perating pressuris aAd gas cooling flow rates on H 2/CO 2 conversionefficiencies and reactor temperature profiles.
43
FIGURE 18REACTOR INSTALLATION
4444
AL
w^ ^ Y<ys _
HAMILTON STANDARD ^
SVHSER 7221
a SlS r
t .-
F1UURE 19GAS MONITOR INSTALLATION
HAMILTON STANDARDSVIISER 7221
45
HAMILTON STANDARDODv ra^oo=. SVHSER 7221
FIGURE 20HEATER INSTALLATION
46
HAMI M STANOAW ^Il^i,. - SVRSER 7a"21
TABLE 7PFW-VFLR71YPE y\BATIER SLAMYS EM
MAKE/WJY :.IyT
,b
QTY. PERASSY. P11RT NO. rmM ND. PART `TAME REMAM
1 SVSK %500 — SABATIER PACKAGE ASSEMBLY MAKE
1 SVSK 96467 ITEM 46 FAN, SABATIER AIR CMLSNG BUY
1 SNSK 96471 TTEM 26 SILENCER, FAN MODIFIED BUY
1 SVSK 99752 — AI wmx, FAN Homm ,MAID;1 SVSK 96490 TTEM 61 ACCIl4QIATM ASSEMBLY MODIFIED Q'E
1 SVSK 96349 ITEM 51 CaC&&M, SABAMER MAKE
1 SVSK 96482 TTEM 91 REACMR, SABATIEA MAKE
1 VSK 96470 ITEM 31 CANISTER, OOJ COAL ,MAKE
1 S17SK 86329 ITEM 545 PIMP ZE5 VSK d4424 I- M 306 VAL'A' ELECMICAL S.Q. GEE
2 SAPSK 84412 nM4 310 ReauLum, wcx PRESS. GFE4 SVSK 84530 TTEM 507 VKLVE, MANDAL S.O. GFE
i MK 84456-100 ITEM 178 SENSOR-COBUbTIBE GAS GFE4 VSK 84456-200 ITE4 178 SENSOR, 40HIMR ASSEMBLY GFE
i SVSK 96466 TIE4 41 'JALM, aMCK BUY
i SVSK 101124 PTTE74 42 'JALVE, allDCX BUY
SVSK 1011: 6 — FILTER, OaMEMER IML.T MAKE
1 SVSK 96465- 1 rITM 81- 1 5mim, TEmPERAr-M BUY
34K 96465-2 IPETI 31-2 -gDSOK, 'IVOPCRATUAE BUY
:= SK 101128-1 BEM 902-i TRANSDUCER. PRESSURE-GAGE MODIFIED GFE
SVSK 101128-2 7:E4 402-2 TRAWDUCER, °REb5Ui3.-GAGE MODIFIM ffE
SJSK 101129 TJ4 907 A-M--MR, LIQUID AATER MAKE
SVSK 100140 — HARNESS, ELECTkICAL !W.T:
i S.SK 101127 :'.BL*;, FL'M(IB[E BUYs -'SK 99'53 — t10(15I.`n;, iE45(gt !4AKESJSK 101130 — . RAKE, iABATIEk V,%' -UU.;E MAKE-;.SK 10! 125-1 — 3W XL-r, W-AL-ION, *[lUNTIM; MARESJSK 1J 1125-2 — 31tA iD T, rCALIILKt, 4047JIING !MAKESJSK 96499 TIE. 82 SCAoR, lVvLpA7jw BUYS.SK 96406 .24 83 HFJ4TER - REAL-MR dUYVSK %465 rM4 85 SENS;,'R, TCMPERAT'-& BUY
i1 SJSK 96497 I7E4 86 A R40LCUPEE, lW&Xr--A La4E:, BUYSVSK 96492 iTsv :59 A_-lP9JIA7UR MODIFIED GFE
tiVSK 764179 rMN d'6 SEfri.)R, JLALITY-A:7J4'LA74DK UFE
— 11"TM d7 ".^ALW LJ0X;PIE, 0OCKEL-AL:MEL BUY°A '01--05 -RIFLE, -Ilr%C , MAKE`A --- 7.M 801-609 ple BUY
DKr&k WO, SABATIER MAKE
4'
1
HAMILTON %OVIMWM* SVHSER 7221
Photographs of the test rig are shown in Figures 21 and 22. Thefacility consists of a reactant and cooling gas conditioning andsupply section, the test hardware, product gas metering, productwater collection, power supplies, instrumentation and data collec-
.0' tion. The display and keyboard is shown in Figure 5.
During all testing a calibrated gas chromatograph shown in Figure23 was used to record outlet gas composition and to verify inletconditions when mixed gas flows were used and to verify thecertified bottle blend when a new bottle was placed on line.
During all subsystem testing the data was recorded as noted inTable 8. The recording times were dependent on the type of testbeing conducted. photograph of the data acquisition unit isshown in Figure 24. During cyclic runs at least one complete"off" and "on" cycle, temperature profiles were recorded everyminut<` and an effluent gas sample was analyzed and plotted outevery nine minutes during the on cycle. A typical sample rawdata test summary sheet is shown. in Figure 25.
Accuracy
All gas flows including CO, Hand N,, were measured with Fischer-Porter flow meters calibrated t operAting pressures and temper-atures. The gas flow meters which were periodically calibratedwith a wet test meter were accurate to +1% full scale. Alleffluent gas flow rates were measured by determining the quantityof flow with a wet test meter for a time interval measured by astop watch. The accuracy of the product gas volume is +18 of thesample volume.
Pressure gages for the reactant, product, and cooling gases spana range oS 0-2.0 atm (0-30 psia) and are capable of reading to1.7 X 10 atm (+0.025 psia). All ga ges were calibrated priorto testing by tFie Hamilton Standard metrology laboratory.
The test rig permitted the option of humidifying the reactantg ases to dewpoints up to room temperature. A Cambridge SystemsModel 880 Dewpoint Hygrometer provided a measure of the humidityof the reactant gases prior to entry into the reaction chamber.Dewpoint readings were within +.055°C (+0.1°F) for the 4.4°C(40°F) to 49°C (120°F) range.
48
!F
ms
- -. .. — —'-0 .'/Ire
HAMILTON STANDiARD^% c^n'i
w SVHSER X221
FIG H RE 21TEST RIG — FRONT
49
4 t►.^..ar. wm
HAMILTON STANDARD S WI S E R 7221
FIGURE 23GAS CHROMATOGRAPH
51
HAMILTON STANDARD l/- "w"negsmLww s s
SVHSER 7221
O0,4"C^,
FIGURE 24DATA AQUISITION UNIT
52
HAMILTON STANDARD rx.SVHSER 7221
DATE: 2 - 19-
RUN NO. 5-3 -
TEST NU. 1?yARATIF,^2
3 MAN CO NT
m. R. 2. 60
17.7 PSIA r °F 77 OF
.l^fS C F M.039 CFM
7.Z ° F
o9Z.^` c 7 m C FM
O F 1$7 OF O-ML/HR 73 °F
A_°F
Qyta OF CONTROL
z^^ z ^ Z °F G.C. RUN N0.
t ^ ^ P-6r- H ).02-
112,5
.2
p —IL OF
CH
CO 2 .-14 oz
°F OVERTEMP 99.* AT ROOM 1PERATURE
r 1
FIGURE 25
SAMPLE RAW DATA TEST SliMD.ARY SHEET
53
I .'
MAMILM StANOAM
SVHSER 7221
r'
TABLE 8
DATA RFrORD MEMOD
WITHOITf CORMLLER WITH CONTROLLERPARAMETER 6 DISPLAY 6 DISPLAY
DATA ACQUISITION 0.140 :ttRoMAIO-'RAPH DATA ACQUISITION HAND CHROMTOL3RAPHPRVIIXIr TAB PRI:?r= PRINTOUT TAB PRIIN7" DISPLAY
TI:ME x x x
P-SUPPLY x x
r M % X
P,^ WAT°R BACK PRESSURE x x
RF ,,-,7N 'rEMPE(<':I'URES (11) x
r-RF: L-MR : CNTR)L x
T-RW70R (7(l DiPERArURE x
',':74--je4SER IN X
T-CONDENSER X r x
FL--W IN--FWWMA-OR x
:7 :1)W OVT--WL r GAS 4ETER X
P 3AROMETER x
Gks 'OMP.7h rT l l)m N x x
,;AS ; O"lPQTTION (17 x
,iATER Xr x
090i P0Ilrr IN x
T-RErl.-T% COOLANT CL i `ET (2) x
T-.,%'4B LE-W x
T-^ XLAHr JVr, MIXED x
;ATER PROW7riCJ RATE x
xx
X X
x
x
x
x
X
x
x
x
X
x x
x
x
x
x
x
x
x x
54
HAMILTONSTANDARDOVWrma^
,°"'0 SVHSER 7221
The gas sampling system was capable of automatically samplingreactants at the inlet to the reactor, product gases at theoutlet of the condenser, and calibration gases. A Hewlett PackardModel 5880A gas chromatograph analyzed for H, CO, CO and CH .Gas composition together with the time of sample injeLion weleautomatically printed. Approximately nine minutes were requiredto analyze a gas sample. The gas chromatograph was programmedand calibrated to analyze for H 2 , CH , CO and CO quantitatively.Product gas accuracies of +0.18 for A , Ca and CO and 0.58 CHwere obtained with this gas chromatograph anit for the expectedpartial pressure ranges. Certified premixed reactant blends wereused in the test program to insure H 2 and CO2 reactant gas accur-acies of +0.01$.
All thermocouples used were type K chromel-alumel thermocouples.The temperature readings were accurate to within +0.58.
Hydrogen conversion efficiencies for H /CO molar ratios < 4.0were calculated by substituting experiAentilly measured valuesinto the following equation:
RH in - x(RTout)8 Hydrogen Efficiency = 2 R X 100
H2in
Where x = 8 H 2 in dry product. sample
RTout = measured dry product flow-out, cc/min
R H 2 in = measured H 2 reactant flow cc/min
Similarly, carbon dioxide conversion efficiencies for H /CO,, molarratios >4.0 were calculated by substitution, experimentdilly`measuredvalues into the following equation:
RCO in - y(RTout)8 Carbon Dioxide Efficiency 2 R X 100CO 2 in
Where y = 8 CO 2 in dry product sample
RTout = measured dry product flow-out, cc/min
RCO2 in = measured CO 2 reactant flow cc/min
The calculated H 2 and CO conversion efficiencies are accurate towithin +0.058. Table 9 summarizes test data tolerances.
55
HAMILTON STANDARD '%oor. 0
SVHSER 7221
TABLE 9
TEST DATA TOLERANCES
Item Tolerance
Product Gas Compositions:H and CO2 +0.18 full scale^3
4+0.58 full scale
Reactant Compositions(Certified Mixtures):
H2 and CO2 +0.02% full scale
Product Gas Volume +18 of sample volume
Product Liquid Volume +18 of sample volume
Temperature ±0.5% of reading
Pressure +0.025 psia
Gas Coolant Flows +28 full scale
56
HAMILTON ►STANDARD 0-om-o'• SVHSER 7221
Subsystem Changes
During the test program the following subsystem changes wereincorporated to improve subsystem operation.
Two orifices, Item 705 around the water pump and Item 704 down-stream of the accumulator were installed because the pump emptiedthe accumulator so fast that a suction pressure was inducedacross the porous plate resulting in gas breakthrough and thepump becoming gas bound. This resulted in a loss of pumpingcapacity. The orifices prevent this from happeling by permittingwater flow around the pump and regulating the rate of waterdischarge from the accumulator. As a result, e%tensive pressuredrop across the porous plate does not occur.
A check valve Item 42 was installed downstream of the condenser/separator outlet to prevent emptying of the water from the sub-system when it is shut down or when the subsystem is dried out bypurging for long periods of time with dry nitrogen. The checkvalve also permits charging of the downstream lines and accumulatorwith water to reduce start-up time and, more important, to purgethe pump of gas during initial subsystem start-up operations.Subsystem operation on a day-to-day basis after the initial gaspurge start-up does not require charging of the subsystem.
Subsystem controller logic was established so that the nitrogenpurge valve, Item 306-3, is closed if an excessive pressure (<1.4atm (6.0 psig)) is sensed upstream of the reactor. This providesoverpressure protection in the event the nitrogen supply pressureis too high to be controlled to an acceptable level by the Item703 orifice. Overpressure protection from the reactant supply issensed by Item 902-1 pressure sensor which closes Item 306-1 andopens Item 306-2.
Eight sample ports were provided (item 801 thru 809) to facilitatetesting, charging of the subsystem, or to provide instrumentationor sampling ports.
Calibration Curves
Calibration curves for the following items were determined or areprovided as noted on the following page:
57
Accumulator Assembly - Figure 26Item 61
HAMILTON STANDARD%Ovwoow@ SVHSER 7221
- This curve is typical,as the original quantitysensor failed due to theuse of the wrong testequipment. A calibrationcurve for the shipmentitem was not run.
Pressure Transducer - Figure 27 - This item was convertedItem 901-1 from an absolute pressure
transducer to a gage pres-sure transducer.
Pressure Transducer - Figure 28 - This item was convertedItem 901-2 from an absolute pressure
transducer to a gage pres-sure transducer.
Temperature Sensor - Table 10 -Items 902-1, 85-1, 81-1 and81-2
Combustible Gas Sensor Per SVSK TR 84456Item 178
Test Time
A total of over 720 hours of test time (versus 324 hours requiredby the contract) with reactant flow through the reactor wasaccumulated during this program. Since the catalyst used in thereactor had been previously used for breadboard testing, thecatalyst now has over 1000 hours of test time on it. No degrada-tion in performance has been experienced, in fact performance hasimproved over this time.
',,-1 11 defines the test time required, the actual test tine-accumulated, whether certified premixed reactant blend gases wererequired, and when actual certified premixed reactant blends wereused. A check in the later columns indicates that as a minimum,the required test item was accumulated using the certified blend.As can be noted, a good portion of the testing was accomplishedusing certified blend gases.
When certified gas blends were not us-4 the gas supply consistedof mixing a shop hydrogen gas supply witt. a bottled supply ofcarbon iaxide at 1.7 atm (25 psia) in the proper proportions asmeasured by calibrated flow meters and verified by the gas chro-matograph to obtain the desired molar ratio.
58
HAMILTON STANDARD- Nwond • SVHSER 7221
16.25
16.15
16.0
^nc.
a. 15.`_
15.1
15.,
b. 14.p 2 4 b 7 b
Figure 26
Accumulator Calibration Curve
59
5.'
4 8 12 16 20 2400
4
1
•
(Gage) After Mod.
00001• New Part No.
SVSK 101128-1
8> 3
y
0
2n
7O
HAMILTON -- -- %°mo°^• SVHSER 7121
(ABS)BeforeMod
Pressure (psi)
Figure 27
Sabatier I 902-1 Pressure Transducer Calibration
Rosemount 1331 AA8 S/N 308HS P/N SVSK 84522 Ref.
Conversion To Gage Transducer
60
Ovwi+al
we amo %SVHSER 7221
/
Eore Mod.(ABS)
4
1
[ r
5
y 3
^o
r,0
za 2
0
0-0 4 8 12 16 2^0 24
Pressure (psi)
Figure 28
Sabatier I 902-2 Pressure Transducer
Rosemount 1310A8 SIN 309HS P/N SVSK 84522 Ref.
61
HAMILTON STANDARD u,, voa^ss .
S VH S E R 7221
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62ORIGINAL PAGE ISOF POOR QUALITY
HAMILTON STANDARD vimumm'. SV-HSER 7221
ORI'GINAQUA
OF Po()^(,,P,
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TABLE 10 (Cairn ED)i • •WOU
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HAMILTON STANDARD 1,: --
UORMOOM S
SVHSER 7221
Table 11
SABATIER TEST LOG
TestNo. Test Description
MolarRatioH2/CO2
TestTimeReq'dHrs.
ActualTestTimeHrs.
CertifiedPremixed GasReq'd Test
1 3 Man Cont. 2.6 2 2.25 3 v'
2 it if 2.6 2 2.0 i/ v"
3 of is 2.6 2 5.0 3 v
4 3 Man Cyclic 2.6 2 2.25
5 " " 1..6 2 4.75 ti/ v
6 to " 2.6 2 3.75 y
7 1 Man Cont. 1.8 2 2.8 V
8 3 Man Cyclic 1.8 2 ' 4.0 V
9 1 Man Cont. 5.0 2 2.0
10 3 Mari Cyclic 5.0 2 3.0 v r
11 1 Man Cont. 1.8 2 3.25
12 3 Man Cont. 1.8 2 4.7 ^!
13 3 elan Cyclic 1.8 2 4.0
14 i 1 Man Cont. 2.6 50 57.0 y
15 3 Man Cont. 2.6 8 12.75
16 it it 2.6 120 120.0
17 2.6 8 84.85 V y ^
18 3 Man Cyclic 2.6 10 38.75
19 10 flan Cont. 2.6 10 12.25
20 1 Man Cont. 3.5 2 5.25
21 3 Man Cont. 3.5 2 8.7 J ^^
22 3 Man Cyclic 3.5 2 5.0133 388.3
64
n Y'YM'LTON STANDARD 0X1 SVHSER 7221
Table 11 (Continued)
SABATIER TEST LOG
TestNo. Test Description
MolarRatioH2/CO2
TestTimeReq'dHrs.
2
ActualTestTimeHrs.
CertifiedPremixedReq'd
GasTest
23 1 Man Cont. 4.0 7.5 3
24 3 Man Cont. 4.0 2 12.5
25 3 Man Cyclic 4.0 2 7.25
26 1 Man Cont. 5.0 2 2.5 ti/
27 3 Man Cyclic 5.0 2 4.0
28 3 Man Cyclici
5.0 2 3.0 V/
29 j 1 Man Cyclic 1.8 4* 18.0*
30 1 3 Man Cyclic 1.8 4* 14.5*
31 j 1 Man Cyclic 2.6 20* 25.4*
32 2 Man Cyclic 2.6 10* 39.C*t
33 3 Man CyclicI
2.6 20* 41.75*
34 I 1 Man Cyclicr
3.5 2* 2.75*
35 3 Man Cyclic 3.5 2* 2.2*
36 I 1 Man Cyclic 4.0 2* 3.6*
37 i 3 Man Cyclic 4.0 2* 15.95*
38 I 1 Man Cyclic 5.0 4* 5.4* y
39 3 Man Cyclic 5.0 4* 13.4*
Other Miscellaneous - - 113.75324 72
* Reactor "On" Time
65
r
HAMILTON STANDARD SVHSER 7221
Cooling Flows
Reactor cooling flow was determined by installing various diameterorifice (Item 701 and 702) sizes in each reactor cooling circuitline until a reasonable reactor temperature profile was obtained.The coolant flow was measured by installing a wet gas meterdownstream of each orifice, one leg at a time, and using thecooling fan, Item 46, to draw cooling flow over the reactor. Thecooling flows selected at room ambient conditions are:
• Middle section (Item 701) - 3600 cc/min (0.092 cfm)• End section (Item 702) - 6000 cc/min (0.212 cfm)
The cabin flow at room ambient conditions is 623,000 cc/min (22 cfm).
Power Consumption
The power consumed was measured using the Hamilton Standard PowerSupply Rig 135B. Component powers were:
Fan, Item 46 53 wattsPump, Item 545 33 wattsHeater, Item 83 100 watts (each)
Effects of Pressure
The effects of variation in total pressure on the reactor hydrogenconversion was theoretically and experimentally determined.Equilibrium hydrogen concentrations and the resulting hydrogenconversion efficiencies at 260°C (500°F) for H,,/COl) reactantmolar ratios varying from 2.0 to 4.0, total prEssures of 1 and1.4 atm (15 and 20 psia), and various inlet dew points (dry, 80°F80 and 100*F) were calculated as shown in Table 12.
The program, NASA SP-273, was utilized to calculated hydrogenequilibrium compositions at the various operating conditions.The equilibrium composition and temperature of a reacting mixtureis obtained by applying a successive approximation procedure tofind the simultaneous solution of the standard ec;uations ofchemical equilibrium, conservation of (atomic) mass, and conserva-tion of energy for specified values of pressure and either temper-ature, enthalpy or entropy.
66
HAMILTON STANDAW %°"uwm^ * SVHSER 7221
TABLE 12
CALCULATED EFFORT OF TOTAL PRESSLTRE
AND DEWPOINf CJN CCNVERSICN EFFICIENCY
H2 Conversion
I let Reactant Dew Points--H2 E7quilibriun
Temperature Pressure`olar Ratio °C (°F) atm( sia) Dry 26.7°;.'(80 °F) 38°C(100 0F)
2.0 260 (500; 1.0 (15) 99.4 99.4 99.4
2.0 260 (500) 1.4 (20) 99.5 99.5 99.5
2.6 260 (500) 1.0 (15) 99.4 99.4 99.4
2.6 260 (500) 1.4 (20) 99.5 99.5 99.5
3.0 260 (500) 1.0 (15) 99.4 99.3 99.3
3.0 260 (500) 1.4 (20) 99.4 99.4 99.4
4.0 260 (500) 1.0 (15) 99.0 99.0 99.0
4.0 260 (500) 1.4 (20) 99.1 99.1 99.1
67
HAMILTON STANDAW /%"'Unamme SVHSER 7221
As indicated by Table 12, increasing the total pressure from 1.0f
atm (15 psia) to 1.4 atm (20 psia) results in an increased hydrogenconversion of 0.1%. Table 13 tabulated results of pressure varia-tion from 1.20 to 1.37 atm (19.7 to 17.7 psia). It should benoted that low hydrogen conversions of 99.2% are attributable tocatalyst chloride contamination which was subsequently clarifiedto give conversions of 99.5% for similar operating circumstances.Based on the results of Table 12, it has been experimentallydemonstrated that reactor performance is negligibly impacted fora 0.14 atm (2 psia) difference in total reactor pressure.
It should be noted that from a subsystem standpoint there is aminimum level at which the subsystem can be operated with auto-matic water removal and no resetting of the pressure regulator tooperate over the crew loading and molar ratios required. Thispressure is 1.2 atm (3 psig) at the 3 man continuous conditionwith a molar ratio of 2.6. At this setting the operating pres-sure will vary from 1.26 atm (3.8 psig) to 1.18 atm (2.6 psig)depending on the crew size and molar ratio. operation below 1.2atm (3 psig) is marginal and not recommended as it can result inthe inability to delivery water automatically which will resultin water carryover in the discharge line and a reduced water pro-duction rate. The minimal pressure is a function of the pressuredrop in the porous plate, the water check valve, the accumulatorspring rate, line height, and the pressure regulator tolerance.
The operating pressure can be lowered to approximately 1.1 atm (1.5to 1.6 psig) by completely bypassing the automatic water removalsystem. However, since the porous plate requires a driving pres-sure equivalent to this pressure, operation is considered marginal.
Effect Of Reactant Dew Point
Table 14 tabulates the theoretical H 2 conversion efficiencies forthree dewpoints at various operating conditions based on gaseousequilibrium at 260°C (500 0 F). A negligible decline in Ei conver-sion efficiency results from an increase in inlet humidify from adry condition to a dewpoint of 37.8°C (1000F).
Similarly, the experimental results as shown in Table 12 agree withthe theoretical predictions. The H conversion efficiency is within 0.1% for when the inlet humidity 2 is varied from a dry conditionto a dewpoi.nt 21.1°C (700F).
68
HAMILTON STANDARD 0 VE"* SVHSER 7221
TABLE 13
J .EFFECT OF PRESSURE CN H2 CCNVF.RSIM
PressureRun # Date CO. Flow Molar Patio atm (psia) % H. Conversion
4 1/31/80 3 Man Cont. 2.52 1.34 (19.7) 99.2
4 1/31/80 3 Man Cont. 2.52 1.29 (18.2) 99.2
5 2/01/80 3 Man Cont. 2.52 1.20 (17.7) 99.2
69
HAMILTON STANDARD "- 0-1 SVHSER 7221
TABLE 14
EFFECT OF REACTANT DEW POINT
Dew PointRun # Date Flora Molar Ratio °C (°F) % H ,, Conversion
18 2/12/80 3 Man Cyclic 2.6 dry 99.5
18 2/20/80 3 Man Cyclic 2.6 21.1 (70) 99.6
%0
HAMILTON STANDARD % °""O' er S VH S ER 7221
Effect Of H :/CO,Mo_lar Ratios - Steadystate
Table 15 summarizes both H and CO steadystate conversionefficiencies for H /CO molar ratios varying from 1.8 to 5.0 and
y CO flows varying iirom 2 1 man continuous to 3 man cyclic. As arule of thumb, H conversion efficiency declines slightly for agiven CO flow ai the H /CO molar ratio is increased from 1.8 to4.0. SiLlarly, CO 2 coAver h on efficiency increases for a givenCO 2 flow as the H /CO molar ratio is increased from 4.0 to 5.0.It should be note thdt tests have demonstrated near completeconversion of the lean component CO when the H /CO 2 molar ratiois increased beyond 4.1. The raw delta test sumAary sheets forthese cases are contained in Appendix B.
CO O Conversion Efficiencies
All testing at a H /CO molar ratio of 5.0 resulted in 100% conver-sion of the CO ledin component. A 3 man cyclic flow test, wasconducted whic varied the H /CO ratios from 4.2 to 4.0 in orderto determine the presence of 2CO t in th effluent flow. At molarratios of 4.2 and 4.1 no CO., wai detected in the outlet flow. CO2conversion efficiencies les§ than 100% were first observed at amolar ratio of 4.06.
Effect Of Air Addition To The Sabatier Reactants
A test was designed and conducted to observe the effects onreactor operation resulting from the addition of 5.1% air to theinlet reactants for 7.5 hours. This test was run at a 3 mancontinuous flow and a H /CO molar ratio of 2.46. Subsequenttesting confirmed that Ao catalyst damaged resulted from thisexposure tc 1% oxygen.
The reaction between H and 0 resulted in increased heat genera-tion and a less desiraole temperature profile within the bed. Asa result, hydrogen conversion efficiency dropped from 99.1% to98.7% with the 5.1% air addition.
Figure 29 shows a comparison of the temperature profile with andwithout air addition.
71
Reactor Bed Temp. Profile3-Man Continuous FlowH 2/Co 2 Molar Ratio 2.46
(o) With 5.1 % air - H Conversion Efficiency = 9(-) Without Air - H 2 Conversion Efficiency 99.
1
i FU-
I
I
I
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013 6 9 12 1S
8.71
Insulated First Cooling Second CoolingJacket Jacket
Position Along Bed Length
Figure 29
Comparison of Reactor PerformanceWith and Without Air Addition
HAMILTON STANDARD '%'"'°- SVHSER 7221
a ,,
649 120
593 1101
538 100(
4621- 90(
427 80(
U
371 70CL ^
v 316 60(
E
E=260 r., 50(
204 40(
149 30(
S3 20(
38 10(
-17.8
72
HAMILTON STANDARD ^'_D"-"
SVHSER 7221
♦ ITable 15
Steadystate Conversion Efficiency Vest Results
CO Flow
H2/CO2 Molar Ratio
1.8 2.6 3.5 4.0 5.0
1 Man Continuous 99.8 99.8 99.6 99.1 100
1 Man Cyclic 99.7 99.7 99.2 98.2 100
2 Man Cyclic 99.7
3 Man Continuous 99.3 99.6 99.3 99.0 100
3 Man Cyclic 99.4 99.6 99.3 98.4 100
10 Man Cyclic 97.2
73
HAMILTON sTA1^AMD '-° ri°^ . SVHSER 7221
Sabatier Cvclic Operation
Subsystem cyclic tests to simulate light side ( 55 minutes on) anddark side ( 39 minutes off) operation were conducted. Nearly allcyclic tests were conducted without use of the TIMES controller.Automatic cycling was accomplished by using a Agastat Programmerwhich cycled the Item 306-1 valve and the Item 306-2 valve todirect reactant into or around the reactor. Cooling flow wasmaintained during the whole cycle. Water was removed from thesubsystem accumulator by a breadboard controller which emptiedthe accumulator by starting the pump based on a signal from thequantity sensor Item 876 in the accumulator in the same manner asthe TIMES controller. The Sabatier reactor was capable of start-ing without heater assistance over a range of operating conditionslisted in Table 18.
Table 16 summarizes the test results for cyclic operation with a55 min reactant flow period followed by a no-flow period of 39min. Improved performance was obtained for the 3-man CO flowconditions after completion of the test program due to rimoval ofthe catalyst chlorides from the aft portion of the reactor bed.Thus, it is thus anticipated that conversion efficiencies of the leancomponent will exceed 99 . 0% except at the stoichiometric ratio of4.0 where conversion efficiencies at the higher CO 2 flows will begreater than 98.5%.
These tests were conducted without cessation of reactor coolingduring the no reactant flow period. However, it is expected thatrestart of the Sabatier reactor without heater assistance will bemarginal for 1 man flows with H 2/CO2 molar ratios less than 1.8.
During the no reactant flow period of cyclic operation, it wasobserved that the reactor pressure decreased to less than ambientin approximately 10 minutes. The pressure decay as shown inFigure 30 results from residual hydrogen reacting with carbondioxide and the condensation of product water vapor in a lockedup volume caused by closing the Item 306-1 valve and the pressureregulator Item 310 acting as a check valve. The reduced pressuretended to suck water ( estimated to be approximately 15 ml) fromin the condenser back into the reactor discharge line. When thereactant flow was cycled back on, some of the liquid water wasexpelled through the condenser and into the overload dump linereducing the water production rate. This was particularly notice-able on some of the one man cases. A test run by shutting offthe reactant gas supply showed a reduced pressure effect ( Figure30) depending on the volume of the upstream line.
It should be noted that hydrogen within the reactor is essentiallyconsumed after reactor shutdown. Thus, the requirement to purgt-hydrogen from the reactor by an inert gas is not necessary. Allcyc l ic runs were conducted without purging after flowing reactantsthrough the catalytic bed.
74
KEY
Pressure decay with humidifieroverhead volume (gas supply shut ofupstream of humidifier unit)
Q Pressure decay without humidifieroverhead volume (gas supply shutoff downstream of humidifier unit)
O
*H Molar Ratio - 2.621CO2
3 Man Cyclic Flow
•• Duty Cycle - 55 Min On & 39 Min Off
Note: Gas supply shut-off to simulate noflow during dark side operation.
• •^O O — O
0 10 2n ^n dr
18.0
17.(
•o
Na0 16.(L7NN41
La
15.0
14.0
MAM^TON sTANDiAROAAW.
SVHSER 7221
Elapsed Time (min)
Figure 30
Pressure vs. Elapsed Time During Off cycle Of
a
*Cyclical Operational Mode
75
NAMIt7^ON sTANaARO '= °"•°' ^. SVHSER 7221
TABLE 16
AVERAGE CCNVERSICN EFFICIENCY DUR11VG CYCLIC TESTING(55 MINUTES CN--39 MINUTES OFF)
CO Flow
H2/CO2 Molar Ratio
1.8 2.6 3.5 4.0 5.0
1 Man 99.6 99.6 99.4 98.6 100
2 Man 99.6 ----
3 Man 99.6 98.8 98.1 97.4 100(99.4) (98.8)
-- Test results after completion of basic testprogrw^ and catalyst treatment
.*
76
HAMILTON STANaARD% ONSM of mws, SVHSER 7221
TABLE 17
CYCLE OPERATING RANGE WITHOUT HEATER ASSISTANCE
CO2 Flow - 1-10 man
H2/CO2 Molar Ratio - 1.8 - 5.0
Duty Cycle - 55 min on/39 min off
Dew Point - Dry - 21.1°C (70°F)
L r1'
77
11AMILT^ON STANOIARD^ ws°°, S VHS ER 7221MS
Water Production
Water production for steadystate operation as a function ofreactant flow is quite predictable. Experimentally measuredwater production was usually < 2.5% the calculated value. Waterproduction rates averaged over long periods of time ( >2 hrs) werequite predictable. However, water production rates experimentallydetermined for short periods often varied widely due to opera-tional variations in the water removal system; i.e., air bubblesin the accumulator, variations in accumulator volumes, etc.
Problems in accurate measurement of water production rates forcyclic operation were introduced by the vacuum anomaly discussedin the previous section. The vacuum created in the reactant offflow period of cyclic operation results in water (approximately15 ml) collecting in the product gas exit lines. Thus the quantityof,water as determined by accumulator volume displacement willprovide erroneous readings which are greater for the nominal lowwater production situations; i.e., lower CO 2 flows and H2/CO2molar ratios.
Water Quality
Product water was periodically analyzed for pH conductivity andchloride content. Water quality improved significantly duringthe course of this program. For example, pH values improved from2.0-4.0 at the very start of the test to 4.5-6.0, chloride contentto levels barely detectable by the sensitive silver nitrate testfrom readily apparent, and conductivity from 300-500 mhos to 20-30 mhos. The improved water quality was obtained during most ofthe Sabatier test program.
Subsystem Malfunctions
During the 720 hours of testing some equipment malfunctionsoccurred. These were:
Heater, Item 83--This item failed after approximately 600hours of testing (estimated). Failure was not detecteduntil operation with the controller and display whichshowed that one heater was not operating at start-up.Start-up times with one heater were slightly longer butjust within five minutes so malfunction went undetectedearlier. The cause of tie malfunction was not determined.
Reactor overtemperature sensor, Item 85,--This item failedshortly after testing began. Failure was caused by thevendor inadvertently using low temperature lead wires.
78
MAMILI^ON STANDiARD ,ww" e SVHSER 7 221
Check valve, Item 41,--This item periodically tended tostick open apparently due to calcium or dirt deposits onthe valve seat. The valve was replaced and filteredwater used to charge the subsystem and the problem did notreoccur.
Air in the Item 545 pump--If the pump becomes air bound itwill not pump; as a result, the lines must be chargedinitially with water and the air removed. Once this isdone there is no further problem.
Water liquid detector, Item 907--The initial design didnot have a sheath on the probes. As a result, moisturewicked up the probe and bridged across to the other proberesulting in a water carryover malfunction indication andan automatic system shutdown. The design was changed perSVSK 101129 and no further problems have been encountered.
Accumulator quantity sensor, Item 876--electrical checkoutof the sensor using a conventional voltmeter resulted inburn-out of the control pot. Any electrical checkout ofthe quantity sensor must be done with a standard highimportance digital meter.
Analysis And Correlation Of Test Data
The development Sabatier reactor was extensively tested as dis-cussed above. Data from this testing was examined and used as abasis for the correlation of the Sabatier computer program.
Table 18 shows steadystate conversion efficiencies for actualtest results composed to simulated computer model predictions.These test conversion efficiencies were calculated from gaschromatograph readings of outlet gas composition, and from flow-rator measurements. The raw data test summary sheets for eachtest condition appear in Appendix B.
79
HAMUXM WfANDARD ^BI^T JISVHSER 7221
cco 00 O
"'^ O^ 01 O Q^QN
LO Qt O^
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71
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80
HAMILTON STANaARD '- °""°^. SVHSER 7221
In addition, catalyst bed temperatures and outlet coolant temper-atures were measured. These appear on the data sheets in AppendixB. Measured temperatures at the head of the bed, however, do notreflect actual bed temperatures because of the fin effect of thethermocouple probe. This only effects the first two thermocouples.Also, coolan^_ temperature measurements are inherently low becauseof thermocouple fin effect, and because the thermocouple islocated seveval inches downstream of the coolant outlet. It isestimated that the low flow temperature reading is approximately708 of the actual and the high flow temperature reading is 848 ofthe actual ( referenced to ambient). Measured bed temperatureprofiles are shown for all steadystate cases in Figures 31 to 51.Corrected coolant temperatures are also depicted on these figures.
This test data was used to correlate the Sabatier Thermal Modeldiscussed in the Design section of this report. Simulations ofall the tests described above were analyzed using the correlatedmodel, with results appearing in Table 18 and Figures 31 to 51.Simulation reactor temperature profiles reflect the temperatureof the thermocouple probe, so they should match the test data.Simulation coolant temperatures indicate actual coolant tempera-tures so they should be compared to corrected test temperatures.
Simulated steadystate conversion efficiencies agree with testdata with deviations of less than 0.18 for most cases. Alsosteadystate temperature profiles are in good agreement with test,except for the very end of the bed in the lower flow conditions.This is attributed to condensation in the end of the bed. Coolantand outlet temperatures do not agree very well with test; however,the thermocouple fin effect and location as noted above on thesetemperature measurements should be sufficient to account forthis. Also, the high f'Ljw coolant temperature is affected bycondensation in the aft portion of the bed.
Table 19 contains a summary of the average conversion efficienciesfor actual testing compound to the simulated computer modelpredictions for the duty cycle of 55 minutes on and 39 .minutesoff, which simulates normal light side/dark side operation. Theimproved efficiency values shown in parenthesis were obtainedafter completion of the test program and after catalyst treatmentto remove additional residual chlorides.
81
1
Test Data ( 0) Simulation (—)'C ( OF)
"C ("F)Low Flow Coolant 84°C (183°F) 10200 (216°F)High Flow Coolant 5100 (123°F) 3200 (90 0F)Conversion Efficiency ao_A 00 -7
I
i
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o
03 6 9 12 15
Insulated First Cooling Second CoolingJacket Jacket
^- Position Along Bed Length ---+^
HAMILTON STAI^ARD00mmanal
SVHSER 7221
649 120
593 1101
538 1001
4821- 901
427E 80111v w
371a^ 701a
316 60a `'aa a
260 50E-4
204} 40
149 30
93 20
38 10
-17 .8
FIGURE 31
SABATIER STEADY STATE BED TEMPERATURES1 MAN CONTINUOUSMOLAR RATIO = 1.8
82
M ;`
I
Test Data (o) Simulation (—)oC ( OF) oC (OF)
Low Flow CoolantHigh Flow CoolantConversion Efficiency
i
i
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0 7^3 6 9 12 15Insulated First Cooling Second Cooling
Jacket Jacket
I--^ Position Along Bed Length —^
FIGURE 32SABATIER STEADY STATE BED TEMPERATURES
1 MAN CONTINUOUSMOLAR RATIO = 2. 6
83
J
NAWLTONSTANOiARDONW602"
.°"'° SVHSER 7221
649 1201
593 110(
538 1001
482 90(
427 80(
^ w'371 70(
10 316 m 60(
a,a aF260 0 501
204 401
149 30
93 201
38 10111
-17.8
A"
Test Data (0) Simulation (—)°C(°F) °C (°F)
Low Flow Coolant ° ) 117°C ( 243°F)High Flow Coolant 730C (164 9F) 34 °C (93 °F)Conversion Efficiency 99.6 99.3
I
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0
649 1201
593 1101
538 100(
482 90(
427 801
V 4W
371 ° 70(^ o
316 601
a aa
E 260 v 50iF
204 40
149 30
93 20 ii
38 1C
-17.83 6 9 12 15
Insulated First Cooling Second CoolingJacket Jacket
Position Along Bed Length
FIGURE 33SABATIER STEADY STATE BED TEMPERATURES
1 MAN CONTINUOUSMOLAR RATIO = 2.5
MAMILT^ON STANDARD , ow«aSVHSER 7221
oaw.
84
0
3 69 12 I15Insulated First Cooling I Second Cooling
Jacket Jacketi
Position Along Bed Length
FIGURE 34SABATIER STEADY STATE BED TEMPERATURES
1 MAN CONTINUOUSMOLAR RATIO = 4.0
MAMS10N^^ D01-1ONGM Of
vmnw0 ••SVHSER 7221
Test Data (o) Simulation (—)oC ( O F) eC ("F)
A'
Low Flow Coolant 157 00 (314°F) 13900 ( 283°F)High Flow Coolant 7840 172 °F 3600 970FConversion Efficiency 99.5
649 1200
593 1100
538 1000-x1
482 900-
427 800-
u m371 ° 700-
^o
316 600-
a aE260 500-
204 400-
149 300-
93 200-
38 100-
-17.8 0
85
MAMILt^ON STANAARD ^=non^.. SVHSER 7221
.. A
Test Data (o) Simulation (—)oC (O F) ,C ('F)
Low Flow Coolant 136 °C (276 °F) 144 00 (291 °F)
High Flow Coolant 7100 (1590F) 38_CC(00_°F)Conversion Efficiency _ 100 _ .S
649 1200
593 1100
538 1000
482 900-,
427 800-
u w371 ° 700 -
w d
316 600-47
Vaa a
H260H
500-
204 400-
149 300-
93 200-
38 100-
-17.8 0
O
3 I 69 12 (15` Insulated First Cooling I Second Cooling
Jacket Jacket
Position Along Bed Length ---MIN
FIGURE 35SABATIER STEADY STATE BED TEMPERATURES
1 MAN CONTINUOUS*SOLAR RATIO = 5.0
86
W ^, omwalSVHSER 7221
..
t '+ .
Test Data (o) Simulation {—)oC ( • F) 'C OF)
Low Flow Coolant 11000 (230 °F) 1029C (216°F)High Flow Coolant 66 00 150 °F 3300 910FConversion Efficiencv99. 7
.
649 1200
593 1100
538 1000
482 900
427 800
^ w371 ' 700
7316 M 600
aE260 F 500
204 400
149 300
93 2000
38 100
-17.8 06 9 12 15
Insulated First Cooling Second CoolingJacket Jacket
^-^— Position Along Bed Length- —^
FIGURE 36
SABATIER STEADY STATE BED TEMPERATURE1 MAN CYCLIC
MOLAR RATIO = 1.8
87
Test Data ( o) Simulation (—)•C (OF) *C
(OF)
Low Flow Coolant 1366C (277 •F) 147 0C (297•F)High Flow Coolant 71 6C '160 °F) 380C 1000FConversion Efficiency 99. 7 99.4
i
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)
O
C96 12 15
Insulated First Cooling Second CoolingJacket Jacket
Position Along Bed Length --^
FIGURE 37SABATIER STEADY STATE BED TEMPERATURES
1 MAN CYCLICMOLAR RATIO - 2.5
MAM^T+ON STANDiARD %°'"°^^ SVHSER 7221
F J10
649 120,
593 1101
538 1001
482 901
427 801
U y„0 311 7011,
fe 316 60
a^aH260
H 50
204 40
149 30
93 20
38 10
-17.8
88
NAM^TON sTANOiARp- Dowano SVHSER 7221
Test Data (o) Simulation (-)•C (*F) *C (*F)
Low Flow Coolant 171*0 (340 6F) 22800 (44)High Flow Coolant 17IMI2Conversion Efficiency
I
649 120
593 1100
538 1000 1 1 10
482E 900
427 800
U w371 700
316 b 600
H260 F 500
204E 40
149 300-
93 200-
38,
100-
-17 8 069 12 115
Insulated First Cooling I Second CoolingJacket Jacket
Position Along Bed Length
FIGURE 38
SABATIER STEADY STATE BED TEMPERATURES1 MAN CYCLIC
MOLAR RATIO - 3.5
89
48
427
U
371w7
00
aE 260
204
149
93
38
-17.8
90t
804
t+.70(
L7
601L
ad 501E-
401
30
201
10111I`
S
_l
MA LION WANDA" OD"Wd
SVHSER 7221
649 1201
593 1101
538 100(
1
Test Data (o) Simulation (—)•C (•F) •C (•F)
Law Flow Coolant 224°C (436°F) 233°C (4520F)High Flow Coolant 80'C (176 11 F) 54 0C (130°F)Conversion Efficiency 98.4 99.0
I
iO
I
I
i
I
1
03 6 9 12 115
Insulated First Cooling Second Cooling IJacket Jacket
Position Along Bed Length
FIGURE 39SABATIER STEADY STATE BED TEMPERATURES
1 MAN CYCLICMOLAR RATIO = 4.0
90
649 120
593 110
538 1001
482
427
UO
371
316vaEF 260
204
149
93
38
-17.8
9011
8011
w701
d
ro 6011$40arxW 5011E•
4011
30
2011
1011
_
MAM^TON STANaAitD 0n ee d ^y SVHSER 7221
Test Data (0) simulation°C (°F) °C (°F)
Low Flow Coolant 70C (441 OF) 719r (456°F)High Flow Coolant 8200 (180°F ) 6000 (140°F)Conversion Efficiency 100 99.1
I
I
I
I
I
1
1
1
I
I
03 6 9 12 1
Insulated First Cooling Second Cooling5
Jacket Jacket
Position Along Bed Length ---^
FIGURE 40SABATIER STEADY STATE BED TEMPERATURES
1 MAN CYCLICMOLAR RATIO = 5.0
91 ._Lf
482
427
U
e 371
yL 316a^aEH 260
204
149
93
38
-17.8
901
801
w701
4.601
wvCL
501E•
40
30
20
10
SVHSER 7221IIA I +ON STANaAW U owmal
649 120
593 1101
538 1001
Test Data (o) Simulation t-4eC (OF) eC (°F)
Low Flow Coolant 25300 (488°F) 298_°C„(56_)High Flow Coolant 17100 (189°F) 82°C (180°F)Conversion Efficiency _ 99.7 _ 99.6
I
I
I
1
I
O
069 1 2
First Cooling'Insulated CoolingJacket Jacket
l ow Position Along Bed Length ---+►^
FIGURE 41SABATIER STEADY STATE BED TEMPERATURES
2 MAN CYCLICMOLAR RATIO = 2.6
92
649 1200-
593 1100-
538 1000-
4821- 900-
427 800-
4 w°371 700-
316 ro 600-LA°'a a
F 260 500-E_
204 400-
149 300-
93 200-.
38 100
-17,8
MAIMLt iON WAIDMO '^ 0~01
SVHSER 7221
Test Data (o) Simulation (—^°C
(°F)°C
(°F)
Low Flc^loolant 1740C (3460F) 186°C (367°F)
Conversion Coolant 716C (1600F)
Efficiency - 9.3'-460C118°1-)
0O
03 6 9 1215
Insulated First Cooling Second Cooling
Position Along Bed Length --1
FIGURE 42SABATIER STEADY STATE QED TEMPERATURES
3 MAN CONTINUOUSMOLAR RATIO - 1.8
93S
Jacket Jacket
I
Test Data (0) Simulation (—)°C (°F) °C (°F)
Low Flow Coolant 232°C 450 °F) 267 °C 151.30FHigh Flow CoolantConversion Efficiency 99.6 9.
I
O
i
I
1
3
1
0
k I
3 6 9 12 15Insulated First Cooling Second Cooling
Jacket Jacket
La Position Along Bed Length
i
MAMIL7 10N $TANOiARD
SVHSER 7221
649 1201
593 110(
538L 100(
4821- 90(
4271- 80(V Gc.
371 d 70(
316 A 601d
Ir
^d s^
E-4 260 F 501
204♦ 401
149 30
93 201
38 10
L-17. 8
FIGURE 43SABATIER STEADY STATE BED TEMPERATURES
3 MAN CONTINUOUSMOLAR RATIO - 2.6
94
U-1110 a I STAIr^AilD%OWW^ _w
Test Data (0) Simulation (—^°C ( OF) °C ( OF)
Low Flow Coolant 285°C (545°F) 349°C (660 °F)High Flow Coolant 107°C (224°F) 109°C (229°F)Conversion Efficiency 99_^ 99.5
I
i
i
I
1
1
1
f
06 9 12 1
InsulateJacket g
Jacketg
—Position Along Bed Length
Insulated First Coolin Second Coolin
SVHSER 7221
649 1201
593 1101
538 100(
482E 90(
427E 80(
u w371 ° 70(
^+ dyto 316
^to 601
d &+^a a
H260 F 501
204. 401
149 301
93 201
38 101
-17.8
FIGURE 44SABATIER STEADY STATE BED TEMPERATURES
3 MAN CONTINUOUSMOLAR RATIO = 3.5
95
ar.n+w
SVHSER 7221
sows-
Test Data (o) Simulation (^eC ( O F) ,C (°F)
Low Flow Coolant 308 0C 586 °F) 360°C 680°F)High Flow Coolant ) 1290C ( 2650F)Conversion Efficiency
I
1
I
I
I
D
J
0
649 1201
593 1101
538 100(
482E 90(
427E 801
u w°371 70(
316 A 601^' w
da260 d 501E-4 E
204F 40
149 30
93 20
38 10
-17.86 9 12 1
Insulated First Cooling Second Cooling5
Jacket Jacket
Position Along Bed Length -----+ I
FIGURE 4`+SABATIER STEADY STATE BED TEMPERATURES
3 MAN CONTINUOUSMOLAR RATIO = 4.0
96
MAMNTON NAIlp '--W=»
SVHSER 7221
ice.
Test Data (0) Simulation (—)eC ( O F) 0C (OF)
Low Flow Coolant 0TC2 630 10 F) 35600 6730EHigh Flow Coolant F) 136 00 12770F)P4Conversion Efficiency
649 120
593 110Uµ"
538 1000O 1 0
482 900
427 800O
U G.
371 700
316 to 600
^ aE260
F500
204 400
149 300
93 200
38 100
L-17 .8 06 9 12 15
Insulated First Cooling Second CoolingJacket Jacket
Position Along Bed Length
FIGURE 46SABATIER STEADY STATE BED TEMPERATURES
3 MAN CONTINUOUSMOLAR PATIO - 5.0
97
i
Test Data (o) Simulation (--)•C (•F) 'C ('F)
Low Flow Coolant 26 ,°C 503°F) jjjOC IN90High Flow Coolant F) 91 0C ( °FConversion Efficiency 99. 4 18
I
11
I
I
i
I
t
)
I
069 12 15
Insulated FirsJacketing Sec Jacket
ling
Position Along Bed Length -^
FIGURE 47SABATIER STEADY STATE BED TEMPERATURES
3 MAN CYCLICMOALR RATIO s 1.8
98
SVHSER 7221
649 120,
593 1101
538L 1001
482E 901
4271- 801
U y371 701
w ^,
316 m 601Id
dh260 5011
E-4
204F 4011
149 30
93 201
38 10
-17.8
HAMILTON S'1'AI^AIl0 °i'°^^ SVHSER 7221
Test Data (0) Simulation (--)°C (°F) °C (°F)
Low Flow Coolant 30300 (578°F) 378°C ( 712°F)High Flow Coolant ° ) 151 2C (304 lConversion Efficiency 9966 99. 7
649 120
593 1100
538 1000
482E 900
427 800
U ^371 700
►+ 1+>y
L 316
>
600
a.H260 H
400
204 400
149 300
93 200
38 100
-17 .8L. 069 12 15
Insulated First Cooling I Second CoolingJacket Jacket
Position Along Bed Length
FIGURE 48SABATIER STEADY STATE BED TEMPERATURES
3 MAN CYCLICMOLAR RATIO - 2.6
l99
48
427
U371
316
6E+ 260
204
149
93
38
-17.8
900
800-
700-
►+
A 600•w
o.aBi 500•E
400•
300
200
100
s-rs
-ok1mgm 0 ONNIM0
SVHSER 7221
649 1200-
593 1100-
538 1000-
Test Data ( 0) Simulation (^.0 (•F) 'C (`F)
Low Flow Coolant 7 •F) 418 00 (78419High Flow Coolant 191-C (376 0F) 2360C (4570F)Conversion Efficiency 94.3 99.4
0
O
I
6 9 12 r15Insulated First Cooling Second Cooling
Jacket Jacket
Position Along Bed Length
FIGURE 49SABATIER STEADY STATE BED TEMPERATURES
3 MAN CYCLISMOLAR RATIO .5
100
SVHSER 7221MAIMLTON ^T#NOiAIlplull, °i'°^^
Test Data (0) Simulation (--)•C ( . F) 'C OF)
Low Flow Coolant 3490C (660 0F) 430_(8^)High Flow Coolant F) 27100 520•F)Conversion Efficiency 9506 98.5
1
1
I
I
I
3
D
0
J
D
0
649 1201
!,93 1101
538 1001
482E 901
427E 801
v ^371 701
w ^
316yw
a 601
O.
V
E 260E 50
204E 40
149 30
93 20
38 10
-17.8 69 12 15
Insulated First Cooling Second CoolingJacket Jacket
INN Position Along Bed Length
FIGURE 50SABATIER STEADY STATE BED TEMPERATURES
3 MAN CYCLICMOLAR RATIO .0
101
SVHSER 7221w
Test Data (0) Simulation (--^•C (•E) 4C (6F)
Low Flow Coolant 356 0C 673'F) W9C 7839F)High Flow Coolant 1960C J384 0F) (5400F)Conversion Efficiency
I
OF
I
1
I
1
0
649 120
593 1101
538L 1001
482E 901
427E 801
U ^,
371 701
oyw 316 q 60
R ^H 260 50
204F 40
149 30
93 20
38 10
-17 .86 9 1
Insulated First Cooling Second pooling5
Jacket Jacket
Position Along Bed Length --1
FIGURE 51SABATIER STEADY STATE BED TEMPERATURES
3 MAN CYCLIMOLAR RATIO .0
102
a^
O
E
c vw oo
AiA
Q (H • M i^
•o5p
Ai•^+ V t O.
GJ e>4
T Aj
O.
Ad
•y w
1
SVHSER 7221
Y
Ey43
Cid
HUMauU ^
00>• Z
i+t CL ZZ^
E ^ OO 2
tn _
> Ln
Z -~U
C7
4
0 ao 0
o °o0 ^ o
^ o 0p
o
N*m-^
W
0
...N L CO
0` 0+>w C0U
U-1
n
N co
ODCh0% m
41
00 ^` o^ v+
O^ Q• ^
0
N A Ti N 10a^
C 0 t1qr S CAD
Muwo -4 UN Nun
r 103
'roN $'^ -°iond SVHSER 7221
Bed temperature profiles at the end of the shutdown and 25 minutesinto the warm-up are shown in Figures 52 to 63 for several trans-ient cases. Also, conversion efficiencies as a function of timeinto warm-up are presented for these runs. Note that for the 2and 3 man cases a large dip in performance occurs about 25 minutesinto the warm-up. The cause of the reduced performance can beseen by superimposing the steadystate profile over the profile at25minutes into warm-up (Figures 67 to 69). In the profiles at 25minutes, the transition from the hot to cold section of the bedis much faster, so that gas residence time in the 260 -316°C (500-600 °F ) area, where final scrubbing occurs, is short. Also noticethat some sections of the bed are warmer at 25 minutes than insteadystate, contributing to the steeper profile.
Transient cool down computer simulation shows good agreement withtest data as can be seen in plots of reactor profiles at the endof the cool down period ( Figures 52, 55, 58, and 61). However,warm- lip is not as well correlated with test as is seen in reactortemperature profiles and conversion efficiency plots ( Figures 33,56, 59, and 62). This discrepancy is due to the warm-up anomalymentioned above.
104
649 1
593 1;
538 1(
482
427
v ^,
371L d
1w7y W
316- i
CL a260 E
204E
149
93
38
-17.8
1lA^T^ON STANaARO ^1/`^^ws+ SVHSER 7221
Jacket - Jacket
-- Position Along Bed Length ---►^
FIGURE 52SABATIER TRANSIENT BED TEMPERATURES
1 MAN CYCLICMOLAR RATIO = 1.8
105
Time Into Warmup 27
(p) Test Data(—) Simulation
!
I
I
)
10
03 6 9 12 1
Insulated First Cooling Second CoolingJacket Jacket
Position Along Bed Length ----^
FIGURE 53SABATIER TRANSIENT BED TEMPERATURES
1 MAN CYCLICMOLAR RATIO = 1.8
MA^TON S7^NAAI1p °^'°^+ SVHSER 7221
W -.-,
649 120,
593 1101
538 1001
482E 901
427E 801U ^.
371 ° 701L Ly ^
316 a 601^ L
^'arr a
260F 501,
204 4011,
149 30
93 20
38 10
-17 .8
106
100
98
v
wwwC4 96
V
COU
94
i
SVHSER 7221
0 10 20 40 60 t!0
Time Into Warm Up (min)
FIGURE 54SABATIER WARM UP CONVERSION EFFICIENCY HISTORY
1 MAN CYCLICMOLAR RATIO = 1.8
.j
107
Time Into Warmup = 0.0
(0) Test Data(—) Simulation
I
i
1
i
I
i1
1
03 6 9 12 15
Insulated First Cooling Second CoolingJacket Jacket
— Position Along Bed Length- ----^
FIGURE 55SABATIER TRANSIENT BED TEMPERA'T'URES
2 MAN CYCLICMOLAR RATIO = 2.6
MAM^TON sTO °"° SVHSER 7221
w
649 120
593 1101
538 100(
482E 901
427 801
U G.
371 ' 70(
y ^L 316 0 601d
F 2601
^°Ja aC) 501
a~
204 401
149 301
93 201
38 101
-17.8
108
HAM IQ N STA ARp , 0~01SVHSER 7221
_
Time Into warmup 27.0
(o) Test DataSimulation
I
IOI
I
iD
D —
0
O
D
0
0
649 120,
593 110
538L 1001
482E 901
427E 80,
371 a, 70i^. L
316 to 60
a^Lyss. arxF260 50
204 F 40
149 30
92 20
38 10
-17.83 6 9 12 15
Insulated First Cooling Second CoolingJacket Jacket
Position Along Bed Length --^
FIGURE 56SABATJER TRANSIENT BED TEMPERATURES
2 MAN CYCLICMOLAR RATIO = 2.6
109
SVHSER 7221
100
0 10 20 40 ou ou
Time Into Warm Up (min)
r
d 98
.,aww
G
a^9E
wa^
0U
9,
FIGURE 57SABATIER WARM UP CONVERSION EFFICIENCY HISTORY
2 MAN CYCLICMOLAR RATIO - 2.6
t¢110
HAMILTON STANOIAND ^, °ir°'°^aors•.
48
427
UO
eJ 371
y316
aEE 260
204
149
93
38
-17.8
901
801
70(a+
601wvaEd 501E-
401
30
201
101
649 1201
593 1101
538 100(
SVHSER 7221
Time Into Warmup = 0.0
(o) Test Data(—) Simulation
I
i
1
I
i
1
)
OL 0
03
71nsulated6 9 12
First Cooling Second CoolingJacket Jacket
I NN Position Along Bed Length
FIGURE 58SABATIER TRANSIENT BED TEMPERATURES
3 MAN CYCLICMOLAR RATIO = 2.6
111
649 120,
593 1101
538 1001
- ompol SVHSER 7221
482 90t
427 801
U
371 70(
19316 a 601
a
F 260 trd 501
204 401
149 30i
93 201
38 101
-17.8
Time into Warmup 24.0
(0) Test Data(—) Simulation
I
iO
I
I
0
0
03 6 9 12 1
Insulated First Cooling Second CoolingJacket Jacket
Igo Position Along Bed Length
FIGURE 59SABATIER TRANSIENT BED TEMPERATURES
3 MAN CYCLICMOLAR RATIO - 2.6
112
4
NANWON STANDAM c^..,.Baas»SVRSCS 1221
100
sv
V
v 98
ww
C0 96ww
c0U
94
0 10 ZO 4U ou ou
Time Into Warm Up (min)
FIGURE 60SABATIER WARM UP CONVERSION EFFICIENCY HISTORY
3 MAN CYCLICMOLAR RATIO - 2.6
1 113
Time Into Warmup = 0.0
(o) Test Data(—) Simulation
I
I
I 1 O
1
1
}O
1 ^
03 69 12 1
Insulated First Cooling Second Cooling5
Jacket,Jacketlow Position Along Bsd Length
FIGURE 61SABATIER TRANSIENT BED TEMPEPATURES
3 MAN CYCLICMOLAR RATIO - 4.0
114
SVHSER 7221wo -0- 0"Wo
649 120,
593 1101
538 100(
482 901
427 801
e rA.
371 0 70(07 7
316 it 601v4. a
F 260 rEr 50,F
204 401
149 30
93 201
t38 101
-17 .8
Time Into Warmup 25.0
(0) Test Data(—) Simulation
I
iO
I
I
I
I
1NL
I O
03 6 9 12 15
Insulated First Cooling Second CoolingJacket Jacket
Position Alung Bed Length
FIGURE 62SABATIER TRANSIENT BED TEMPERATURES
3 MAN CYCLICMOLAR RATIO - 4.0
HAMILTON s't^MOAAO0- NIWO . SVHSER 7221
649 1201
593 1101
538 1001
4821- 901
427 801
u ra.
371 ' 70(L ^
11 316 0 601Ql
1.1
^'a a
F 260 cE, 501E
204 401
149 30
93 201
38 101
-17 .8
115
MA TON sTANt^ ►RA 0~0 SVHSER 7221
100
w
v98
Nrww
C
^ 96mVd
COu
94
0 10 20 40 bu
dU
Time Into Warm OF (min)
FIGURE 63SABATIER WARM UP CONVERSION EFFICIENCY HISTORY
3 MAN CYCLICMOLAR RAT I 0 - 4.0
116
E..*- :
0
100
sVy,'V
98
ww
C
w91
wdc0u
94
0 10 20 40 ou Hsu
Time Into Warm Up (min)
FIGURE 64SABATIER WARM OF CONVERSION EFFICIENCY HISTORY
1 MAN CYCLICMOLAR RATIO = 2.6
4
117
0.Q O
4
100
v
V9
U•.rwwwe
NdC0U
8
9 6
9
4.
s
0 10 20 40 Du vu
Time Into Warm Up (min)
FIGURE 65SABATIER WARM UP CONVERSION EFFICIENCY HISTORY
1 MAN CYCLICMOLAR PATIO = 3.5
118
100
a►v>1Ud 98U
ww
C96
►ra^
c0U
94
0 10 20 40 60 80
Time Into Warm Up (min)
FIGURE 66SABATIER VAR.M UP CONVERSION EFFICIENCY HISTORY
3 MAN CYCLICMOLAR RATIO - 3.5
119
649 1201
593 1101
538 100
48
427
Ue
371
w
y^ ?1647C.
E 260
204
149
93
38
-17.8
901
s01
70(aL
A 601V"Ja25 50E-
40
30
20
10
NA6IMLTON S?ANOARO• °wioYi^..r SVHSER 7221
Time Into Warmup = 27.0
(o) Test Data(-) Simulation
I
i
I
Aq1
I
o
e
03 6 9 12 15
Insulated First Cooling Second CoolingJacket Jacket
-Position Along Bed Length ---
FIGURE 67SABATIER COMPARISON OF STEADY STATE AND
TRANSIENT BED TEMPERATURES2 MAN CYCLIC
MOLAR RATIO - 2.6
120
649
593
538
482
427
u371
3161daEE 260
204
149
93
38
-17.8
1201
1101
10 011
901
801
701eV
A 60
vCL
E 50a~
40
30
20
10
MANN20H '^'^ owswo SVHSER 7221
Time Into Warmup 24.0
(o) Test Data(-) Simulation
1
1
I
I
A
D
D
AD
0
05
InsulatedJacket
gJacket
^-- Position Along Bed Length
FIGURE 68
SABATIER COMPARISON OF STEADY STATE ANDTRANSIENT BED TEMPERATURES
3 MAN CYCLICMOLAR RATIO = 2.6
3 6 9First Cooling
12Cooling
1
121
482E 901
427 801
u ^,
371 ° 70(L ^
M 316 a 601CJWG.
H260 ce, 50111
r~
204 40,
149 30
93 2011,
38 10"
-17.8
649 120,
593 1101
538 1001
Time Into Warmup 25.0
(o) Test Data(-) Simulation
I
i Al
e
I
i
I
1
1
O
0
aInsulatedJacket g
9
Jacketg
^+---- Position Along Bed Length
FIGURE 69SABATIER COMPARISON OF STEADY STATE AND
TRANSIENT BED TEMPERATURES3 MAN CYCLIC
MOLAR RATIO z 4.0
3 6First Coolie
12 1Second Coolie
122
NAMIL7^OM $TANDARpAwl °CMS
SvHSER 7221
SUBSYSTEM DELIVERY
The following hardware was shipped under this contract to NASA/JSC.
Sabatier Package Assembly SVSK 96500Sabatier Driver Box SVSK 97813Connectors, Electrical (1 each)
>901 - PT06A-12-105>700 - PT06A-12-105>701 - PT06A-8-4SMating miniature thermocouple connectors (11) (Item 86)
Prior to delivery of this hardware, the Sabatier Package Assemblywas refurbished. This consisted of:
- Replacing heater, SVSK 96486 (Item 83)- Replacing overtemperature probe SVSK 96465 (item 85)- Catalyst treatment, to remove additional residual chlorides- Installation of name tags dnd component item numbers- Tie down of electrical leads and harnesses.
Reactor cooling air temperature sensors, Items 87-1 and 87-2,although not on the subsystem parts list, were left installed inorder to facilitate testing at NASA/JSC.
After refurbishment the subsystem was setup and tested to verifyproper function and performance and various failure modes.Performance was improved as discussed previously. Water wasdrained and then the subsystem purged for 24 hours with drynitrogen. Inlet and outlet ports were capped and double baggedand the unit delivered to the shipping department where it wascrated and subsequently delivered to NASA/JSC by a North Americanair ride van.
LA-*
123
MAMILI^ON s'TANDiAR^, D'awdSVHSER 7221
COORDINATION WITH RLSE
The Sabatier CO Reduction Subsystem schematic is shown in Figure1. The subsystem closely matches the RLSE program Sabatier COReduction Subsystem and provides the same interfaces, functionand internal componentry to be fully compatible with the overallRLSE System requirements. The Sabatier package assembly, driverbox, and TIMES controller will fit into the space provided in theNASA/JSC Advanced ECS laboratory. The TIMES controller anddisplay is installed in a standard NASA supplied electronic rackfor use in the NASA laboratory. Ten meters of leads wire isprovided by the TIMES program to permit this remote location. Alead (10 meters long) for an external remote discrete shutdownswitch was also provided as part of the Sabatier subsystem harness.
Interfaces for the Sabatier subsystem are as defined in NASA'sRLSE study. A mixture of hydrogen and carbon dioxide is receivedfrom the EDC. A charcoal bed in the Sabatier subsystem willprotect the Sabatier reactor if there are trace amounts of contam-inant carryover from the EDC or WVE. CO concentrator pressureis controlled to 1.2 atms (3.5 prig) by ilressure regulatorscontained within the Sabatier reactor system. If the primaryregulator fails closed, a bypass valve (Item 306-2) will be auto-matically activated diverting flow to a bypass regulator thusprotecting upstream equipment.
A pump is provided to deliver water to the water managementsystem at 2 atms (30 psia) which is the upper pressure limitdefined by RLSE. The preprototype unit has its own cooling fan,however, the air cooling jacket at the reactor is designed tooperate at low flow with the pressure drop available from normalSpacelab rack cooling air. Air cooling is used to simplify inte-gration of the subsystem, consistent with RLSE guidelines.
124
STANaA!!O !. °" L, SvKSER 7221
DOCUMENTATION
Table 20 defines the contract documentation required and thedocuments submitted in response to the data requirements for thisprogram test by Hamilton Standard.
I125
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SVHSER 7221
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MA l^ON sT ARD Noce
.s^ SVHSER 7221
SUPPORT REQUIREMENTS
- Below is a list of Government Furnished Property (GFP) madeavailable by the NASA/JSC in support of this contract. Items notused were returned to the Government after the preprototypeSabatier subsystem was shipped.
Quantity Delivered WithSupplied Subsystem Description
5 4 SSP Item 178Combustible Gals SensorSVSK 84456-100 Sensing Assy.SVSK 84456-200 Monitor Assy.With Elec Harness
6 5 SSP Item 306Valve, Elec Shutoff, ManualOverrideSVSK 84424-100With Elec Harness
1 - SSP Item 368Backpressure Regulator ValveSVSK 84519
5 4* SSP Item 507Manual Shutoff ValveSVSK 84530-1
1 1 SSP Item 545Water RappSVSK 96329-2
2 2* SSP Item 902Pressure TransducerSVSK 86339-3 (Ref:SVSK 84522-3)With Elec Harness
2 - SSP Item 907Water Detector SensorSVSK 86587
- With Elec Harness
1 1* Space Shuttle Assembly(less spares) Accumulator Assy.
SV755518-1With Spare Parts
*Items modified for use in Sabatier subsystem
127
.. -J.-
MAC?SON STAI^ARp °wioSVHSER 7221
QUALITY ASSURANCE
The objective of the Quality Assurance Program was to search outquality weakness and provide appropriate corrective actions.Quality assurance considerations were included during the COReduction Subsystem Design, engineering evaluations, procuregentand fabrication activities. All vendor-supplied items werechecked out and inspected per engineering instructions prior toassembly into the subsystem. Prir to delivery of the hardware, aFirst Article System Inspection (FASI) was held. The reviewcommittee consisted of senior engineering, reliability and qualitypersonnel. Only minor quality deficiencies consisting mostly ofelectrical wiring harness locations were identified and requiredcorrections.
128
as SOLIMAMGy`^...., SVHSER 7221
RELIABILITY
The CO Reduction Subsystem, as concepted, has a high inherent'APO reliability. The Sabatier reactor and the water separator are
passive devices. In the flight configuration, cooling is pro-vided by a constant supply of avionics cooling air flow. Theaddition of a charcoal filter in the process line minimizes thesensitivity of the reactor to upsets in upstream subsystems.
The water quantity measurement and delivery equipment consists ofa pump and a calibrated accumulator. The cylic operative of theaccumulator is estimated at 1500 cycles per month. This resultsin a pump on-time of only 25-50 hours. At this low usage rate,this equipment would not be considered limited life.
The backpressure regulator is backed up by an in-line shutoffvalve which provides isolation, and automatic switchover to asecond regulator. The automatic switchover function, activatedby an inlet pressure sensor, permits uninterrupted operation andventing of upstrean subsystems.
Equipment safety is enhanced through design simplification, andautomatic failure detection and shutdown. All components whichcontain H or CH are of a welded construction and incorporatestatic seals. SAfety critical parameters, such as pressure,temperature, and external gas leakr_ge, have redundant sensing andshutdown capability.
The Failure Mode and Effects Analysis (FMEA) completed as a partof this program is contained in Appendix C of this report.
129
suw^en ^^^. SVHSER 7221
SAFETY
Safety was a prime consideration in design of the CO 2 ReductionSubsystem because of the presence of hydrogen gas in the subsystem.During the design of the subsystem safety was enhanced by in-corporating the following safety features in the hardware and/orsubsystem:
1. Utilization of a catalyst that has a low start temper-ature and a reaction that is temperature limited regardlessof flow.
2. Incorporates a dedicated overtemperature sensor toinitiate automatic subsystem shutdown.
3. A single failure in one component will not cause suces-sive failures in other components.
4. All manual valves and manual overrides in electricalvalves are readily accessible from the front face of thesubsystem.
5. The controller prAvides automatic hands-off operation andautomatically purges with nitrogen the subsystem duringany shutdown.
6. A visual and audio alarm is provided during any abnormalcondition.
7. Four combustible gas detectors are provided in the sub-system.
8. All interfaces and connectors are clearly labeled.
9. Circuit breakers are incorporated to protect electricalequipment.
10. In all connectors, the hot connector is a femalesocket.
11. Overpressure of the subsystem is presented by design(reactor is sent straight through tube design), by aflow limiting orifice in the nitrogen line, bypressure regulators, and pressure sensors which willsignal the controller to bypass inlet flow or shutoffnitrogen flow if the pressure level exceeds a predeter-mined value.
130
z-i
NA^TOM STAI^A11p ^^^Dim d
SVHSER 7196wz^ ' Revision A
HAMILTON STANDARD
DIVISION OF UNI_'ED TECHNOLOGIES CORPORATION
JANUARY, 1979*.
MASTER TEST P ,F. 1
FOR
PREPROTOTYPE SABATIER SUBSYSTEM
CONTRACT NAS 9-15470
PREPARED BY: i- G"^'NCENT A. CELINO
PROJECT ENGINEER
APPROVED BY:
i' „_iceHAR AN F. BROSEPROGRAM MANAGER
*REVISED JANUARY, 1980
3
A-1
SVHSER 7196Revision A
r 1.0 INTRODUCTION
Testing for the Preprototype Sabatier Subsystem shall be per-formed at the component and subsystem levels. Each componentshall be tested as described herein to assure critical perfor-mance and operational characteristics as required prior to sub-system testing. Subsystem level testing shall be performed toverifv subsystem design features, startup and shutdown charac-teristics, :irarating pressure level capabilities, failure modecharacteristics and parametric Sabatier Reactor and subsystemperformance under steady state, cyclic and transient conditions.
Tables I and II show the specific component tests to be run;Tables III and IV show specific subsystem tests to be run.
2.0 TEST DESCRIPTIONS
k.1 Examination of Product - Each specified component in Table Ishall e examine to determine that the material and work-manship requirements have been met and that all externaldevices such as flanges, mounting provisions, and connectorlocations are as specified.
2.2 Base Point Calibration - Each specified component will beoperated to demonstrate that the unit meets specified func-tional and baseline performance requirements, includingstartup and shutdown.
2.3 Proof Pressure - A proof pressure test will be conducted onfluid system pressure carrying components and assemblies.The pressure will be 1.5 times maximum operating pressureand will be held for a period -:f five minutes at room tem-perature. At the conclusion of the proof pressure test, thecomponents will be examined to verify that no damage orpermanent deformation has occurred.
2.4 Leakage - Fluid system components will be subjected to anexternal and an internal leakage test, as applicable.
2.5 Performance - Each component shall be subjected to a perfor-mance test except where a base point calibration is suffi-cient prior to subsystem testing. Performance tests arecategorized in four ways:
2.5.1 Operational Check - This test demonstrates that the com-ponent operates when it is subjected to the appropriatestimuli. This test is primarily for commercially avail-able components.
2.5.2 Performance ciao - These are more extensive tests to beconducted on the reactor and condenser in the subsystem.These tests are described in more detail in Section 4.0.
A-2
1
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TABLE I TEST SUMMARY
TEMN0.
DESCRIPTION
ISVSK96471-1
P/N EOP BASEPOINTCAL
PROOFPRESS
LEAKAGE PERFORM
26 SILENCER X
31 CHARCOAL CANISTER SVSK96470-1 X X X
41 CHECK VALVE SVSK96466-1 X X OP
42 CHECK VALVE SVSK101124 X X
46 FAN SVSK96462-1 X OP
51 CONDENSER/SEP SVSK96349-1 X X X X
61 ACCUMULATOR SVSK96490-1 X CAL
71 DRIVER BOX SVSK97813 X OP
81 TEMP SENSOR SVSK96465-1 X CAL
82 TEMP SENSOR SVSK96499-1 X CAL
83 HEATER SVSK96486-1 X X
85 TEMP SENSOR SVSK96465-2 X CAL
91 REACTOR SVSK96482-1 X X X X
178 COMB GAS DETECTOR SVSK84456_188 Y X CAL
306 ELEC S.O. VALVE SVSK84424-100 X X OP
310 BACK PRESS. REG SVSK84412-1 X X X X
507 MAN S.O. VALVE SVSK84530-1 X X X
545 PUMP SVSK86329-2 X X X X
876 QUANT SENSOR SV764179-1 X OP
902 PRESSURE TRANSDUCER SVSK101128 X X X CAI,907 LIQUID WATER DETECTOR SVSK101129 X X X X
259 ACCUMULATOR SVSK96492 x X X
SUBSYSTEM SVSK96498* X X X X A^CEP
CODE: OP - OPERATIONAL CHECK
*REFERENCE SABATIER PACKMAP - PERFORM MAPCAL - CALIBRATION OVER RANGE
ACCEPT - ACCEPTANCE TEST
A-3
ORIGINAL PAGE 10(IF POOR QUAI.ry
2
SVHSER 7196Revision A
LEAKAGE PERFORM©
POWERCONSUMPT
CONTINUITY ENDUR FAIL MODECHECKOUT
X
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2.5.3 Calibration - Components as indca i rate -over the operationalare limited to those generatingcontroller.
SVHSER 7196Revision A
icated in Table I shall berange. These componentssignals for use in the
2.5.4 Acce tance Tests - This is a series of tests to be conduc-ted at the subsystem level and are described in moredetail in Section 5.0.
2.6 Power Consum tion - Electrically operated items will becycled—and the power consumption measured.
2.7 Continuity - All specified electrical components will be ex-amined to assure proper wiring.
2.8 Endurance Testing - Shall be performed as part of subsystemtests. These tests are described in Section 5.0.
2.9 Failure Mode Identification - The principal failure modesor eacH component or assembly will be identified and theeffect determined. Identification of safety hazards willalso be noted. These tests shall be conducted on the con-troller and the subsystem.
3.0 LABORATORY TEST SYSTEM SCHEMATICS
The tests indicated in Table II will be run with the test rigshown in Figure 1. The effects of variation in total pressureand air cooling flow rates on H CO 2 conversion will be deter-mined with this setup. These tests will establish the coolingflow rate to be used for all subsequent'reactant process rates.
Figure 2 shows the flow schematic to be employed for measuringSabatier reactor cooling flow. The existing test rig will bemodified to accommodate integrated subsystem testing.
Test equipment shail permit testing on a continuous basis overthe full range of reactant compositions and flows currentlyanticipated in order to determine the effects of variation inH /CO22 molar ratios, reactant flow rates, reactant operatingpiessares and gas cooling flow rates on H /CO conver.sior ► tiEfi-ciencies and reactor temperature profiles.
2
3.1 Reactant Gas Supplies - Certified premixed reactant blendsshall Be used for test points 1 through 10 in Table II andfor test points 12, 15, 17, 21, 24 and-27 in Table III. Thepremixed reactant flowmeter shall be calibrated with thereactant mix_zres at the flowmeter pressure to be usedduring test . 1s. The reactant mixtures for the remainingtest points in Tables III and IV shall be established bymetering hydrogen and carbon dioxide individually and mixingthem.
A-4
3
0/' owamot SVHSER 7196Revision A
TABLE II
SABATIER REACTOR Ain CONDENSER/SEPARATOR
COMPONENT TESTS
H2/Co2 MOLAR RATIO I 1.8 I 2.6
TEST # FLOW ON I TEST #
Cot MAN FLOW
1 7 2
5.0
9 2
3 (2)1 2
(2) 2 2
(2)3 2
(1) 3 CYCS.I' 8 2 (3)4 2 1C 2
(3) 5 2
(3) 6 2
TOTAL HOURS 4 + 12 + 420 hra total
(1) Flow is 1.71 times steady state flow
(2) Tests 1, 2 and 3 establish effect of air cooling flows thereby permittingselection of constant air cooling flow for all process reactant flows.
(3) Teats 4, 5, and 6 determines effect of reactor pressure on H2 conversionefficiency.
' A-5
4
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PREMIXEDCERTIFIEDREACTANTGAS
CO2
SHOPNZ
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400 HZ
DNG PACE KAM NOT FKMD 10 PHASE
Ft)tlx-4jT FRAM
SVHSER 7196Revision A
HEATED,G. C. SAMPLE
LINES
SAMPLE
PRODUCT GAS OUTLET
TO VENT
SABATIER SUBSYSTEMSVSK96500
REF. SVSK96498 PRODUCT
FOR SCHEMATICWATEROUTLET
GRADUATEDCYLINDER
TEMPERATURE5 VAC READOUT
0 HZ
3 PHASE
FIGURE 2
A-6 ^l
1AWN AW,DOW^ SVHSER 7196
Revision A
3.2 Laboratorx Gas Analysis - Product gas mixture analysis shallbe determined by gas chromatographic tests. Accuraciesshall be as follow:
ConcentrationRange Accuracy
H 2 0 - 58 + 0.18
CO2 0 - 58 + 0.18
CH 0 - 258 + 0.58
4.0 SABATIER REACTOR AND CONDENSER/SEPARATOR TESTS
The test sequence in Table II shall be performed on the Reactor-Condenser group in the rig setup shown in Figure 1. Reactorcoolant air flows shall be measured as shown in Figure 2.
5.0 SUBSYSTEM TESTING
Subsequent to component testing, the subsystem shall be operatedat baseline conditions both at the beginning and at the end of thetest program to determine the effect of operating time on systemperformance. The contractor shall demonstrate the Sabatier sub-system capability of satisfying an off-nominal requirement byoperating at the one-man rate for two days. A 120 hour continuousendurance test shall also be conducted. System power and H /CO2conversion efficiency shall be recorded during this operation.An acceptance test shall tht-n lhN and witnessed by theNASA technical monitor. This testing shall include a subsystemshutdown after the off-nominal operation and system startup andoperation at baseline conditions. Cyclic operational performanceshall also be demonstrated. The parametr ic! r,Nsi:, i l iall includeconditions comparable to 1, 2, and 3 man loadings. In addition,off-design testing shall he conducted which exhibits H 2 conversionefficiencies of approximately 908 and 808.
The subsystem test proyrnrn shall be conducted as shown in Figure 1and shal l a ii i.iimum of 304 hours of reactant flow in theconduct of parametric, endurance, and acceptance testin(3 as le-
i ^^d in Tables III and IV.
6.0 TEST REPORTS
The data from each test will 'Lie recorded on Hamilton Standard Lo>t31-,t i - p i?' • -i;ist of the rig operational ;^rlrtllr;.-
j ?? J; ; ilts of gas, chemical and physical analyssiA,)arformed. The performance data calculated from each test willbe plotted and compared with per formatw^ by computermodels. A test report shall he prepared and included in the finalreport.
A-7
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