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Chemical Engineering at
NASA

Jacob Collins
Energy Systems Division
 Overview
Background Information
JSC Engineering Directorate Organization
My Role as a Chemical Engineer in the
Space Industry
Battery Testing
Why test batteries?
Types of Tests
Capabilities
ISRU
Propulsion and Cryogenics
Questions and answers
 Background Information
First engineer in my family
Didnt have a lot of money so I started at a junior
college
Alvin Community College
Associate in Arts Degree in General Liberal Arts
Various Construction and Sales Jobs
I wanted something more
University of Houston
Reasons I choose Chemical Engineering
I wanted a versatile, challenging, & rewarding career
Even if I did not receive myy dream jjob,, I would ensure a healthyy salaryy for myy
family
Bachelor of Science in Chemical Engineering with a Minor in Chemistry
You can find your dream job from any school
Its not the school but what you make of it
I was labeled a B student as an undergraduate
But I never stopped working and found a career in my desired field
 Background Information
Highly recommend a Co-op or Internship
Experience gained is worth a few points to your GPA
No more Roman noodles and water everyy nightg
Learn what career path best fits your personality
Food Industry: Maxwell House (Soluble Processes)
Plastics Industry: Bayer Corporation (Polycarbonate Division)
Great jobs but something was missing
Shortly before graduation I began working my Law of Averages
Sales term that means if you try everywhere, someone will buy it
Went on a lot of interviews and got turned down a lot
R i d offers
Received ff from
f some off the
h major
j oilil companies
i andd NASA
I choose the Aerospace Industry over salary because nothing, in my opinion, is
more important than space travel
NASA is composed
p primarily
p y of Aerospace,
p , Mechanical,, and Electrical
Engineers
NASA promotes diversity
I often find myself offering unique information due to my background
University of Houston Clear Lake
Attended night courses while working for NASA
Masters of Science in Physics
 JSC Organization
Before discussing the details of my experiences at NASA
Show the JSC organization:
AA: Office of the Director
BA: Office of Procurement
CA: Flight Crew Operations Directorate
DA: Mission Operations Directorate
EA: Engineering Directorate
IA: Information Resources Directorate
JA: Center Operations Directorate
KA: Astromaterials Research and Exploration Science Directorate
LA: Chief Financial Officer
MA: Space Shuttle Program
NA: Safety and Mission Assurance Directorate
OA: International Space Station Program Office
QA: Commercial Crew/Cargo Project Office
RA: White Sands Test Facility
SA: Space Life Sciences Directorate
W JS NASA Office
W-JS: Offi off Inspector
I t General
G l
WE: NASA Engineering and Safety Center
WR: Department of Defense Payloads Office
WS8: NOAA-National Weather Service, Spaceflight Meteorology Group
XA: Extravehicular Activityy Office
ZA: Constellation Program Office
Many different possibilities for Chemical Engineering at NASA and in the Aerospace Industry
Engineering Directorate Organization
 Energy Systems Division
Organization
ENERGY SYSTEMS
DIVISION

PROPULSION &
POWER SYSTEMS ENERGY SYSTEMS
FLUID SYSTEMS
BRANCH TEST BRANCH
BRANCH

Fluid Systems
y and Power Generation,, Storage,
g , 6 Test Facilities and
Components and Distribution Support Services
Attitude Control System Pyrotechnics Environmental Test
APU/Hydraulics Batteries Services
Electromechanical Actuators Fuel Cells
In-Situ Resource Electrical Power System
Utilization/In-Situ Propellant Laboratory
Production
 My Role at NASA
Cannot speak for all NASA Chemical Engineers
Some are in management
Some are in other directorates I am not familiar with
Some are astronauts
Will not go into all of the details but mention specific items related to my
p
experiences
Became a Test Director
Manage many different test programs from the planning, development,
operations, and reporting phases
Define test requirements, conditions, and procedure
Establish technique to meet requirements and schedule and perform any
necessary procurements
Work closely with the technicians and get hands on experience
Supported test programs in the areas of:
Chemical Storage (primary focus)
In-situ Resource Utilization (ISRU)
Recently began learning Propulsion and Cryogenic systems
 Why Test Batteries?
Batteries are used for many aerospace applications ranging from shuttle to
station projects
Many batteries are high energy and all of them are toxic to some degree
High energy batteries are often high voltage and can potentially cause a lethal
electrical shock
High temperatures can be generated during charging and discharging causing
a touching hazard
Fire is a constant danger working around batteries since many of the batteries
use an electrolyte that is flammable
A toxic atmosphere can occur during such a fire which would cause a
catastrophe in an enclosed life support system such as a spacesuit, in the
shuttle, or on station
A lleak
k in
i a zero-g atmosphere
h couldld cause blindness,
bli d death,
d h or even lead
l d to
long term problems
The manufacturers of these batteries do not test for many of the situations
NASA will routinely subject them to
 Flight Testing
Acceptance testing on hardware
before flight
Involves independent
verification from Quality
Control
Support many Shuttle and
Station projects
Laptops
aptops
Handheld PDAs
Bar code readers Astronaut Michael Fincke holding
EAPU for shuttle the PDA I tested onboard the ISS
Life Support Systems for Space
Suit
g of Station batteries
Life testing
etc
 Battery Performance
Long and Short Term
Cycling
Determine capacity of
batteries
Determine optimal
charge/discharge rates
Capacities at different
thermal environments
Vacuum tolerance
 Battery Abuse
We do everything the label
tells you not to
Overcharge / Over
discharge
Short Circuit
Thermal/Heat-to-Vent
Drop
D T
Testt
Crush Test
Vibration
Vent/Burst
 Battery Abuse
Positive Temperature
Coefficient (PTC)
Polymer expands and increases
in resistance as the temperature
or current increases
Decreases current and voltage
PTC resets when the load is
removed
Current Interrupting Device
(CID)
Aft
After 5.0V,
5 0V the
th electrolyte
l t l t
decomposes into vapor and
increases the pressure of the cell
CID fli
flips andd the
th cell
ll loses
l
electrical contact
Cannot be recovered (fail safe)
 Battery Abuse
Overcharge and Over-
discharge testing:
P
Performed
f d on th
the cell
ll andd
battery level
Many different methods:
High currents for short
periods of time
Low current for long
periods of time
Perform standardized
charge/discharge cycles Battery containment box
before and after testing
 Battery Abuse
CELL OVERCHARGE
ge (V) and Currrent (A)

5 60
CID activated

C)
4 50

Temperature ( C
o
3 Current (A) 40
Voltage (V)
2 o
Temperature ( C) 30
1 20
Voltag

T
0 10
0 2,00 0 4,000 6,000 8,000 10,000
Test Time (Sec)

CELL OVER DISCHARGE

ge (V) and Currrent (A)

70
4

C)
60

Temperature ( C
o
Reached Cut-off Point
0 50
Current (A)
Voltage (V) 40
-4 o
Temperature ( C) 30
Voltag

T
20
0 200 400 600 800 1,000 1,200 1,400
Test Time (Sec)
 Battery Pack Over Discharge
8 90
Dead Cell Temperature
80
Volltage (V) annd Current ((A)

6
Voltage
70

Temperatture ( C)
4

o
Temperature
60
2
50
0
Current 40

-2 30
Dead Cell Voltage
-4 20
0 1 2 3 4 5
Test Time (Hr)

Place 3 charged D cells in series with 1 discharged cell in your flashlight

and
d lleave it on overnight
i ht
Discharged cells will go into reversal
Standard alkaline D cells can reach 193oF (89oC)
 Battery Abuse
Short Circuit (Hard

Voltaage (V) and Cuurrent (A)

30 70
Current (A)
Short):

Temperature ( C)
Voltage (V) 60
20

o
o
Temperature ( C)
Apply different 50
resistance across 10 40
positive and negative 30

T
terminal
i l 0
20
Typically 10-50 0 5 10 15 20 25 30
mOhm Test Time (Sec)
Load maintained Current (A) 25 70
until temperature

Temperaturee ( C)
increase levels off 20 60

o
Volttage (V) and C

15 50
10 Current (A) 40
Voltage (V)
o
5 Temperature ( C) 30
0 20
0 200 400 600
Test Time (Sec)
 Battery Abuse
Thermal and Heat to Vent:
Chamber purged with nitrogen and a baseline gas sample obtained
Ch b temperature
Chamber t t increased
i d to
t 180F and d maintained
i t i d for
f 2 hours
h
Temperature is then increased until venting occurs
A contaminated gas sample is obtained
The chamber is then purged with GN2 for 12 hours
The weight before and after temperature treatments is recorded
Example of thermal test:
5 250

ure ( C)
4 200

o
Voltage
Voltagee (V)

o
Temperature ( C)
3 150

Temperatu
2 100
1 50
0 0
0 1 2 3 4 5
Test Time (Hr)
 Battery Abuse

Before Test After Test

 Battery Abuse
Drop Test:
Dropp cells 6ft onto the
concrete
Test stand is located behind a
blast wall
Door is remotely opened
Temperature is measured
before handling
Litmus paper utilized to
check for leaks
Performed pre and post
charge discharge cycles to
verify
if ffunctionality
i li
 Battery Abuse
Crush Test:
Simulates an internal short
Cause deformation without
penetration
Can measure pressure of
hydraulic cylinder and
calculate force
Monitor OCV and
temperature
 Battery Abuse
Vent/Burst Test Stand
Remove electrolyte in chemical
laboratory
Epoxy/weld fitting to battery
Apply water pressure to battery
and measure the pressure the
battery vents.
Can block vent hole and
measure the pressure the
battery bursts
 Battery Abuse
Vibration
Lots of vibration at launch
Poorly constructed battery
prone to internal short
Screen all batteries before
flight
Vibrate in the x,
x y and z axes
to a defined spectrum
Cells and batteries undergo
g
charge & discharge cycling
before and after testing
Shock
Sh k ttesting
ti isi also
l
performed
 Capabilities
Automated Battery Test Stands
12 Systems ranging from low
current/voltage to high
current/voltage
Off
Off-the-shelf
the shelf units (Arbin
(Arbin,
Maccor, PEC)
NASA constructed units
(L b i )
(Labview)
Each channel is independent
of the other
Can record voltage, current,
and temperature
Constant voltage, current, &
Power modes
 Capabilities
Battery Abuse Chambers
2" and 4" Chamber: 0.1 p
psigg to 700
psig
4" Chamber: 10-3 torr to 700 psig
All systems are equipped with a relief
valve set at 45 psig
TNRCC approved for controlled purge
of battery vents products
An Arbin 8Ch 15V 15A test stand is
connected (System 434A)
The Labview power system has 6Ch
40V 30A and the data system has 24
voltage, 4 current, and 24 temperature
measurements (System 434B)
 Capabilities
Bell Jar Vacuum Chamber
10-4
10 4 torr
16" diameter x 24" high
Pyrex
 Capabilities
Crush Test Stand
Operator protected by a blast
wall
Simulates an internal short
Cause deformation without
penetration
Can measure pressure of
hydraulic system and calculate
force
Monitor OCV and temperature
Video camera capability
 Capabilities
Drop Test Stand
Trap door operated by solenoid
valve connected to a remote
switch behind blast wall.
6" long x 7" wide trap door
Adjustable drop height of 0' to
8
8'
Video camera capability
 Capabilities
Machine Shop
Disk Sander
Drill Press
Band Saw
Grinder
Vice

Spot Welding
Can spot weld tabs onto
batteries
 Capabilities
Thermal Chambers
g g from 2ft3 to
Various chamber ranging
8ft in diameter
Many have Cryogenic capabilities
Can reach up to 500oF (260oC) in
some chambers
Precise humidity control
Unattended operation
 Capabilities
Vent/Burst Test Stand
Can apply
pp y water pressure
p to batteryy
and measure the pressure the battery
vents.
Can block vent hole and measure the
pressure the battery bursts
MAWP 2500psig
 Capabilities
Walk-in Freezer
Temperature
p g -4oF to 80oF ((-
range:
20oC to 27oC)
Usable Envelope:
40' long x 9.5' height x 8' width
8' entrance with 2 swing doors
Temperature data recording
Alarm
Fire Protection System
 Sabatier Reactor Testing
Objectives:
Advance the understanding of Sabatier reactors
Develop an innovative reactor design
Design, fabricate, and test the reactor in-house
Compare
p results from testingg to previous
p designs
g
Potential uses:
Life Support on Space Station
Convert
Con ert crew
cre exhaled
e haled CO2 and H2 (from electrolyzed
electrol ed H2O) into
CH4 and H2O
Potential reduction of H2O delivered to ISS by 2,000 lbs/yr for a
three person crew
Propellant Production
Potential Earth launch mass reduction of 20% - 45%
Convert Mars atmospheric CO2 and Earth transported H2 into CH4
(f l) andd O2 (oxidizer)
(fuel) ( idi )
O2 produced can also be used as back-up to habitat ECLSS
(Environmental Control and Life Support System)
 Sabatier Reactor Testing
Sabatier Reactor Specifications
Regeneratively cooled, single-pass, packed-bed reactor
Exothermic pressure reducing reaction
Ruthenium on alumina catalyst pellets
Power only required for initial heating of catalyst to kick start reaction
Reactor sized for In-Situ Resource Utilization (ISRU) based Mars
S
Sample
l RReturn Mi
Mission
i
Nominal Operating Conditions
Nominal Flow Rates:
H2 (g)
( ) In: 33,000
000 sccm @ 50 psia
CO2 (g) In: 750 sccm @ 50 psia
CH4(g) Out: 750 sccm @ 45 psia
H2O(g) Out: 1,500 sccm @ 45 psia
Core Temperature can reach 593 oC (1100 oF)
Optimum thermal profile includes high temperatures of inlet catalyst
(357-593 oC) and low temperatures of outlet catalyst (27-127 oC)

cat
CO2 (g) + 4H2 (g) CH4 (g) + 2H2O (g) + 180KJ
357 oC (674 oF)
 Sabatier Reactor Testing
Heater used for initial heating of
reactor. As the reaction begins, the
exothermic process supplies enough
heat to sustain the reactor.

Catalyst
Countercurrent-flow design cools
bottom of bed while pre-heating
reactants
Inlet

Possible Future
Temperature
Sensors
Outlet Inlet

Multi-point
Thermocouple
 Catalyst

Multi-point
Thermocouple
p

Porous metal
Heater
plug
 Outlet Heater

Possible Possible
Temperature Temperature
Sensor Sensor

Inlet Inlet

Multi-point
Thermocouple
p
 45 psig F-200 HV-202 FC-204
H2 T-218
Sabatier
Reactor
HTR-238 Nitrogen RV-1500 MV-1501 Vacuum 1/2 by .035
SBR-236
PT-206 T-210 60 psig Generator Vent
E 1502
E-1502
45 psig F-1600 HV-1602 FC-1604
CO2 HV-212 DP-214

Multi-Point TC CV-300 HV-314

MT-220
MT-222
RV on inlet MT-224
System set to MT-226
55 psig MT-228
MT-230 T-302 PT-304 RV-208 HV-306 Desiccant Bed FM-310 BPR-312
MT-232 DRY-308
MT-234

DP-802 TANK
TK-800

HV-316
T-804

ASTM A-269 by .035

HV-806

HV-216

Drain RGA
MWAP 400 psia
y
PPD & RV System
Jacob Collins
Jacob Collins
Martin McClean
Scott Burge
 Vacuum Generator

Sabatier Reactor

Metering Valve Pressure

Transducer

Relief Valves To Vent

Pressure
Nitrogen
Gauge/Transducer
Feed

To RGA
Reactant Flow
Feeds Meter

Desiccant Bed

Sabatier Reactor
System
 Conclusion
My background is similar to yours
JSC Engineering Organization
Potential for chemical engineering at NASA
Whyy we test batteries
Types of Tests
Performed on a variety of Battery chemistries (li-ion,
NiMh Alk
NiMh, Alkaline,
li Pb-acid,
Pb id etc))
Flight
Performance
Safety and Abuse
Capabilities
Other relevant Chemical Engineering Testing in
Aerospace field