System and method for co-production of a densified liquid oxygen product and densified liquid methane product
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Solution Overview
Problem
Current propellant and oxidant densification processes for space vehicle launches are inefficient, requiring large volumes of liquid nitrogen for cooling, which increases logistics burdens and costs, and there is a need to reduce the transport of liquid oxygen to launch facilities while improving the supply of liquid propellants and oxidants.
Innovation Solution
A system for co-production of densified liquid oxygen and liquid methane using a multi-stage refrigeration process involving nitrogen and mixed refrigerants like helium and neon, which reduces the need for liquid nitrogen transport by achieving higher densities through subcooling and liquefaction, allowing for more efficient storage and use of propellants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If liquid nitrogen is used for densification cooling, then the densification function is achieved, but the logistics burden and cost increase due to requiring more trailers of liquid nitrogen
Solution Approach 1:
The system uses the liquid oxygen itself as the refrigerant to densify itself and also to densify liquid methane, eliminating the need for external liquid nitrogen supply. The liquid oxygen is cooled to sub-ambient temperatures and used as a refrigerant in a heat exchanger, where it absorbs heat from the liquid methane, densifying both substances without requiring additional cryogenic refrigerant deliveries.
Solution Approach 2:
The liquid oxygen serves multiple functions: it is both the product being densified for rocket propulsion and the refrigerant used to densify the liquid methane. This multi-functionality eliminates the need for separate liquid nitrogen deliveries specifically for cooling purposes, reducing overall logistics burden.
2Quantity of substance
If cryogenic refrigeration systems are used for propellant densification, then the density of liquid propellant increases, but the operational and capital cost increases
Solution Approach 1:
The system eliminates the need for separate external refrigerant deliveries by using the liquid oxygen itself as the cooling medium. This self-service approach reduces operational costs associated with purchasing and transporting liquid nitrogen while achieving the desired densification of both liquid oxygen and liquid methane.
Solution Approach 2:
Instead of discarding the cooling function to external liquid nitrogen deliveries, the system recovers and utilizes the cold temperature of the liquid oxygen itself as a resource for cooling and densifying the liquid methane, thereby eliminating the need for separate refrigerant supplies.
3Quantity of substance
If liquid oxygen is trucked to the launch facility for densification, then the supply of liquid oxygen is ensured, but the time to achieve desired temperatures increases
Solution Approach 1:
The system performs preliminary cooling of the liquid oxygen to sub-ambient temperatures before it is used as the refrigerant. This pre-cooled liquid oxygen then rapidly cools and densifies the liquid methane in the heat exchanger, reducing the overall time required to achieve the desired temperatures for both substances compared to delivering warm liquid oxygen that would need to be cooled on-site.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves a 10-14% increase in density for liquid oxygen and 4-7% increase for liquid methane, reducing the volume and weight of storage tanks, thereby minimizing logistical burdens and costs, and enabling more efficient rocket fuel supply.
Implementation Method 1
flow the first refrigerant through a first primary heat exchanger to cool the gaseous oxygen stream
Implementation Method 2
subcool and liquefy the cooled gaseous oxygen stream via indirect heat exchange with a residual portion the first refrigerant
Implementation Method 3
flow a second refrigerant through the second heat exchanger to subcool the liquid oxygen stream and yield a densified, liquid oxygen stream
Implementation Method 4
densify a stream of liquid methane via indirect heat exchange with a diverted portion of the first refrigerant stream
Data Source
AI summary
A system and method for the co-production of a densified, liquid oxidant and a densified liquid methane fuel to a space vehicle launch facility is provided. In one embodiment, a low pressure gaseous oxygen stream is piped from a nearby air separation unit to the space vehicle launch facility where it is then liquefied and densified in a two-stage, integrated liquefaction/densification system that also densifies a source of liquid methane. In an alternate embodiment, a liquid oxygen stream produced at an air separation unit is densified in a two-stage, integrated densification system configured to densify both the liquid oxygen as well a source of liquid methane at or near the air separation unit with the resulting densified liquid products transported via truck/trailer to a nearby space vehicle launch facility.