Brian J. Motil

Hydrodynamics of Packed Bed Reactor in Low Gravity

Abstract Packed bed reactors are well known for their vast and diverse applications in the chemical industry; from gas absorption, to stripping, to catalytic conversion. Use of this type of reactor in terrestrial applications has been rather extensive because of its simplicity and relative ease of operation. Developing similar reactors for use in microgravity is critical to many space-based advanced life support systems. However, the hydrodynamics of two-phase flow packed bed reactors in this new environment and the effects of one physiochemical process on another has not been adequately assessed. Surface tension or capillary forces play a much greater role which results in a shifting in flow regime transitions and pressure drop. Results from low gravity experiments related to flow regimes and two-phase pressure drop models are presented in this paper along with a description of plans for a flight experiment on the International Space Station (ISS). Understanding the packed bed hydrodynamics and its effects on mass transfer processes in microgravity is crucial for the design of packed bed chemical or biological reactors to be used for water reclamation and other life support processes involving water purification.

NASA'S MICROGRAVITY FLUID PHYSICS STRATEGIC RESEARCH ROADMAP

The Microgravity Fluid Physics Program at NASA has developed a substantial investigator base engaging a broad cross-section of the US scientific community. As a result, it enjoys a rich history of many significant scientific achievements. The research supported by the program has produced many important findings that have been published in prestigious journals such as Science, Nature, Journal of Fluid Mechanics, Physics of Fluids, and many others. The focus of the program so far has primarily been on fundamental scientific studies. However, a recent shift in emphasis at NASA to develop advanced technologies to enable future exploration of space has provided motivation to add a strategic research component to the program. This has set into motion a year of intense planning within NASA including three workshops to solicit inputs from the external scientific community. The planning activities and the workshops have resulted in a prioritized list of strategic research issues along with a corresponding detailed roadmap specific to fluid physics. The results of these activities were provided to NASA’s Office of Biological and Physical Research (OBPR) to support the development of the Enterprise Strategy document. 1 This paper summarizes these results while showing how the planned research supports NASA’s overall vision through OBPR’s organizing questions.

Two-Phase Flow in Packed Columns and Generation of Bubbly Suspensions for Chemical Processing in Space

ABSTRACT For long-duration space missions, the life support and In-Situ Resource Utilization (ISRU) systems necessary to lower the mass and volume of consumables carried from Earth will require more sophisticated chemical processing technologies involving gas-liquid two-phase flows. This paper discusses some preliminary two-phase flow work in packed columns and generation of bubbly suspensions, two types of flow systems that can exist in a number of chemical processing devices. The experimental hardware for a co-current flow packed column operated in two ground-based low gravity facilities (two-second drop tower and KC-135 low-gravity aircraft) is described. The preliminary results of this experimental work are discussed. The flow regimes observed and the conditions under which these flow regimes occur are compared with the available co-current packed column experimental work performed in normal gravity. For bubbly suspensions, the experimental hardware for generation of uniformly sized bubbles in Couette flow in microgravity conditions is described. Experimental work was performed on a number of bubbler designs, and the capillary bubble tube was found to produce the most consistent size bubbles. Low air flow rates and low Couette flow produce consistent 2-3 mm bubbles, the size of interest for the “Behavior of Rapidly Sheared Bubbly Suspension” flight experiment. Finally the mass transfer implications of these two-phase flows is qualitatively discussed.

Key Gaps for Enabling Plant Growth in Future Missions

Growing plants to provide food or psychological benefits to crewmembers is a common vision for the future of human spaceflight, often represented in media and in serious concept studies. The complexity of controlled environment agriculture, and plant growth in microgravity have and continue to be the subject of dedicated scientific research. However, actually implementing these systems in a way that will be cost effective, efficient, and sustainable for future space missions is a complex, multi-disciplinary problem. Key questions exist in many areas: human medical research in nutrition and psychology, horticulture, plant physiology and microbiology, multi-phase microgravity fluid physics, hardware design and technology development, and system design, operations and mission planning. This paper describes key knowledge gaps identified by a multi-disciplinary working group within the National Aeronautics and Space Administration (NASA). It also begins to identify solutions to the simpler questions identified by the group based on work initiated in 2017. Growing plants to provide food or psychological benefits to crewmembers is a common vision for the future of human spaceflight, often represented in media and in serious concept studies. The complexity of controlled environment agriculture, and plant growth in microgravity have and continue to be the subject of dedicated scientific research. However, actually implementing these systems in a way that will be cost effective, efficient, and sustainable for future space missions is a complex, multi-disciplinary problem. Key questions exist in many areas: human medical research in nutrition and psychology, horticulture, plant physiology and microbiology, multi-phase microgravity fluid physics, hardware design and technology development, and system design, operations and mission planning. This paper describes key knowledge gaps identified by a multi-disciplinary working group within the National Aeronautics and Space Administration (NASA). It also begins to identify solutions to the simpler questions identified by the group based on work initiated in 2017.

Investigation of Multiphase Flow in a Packed Bed Reactor Under Microgravity Conditions

In this paper we study the two-phase flow phenomena in a packed bed reactor using an integrated experimental and numerical method. The cylindrical bed is filled with uniformly sized spheres. In the experiment water and air are injected into the bed simultaneously. The pressure distribution along the bed will be measured. The numerical simulation is based on a two-phase flow solver which solves the Navier-Stokes equations on Cartesian grids. A novel coupled level set and moment of fluid method is used to construct the interface. A sequential method is used to position spheres in the cylinder. Preliminary experimental results showed that the tested flow rates resulted in pulse flow. The numerical simulation revealed that air bubbles could merge into larger bubbles and also could break up into smaller bubbles to pass through the pores in the bed. Preliminary results showed that flow passed through regions where the porosity is high. Comparison between the experimental and numerical results in terms of pressure distributions at different flow injection rates will be conducted. Comparison of flow phenomena under terrestrial gravity and microgravity will be made.

Development of the Packed Bed Reactor ISS Flight Experiment

Packed bed reactors are compact, require minimum power and maintenance to operate, and are highly reliable. These features make this technology a leading candidate as a potential unit operation in support of long duration human space exploration. On earth, this type of reactor accounts for approximately 80% of all the reactors used in the chemical process industry today. Development of this technology for space exploration is truly crosscutting with many other potential applications (e.g., in-situ chemical processing of planetary materials and transport of nutrients through soil). NASA is developing an ISS experiment to address this technology with particular focus on water reclamation and air revitalization. Earlier research and development efforts funded by NASA have resulted in two hydrodynamic models which require validation with appropriate instrumentation in an extended microgravity environment. The first model developed by Motil et al., (2003) is based on a modified Ergun equation. This model was demonstrated at moderate gas and liquid flow rates, but extension to the lower flow rates expected in many advanced life support systems must be validated. The other model, developed by Guo et al., (2004) is based on Darcy s (1856) law for two-phase flow. This model has been validated for a narrow range of flow parameters indirectly (without full instrumentation) and included test points where the flow was not fully developed. The flight experiment presented will be designed with removable test sections to test the hydrodynamic models. The experiment will provide flexibility to test additional beds with different types of packing in the future. One initial test bed is based on the VRA (Volatile Removal Assembly), a packed bed reactor currently on ISS whose behavior in micro-gravity is not fully understood. Improving the performance of this system through an accurate model will increase our ability to purify water in the space environment.

On Flow Stagnation in a Tube Radiator

An analysis of the physical process for occurrence of flow stagnation in a space tube-radiator is performed and the mechanism and mathematic description for the flow stagnation are presented. Two causes for pressure drop unbalance between tubes of the radiator are identified: non-uniform cooling environment and different local flow resistances between the tubes. This analysis provides a theoretical basis for experimental simulations of the flow stagnation in a ground-based lab as well as two suggested methods to experimentally simulate flow stagnation. Criteria for the flow stagnation, depending on the viscosity data regressive polynomial, are derived from the extreme condition of the pressure drop in colder tubes. A preliminary numerical calculation is conducted for a space tube-radiator model which confirms the physical and mathematical analyses. The prediction by the criteria for flow stagnation in the tube-radiator model coincides with the numerical calculation result.

Formation and Growth of Micro and Macro Bubbles on Copper-Graphite Composite Surfaces

Micro scale boiling behavior in the vicinity of graphite micro-fiber tips on the coppergraphite composite boiling surfaces is investigated. It is discovered that a large number of micro bubbles are formed first at the micro scratches and cavities on the copper matrix in pool boiling. In virtue of the non-wetting property of graphite, once the growing micro bubbles touch the graphite tips, the micro bubbles are sucked by the tips and merged into larger micro bubbles sitting on the tips. The micro bubbles grow rapidly and coalesce to form macro bubbles, each of which sitting on several tips. The growth processes of the micro and macro bubbles are analyzed and formulated followed by an analysis of bubble departure on the composite surfaces. Based on these analyses, the enhancement mechanism of the pool boiling heat transfer on the composite surfaces is clearly revealed. Experimental results of pool boiling heat transfer both for water and Freon-113 on the composite surfaces convincingly demonstrate the enhancement effects of the unique structure of Cu-Gr composite surfaces on boiling heat transfer.

Measurement of the Shear Lift Force on a Bubble in a Channel Flow

Two-phase flow systems play vital roles in the design of some current and anticipated space applications of two-phase systems which include: thermal management systems, transfer line flow in cryogenic storage, space nuclear power facilities, design and operation of thermal bus, life support systems, propulsion systems, In Situ Resource Utilization (ISRU), and space processes for pharmaceutical applications. The design of two-phase flow systems for space applications requires a clear knowledge of the behaviors of the dispersed phase (bubble), its interaction with the continuous phase (liquid) and its effect on heat and mass transfer processes, The need to understand the bubble generation process arises from the fact that for all space applications, the size and distribution of bubbles are extremely crucial for heat and mass transfer control. One important force in two-phase flow systems is the lift force on a bubble or particle in a liquid shear flow. The shear lift is usually overwhelmed by buoyancy in normal gravity, but it becomes an important force in reduced gravity. Since the liquid flow is usually sheared because of the confining wall, the trajectories of bubbles and particles injected into the liquid flow are affected by the shear lift in reduced gravity. A series of experiments are performed to investigate the lift force on a bubble in a liquid shear flow and its effect on the detachment of a bubble from a wall under low gravity conditions. Experiments are executed in a Poiseuille flow in a channel. An air-water system is used in these experiments that are performed in the 2.2 second drop tower. A bubble is injected into the shear flow from a small injector and the shear lift is measured while the bubble is held stationary relative to the fluid. The trajectory of the bubble prior, during and after its detachment from the injector is investigated. The measured shear lift force is calculated from the trajectory of the bubble at the detachment point. These values for the shear lift are then compared with the theoretical predictions from various published works on shear lift in the open literature, which include asymptotic solutions at low bubble Reynolds number, potential flow predictions and numerical studies that deal with intermediate bubble Reynolds numbers.

Gravity gas and liquid flows - Simple data for complex problems

While there have been many studies for two-phase flow through straight cylindrical tubes, more recently, a new group of studies have emerged that examine two-phase flow through non-straight, non-cylindrical geometries, including expansions, contractions, tees, packed beds and cyclonic separation devices. Although these studies are still, relatively speaking, in their infancy, they have provided valuable information regarding the importance of the flow momentum, and the existence of liquid dryout due to sharp comers in microgravity.