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A Carbon Dioxide Reduction Unit Using Bosch Reaction and Expendablecatalyst Cartridges

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A Carbon Dioxide Reduction Unit Using Bosch Reaction and Expendablecatalyst Cartridges NASACONTRACTOR REPORT N 00 *o P I i er 1 U A CARBON DIOXIDE REDUCTION UNIT USING BOSCH REACTION AND EXPENDABLECATALYST CARTRIDGES by R. F. Holmes, E. E. Keller, dad C. D. Kilzg Prepared by CONVAIRDIVISION OF GENERAL DYNAMICSCORPORATION San Diego, Calif. 92112 for LangleyResearch Center NATIONALAERONAUTICS AND SPACE ADMINISTRATION WASHINGTON,D. C. NOVEMBER 1970 1. Report No. 2. Government Accession No. 3. Recipient'sCatalog No. NASA CR-1682 4. Title and Subtitle 5. Report Date A CARBON DIOXIDE REDUCTION UNIT USING BOSCH November 1970 REACTION AND EXPENDABLE CATALYST CARTRIDGES 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. I R. F. Holmes, E. E. Keller, and C. D. King 10. Work Unit No. 9. Performing Organization Name and Address I Convair Division of General Dynamics Corporation 11. Contract or Grant No. San Diego, Calif. NAS 1-8217 13. Type of Report and Period Covered 12. Sponsoring AgencyName and Address Contractor Report National Aeronautics and Space Administration I 14. Sponsoring AgencyCode Washington,D.C. 20546 15. Supplementary Notes 16. Abstract The feasibility of producing an efficient and reliable flight-qualified carbon dioxide reduction unit for use in life support systems for long-duration space missions has been demonstrated. A prototype reduction unit utilizing the Bosch catalytic reaction and expendable catalyst cartridges was developed for theNational Aeronautics and Space Administration, Langley Research Center. The unit has two reactors with replaceable catalyst cartridges, each reactor having process capacity for continuous reduction of the carbon dioxide which would be produced metabolically by a four-man crew. Reaction was easily alternated between the two reactors allowing cartridge replacement without process interruption. Reaction within the catalyst cartridge was readily initiated and maintained. No carbon migrated from the cartridge or was formedby reactions outside of the cartridge. Cartridge life was approximately three days and replacement was a simple and clean operation. 17. Key Words(Suggested byAuthor(s)) 18. Distribution Statement I -~~Op-edudion-~- ~- I wchreaction .- - Unclassified - Unlimited 1. Oxygen- I55 & Life support 19. Security Classif. (ofthis report) - u 20. Security Classif. (of this page) 21. No. of Pages 22.Price' U nclassified Unclassified Unclassified 67 $3.00 For sale by the National Technical InformationService,Springfield, Virginia 22151 Foreword The Bosch process recovers oxygenfrom metabolically produced C02 and precipitatesout the carbon, Previous programs for develop- ment of this process attempted to produce a continuously operating reactor with the carbon being removed while the unit was in operation. Problems were experienced in clogging of the carbon and precipitation of carbon on surfaceswhere it was notdesired, The presentprogram was therefore oriented toward elimination of thecarbon removal problem by using a removable cartridge in which the carbon was precipitated. The cartridge is replaced when it is full by providing two cartridgesin the system. Replacement can be accomplishedwithout interruption of the process. Optimization of weight volume or power were not objectives of this program. Additionaleffort is thereforerequired to determine an optimum design and a trade off with a continuouscarbon removal system to determine the optimum systemshould be made. The technicalmonitor of this program forthe Langley Research Center was Lenwood G. Clark.Funding for this effort was provided by theBiotechnology and Human ResearchDivision, NASA Office of Advanced Research and Technology,Washington, D.C. Lenwood G. Clark Aerospace Technologist LifeSupport Branch iii TABLE OF CONTENTS Page No . SUMMARY .................... 1 1.0 INTRODUCTION .................. 2 2.0 OBJECTIVES ................... 3 3.0 APPROACH .................... 4 3.1 Development ................. 4 3.2Demonstration ................. 4 3.2.1 Prototype Unit Specifications ......... 4 3.2.2 Prototype Unit Performance Requirement . 5 4.0 TECHNICALDISCUSSION ............... 6 4.1 ProcessFactors ................ 7 4.2 Materials .................. 7 4.2.1Catalyst ................ 7 4.2.2Carbon Containment Material ......... 7 4.2.3 CartridgeShell .............. 8 4.2.4 ReactorShell and Heat Exchanger ........ 8 5.0 DEVELOPMENT5.0 PROGRAM .............. 9 5.1 Development Reactor and Heat Exchanger ........ 9 5.1.1 ReactorShell Configuration ......... 9 5.1.2 CatalystCartridge Configuration ........ 9 5.1.3 ReactorSeals .............. 12 5.1.4 HeatExchanger ............. 12 5.1.5 ThermalInsulation ............ 12 5.2 Development Unit Controls ............ 12 5.2.1 TemperatureControls ........... 13 5.2.2 Mixture Controls ............. 13 5.2.3 ProcessRate Control ............ 15 5.2.4 Leakage RateDetermination ......... 15 5.3%Development Unit Fabrication ............ 15 5.3.1 ProtectivePlating ............. 15 5.3.2 CatalystPacking ............. 16 5.3.3Sectional Assembly ............ 16 5.4 Development Unit Performance ........... 17 5.4.1 Gas Mixture Composition .......... 17 5.4.2 Recycle Flow Rate ............ 17 5.4.3 CartridgePressure Drop .......... 18 5.4.4 ProcessTemperatures ........... 18 V . TABLE OF CONTENTS. Contd Page No . 5.5 Materials Evaluation ............. 22 5.5.1 EvaluationTechniques .......... 22 5.5.2 Evaluation Results ............ 22 6.0 PROTOTYPE DESIGN CRITERIA .......... 27 6.1Process Parameters ........... 27 6.2 ThermalAnalysis ............. 27 6.2.1 Heat Exchanger Temperatures and Design Load . 27 6.2.2 Condenser Temperatures and Heat Dissipation . 30 6.2.3 Heat of Reaction ........... 30 6.2.4 Compressor Heat Input ........ 30 6.2.5 ReactorInsulation Heat Loss . 30 6.2.6 Reactor Heater ............ 30 6.3Prototype Component Sizing . 30 6.3.1 Reactor Shell ............. 30 6.3.2 Cartridge .............. 31 6.3.3 Insulation ............. 32 6.3.4 Heater ............... 32 6.3.5 Heat Exchanger ............ 32 6.3.6 Condenser and Separator Assembly . 32 6.3.7 Compressor . 33 6.3.8 Gages.Valves. Fittings. and Connective Plumbing .............. 33 6.4 PrototypeControls ............ 33 6.4.1 TemperatureControl .......... 33 6.4.2 Pressure Control .......... 35 6.4.3 ProcessRate Control ......... 35 6.4.4 Recycle Gas MixtureControl ....... 35 6.4.5 LeakageControl ........... 35 6.4.6 Cartridge Exchange ProcedureControls . 35 6.5 Prototype Materials Criteria ......... 37 7.0 PROTOTYPE DESIGN AND FABRJCATION ........ 39 7.1 MaterialSelections .............. 39 7.1.1 Low-Temperature Components ....... 39 7.1.2 Insulation .............. 39 7.1.3 Catalyst ............... 39 7.1.4 Reactor and Heat Exchanger ........ 39 7.2 Configuration ................ 40 7.3 Fabrication ................. 43 vi TABLE OF CONTENTS. Contd Page No . 8.0 PROTOTYPEPERFORMANCE ............ 48 8.1 ProcessRate Control ............. 48 8.1.1 ReactorTemperature .......... 48 8.1.2 RecycleFlow Rate ........... 49 8.1.3 Recycle Gas Composition ......... 49 8.2 CarbonContainment and External Growth Prevention ... 50 8.3 Feed Gas Impurities .............. 50 8.4 Repairs .................. 52 8.5 Proof Pressure ............... 52 8.6 Automatic Heater Shut-Off ........... 52 8.7 EquivalentLeakage Rate ............ 53 8.8 PrototypeCartridge Pressure Differential ...... 54 8.9 ReactorStarting and Changeover Characteristics .... 56 8.9.1 Characteristics Without Catalyst Pretreatment ............. 56 8.9.2 Characteristics With CatalystPretreatment ... 56 8.10 Power Consumption ............. 58 9.0 CONCLUDINGREMARKS .............. 59 LIST OF TABLES Table Page No . 5.1 Gas Constants .................. 22 5.2 Development Reactor Component Materials ........ 23 5.3 Materialsthe Evaluated in Development Reactors ...... 24 6.1 PrototypeReduction Unit Design Parameters ........ 28 6.2 PrototypeDesign ProcessRates ............ 28 8.1 ReactorStarting Characteristics ............ 57 Vii -" . .... I LIST OF FIGURES Figure Page No. 4.1 Bosch Process Flow Diagram 6 5.1 Development Reactor Sketch ............ 10 5.2 Final Development Unit Cartridge Configuration ..... 11 5.3 Initial Development Unit Configuration ........ 13 5.4 Development Reduction Unit Flow Diagram ....... 14 5.5 Component Gas Viscosities ............ 18 5.6 Component Gas Specific Heats ........... 19 5.7 Component Gas Thermal Conductivities ........ 20 5.8 Development Cartridge Pressure Differential Versus CarbonDensity ................ 21 6.1 ProcessParameters for PrototypeDesign . 29 6.2 Prototype Reduction Unit Flow Diagram ........ 34 6.3 Prototype Unit LeakageRate Curve .......... 36 7.1 PrototypeReactor Assembly ............ 41 7.2 PrototypeCartridge Components .......... 42 7.3 Catalyst-PackedCartridge ............ 42 7.4 Cartridge Ready forInstallation .......... 43 7.5 Reactor and Heat Exchanger Assembly ......... 44 7.6 Sketch of InsulationArrangement .......... 45 7.7 Prototype Reduction Unit Assembly ......... 46 8.1 C02 Processed Versus Time for the 120-hour PerformanceDemonstration Test .......... 49 8.2 PerformanceDemonstration Test Cartridges ...... 50 8.3 Cartridge P-6 Showing Carbon Block ......... 51 8.4 PrototypeReactors After PerformanceDemonstration ... 51 8.5 Prototype Cartridge Pressure Differential Versus CarbonDensity ................. 55 8.6 Catalyst Conditions After PretreatmentTests ...... 58 viii A CARBON DIOXIDE REDUCTION UNIT USING BOSCH REACTION AND EXPENDABLE CATALYST CARTRIDGES By R. F. Holmes, E. E. Keller, and C. D. King Convair division of General Dynamics SUMMARY A prototype carbon dioxide
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