Air Launch Aerospace International Project

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27TH INTERNATIONAL CONGRESS OF THE AERONAUTICAL SCIENCES

AIR LAUNCH AEROSPACE INTERNATIONAL PROJECT

A. Karpov, R. Ivanov, M. Kovalevsky, Air Launch Aerospace Corporation, Russia

Keywords: launch vehicle (LV), carrier aircraft (CA), satellite, spaceport, space

Abstract The present paper provides some results of the commercial Air Launch Project, which is A concept of the Air Launch International a joint effort of the Russian, Ukrainian, Aerospace Project is described hereunder. The Indonesian and Germany aeronautical and Project goal is to develop the LV available at rocket-and-space companies, implemented at the world launch market to put lightweight the initiative of the Russian Air Launch satellites in space. The Project is based on the Aerospace Corporation for the purpose to idea of air launch from the serial cargo develop a new air launch system with improved An-124-100 Ruslan modified into heavy CA. The performance characteristics. This system Air Launch spaceport is under development on ensures launches of lightweight satellites to low the equator to enable satellite (Spacecraft – SC) orbits (LEO) (up to 2,000 km), medium orbits launches into any near-earth orbits including (MEO) (10,000-20,000 km), GTO, GEO, as geotransfer (GTO) and geostationary (GEO) well as translunar and interplanetary escape orbits, as well as translunar and interplanetary trajectories, using a 100-ton LV. escape trajectories. Environmentally friendly

Russian space launch vehicle (SLV) technologies, proven and tested to high 2 Air Launch Project Concept reliability under piloted and lunar programs are The Project stipulates ejection of the LV with used for the Project. Aeronautical and rocket- the LV-based satellites at an altitude of 10 to and-space companies from Russia, Ukraine, 11 km from the modified serial cargo Аn-124- Indonesia and Germany participate in the Air 100 Ruslan, the heaviest aircraft in the world, Launch Project development. used as a flying launch pad. To provide favourable conditions for the 1 Introduction LV ejection and initial phase of the LV flight, High cost of launch vehicles comparable to the the CA performs a special pull-up maneuver to cost of satellites is an essential boundary for parabolic trajectory, which ensures near-zero many countries of the world that restricts their gravity conditions within 6-10 seconds, while use of space for the purpose to launch their own the LV normal load factor does not exceed 0.1 communication and telecommunication, remote to 0.3 points. It enables to increase the LV sensing and scientific research satellites, as well ejected mass into 2 to 2.5 times compared to the as to meet other challenges for economic usual level flight ejection and accordingly development. increase its payload capability. At the moment Therefore countries with their own space when the CA reaches maximum flight path launch vehicle technologies have long angle during pull-up maneuver (pitch-up angle contributed to the improvement of launch of appr. 20 degrees), the LV is ejected from the vehicles: reduced their costs, increased payload CA, using a special transporting and launching capability, extended application areas, improved container (TLC) with a pneumatic ejection unit launch operationability, as well as launch safety. (with hot-gas pressurized accumulator).

1 A. KARPOV, R. IVANOV, M. KOVALEVSKY

The ejection process time does not exceed equipped with the upper stage booster (USB), 3 seconds, while longitudinal load factor does which is an advanced modification of Molnya not exceed 1.5 points. LV “L” USB. For the development of the Air Launch Russian space launch technologies used in two-stage Polyot LV (Figure 1) advanced space the Project ensure the Air Launch minimal launch vehicle technologies are used, designed development costs and terms, as well as its best in Russia on the basis of the modified Soyuz performance characteristics. LV, which proved high reliability and safety. To reach the LV maximum payload capability

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SLV Main Characteristics

Lift-off weight, tons: up to 102 Payload capability, tons Baseline orbit Н =200 km i=90 degr. appr. 3.0 i= 0 degr. appr.4.0

HEO and GTO up to 1.77 0

0 GEO up to 0.8

6 5 3 Propellant components LOX+Kerosene SLV Propulsion unit characteristics 1st Stage

Engine type NK-43M

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1 Thrust vacuum, ton-force 211.7 4 2 Specific impulse vacuum, sec 346 2nd Stage Engine type RD0124 Thrust vacuum, ton-force 30 Specific impulse vacuum, sec 359 USB Engine type RD0158 Thrust vacuum, ton-force 5.0 Specific impulse vacuum, sec 370 Dimensions (length × diameter), m SLV 35.60 × 2.70 LV 24.15 × 2.66 Payload envelope w/o USB 10.00 × 2.40 with USB 6.20 × 2.40 LV reliability 0.99 Commencement of operation 2013-2014 Ф2066

Fig. 1. Polyot Launch Vehicle

For the fist stage of Polyot LV modified to GTO and GEO, spaceport for the Air liquid propellant engine NК-43 (NК-33-1) is Launch System is constructed on the used, designed for the lunar N-1 LV and proved equatorial island of Biak (Figure 2), Indonesia to 0.998 degree of reliability, while for the on the basis of Frans Kaisiepo Airfield second stage - the third stage of Soyuz-2 LV (Figures 3, 4) with the required CA, LV, with advanced RD-0124 liquid propellant USB and satellite operations facilities and engine. Polyot LV utilizes pollution-free systems, as well as prelaunch operations and propellant components (liquid oxygen + launch control facilities, including Mission kerosene). Control Center. For the purpose to put satellites in different high orbits and escape trajectories, the LV is

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BIAK (WABB) Frans Kaisiepo International Airport (01011′30.52″ S 136006′35.52″E) Biak IslandIsland

I R I A N J A Y A

Biak Island

PAPUA NEW GUINEA

Fig. 2. Frans Kaisiepo Launch Airfield (Biak Island, Indonesia)

Fig. 3. General View of Frans Kaisiepo Airfield on the Biak Island

3 A. KARPOV, R. IVANOV, M. KOVALEVSKY

Access road on North side 1. CA Maintenance Area (first stage) of the airport 2. CA Maintenance Area (second stage) 3. CA Maintenance and Checkout Facility Residents 4. SV – S/C Maintenance and Checkout Facility. Second Mission Control Center 5. SLV Maintenance and Checkout Facility 6. Parking Site 7. Compressed Gasses Production and Storage System 8. Fire-Protection Water Storage 9. Oxygen-Nitrogen Plant 10. SLV Fuelling Complex

____ First Stage Facilities --- Second Stage Facilities

Dimensions of facilities are given Offices in meters

Ground Preparation Facilities of the Air Launch STS Sea Port Runway Airport Fence

Fig. 4. Air Launch System Spaceport

3 Air Launch System Operation Concept the CA flight to the selected launch area, execution of the preflight pull-up Figure 5 presents the Air Launch System maneuver, the LV ejection from the CA, operation stages, which start with loading of the followed by the LV first and second stages LV with USB, placed within TLC and subjected ignition and USB flight, as well as satellite to a complete testing cycle, into the CA cargo release on a baseline orbit will be performed. compartment at Bezymyanka Airfield, located At the present time a possibility to in Samara (Russia) near the Progress develop the Payload Pre-Integration Center in manufacturing plant. Germany at Munich Airfield is studied. In this After the delivery of the LV and USB to case satellites will be prepared at the Pre- the spaceport in Indonesia, integration of the LV Integration Center and assembled with the LV, with the satellite, which has been preliminary after it has been delivered from Russia to delivered to the spaceport and passed the Germany by the CA. After checkout and tests of required preflight tests, will be performed, as the assembled launch system, a number of well as installation of necessary components operations for placing the satellite into intended and propellants loading. The satellite may be orbit will be executed, such as flight to the mounted on the LV at the Maintenance and spaceport on the Biak Island, prelaunch Checkout Facility, built at the spaceport, or operations and processing, flight to the launch directly inside the CA. area, etc. After completion of the launch system assembly, its preflight tests and filling of the CA, LV, USB with propellants and gases,

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Baseline-to- 1st Stage operational orbit 1stand Stage fairing spacecraft transfer separation, by the USB and2nd fairing Stage separation,ignition USB with SC 2nd Stage release on a baseline orbit ignition

1st Stage ignition

SLV ejection in the SLV flight launch area monitoring

CA flight to Flight to the SLV the post-launch launch area landing airfield SLV (w/o SC) delivery from the manufacturer to the Launch Airfield

SLV processing at the CA arrival at the post- Launch Airfield. CA flight launch landing airfield, to the launch area and flight to Russia

Fig. 5. Air Launch System Operation

4 Flight Route fuelled LV and satellite, total weight of which is appr. 100 tons to the launch area, located at a The Air Launch Flight Route (Figure 6) distance of up to 4,500 … 5,000 km from the ensures launches into near-earth orbits with Biak spaceport. At this the launch area for the any inclination, using the CA flight with specified flight will be selected depending on

60° 40° 20° West 0° East 20° 40° 60° 80° 100 120 140° 160° East 180° West1160° 140° 120° 100° 80° 60° SLV transportation from the Base Airfield (Samara, RF) to the Launch Airfield (Biak). 80° Intermediate flight stop for the Carrier Aircraft refueling at Vladivostok (RF). 80° Flight range 12,185 km Base Airfield: Samara (UWWG), RF 60° 60° SamaraSamara VladivostoVladivostok 40° 40°

20° SLV launch area: φ=0°; λ=136...139° East 20° Inclination range: i= 0...30° Launch airfield: Biak (WABB), Indonesia 0° 0°

SLV launch area: φ=11...12° South; λ=110...122° East 20° Inclination range: i=80...115° 20°

40° SLV launch area: 40° φ = 6...10° South; λ=148...151° East Inclination range: i=30...80°

60° 60°

60° 40° 20° West 0° East 20° 40° 60° 80° 100° 120° 140° 160° East 180° West1160° 140° 120° 100° 80° 60° Fig. 6. Air Launch Flight Route

5 A. KARPOV, R. IVANOV, M. KOVALEVSKY

the calculated orbit inclination, location of flight It indicates that Polyot LV is capable to launch route and impact areas for the detachable LV satellites of up to 3.5 tons in mass to low polar components over the ocean with limited orbits, up to 4.5 tons - to low equatorial orbits, navigation, as well as the necessity to land the up to 0.85 ton - to Glonass and Galileo-type CA at the nearest airfields, capable to land navigation systems orbits, up to 0.8 ton - Аn-124-100 Ruslan aircraft, after the LV has to GEO. Provided satellites are equipped been launched. with apogee propellant engine, which ensures Figure hereunder shows three launch transfer of a satellite from GTO to GEO, areas as an example, located at a distance of it will allow Polyot LV to put satellites 150 to 2,500 km from the Biak of up to 1 ton in GEO. The Air Launch System Airfield for launches from equatorial orbits will ensure launches of 1 to 1.2 tons spacecrafts to orbits with inclinations of 115 degrees and to translunar orbits and escape trajectories. more. The Air Launch System demonstrates The Air Launch applicable range of orbit such payload capabilities owning to the air inclinations ensures insertion of all types of launch of the LV at an altitude of 10 to 11 km. lightweight satellites available at the world Figure 8 presents benefits of the LV air launch market within the range of their payload launching over conventional ground launching: capacity. possibility of utilization of high-altitude nozzle Satellites launched, the CA lands at in the LV first-stage liquid engine, selection of the Biak Airfield for launches to orbits optimum trajectory owing to the exclusion of with inclinations of 0 to 30 degrees, at Port the initial vertical flight path, necessary for the Moresby Airport in Papua New Guinea for ground launch, use of the CA initial velocity for launches to orbits with inclinations of 30 to the LV, aerodynamic and gravity characteristic 80 degrees and at Java and Timor Islands velocity losses reduction at the orbit ejection, Airfields in Indonesia for launches to orbits for the LV will overcome less than 1/3 of with inclinations of 80 to 115 and more atmospheric resistance with launch of the LV at degrees. an altitude of 10 to 11 km. Further, when selecting flight route over the world ocean, optimum impact areas may be selected for the 5 Air Launch Payload Capabilities detachable LV components without payload capability decrease to orbit. Figure 7 presents Air Launch payload Total payload capability of the air- capabilities. launched LV is 1.5 times larger than that of analogous ground-launched LV. 4.5 Location of the Air Launch spaceport in 4.0 Equatorial orbits (i=0o) immediate proximity to the equator, in latitude 3.5 Elliptic orbits 3.0 appr. 1 degree South (Figure 2), is a significant Нп= 200 km 600 km 2.5 benefit. Circular orbits 1,000 km 2,000 km 2.0 It enables launches to GEO with lesser

Polar orbits (i=90o) 1.5 characteristic velocity loss compared to Pay - Pay weight, t - load 1.0 launches from the Russian Plesetsk and

0.5 Baikonur spaceports, into 1200 m/s and 0.0 900 m/s, respectively. 012345678910111220 36 (GEO) Altitude of a circular orbit (apogee), th.km. Figure 9 presents comparative performance capabilities of the ground based Fig. 7. Air Launch Payload Capabilities lightweight LVs and those of the Air Launch System to launch GEO satellites from

6 AIR LAUNCH AEROSPACE INTERNATIONAL PROJECT

% Increase of LV payload capability in air launch from Biak (i =0° ) 60 as compared to the ground launch from Baikonur Baykonur (i =51 =51° °) ) +54%

Increase of LV payload capability after 10% 50 Reduction of the LV ΔV-1=72 m/s displacement of launch site from characteristic speed in ch BaykonurBaikonur to the equator +10% launch from equator

11% 40 Increase of LV payload capability after removal of limitations on the drop zones Removal of limitations on the drop zones in in launch from Biak +11% launch from BaykonurBaikonur

7% 30 CA velocity ΔV= -136 m/s utilization ch

18% 20 Reduction of gravitational and ΔV-ch= 320... 3 50 m/s aerodynamical losses Increase of LV payload capability 10 in air launch as compared to the 8% ground launch from any launch site Utilization of high-altitude nozzle ΔI =+15 s +33% in the LV first-stage liquid engine sp I 0 GroundGround launch from BaikonurBaykonur (i=51 (i =51 °)° )

Fig. 8. Comparative Payload Capabilities of Ground- and Air-Launched LVs to 200 km-altitude Low Near-Earth Orbit the Russian spaceports and from the equator and 6 Reliability, Safety clearly demonstrates the benefits of the Air Launch System. Special attention for the development of the Air Launch Aerospace System is paid to the 890% 900% Payload capability for GEO 800% assurance of its high reliability and safety. As 700% said above, most important System components, 600% Air Launch

500% 477% Ground Launch such as: CA, LV, USB, as well as ground 400% With the use of existing drop 325% zones launch preparation and mission control facilities 300% Comparison base for GEO 200% insertion 160% are developed on the basis of high-reliability 100% 100% 75% and well-proven aviation and SLV technologies. - 20% Payload capabiliti for LEO (Hc = 200 km) 144% All CA flight modes, including pull-up 140% 133% Comparison base for LEO 127% 120% 110% insertion maneuver, shall be executed within the range of 100% 100% 94% 90% 80% operational Аn-124-100 Ruslan aircraft 60% 40% performance characteristics and do not exceed 20% airworthiness standards for this aircraft. Biak Island (i=0 deg.) Baikonur (i=51 deg.) Plesetsk (i=64 deg.) Launch sites The ejection of the LV with a satellite from the CA, using a transporting and launching Fig. 9. Comparative Performance Capabilities of container with a pneumatic ejection unit, Air- and Ground-Launched Launch is based on a great number of launches of Vehicles to LEO and GEO ground- and sea - based operational ballistic

7 A. KARPOV, R. IVANOV, M. KOVALEVSKY

missiles, implemented in Russia and other explosion simulation in case of emergency countries, having rocket weapons. This ejection disintegration of the above-mentioned engine method practically does not depend on various and the LV at an altitude of 10 to 11 km. The atmospheric and aerodynamic disturbances, Air Launch System environmental safety is which could otherwise affect the ejection, and ensured by utilization of pollution-free ensures optimal reliability compared to other propellant «liquid oxygen + kerosene». methods, using parachutes. In total, the Air Launch System LV and 7 Air Launch System at the World Launch USB use three main engines, which are Market potentially most hazardous sources of failures The Air Launch Aerospace System in the and emergency situations for all SLV systems. judgment of its developers will have a great run Using minimum number of high-reliable main at the world launch market due to its attractive engines (one for each SLV unit) ensures high consumer properties: high reliability of well- reliability insertion of satellites into space by the proven Russian SLV technologies, application Air Launch System, which is estimated at universality for the insertion to any near-earth 0.99 degree. orbits and escape trajectories, environmental The Air Launch System developers pay safety, as well as moderate launch prices for significant attention to the safety of the CA lightweight satellites. crew, the LV and satellite operators onboard Figures 10 and 11 present payload cost the CA. factors (launch cost of 1 kg) for launches to low In case of non-studied situations or abort of 70 a planned launch during flight to the launch area Operable LV J-1 LV under development JPN of the CA with the LV and the LV-based 60 satellite, the following operations shall be M-5 Pegasus JPN 50 USA Average specific commercial costs executed: overboard dumping of liquid oxygen CZ-4A CHN of PL insertion by operable LV from the LV tanks into atmosphere, kerosene 40 Athena-1 Average specifical costs of PL USA insertion by LV under development transferring to the reserve CA tank and landing Taurus XL 30 USA Falcon-1 of the CA with dry LV at the airfields, which USA Taurus CZ-3 Delta-II CHN USA Vega USA 20 Falcon-1e ESA Start-1 CZ-2C Titan-II ensure the crew, LV and satellite safety, as well USA Athena-2 USA RUS CHN Falcon-5 USA Start Athena-3 США Soyuz-1 RUS USA RUS Molnya-М Kosmos-3М RUS as re-ignition capability (first safety level). 10 RUS Strela Rokot Tsiklon-2К

Specific Commercial Launch Cost for PL Insertion, Cost Launch for thousand/kg USD PL Insertion, Commercial Specific Polyot CZ-4A RUS RUS UKR Dnepr-1 Dnepr-М CHN In case of the second failure during flight to RUS-UKR RUS-UKR 0 the launch area (second non-studied situation), 0 1000200030004000 excluding the LV propellant overboard LV carrying capability for PL insertion to a baseline orbit Н=200 km, i=90о, kg dumping, the CA crew may perform Fig. 10. Payload Cost Factor for Low Reference unscheduled ejection of the LV without Orbit Н=200 km, i=90° insertion of the satellite into space, in which 130 case the LV and the satellite will be lost, the CA Delta-II 7326 10 Operable LV 120 USA with a crew and operators will land at the 110 Delta-II 742510 projected airfields (second safety level). 100 USA 90 Delta-II 7920 USA The third safety level of the crew and 80 Soyuz-FG, Soyuz-2-1А (Baikonur) Delta-II 7925 10 Average specific commercial costs operators, when it is impossible to dump 70 RUS USA of PL insertion by operable LV Delta-II 7925 60 Soyuz-2-1B USA propellant and perform unscheduled ejection of (Baikonur) Delta-II 7925Н 10 Atlas V 401 50 RUS USA Delta 4 USA Medium-Plus (5.4) Ariane 5 PSLV Polyot CZ-3A USA the LV, is the escape of the crew and operators CHN Proton-М ESA 40 IND Soyuz-2-1B Delta 4 (Breeze M) GSLV (Kourou) Heavy RUS RUS Zent-3 SL Mark 2 Delta 4 Atlas V 431 USA 30 Medium RUS-UKR from the CA, using personal equipment and IND USA Zent-3 SLB USA Falcon 9 (Baikonur) Delta 4 20 (Cape Canaveral) RUS-UKR USA GSLV Medium parachutes, provided in a military Аn-124 Plus (4.2) Mark 3 USA 10 IND

Ruslan aircraft. kg / thausand USD GEO, the to insertion PL of cost Specific 0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 To ensure safety of the CA, as well as its crew LV carrying capability to the GEO, kg and operators safety, the CA first stage engine shall be ignited after the LV moving away from the CA at a Fig. 11. Payload Cost Factor for GEO (for the safe distance (appr. 250 m), resulting from the propellant transfer from GTO to GEO using satellite engine)

8 AIR LAUNCH AEROSPACE INTERNATIONAL PROJECT

near-earth obits and GEO, respectively. Spaceport construction works in Diagrams on these figures indicate that the Indonesia at the Frans Kaisiepo Airfield (Biak Air Launch System has the smallest payload Island) will be executed by the Air Launch cost factor and is next best to that of the Centra Nusa, which is a joint Russian- conversion launch vehicles, modified versions Indonesian venture company. Air Launch of operational ballistic missiles. Centra Nusa will also participate as a launch Analysis of the World Launch Market for operator for providing launch services at the up to 2018, published in 2009 by Euroconsult, territory of Indonesia. showed that the Air Launch System is capable It is projected that Germany companies, to launch practically all types of lightweight developers and operators of different spacecrafts satellites (Figure 12) to low near-earth orbits, as will construct the European Pre-Integration well as Russian and European Glonass and Center and the Air Launch System in Germany. Galileo-type navigation systems satellites to Coordination works upon the Air Launch medium orbits, spacecrafts of up to 1 ton in Project in these countries will be carried out by mass – to GEO and escape trajectories. the Air Launch Aerospace Corporation.

100 Polyot Tsiklon‐4 Delta‐II 90 9 Conclusion Soyuz‐1 Angara‐1.2 80

70 Dnepr‐М The innovative Air Launch Aerospace Project Angara‐1.1 60 Кosmos‐3M Tsiklon‐2K Dnepr‐1 presented in the paper is developed with the Strela 50 Vega Rokot purpose to expand opportunities for the space 40 Falcon‐1е LEO market coverage 30 area exploration in the interests of economy Operable LV 20 Pegasus‐XL LV under development development and raising of living standard of 10 Start LV Polyot LEO market coverage, percents Start‐1 people all over the world. 0 Falcon‐1 0 50 100 150 200 250 LV launching mass, tons Fig. 12. Operational and Developed Lightweight 10 Contact Author Email Address LVs LEO Market Share for Payload [email protected] Delivery (percent market share)

8 International Cooperation on the Project

The Air Launch Project is implemented in cooperation with a great number of aeronautical and rocket-and-space Russian, Ukrainian, Indonesian and Germany companies.

Russian Air Launch Aerospace Corporation and State Rocket Center named after

Academician V.P. Makeev undertook the principal function upon the Project: the Project general technical conceptual design, Copyright Statement development of the Air Launch SLV The authors confirm that they, and/or their company or components, their ground and flight test organization, hold copyright on all of the original material and experimental checkout, as well as included in this paper. The authors also confirm that they final flight tests of the system with the have obtained permission, from the copyright holder of insertion of payload or spacecraft models into any third party material included in this paper, to publish space. it as part of their paper. The authors confirm that they give permission, or have obtained permission from the Ukrainian Antonov company is a developer copyright holder of this paper, for the publication and of the CA, built on the basis of the heavy cargo distribution of this paper as part of the ICAS2010 An-124-100 Ruslan aircraft, which will be modified proceedings or as individual off-prints from the at the Russian aeronautical Aviastar-SP plant. proceedings.