Description: Ultra-lightweight BHL composite transfer lines reduce chill-down time over 90% compared to equivalent stainless steel lines. BHL tubes have ¼ the mass of comparable systems, and 5-10 times less thermal mass. The use of BHL in cryogenic storage and transfer systems will significantly reduce propellant required for pre-chilling lines or tanks, thereby reducing waste propellant by 5-10 fold. Furthermore, the reduced thermal mass will allow for easier no-vent filling as the system can chill down far easier. This will expand the operational envelope of cryogenic systems in space, improving the efficiency of a cryogenic propellant economy. BHL composite transfer lines and tanks In this phase II effort, full scale transfer lines were produced and tested with liquid nitrogen to obtain key data, which validated the performance advantages and robustness of the BHL composite transfer lines. The Phase II testing included rapid chill-down testing of a BHL tank with a LN2 spray bar, verifying the thermal benefits of BHL composite tanks. In the proposed Phase II Extension effort, GTL will test BHL composite tubes with liquid hydrogen to obtain critical thermal performance data. The effort will also demonstrate BHL dewar-tank and dewar-cup operation with liquid hydrogen. These tests will extend the BHL composite operation to include LH2, thereby expanding the market applications for the technology to include LH2 space systems and the emerging hydrogen aviation market.

Benefits: BHL composite transfer lines and tanks can be used in a wide array of NASA applications, including launch vehicles, orbit transfer vehicles, in-space propellant depots, lunar landers, lunar bases, and Mars missions. When fitted with vacuum jacket insulation, BHL composite transfer lines can be used in terrestrial cryogenic fluid systems (LH2, LOX, LN2, LCH4) to reduce propellant losses, which reduces cost and improves safety. BHL composite lines and dewar-tanks can be used in upcoming NASA hydrogen powered aircraft demonstrators.

BHL composite lines and dewar-tanks greatly improve LH2 storage performance for hydrogen powered airplanes, helicopters, airships, trucks, and ships. It can also be used in LNG systems for autos, buses, and trucks. BHL lines and dewar-tanks can also be used for LH2 and LNG pipelines and storage tanks, and distribution vehicles. BHL lines can be used for commercial and DoD space and launch systems.