Optimization of a Reusable Rocket-Powered, VTVL Launch System:

A Case Study of the Falcon 9-R

04 August 2014
John E. Bradford, Ph.D.
President, Principal Engineer
john.bradford@sei.aero | 1+770.379.8007

Brad St. Germain, Ph.D.

Director, Advanced Concepts Group
brad.stgermain@sei.aero | 1+770.379.8010

Kevin Feld
Sr. Aerospace Engineer
kevin.feld@sei.aero | 1+770.379.8005

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Case Study
SpaceWorks was interested in examining the performance of the SpaceX Falcon 9-R system that
is currently under development as a test case for the VTVL simulation
System closure simulation created in PHX ModelCenter allowed us to quickly reverse engineer
the baseline Falcon 9 system and anchor the models to various pieces of public information
Gross mass and propellant loads
Engine performance specifications
Vehicle dimensions and fairing geometry
Mission launch profile (times, altitudes, velocities)
Statements made by SpaceX employees

Anticipate that as additional details on the F-9R performance are released, the model can be
further validated and/or calibrated
Using the reference closure model, we were then able to assess the impact of reusability on the
system and explore various sensitivities

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Reference Concept
Non-proprietary Falcon 9 v1.1 system
Public data sources and engineering models calibrated for:
Geometry
Propellant loads
Propulsion
Aerodynamics
Trajectory
Fairing
Assumed flight constraints common for expendable launch systems

Parameter Value
Gross Liftoff Weight 1,115,200 lbm
Upperstage Gross Weight 246,150 lbm
Total Height 224 feet
Diameter 12 feet
Liftoff T/W 1.2
Reported Payload to LEO 28,990 lbm
Image Credit: SpaceX

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VTVL Assessment
Examined downrange booster recovery as well as RTLS option
Fixed vehicle size and mass, per the reference concept
Booster stage mass model includes landing system/legs
Recovery/Landing Requirements:
Vertical orientation (gamma -90 deg) at touchdown
Velocity @ touchdown < 20.0 fps
Single-engine operation for terminal maneuver
3 engines operable for any initial boostback burn
Max. heat rate constraint of 15 BTU/ft2-s (assumed)
Optimization: Maximum upperstage payload mass that can be delivered to LEO for either the
expendable booster case, booster with RTLS recovery, or booster with downrange landing

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VTVL Concept Simulation Model
Created a multi-disciplinary simulation using Phoenix Integrations ModelCenter
engineering environment

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Results : FlightSight Images

Downrange Landing
Booster Parameter Value
Flight Time 390 sec

Final Downrange Distance 156 nmi

Max Downrange Distance 156 nmi

Mach Number @ Staging 7.1

Altitude @ Staging 201,500 feet

Peak Altitude 271,500 feet

RTLS Maneuver
Booster Parameter Value
Flight Time 480 sec

Final Downrange Distance ~0 nmi

Max Downrange Distance 57 nmi

Mach Number @ Staging 6.0

Altitude @ Staging 187,000 feet

Peak Altitude 423,500 feet

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Results : Trajectory Details
Altitude vs. Time

Mach Number vs. Time

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Results : Trajectory Details(2)
Downrange vs. Time

Thrust vs. Time

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Results: Performance Summary

Booster Parameter Expendable Downrange RTLS

Landing Propellant Used 0 lbm 44,350 lbm 84,680 lbm

Recovery Propellant (% Booster Total Prop) 0.0 % 5.5 % 10.5 %

Staging Mach Number 8.4 7.1 6.0

Videal Post-Staging 0 fps 5,400 fps 8,900 fps

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Trade Study
Examined impact of removing max. heat rate constraint for recovery trajectories
RTLS trajectory was not impacted (inactive constraint), but the downrange case was impacted
significantly

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Conclusions

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Summary
SpaceWorks has developed a system closure and optimization model for VTVL concepts
Simulation capability was tested using performance data for the SpaceX Falcon 9 v1.1
PHX ModelCenter implementation enabled rapid trade studies and system sensitivity analyses

For case study, the performance impacts of two different first stage propulsive recovery options
(downrange landing and RTLS) were evaluated and compared to non-recoverable options
Downrange propulsive landing results in a ~20% drop in payload performance compared to expendable
booster mission; RTLS results in a ~40% drop in payload compared to expendable (no recovery)
approach

Regarding the cost savings due to reusability, gains must outweigh performance reductions
Expendable upperstage, estimated at ~$20M, establishes floor for $/lbm-payload
Must also include booster propellant and refurbishment costs (at a minimum)
Cost savings may not be as significant as some claim, but appears to still be a net gain

Progress is being made, but we need to continue push for full reusability on these systems

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