Purdue University ZL9 & High-Pressure Air Plant

Purdue University’s Maurice J. Zucrow Laboratories needed to expand their testing capabilities for larger propulsion experiments and replace the existing High Pressure Air Plant (HPAP). ZL9 features new testing capabilities for innovative research in rocket combustion and gas turbine engines, continuing Purdue’s history of world-class research and development in those areas at a scale only found in government or large defense contractor facilities.

The project was challenged to create spaces to conduct testing for capacities 10x greater than their existing facilities. The team had to develop solutions for systems at scale while iterating with the Purdue researchers and engineers as they fine-tuned their testing designs and requirements. The high temperature, high pressure compressed gas systems required special nickel-alloy piping and critical pipe stress analysis to ensure the systems meet ASME code requirements. The quantity of fuels and gases needed for storage and testing required in-depth review of Building, fuel/gas, and fire protection codes.

MNA provided architecture and engineering services for the study, concept design, detailed design, and commissioning phases of the project. The 54,500 SF Lab included five reinforced concrete test cells with associated laser labs, control rooms, workshop assembly spaces, electronics lab, and a machine shop. Construction of the test cell portion includes the associated facility piping, valves, pressure vessels, liquid jet fuel tanks, pumps, high-pressure storage vessels and instrumentation. Specialized hot air piping will be required and will need to deliver air at 1,500 degrees Fahrenheit and 800 psi. The High-Pressure Air Plant can produce 3,400 psi air at 5lbm/second.