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Tsyklon-4M (Cyclone-4M) prepares a move to Canada

Ukrainian space engineers are finalizing the design of a prospective commercial space launcher for a speedy development based on extensive engineering heritage of the Antares, Zenit and Tsyklon (Cyclone) rockets. The newly designed vehicle, to be based in Canada, is being positioned as a highly competitive player in the small satellite launch market, costing its passengers $45 million per shot.

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Preliminary architecture of the Tsyklon-4M launcher. Credit: MLS

Tsyklon-4M (Cyclone-4M) rocket at a glance:

Liftoff mass
260 tons
Number of stages
2
Full length
39 meters
Price per launch
$45 million
PAYLOAD CAPABILITIES
-
200-kilometer orbit; inclination: 45.2 degrees toward the Equator
5,000 kilograms
700-kilometer Sun-synchronous orbit;
3,350 kilograms
Geostationary transfer orbit, GTO, 180 by 35,768-kilometer; 45.2 degrees*
910 kilograms
Super-synchronous geostationary transfer orbit, SGTO, 180 by 180,000 kilometers; 41.22 degrees
320 kilograms
STAGE I
Stage I propulsion system
Four RD-120-based engines
Stage I oxidizer
Liquid oxygen
Stage I fuel
Kerosene
Stage I total thrust
360 tons
Stage I diameter
3.9 meters
STAGE II
Stage II propulsion system
One RD-861K
Stage I oxidizer
N2O4
Stage I fuel
UDMH
Stage I total thrust
8 tons
Stage I diameter
3.9 meters

*It will require an additional maneuver delivering extra acceleration (Delta V) of 2,250 meters per second to reach geostationary orbit;

**It will require an additional maneuver delivering extra acceleration (Delta V) of 1,500 meters per second to reach geostationary orbit;

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Despite the difficult economic situation inside the country and a very competitive launch market worldwide, the Ukraine-based KB Yuzhnoe design bureau began work on the preliminary design of a new launch vehicle in 2016. The architecture of the proposed two-stage Tsyklon-4M (Cyclone-4) rocket is built around the first stage booster derived from the US Antares and the Ukrainian Zenit rockets and burning liquid oxygen and kerosene. Both stages for Tsyklon-4M were developed and produced in the Ukrainian city of Dnepropetrovsk, the home of KB Yuzhnoe. The Antares is operated by Orbital ATK from a spaceport on the Wallops Island, Virginia, to launch the Cygnus cargo ships toward the International Space Station, ISS.

Origin of the idea

In 2015 and 2016, KB Yuzhnoe began looking at various applications for the Tsyklon-4 rocket, which was in an advanced stage of development for a Ukrainian-Brazilian joint venture. Originally the rocket was to be based in Alcantara, in the equatorial region of Brazil, well suited for launches to the geostationary orbit. However, in 2015, after more than a decade of work, the Brazilian government unilaterally exited the deal due to a host of political and financial reasons, which reportedly included pressure from Russia.

The collapse of the Tsyklon-4 joint venture prompted KB Yuzhnoe to seek new partnerships that would give Tsyklon-4 a new launch pad and, in the process, enable the country's space industry to survive the economic transition, very much like the Russian space industry had done during the 1990s.

Ironically, the violent breakup between Russia and Ukraine in 2014, opened new opportunities for Tsyklon-4. The conflict between the two former Soviet republics essentially grounded the leading low-cost launchers of small satellites -- Dnepr and Rockot. At the same time, Russia's new-generation light-weight Angara-1 rocket was continuously delayed, while the European Vega was too expensive for many small satellite operators. Although the US-based SpaceX attempted to fill the void with its competitive prices, the company's Falcon-9 rocket is often oversized for many small-satellite missions. It left the Indian PSLV rocket as the one vehicle well-suited for that particular market niche.

Suddenly, it looked promising for KB Yuzhnoe to re-target Tsyklon-4 from equatorial orbits to the near-polar orbits frequented by small satellites, such as those comprising future remote-sensing constellations.

Looking for a new home

After the breakup of the Ukrainian-Brazilian venture, the Ukrainian space agency, GKAU, delegated to KB Yuzhnoe the search for a new home base for Tsyklon-4. In a March 2017 interview with the UNIAN news agency, Deputy Head of GKAU Vladimir Mikheev said that the company had considered more than 10 different countries for a new spaceport. Experts reportedly looked at such exotic places as Pacific islands and various locations across the United States. In the end, despite the political re-alignment of the Ukrainian government from Moscow toward Washington, US sites were all rejected due to high cost and potential political issues. The election of Donald Trump, a self-styled populist with isolationist tendencies, drove the last nail into the coffin of a US-based launch site for Tsyklon-4.

Instead, developers explored the possibility of putting the rocket in Canada, not unlike a circa 1990s plan to base Russia's light-weight Start booster in Churchill, Manitoba.

The home of a large Ukrainian diaspora, Canada maintained good relations with Ukraine and the Canadian political climate looked much more favorable for an international venture. After several trips to Canada and meetings with local authorities, including fishing and environmental regulators, experts at KB Yuzhnoe focused their attention on the coast of Nova Scotia on the east coast of Canada.

Tsyklon-4M takes shape

On Sept. 1, 2016, the Ukrainian space agency gave formal permission to KB Yuzhnoe to proceed with the development of a joint venture for the Tsyklon-4 rocket in North America.

However, in order to adapt Tsyklon-4 for its new role in the new economic and political environment, Tsyklon-4 was drastically re-designed. The original booster stage of the rocket with a diameter of three meters, which was inherited from the Soviet Tsyklon-2 and -3 launchers and the R-36 ballistic missile, was abandoned in favor of Zenit's and Antares' 3.9 meter caliber still in production and using non-toxic propellant.

Not coincidently, the newly adopted diameter of the first stage precisely matched the caliber of the upper stage developed for the old Tsyklon-4. This new combination became the basis of the new architecture dubbed Tsyklon-4M, even though the rocket more resembled Zenit than Tsyklon.

On March 7, 2017, Ukrainian engineers made a presentation of the Tsyklon-4M concept rocket at a closed-door meeting in Dnepropetrovsk. The work on the project was reportedly delegated to a team led by the son of the Designer General at KB Yuzhnoe, who had previously overseen the successful work on the Antares.

While retaining the diameter of 3.9 meters inherited from Zenit and Antares, the new first-stage booster of the 39-meter-tall Tsyklon-4M will be shorter to optimize it for its new role. According to original plans, the first stage of the new rocket was to be propelled by four modified RD-120 engines borrowed from Zenit's second stage, replacing the Russian-built RD-171 propulsion system on the first stage of the Zenit.

Although RD-120 was also developed at NPO Energomash in Moscow, it is serially produced in Ukraine and available for the new rocket. However due to a number of Russian parts, it is expected to be upgraded in Ukraine with indigenous components. As of March 2017, plans were made to equip the first stage of Tsyklon-4M with a Ukrainian-built engine designated RD-870, which was previously proposed for the Antares rocket.

Unlike its static position on the second stage of Zenit, each main engine will be attached to the first stage of the future Tsyklon-4M via a special gimbal mechanism, enabling it to tilt slightly away from its vertical axis and, thus, steer the rocket in flight.

The second stage for Tsyklon-4M will be borrowed from the "old" third stage of the Tsyklon-4 rocket. It will use a hypergolic (or storable) propellant. Although both of its components are toxic, they remove all time limitations of easily evaporating cryogenic propellants. As a result, the upper stage can be restarted multiple times and operate in space almost indefinitely, performing elaborate maneuvers.

The payload fairing for the new rocket will also be borrowed unchanged from Tsyklon-4.

Given the advanced level of development and proven reliability of all key components of the proposed rocket, Tsyklon-4M has a good chance of success in the industry, whose history is littered with failed commercial ventures. The biggest challenge for the company would be building its launch site largely from scratch.

Tsyklon-4M to fire from Nova Scotia

In February 2017, three US firms formed a joint venture called Maritime Launch Services, MLS, which was based in Halifax, the capital of Nova Scotia. On March 14, MLS announced that it would build a launch facility near Canso and Hazel Hill in Guysborough County, Nova Scotia, for the Tsyklon-4M rocket. The company promised to invest between $100 and $110 million of private funds into the project.

According to MLS, initial funding for the project was obtained in 2016 from United Paradyne Corporation, UPC, in Santa Maria, CA. Since then other investors have come up with significant amount of cash, sources said.

The chosen geographical location enables Tsyklon-4M to deliver 3,350 kilograms of payload into a near-polar orbit, when launched southward over the Atlantic. Up to 5,000 kilograms could be delivered to a variety of low Earth's orbits with an altitude up to 600 kilometers.

Surprisingly, calculations showed that Tsyklon-4M could also deliver nearly a ton of cargo to a geostationary orbit over the Equator, which could potentially be useful for some potential customers. Moreover, the orbit of the International Space Station, ISS, will also be reachable from Nova Scotia, KB Yuzhnoe sources said.

While located in a sparsely populated area, the launch site also presented good transportation infrastructure. The local authorities and population, which had experienced economic downturn due to the declining fishing industry, was reported to be open to the plan. The MLS announcement for the launch site was preceded by an open house with the local residents in February 2017. The company expected to rent the land for the spaceport for at least 20 years.

However, the rocket ascent trajectory from the site would have to be approved by Canadian transportation authorities, taking into consideration the fact that it would be crossing a popular airline route between Europe and North America. The local fishing industry might also impose some seasonal restrictions for launches.

The proposed space center will include a launch pad and a processing facility separated by a distance of around two kilometers. At least some equipment developed for the Tsyklon-4 rocket could be recycled for the new space center.

The construction at the spaceport was promised to commence as early as 2018, if the MLS fund-raising effort goes as planned. According to the company, commercial launches from the spaceport could begin in 2019 or 2020 and by 2022, Tsyklon-4M could fly up to eight missions per year.

The key to the commercial success of the enterprise should be its competitive price reported to be $45 million per launch.

(To be continued)

 

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The article and illustrations: Anatoly Zak; Last update: March 26, 2017

Page editor: Alain Chabot; Last edit: March 16, 2017

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architecture

A preliminary architecture of the Tsyklon-4M rocket. Credit: KB Yuzhnoe


Production

A production line of Tsyklon rockets at Yuzhmash plant in Dnepropetrovsk, Ukraine, circa 1990s. Credit: KB Yuzhnoe


RD-120

The Ukrainian-built version of the RD-120 (11D123) engine will propel the first stage of the Tsyklon-4M rocket. Copyright © 2001 Anatoly Zak


RD-861K

The RD-861K engine developed for the third stage of the Tsyklon-4 rocket. Copyright © 2005 Anatoly Zak


Tsyklon-4

Scale models of Zenit and Tsyklon-4 (right) boosters. Copyright © 2005 Anatoly Zak