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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2017

Final Test Results for the Ground Operations Demonstration Unit for Liquid Hydrogen

Described herein is a comprehensive project—a large-scale test of an integrated refrigeration and storage system called the Ground Operations and Demonstration Unit for Liquid Hydrogen (GODU LH2), sponsored by the Advanced Exploration Systems Program and constructed at Kennedy Space Center. A commercial cryogenic refrigerator interfaced with a 125,000 liter liquid hydrogen tank and auxiliary systems in a manner that enabled control of the propellant state by extracting heat via a closed loop Brayton cycle refrigerator coupled to a novel internal heat exchanger. Three primary objectives were demonstrating zero-loss storage and transfer, gaseous liquefaction, and propellant densification. Testing was performed at three different liquid hydrogen fill-levels. Data were collected on tank pressure, internal tank temperature profiles, mass flow in and out of the system, and refrigeration system performance. All test objectives were successfully achieved during approximately two years of testing. A summary of the final results is presented in this paper.

Zero Boil Off↗
NASA NTRS2018

Large Scale Cryogenic Storage with Active Refrigeration

Storage and transfer of cryogenic liquefied gases on volume scales from under 10 liters for lab use, up to hundreds of millions of liters for industrial applications is of paramount importance across a vast range of industries. Traditionally, these commodities have been stored at or near the normal boiling point due to relative ease of operation and safety-related considerations; however, this also means that some percentage will always be lost due to environmental heat leaking into the vessel and causing boil-off. These losses become more concerning as scales increase, and are of particular importance for high-cost commodities such helium and hydrogen. Additionally, the normal boiling point marks the highest liquid density achievable; which becomes a strong driver of end-use system designs such as space launch vehicles. Recent development and testing of an Integrated Refrigeration and Storage (IRAS) system for liquid hydrogen has proven that next generation cryogenic storage operations such as zero boil-off and densification are feasible on a large scale. This IRAS system married an 850 Watt at 20 Kelvin reverse-Brayton cycle commercial cryogenic refrigerator with a 125,000 liter LH2 storage tank via and internal tubular heat exchanger. This allowed heat to be removed directly from the hydrogen, and by extension, provided a means to control the bulk thermodynamic state. Zero boil-off, in-situ liquefaction, and densification down to the triple point was performed during testing, and data such as fluid temperature profiles and tank pressure were gathered. Details regarding the design, setup, and testing of the IRAS system are discussed herein, and the data used to anchor various physics models created to predict the behavior of the system during transient and steady state operation. It is hoped that these efforts will provide a useful basis for the design and implementation of future large scale IRAS systems across numerous industries.

Swanger, Adam M.↗
NASA NTRS2019

Oxygen Production System for Refueling Human Landing System Elements

Current NASA plans for lunar exploration include a human lunar landing system, comprised of separate descent andascent modules, with the eventual goal of reusability. Different oxygen production processes were studied to evaluatethe feasibility of producing 10 tons of oxygen per year assuming a high latitude landing location. The study includesconsideration of packaging the ISRU components on the descent module, methods to transfer the regolith from theexcavators to the processing plant which may be mounted well above the lunar surface, and general concept ofoperations for excavation, oxygen production, and liquefaction and storage. A solar-based power system was alsodesigned and packaged on the lander, including the use of direct solar thermal energy where appropriate.

Linne, Diane↗
NASA NTRSDate not supplied

Lunar Water Pilot Plant Conceptual Design

A study was conducted to determine mass, power, and concept of operations for a polar water pilot plant that can produce 1000 kg of oxygen in a year from 1125 kg of water extracted from the icy regolith in a permanently shadowed region(PSR). Icy regolith in the PSR is excavated and delivered to a stationary dryer that extracts the water which is frozen in an ice tanker and delivered up to the ridge for further processing into oxygen and hydrogen. This study assumed a previously landed nuclear reactor was available in the PSR to provide power for the water extraction, which requires 2.4 kW of power, including a 30 percent margin. At 325 kg, the ISRU system massin the PSR, including the excavator, should be deliverable by one of the Commercial Lunar Payload Services (CLPS) landers, and the packaging and concept of operations are shown using one specific CLPS lander. The mass and power of the ISRU system components on the ridge for water electrolysis and liquefaction and storage of the oxygen and hydrogen are estimated at 840 kg and 4.3 kW.

Lunar↗
NASA NTRSDate not supplied

Lunar Water Pilot Plant Conceptual Design

A study was conducted to determine mass, power, and concept of operations for a polar water pilot plant that can produce 1000 kg of oxygen in a year from 1125 kg of water extracted from the icy regolith in a permanently shadowed region(PSR). Icy regolith in the PSR is excavated and delivered to a stationary dryer that extracts the water which is frozen in an ice tanker and delivered up to the ridge for further processing into oxygen and hydrogen. This study assumed a previously landed nuclear reactor was available in the PSR to provide power for the water extraction, which requires 2.4 kW of power, including a 30 percent margin. At 325 kg, the ISRU system mass in the PSR, including the excavator, should be deliverable by one of the Commercial Lunar Payload Services (CLPS) landers, and the packaging and concept of operations are shown using one specific CLPS lander. The mass and power of the ISRU system components on the ridge for water electrolysis and liquefaction and storage of the oxygen and hydrogen are estimated at 840 kg and 4.3 kW.

Lunar↗
NASA NTRSDate not supplied

Case Study for Lunar ISRU Systems Utilizing Polar Water

In-Situ Resource Utilization (ISRU) is key to long term presence at any extraterrestrial destination. Current NASA direction is to achieve a sustainable presence on the lunar surface by 2028. Mission plans currently target the lunar South Pole to leverage the extended periods of solar illumination and allows for potential access to water ice in the permanently shadowed areas around the poles. With water, it is possible to produce both fuel and oxidizer to fully refuel a vehicle. In order to address ISRU infusion into mission planning, a study of an end-to-end ISRU propellant production system was initiated to assess ISRU architectures and obtain mass and power estimates for each. The results of these case studies will be presented. For this study, The ISRU system architecture involved two sites; the mine site in a shadowed crater where water ice is excavated and extracted from the regolith and the propellant production site at an illuminated ridge where the water is processed into liquefied O2 and H2 propellants. Fixed hardware would be emplaced at each site, with two alternating water tankers to transport water between them. Notional lunar sites were identified for this architecture for baseline environmental parameters. Technology solutions for each subsystem were selected based on those with the highest fidelity models or those that have empirical laboratory data to anchor to. While power needs were identified for each location, a power solution was not prescribed, therefore the masses presented do not include surface power systems. The baseline case in this study assumed that 10 mT of oxygen, along with enough hydrogen to support a propulsion mixture ratio of 6, must be produced in 225 days. Therefore 15 mT of water would need to be collected and processed. The baseline solution resulted in a system mass of5 mT and a total required power of 68kW. The majority of the mass was split between the ridge site system and the two water tankers (2.6 mTand 1.8mTrespectively). The majority of the required power was with three subsystems at approximately 20 kW each: hydrogen liquefaction, electrolysis, and the water extractor subsystem. Trades for four key variables are also presented, namely production rate, water concentration, dry overburden depth, and number of water transport trips. This can be compared to a system that targets oxygen from the minerals in the surface regolith material. A carbothermal reduction reactor system was used for this comparison. The use of direct solar thermal energy to process the regolith and the ease of access of the resource resulted in significantly lower values for the oxygen case: approximately 2.7 mT and 11.8 kW. However, the mass trade would favor the water case over successive missions where the hydrogen up-mass of 2 mT per mission will accrue against the oxygen system.1Aerospace Research Engineer, Chemical and Thermal Propulsion Systems Branch, Senior Member.2Mechanical Engineer, Propulsion and Power Division/Energy Conversion Systems, 2101 Nasa Pkwy/Mailcode EP3 Houston, TX 77058, AIAA member.

Lunar↗
NASA NTRSDate not supplied

Technology Assessment for Producing Propellant From Lunar Water

Introduction: The presence of water ice in permanently shadowed regions (PSRs) on the lunar surface may enable a sustained human presence on the Moon with minimal need for consumables. One of the most valuable uses of lunar water is to produce rocket propellant. A sustained human presence on the Moon will re-quire frequent launches from the lunar surface, and each launch will require tons of propellant. However, many other volatiles are likely to be present in the areas where lunar water is stable1. Producing propellant from lunar water in-situ will require the separation and purification of water before it can be electrolyzed into oxygen and hydrogen gas. The Resource Exploration and Science of OUR Cosmic Environment (RESOURCE) project, funded by the Solar System Exploration Research Virtual Institute (SSERVI) program, includes a task to demonstrate the end-to-end process of water extraction, capture, purification and electrolysis to produce pure/dry oxygen gas sourced from an icy regolith mixture. Water Purification: The requirements for water purity are driven by the type of water electrolyzer used. For example, the water electrolyzer currently used on the International Space Station is based on proton ex-change membrane (PEM) technology. PEM-based electrolyzers require water to be ultrapure and deionized (>10 MegaOhm-cm) so that electrical conductivity is limited to the membranes themselves, where electrical current is used to convert H2O into H2 and O2.. A practical first step toward purifying water that is sourced from a lunar PSR is to use freeze distillation to separate water from other volatiles2. A sub-micronic filter can also be used to ensure that a minimal amount of dust is present in any lunar water that is captured. The combination of freeze distillation and sub-micronic filtration will result in relatively pure water but would require a deionization step if being fed into a PEM electrolyzer. Water Electrolysis: An alternative to PEM electrolysis is to use a Solid Oxide Electrolyzer (SOE). This technology operates at a much higher operating temperature (~800oC) and has a limited pressure range but does not require water to be ultrapure and deionized. Another advantage of SOE technology is that it produces pure dry oxygen gas without the need of an additional drying step. PEM electrolyzers produce humid oxygen gas and the humidity must be removed prior to liquefaction. Assessment: In order to compare PEM and SOE technologies side-by-side, they must be compared at a system level that includes water purification and gas drying steps. Engineers at the Johnson Space Center up-dated and utilized a detailed In-Situ Resource Utilization (ISRU) system model to compare and select the best option for the RESOURCE project which will conclude with a laboratory demonstration of the process of producing pure/dry oxygen from an icy regolith mixture in 2025.

A.J. Paz↗
NASA NTRSDate not supplied

Technology Assessment for Producing Propellant From Lunar Water

Introduction: The presence of water ice in permanently shadowed regions (PSRs) on the lunar surface may enable a sustained human presence on the Moon with minimal need for consumables. One of the most valuable uses of lunar water is to produce rocket propellant. A sustained human presence on the Moon will re-quire frequent launches from the lunar surface, and each launch will require tons of propellant. However, many other volatiles are likely to be present in the areas where lunar water is stable1. Producing propellant from lunar water in-situ will require the separation and purification of water before it can be electrolyzed into oxygen and hydrogen gas. The Resource Exploration and Science of OUR Cosmic Environment (RESOURCE) project, funded by the Solar System Exploration Research Virtual Institute (SSERVI) program, includes a task to demonstrate the end-to-end process of water extraction, capture, purification and electrolysis to produce pure/dry oxygen gas sourced from an icy regolith mixture. Water Purification: The requirements for water purity are driven by the type of water electrolyzer used. For example, the water electrolyzer currently used on the International Space Station is based on proton ex-change membrane (PEM) technology. PEM-based electrolyzers require water to be ultrapure and deionized (>10 MegaOhm-cm) so that electrical conductivity is limited to the membranes themselves, where electrical current is used to convert H2O into H2 and O2.. A practical first step toward purifying water that is sourced from a lunar PSR is to use freeze distillation to separate water from other volatiles2. A sub-micronic filter can also be used to ensure that a minimal amount of dust is present in any lunar water that is captured. The combination of freeze distillation and sub-micronic filtration will result in relatively pure water but would require a deionization step if being fed into a PEM electrolyzer. Water Electrolysis: An alternative to PEM electrolysis is to use a Solid Oxide Electrolyzer (SOE). This technology operates at a much higher operating temperature (~800oC) and has a limited pressure range but does not require water to be ultrapure and deionized. Another advantage of SOE technology is that it produces pure dry oxygen gas without the need of an additional drying step. PEM electrolyzers produce humid oxygen gas and the humidity must be removed prior to liquefaction. Assessment: In order to compare PEM and SOE technologies side-by-side, they must be compared at a system level that includes water purification and gas drying steps. Engineers at the Johnson Space Center up-dated and utilized a detailed In-Situ Resource Utilization (ISRU) system model to compare and select the best option for the RESOURCE project which will conclude with a laboratory demonstration of the process of producing pure/dry oxygen from an icy regolith mixture in 2025.

ISRU↗
NASA NTRSDate not supplied

Electrified Aircraft Propulsion Integration Concepts: Primary Fuel Cells and Cryogenic Hydrogen Storage

This presentation leverages lessons learned from the multiple activities funded by the National Aeronautics and Space Agency (NASA) to convey development paths for implementing an Electrified Aircraft Propulsion (EAP) system powered by primary fuel cells systems and fueled by cryogenically stored hydrogen. To reduce greenhouse gas emissions associated with all aspects of hydrogen-fueled aviation, this work minimizes required energy and time per payload distance at take-off so as to reduce emissions associated with ground operations and the production, liquefaction, transfer, and storage of hydrogen. The approach targets efficient system integration, maximizing hydrogen utilization efficiency, maximizing power system efficiency, and viable operational concepts for delivered payload distances. The discussion outlines the performance and compliance challenges revealed by analyses of current fuel cell and cryogenic management technologies. The conclusion offers potential mitigation strategies to the identified the performance and compliance challenges.

Fuel Cell↗
NASA NTRSDate not supplied

Addressing CFM Modeling Gaps for Application into NASA’S Future Cutting Edge Missions

NASA, the US industry, and international partners are crafting frameworks to enable sustaining lunar missions. The ongoing programs, led by the agency, and prominent industry players, encompass plans for the sustained use of cryogenic propellants in lunar landers and in-space propellant refueling depots. NASA’s proactive funding initiatives have fueled the advancement of predictive computational models tailored to enhance the storage and transfer of cryogenic propellant. This paper aims to spotlight the latest advancements in this arena and delve into the collaborative efforts surrounding predictive model development within internal NASA programs as well as current and previous collaborations with industry and international partners. The paper presents an overview of recent advancements in cryogenic fluid management model development, along with their correlation with recent microgravity and large-scale cryogenic ground tests. The tests include key experiments such as the ISS Zero-Boil-Off Tank (ZBOT) series of experiments and the (Robotic Refueling Mission 3) RRM3 test during which liquid methane was stored on-orbit for an extended period of five months. The paper also highlights the anchoring of propellant tank pressurized drain tests involving sloshing that were conducted with liquid methane propellant during the Apollo/Saturn Era. Additionally, the paper discusses model anchoring against more recent sloshing tests carried out with liquid hydrogen propellant. Notable large-scale tests, such as a liquid oxygen propellant transfer test conducted by SpaceX were also used to help correlate a two-phase propellant transfer model using the valuable data measured during the test. The paper further showcases model correlations against a substantial oxygen liquefaction test undertaken by NASA to validate In-Situ-Resource-Utilization (ISRU) technologies that will prove pivotal for a sustained lunar presence.

Low-gravity fluid modeling↗
NASA NTRSDate not supplied

A Summary of Recent SBIR and STTR Projects in Support of Cryogenic Fluid Management Modeling

Over the last five years, NASA has invested in development of sub-models to improve the current capabilities of Computational Fluid Dynamics (CFD) codes utilized for cryogenic fluid management (CFM) predictions. The goal is for the submodels to be modular so that they can easily be implemented into NASA’s CFD codes such as ANSYS Fluent, Siemens STAR-CCM+, and Streamline Numerics Loci-Stream. These technologies are being developed through Small Business Innovative Research (SBIR) and Small Business Technology Transfer (STTR) contracts under the CFM subtopic solicitation and funded by the CFM Portfolio Project. All contracts presented include cryogenic experiments to enable model validation. A sub-grid boiling model has been developed by Combustion Research and Flow Technology Inc. and Massachusetts Institute of Technology for cryogenic line chilldown predictions and has completed Phase III. A spray chill-and-fill model for cryogenic tankage is being developed by Combustion Research and Flow Technology Inc. and University of Connecticut and is currently in Phase II. Last, film condensation modeling to support cryogenic liquefaction was progressed through a Phase I contract with Combustion Research and Flow Technology Inc. and University of Connecticut. A summary of accomplishments for each contract is presented.

cryogenics↗
NASA NTRSDate not supplied

System Modeling of a Lunar Molten Regolith Electrolysis Plant

Introduction: In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO2, MgO, Al2O3) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The System Engineering and Integration (SE&I) ISRU Modeling and Analysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) [1] as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant. System Model: Figure 1: MRE Plant Block Diagram The regolith excavation model determines the mass and power needed to excavate sufficient regolith. The preheating auger initiates the regolith heating process before regolith enters the MRE re-actor to reduce the energy required to turn the solid into a molten liquid. The MRE reactor is modeled in COMSOL Multiphysics and based on the research by Dominguez, Sibille, and Schreiner [2, 3, 4]. This preliminary reactor model provides an accurate calculation of thermal equilibrium during electrochemical operation of the reactor system to assess the optimal mass and power required to process the inlet flow of regolith. The model also computes the outlet flowrates of oxygen and molten products. For this analysis, the primary components of the metal alloy considered were iron and silicon. The oxygen is then purified using an Yttrium Stabilized Zirconia (YSZ) electrode, followed by liquefaction using a 90K cryocooler to be stored as liquid oxygen in insulated cylindrical tanks. In future iterations of the system model, the molten metal tapped from the MRE reactor will undergo additional processing or refinement. However, downstream handling of metals is currently a technology gap that is missing a high TRL subsystem model. Therefore, for this analysis, the accumulated metal alloy stream terminates after leaving the MRE reactor. Study Goals: This analysis investigates multiple input variables to the system to determine the sensitivity of a (near) complete plant at full-scale. This preliminary investigation ran parametric sweeps on the MRE reactor geometry, electrical current supply, layers of multi-layer insulation (MLI) on the reactor, size of the electrodes in the oxygen purification model, and regolith composition (based on landing site location). Three production targets of oxygen (1,000, 10,000, and 50,000 kg/yr) were investigated for this analysis. The parametric sweeps conducted in this analysis provide valuable insight into the expected impact of the various model inputs on plant size. This information can be used to identify the most critical components of the plant and guide future decisions on allocating funding for research and development, providing subsystem developers with appropriate interfaces with downstream and upstream processes, and assessing the overall feasibility of MRE when compared to other ISRU plants. References: [1] Carlson, A. et al. (2024) ICES, ICES-2024-53. [2] Dominguez, D.A., and Sibille, L. (2011) AIAA, AIAA-2011-700. [3] Schreiner, S.S. (2015) MIT, Dissertation. [4] Schreiner, S.S. et al. (2016) ASR, 57(7), pp.1585-1603.

ISRU↗
NASA NTRSDate not supplied

Characterization Testing of a 20 Kelvin Cryocooler for Space Applications

Future NASA space exploration missions will require long-duration storage and liquefaction of cryogenic liquids, enabled by active cooling provided by cryocoolers. Recent gap analyses of Lunar and Mars transportation systems have identified 20 K-class cryocoolers as a critical enabling technology for chemical and nuclear thermal propulsion architectures using liquid hydrogen propellant. To address this technology gap, NASA has undergone the development of a high-efficiency, high-capacity 20 K cryocooler via an SBIR partnership with Creare. While the January 2025 testing demonstrated functionality and compliance with contractual requirements, the objective of the NASA-led characterization effort was to generate a dataset for supporting future mission designs across a broader operating envelope, including off-nominal conditions. The cryocooler demonstrated strong performance, achieving a peak coefficient of performance of 17.68% relative to Carnot efficiency and a maximum lift capacity of 24.4 W at 21 K. Overall, the results confirm that the 20 W 20 K cryocooler provides a flexible range of capabilities to enable zero boil-off storage of liquid hydrogen for future Lunar and Mars missions. The data collected provide a strong foundation for model validation and future system design efforts.

Cryocooler↗
NASA NTRSDate not supplied

Characterization Testing of a 20 Kelvin Cryocooler for Space Applications

Future NASA space exploration missions will require long-duration storage and liquefaction of cryogenic liquids, enabled by active cooling provided by cryocoolers. Recent gap analyses of Lunar and Mars transportation systems have identified 20 K-class cryocoolers as a critical enabling technology for chemical and nuclear thermal propulsion architectures using liquid hydrogen propellant. To address this technology gap, NASA has undergone the development of a high-efficiency, high-capacity 20 K cryocooler via an SBIR partnership with Creare. While the January 2025 testing demonstrated functionality and compliance with contractual requirements, the objective of the NASA-led characterization effort was to generate a dataset for supporting future mission designs across a broader operating envelope, including off-nominal conditions. The cryocooler demonstrated strong performance, achieving a peak coefficient of performance of 17.68% relative to Carnot efficiency and a maximum lift capacity of 24.4 W at 21 K. Overall, the results confirm that the 20 W 20 K cryocooler provides a flexible range of capabilities to enable zero boil-off storage of liquid hydrogen for future Lunar and Mars missions. The data collected provide a strong foundation for model validation and future system design efforts.

Zero boil-off↗