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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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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Series Bosch Carbon Formation Reactor Trade Study and Down-Select

Human exploration missions to Mars and other destinations beyond low Earth orbit require highly robust, reliable, and maintainable life support systems that maximize the recovery of oxygen (O2). One process in development and under consideration is the Series-Bosch System (S-Bosch). This system is a two stage reactor process that reduces carbon dioxide (CO2) with hydrogen (H2) to produce water and solid carbon. Theoretically, the Bosch process can recover 100% of the O2 from CO2 in the form of water, making it an attractive option for long duration missions. The Series Bosch system includes a reverse water gas shift (RWGS) reactor, a carbon formation reactor (CFR), a H2 extraction membrane, and a CO2extraction membrane. To further the development of oxygen recovery systems, NASA awarded Phase I contracts to several entities under the Game Changing Development Program addressing Spacecraft Oxygen Recovery (SCOR). Two of the hardware deliverables were integrated into the Carbon Dioxide Reduction Test Stand (CORTS) as carbon formation reactors and performance evaluations were executed at Marshall Space Flight Center. A trade study was performed between these two reactors along with one developed at MSFC. This paper provided the necessary information for the Advanced Exploration Systems/Life Support Systems Project (AES/LSS) managers to select a CFR for further development and discusses the process of selection.

Bosch↗
NASA NTRS1999

Elemental Metals or Oxides Distributed on a Carbon Substrate or Self-Supported and the Manufacturing Process Using Graphite Oxide as Template

A process for providing elemental metals or metal oxides distributed on a carbon substrate or self-supported utilizing graphite oxide as a precursor. The graphite oxide is exposed to one or more metal chlorides to form an intermediary product comprising carbon, metal, chloride, and oxygen. This intermediary product can be further processed by direct exposure to carbonate-solutions to form a second intermediary product comprising carbon, metal carbonate, and oxygen. Either intermediary product may be further processed: a) in air to produce metal oxide; b) in an inert environment to produce metal oxide on carbon substrate; c) in a reducing environment to produce elemental metal distributed on carbon substrate. The product generally takes the shape of the carbon precursor.

Hung, Ching-Cheh↗
NASA NTRS1997

Demonstration of Oxygen and Carbon Monoxide Propellants for Mars Missions

Currently, proposed planetary exploration missions must be small, with low costs and a short development time. Relatively high-risk technologies are being accepted for such missions if they meet these guidelines. For a Mars sample-return mission, one of the higher risk technologies is the use of return propellants produced from indigenous materials such as the Martian atmosphere. This consists of 96 percent carbon dioxide, which can be processed into oxygen and carbon monoxide. This year, the NASA Lewis Research Center completed the experimental evaluation and subscale technology development of an oxygen/carbon monoxide propellant combination. Previous research included ignition characterization, combustion performance, and heat transfer characterization with gaseous propellants at room temperature. In this year s tests, we studied the ignition characteristics and combustion of oxygen and carbon monoxide at near liquid temperatures. The mixture ratio boundaries for oxygen and carbon monoxide were determined as a function of propellant temperature in a spark torch igniter. With both propellants at room temperature, the ignition range was between 0.50 and 1.44; and with both propellants chilled to near-liquid temperatures, it was between 2.4 and 3.1. Statistical analysis of the mean value of the ignition boundaries provided models that describe the combination of oxygen temperature, carbon monoxide temperature, and mixture ratio that resulted in ignition. This range is the larger boxed area shown in the figure. The smaller boxed area indicates the range at which there is a 90-percent confidence that ignition will occur. The relatively small range at only 90-percent confidence indicates that using the oxygen/carbon monoxide combination as its own ignition source may not be the best design for a remote engine operating on Mars. Tests also were performed in a simulated small rocket engine that used oxygen/hydrogen combustion gases as the ignition source for oxygen/carbon monoxide. In these experiments, the oxygen/carbon monoxide was successfully ignited in eight of eight tests at a mixture ratio of 0.52. In addition, the oxygen/carbon monoxide maintained steady combustion after the oxygen/hydrogen ignition source was removed, verifying that the oxygen/carbon monoxide rocket engine should continue to be included in mission plans as return propulsion from Mars.

Linne, Diane L.↗
NASA NTRS1975

Fractography of the high temperature hydrogen attack of a medium carbon steel

Microscopic fracture processes were studied which are associated with hydrogen attack of a medium carbon steel in a well-controlled, high-temperature, high-purity hydrogen environment. Exposure to a hydrogen pressure and temperature of 3.5 MN/m2 and 575 C was found to degrade room temperature tensile properties with increasing exposure time. After 408 hr, yield and ultimate strengths were reduced by more than 40 percent and elongation was reduced to less than 2 percent. Initial fissure formation was found to be associated with manganese rich particles, most probably manganese oxide, aligned in the microstructure during the rolling operation. Fissure growth was found to be associated with a reduction in carbide content of the microstructure and was inhibited by the depletion of carbon. The interior surfaces of sectioned fissures or bubbles exhibit both primary and secondary cracking by intergranular separation. The grain surfaces were rough and rounded, suggesting a diffusion-associated separation process. Specimens that failed at room temperature after exposure to hydrogen were found to exhibit mixed mode fracture having varying amounts of intergranular separation, dimple formation, and cleavage, depending on exposure time.

Melson, H. G.↗
DOE OSTI2024

Achieving Unprecedented CO 2 Utilization InCO 2 Concrete™: System Design, Product Development and Process Demonstration

Anthropogenic sources of carbon dioxide are generated from a number of sources, but the key among these are ordinary Portland cement (OPC) production and combustion of fossil fuels. Cement production is the largest global CO 2 source from the mineral decomposition of carbonates. This is due to the clinkering process whereby limestone (mainly consisting of CaCO 3 ) is decomposed into CaO and CO 2 , and combined with silica rich clays at high temperatures to form clinkers (i.e. the four key minerals that comprise cement). The high temperature range of 1400 – 1550°C required for this process accounts for up to 60% of the generated CO 2 from cement production. Combination of the limestone decomposition and thermal requirements of the clinkering process causes cement production to contribute 8-9% of annual global CO 2 emissions. Combustion of fossil fuels (coal, oil and gas) was shown to contribute a much larger portion of global CO 2 emissions. As of 2018, combustion of fossil fuels accounted for 65% of global CO 2 , where 41% was derived from stationary sources for electricity and heat generation and the other 24% was related to transport. To reduce these contributions, key steps forward in CO 2 utilization technologies are required. Therefore, a CO 2 mineralization technology (CO 2 mineralization concrete) to reduce the OPC content in concrete, while utilizing flue gas emissions from fossil fuel combustion has been developed to address both areas simultaneously. This Reversa™ technology utilizes low-carbon cementation agents produced by in situ CO 2 mineralization (“mineral carbonation reactions”) to offer a promising alternative to OPC. CO 2 mineralization relies upon the reaction of dissolved CO 2 with inorganic alkaline reactants to precipitate mineral carbonates (e.g., CaCO 3 ), which bind proximate particles and achieve cementation. Herein, a concrete green body, which is composed of a mixture of binder, water, and mineral aggregates, is exposed to CO 2 borne in industrial flue gas streams. This manner of CO 2 mineralization allows the production of construction components that feature equivalent engineering attributes as their OPC-based counterparts while featuring a much smaller embodied carbon intensity (eCI). The purpose of this project is to demonstrate the feasibility of the Reversa process evolving from a TRL-3 technology at the bench-scale up to TRL-6 technology at the pilot-scale. The reliability of the Reversa technology was tested to prove the effective production of three standard industrial concrete products selected during the course of the project. The results detailed herein will demonstrate the evolution of this technology to the industrial scale. The culmination of this work resulted in 9 production runs completed at the National Carbon Capture Center (NCCC), Wilsonville, AL, using natural gas (NG) flue gas as the CO 2 source. Over the course of the production runs at NCCC, the CO 2 utilization as a function of time, 24-h CO 2 uptake, electricity usage, and 28-d net area compressive strength recorded for each run. Collection of this data will be used to determine the success of the demonstration goals: (1) achieving in excess of 0.2gCO 2 /g reactant , (2) achieving greater than 50% reduction in global warming potential compared to standard produced units, and (3) ensuring compliance of carbonated concrete with industry standard specifications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Process and environmental safety of thermochemical conversion of biomass

Biomass presents a promising opportunity for converting waste into valuable energy, fuels, and chemicals through various thermochemical processes, including hydrothermal carbonization, hydrothermal liquefaction, pyrolysis, gasification, and combustion. However, these processes operate under extreme conditions, introducing significant safety hazards that necessitate meticulous management to prevent accidents. This review discusses potential hazards, risk mitigation strategies, and safety management practices, emphasizing the importance of integrated safety measures into the design and operation of these processes. It also highlights the critical need for robust safety engineering and environmental management strategies tailored to each thermo-chemical process. As these processes transition from laboratory to industrial scale, there is an imperative to develop a clear and concise pathway for emerging industries to achieve regulatory compliance, achieve safety certification, and enable effective stewardship of potential fugitive emissions. By addressing safety and environmental concerns, stakeholders can optimize economic benefits, rural development, and achieve sustained domestic energy generation benefits offered by biomass conversion technologies. Further research on plant design optimization, operational safety, environmental evaluation standardization, and innovative waste management solutions will support the safe and effective scaling of these technologies, ultimately contributing to sustainable management and resource recovery.

09 - BIOMASS FUELS↗
DOE OSTI2026

Developing a one-step, acid-free microbial process to recover and separate REE (CRADA Final Report)

The project aimed to develop and test microbial strains for increased bioleaching, bioconcentration, and/or bioaccumulation of REEs, and for enhanced separation of REEs from other metals and of individual REEs from one another. The team secured and tested unconventional REE feedstocks to evaluate strains/processes for bioleaching, bioconcentration, and bioaccumulation, including but not limited to wastewater, geothermal brines, red mud, and electronic waste. purified and chemically analyzed REE granules from the microbial platform; determined metabolite and biosynthetic impacts of growth with REEs and the composition of extracellular material(s) produced by platform strains; optimized the growth process with alternative carbon feedstocks to reduce the cost of the fermentation process; and scaled the process from 1 mL to 10 L.

36 MATERIALS SCIENCE↗
NASA NTRS2014

Series-Bosch Technology for Oxygen Recovery During Lunar or Martian Surface Missions

Long‐duration surface missions to the Moon or Mars will require life support systems that maximize resource recovery to minimize resupply from Earth. To address this need, NASA previously proposed a Series‐Bosch (S‐Bosch) oxygen recovery system, based on the Bosch process, which can theoretically recover 100% of the oxygen from metabolic carbon dioxide. Bosch processes have the added benefits of the potential to recover oxygen from atmospheric carbon dioxide and the use of regolith materials as catalysts, thereby eliminating the need for catalyst resupply from Earth. In 2012, NASA completed an initial design for an S‐Bosch development test stand that incorporates two catalytic reactors in series including a Reverse Water‐Gas Shift (RWGS) Reactor and a Carbon Formation Reactor (CFR). In 2013, fabrication of system components, with the exception of a CFR, and assembly of the test stand was initiated. Stand‐alone testing of the RWGS reactor was completed to compare performance with design models. Continued testing of Lunar and Martian regolith simulants provided sufficient data to design a CFR intended to utilize these materials as catalysts. Finally, a study was conducted to explore the possibility of producing bricks from spend regolith catalysts. The results of initial demonstration testing of the RWGS reactor, results of continued catalyst performance testing of regolith simulants, and results of brick material properties testing are reported. Additionally, design considerations for a regolith‐based CFR are discussed.

Abney, Morgan B.↗
NASA NTRS2014

Series-Bosch Technology for Oxygen Recovery During Lunar or Martian Surface Missions

Long-duration surface missions to the Moon or Mars will require life support systems that maximize resource recovery to minimize resupply from Earth. To address this need, NASA previously proposed a Series-Bosch (S-Bosch) oxygen recovery system, based on the Bosch process, which can theoretically recover 100% of the oxygen from metabolic carbon dioxide. Bosch processes have the added benefits of the potential to recover oxygen from atmospheric carbon dioxide and the use of regolith materials as catalysts, thereby eliminating the need for catalyst resupply from Earth. In 2012, NASA completed an initial design for an S-Bosch development test stand that incorporates two catalytic reactors in series including a Reverse Water-Gas Shift (RWGS) Reactor and a Carbon Formation Reactor (CFR). In 2013, fabrication of system components, with the exception of a CFR, and assembly of the test stand was initiated. Stand-alone testing of the RWGS reactor was completed to compare performance with design models. Continued testing of Lunar and Martian regolith simulants provided sufficient data to design a CFR intended to utilize these materials as catalysts. Finally, a study was conducted to explore the possibility of producing bricks from spent regolith catalysts. The results of initial demonstration testing of the RWGS reactor, results of continued catalyst performance testing of regolith simulants, and results of brick material properties testing are reported. Additionally, design considerations for a regolith-based CFR are discussed.

Abney, Morgan B.↗
NASA NTRS2000

Diagnostics of Carbon Nanotube Formation in a Laser Produced Plume

This research has involved the analysis and interpretation of spectroscopic data taken over a two year period from 1998 to 1999 at the Johnson Space Center. The data was taken in an attempt to perform diagnostic studies of the formation of carbon nanotubes in a laser produced plume. Carbon nanotubes hold great promise for the development of new materials with exciting properties. Current production processes are not sufficient to meet research and development needs. A better understanding of the chemical processes involved in carbon nanotube formation will suggest better production processes that would be more able to meet the demands of research and development. Our work has focused on analysis of the emission spectra and laser induced fluorescent spectra of the carbon dimer, C2, and the laser induced fluorescence spectra of the nickel atom, which is a necessary reagent in th formation of carbon nanotubes.

DeBoer, Gary↗
NASA NTRS2006

Method for manufacturing high quality carbon nanotubes

A non-catalytic process for the production of carbon nanotubes includes supplying an electric current to a carbon anode and a carbon cathode which have been securely positioned in the open atmosphere with a gap between them. The electric current creates an electric arc between the carbon anode and the carbon cathode, which causes carbon to be vaporized from the carbon anode and a carbonaceous residue to be deposited on the carbon cathode. Inert gas is pumped into the gap to flush out oxygen, thereby preventing interference with the vaporization of carbon from the anode and preventing oxidation of the carbonaceous residue being deposited on the cathode. The anode and cathode are cooled while electric current is being supplied thereto. When the supply of electric current is terminated, the carbonaceous residue is removed from the cathode and is purified to yield carbon nanotubes.

Benavides, Jeanette M.↗
DOE OSTI2025

A Business Case Evaluation of Gas Switching Reforming (GSR) Technology: A Promising Technology for Natural Gas Reforming with Integrated CO2 Capture

Hydrogen is essential in the transition to sustainable energy, and developing low-carbon production methods is a key research focus. Traditional steam methane reforming (SMR) dominates the hydrogen industry but contributes substantially to CO2 emissions. In response, Gas Switching Reforming (GSR) has emerged as a novel process that integrates carbon capture and utilizes process heat more efficiently. Unlike other reforming methods, GSR consolidates oxidation and reduction reactions within a single reactor, which minimizes external energy inputs and simplifies scaling. Like conventional steam methane reforming (SMR), GSR can be integrated with water-gas shift and pressure swing adsorption units for pure hydrogen production. This work presents a comprehensive business case analysis of GSR technology based on experimental results in Technology Readiness Level 3, Life Cycle Assessment (LCA) and Techno-Economic (TEA) evaluation incorporating ASPEN Plus process modeling considering different configurations and energy scenarios. The TEA incorporates data from kinetic experiments from various catalysts to evaluate the GSR process under various conditions. The goal of this work is to evaluate GSR’s potential to serve as a low-carbon alternative to SMR, focusing on global warming potential and additional impact categories to evaluate a wide spectrum of environmental impacts. Comparative assessments were conducted with SMR, chemical loop reforming (CLR), and proton exchange membrane (PEM) electrolysis to explore trade-offs across environmental metrics. The environmental impact assessment of this work encompasses the entire hydrogen production lifecycle from raw material extraction to plant decommissioning, using a cradle-to-gate boundary. Preliminary findings highlight that GSR, when integrated with low-carbon energy sources, could significantly reduce environmental impacts, making it a promising candidate for low-carbon hydrogen infrastructure. The insights from this business case evaluation aim to guide industry in scale-up and commercialization of this promising clean energy technology.

03 NATURAL GAS↗
NASA NTRS1974

Further development of chemical vapor deposition process for production of large diameter carbon-base monofilaments

The development of large diameter carbon-base monofilament in the 50 micron to 250 micron diameter range using the chemical vapor deposition process is described. The object of this program was to determine the critical process variables which control monofilament strength, monofilament modulus, and monofilament diameter. It was confirmed that wide scatter in the carbon substrate strength is primarily responsible for the scatter in the monofilament strength. It was also shown through etching experiments that defective substrate surface conditions which can induce low strength modular growth in the monofilament layers are best controlled by processing improvements during the synthesis of the substrate. Modulus was found to be linearily proportional to monofilament boron content. Filament modulus was increased to above 27.8MN/sq cm but only by a considerable increase in monofilament boron content to 60 wt. % or more. Monofilament diameter depended upon dwell time in the synthesis apparatus. A monofilament was prepared using these findings which had the combined properties of a mean U.T.S. of 398,000 N/sq cm, a modulus of 18.9 MN/sq cm (24,000,000 psi), and a diameter of 145 microns. Highest measured strength for this fiber was 451,000 N/sq cm (645,000 psi).

Hough, R. L.↗
NASA NTRS1988

Exobiology and the search for biological signatures on Mars

In preparation for a Mars Rover/Sample return mission, the mission goals and objectives must be identified. One of the most important objectives must address exobiology and the question of the possibility of the origin and evolution of life on Mars. In particular, key signatures or bio-markers of a possible extinct Martian biota must be defined. To that end geographic locations (sites) that are likely to contain traces of past life must also be identified. Sites and experiments are being defined in support of a Mars rover sample return mission. In addition, analyses based on computer models of abiotic processes of CO2 loss from Mars suggest that the CO2 from the atmosphere may have precipitated as carbonates and be buried within the Martian regolith. The carbon cycle of perennially frozen lakes in the dry valley of Antarctica are currently being investigated. These lakes were purported to be a model system for the ancient Martian lakes. By understanding the dynamic balance between the abiotic vs. biotic cycling of carbon within this system, information is gathered which will enable the interpretation of data obtained by a Mars rover with respect to possible carbonate deposits and the processing of carbon by biological systems. These ancient carbonate deposits, and other sedimentary units would contain traces of biological signatures that would hold the key to understanding the origin and evolution of life on Mars, as well as Earth.

Mancinelli, Rocco L.↗
NASA NTRS2002

Pure Water From a Pure Genius

Ammonium perchlorate is widely used throughout the aerospace, munitions, and pyrotechnics industries as a primary ingredient in solid rocket and missile propellants, fireworks, and explosive charges. This highly soluble salt has tainted soils and water sources all over the world, and is believed to be an endocrine disrupter, adversely affecting the growth patterns of a fetus or a young child. UMPQUA Research Company (URC), once a small drinking water testing laboratory and a research and development contractor for NASA's manned spaceflight applications, has evolved to become a leader in water purification and analysis. With a total of 11 patents issued for new technologies created by URC under NASA SBIR contracts and a 25-year commitment to water recycling, the company clearly possessed the qualifications necessary to tackle the presence of perchlorate in water. An SBIR contract with NASA's Marshall Space Flight Center that concentrated on the stringent water quality requirements of long-term, manned spaceflight was the source for URC's process and catalyst to facilitate the destruction of perchlorate and nitrate in water. URC licensed the rights of its unique reduction reaction process to Calgon Carbon Corporation for use with the company's perchlorate/nitrate remediation process, otherwise known as ISEP(R).

Source record↗
NASA NTRS2000

Mechanisms of Carbon Nanotube Production by Laser Ablation Process

We will present possible mechanisms for nanotube production by laser oven process. Spectral emission of excited species during laser ablation of a composite graphite target is compared with that of laser irradiated C60 vapor. The similarities in the transient and spectral data suggest that fullerenes are intermediate precursors for nanotube formation. The confinement of the ablation products by means of a 25-mm diameter tube placed upstream of the target seems to improve the production and purity of nanotubes. Repeated laser pulses vaporize the amorphous/graphitic carbon and possibly catalyst particles, and dissociate fullerenes yielding additional feedstock for SWNT growth.

Scott, Carl D.↗
NASA NTRS1988

Thermoplastic coated carbon fibers for textile preforms

A continuous process for producing prepreg from carbon fiber and thermoplastic matrix is described. After the tow has been spread using a pneumatic device, the process utilizes a fluidized bed to apply thermoplastic powder to the bundle. Finally, direct electrical heating of the coated fiber tow melts the polymer on the individual fibers, creating a uniform and extremely flexible prepreg. The efficiency of the process was evaluated during initial trials in which a thermoplastic polyimide, LaRC-TPI, was applied to T-300, 3K (3000 filament) carbon fiber tow. The physical properties of unidirectional composite specimens fabricated from this prepreg were measured, and the matrix uniformity and void content of the samples was determined. The results of these evaluations are detailed and discussed.

Allen, L. E.↗