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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Bioreactor Development for CO2-Based In Situ Resource Utilization Manufacturing

Sustainable long-duration manned missions on both the Moon and Mars will require in situ resource utilization (ISRU). Carbon dioxide (CO2) has great potential as a harvestable resource, making up 95% of the atmosphere on Mars and being produced as respiratory waste in spacecraft and future planetary habitats. Through ISRU, biomanufacturing has the capability to produce a near limitless array of products from local space resources, which include pharmaceuticals, bioplastics, chemical feedstocks, and industrial enzymes. Here, a CO2-based ISRU recombinant protein bioreactor and associated biomanufacturing organisms were designed to produce a highly stable carbonic anhydrase (CA). Initial work characterized candidate organisms for growth on acetate and formic acid, carbon substrates that can be synthesized via electrochemical conversion of CO2. To improve growth on the CO2 producing substrate formic acid and for direct integration of ISRU CO2, a synthetic Calvin-Benson-Bassam cycle was designed for use in Cyberlindnera jadinii and Escherichia coli. Genetic modifications in E. coli will be facilitated by a tailored CRISPR/Cas9 and λ red recombineering two-vector system. For expression of CA, a blue light regulated T7 promoter was employed for dynamic and small molecule free induction. Efficient bioproduction through a fed-batch exponential feeding strategy was determined via mass balance calculations from ISRU substrates to biomass and CA yield. Flux balance analysis was used to model ISRU substrate metabolism and metabolic pathway engineering in candidate organisms under cultivation strategy conditions for both metabolism reconstruction and pathway design optimization. Finally, a small-scale, disposable bag bioreactor concept for use in the NASA Bioculture System infrastructure was designed to enable CO2-based CA production in reduced-gravity environments.

Biomanufacturing, Pathway Engineering, Flux Balanc↗
NASA NTRSDate not supplied

Bioreactor Development for CO2-Based In Situ Resource Utilization Manufacturing

Sustainable long-duration manned missions on both the Moon and Mars will require in situ resource utilization (ISRU). Carbon dioxide (CO2) has great potential as a harvestable resource, making up 95% of the atmosphere on Mars and being produced as respiratory waste in spacecraft and future planetary habitats. Through ISRU, biomanufacturing has the capability to produce a near limitless array of products from local space resources. Here, a CO2-based ISRU recombinant protein producing bioreactor and associated biomanufacturing organisms were designed to produce a highly stable carbonic anhydrase (CA). Candidate organisms were selected by growth characterization on acetate and formic acid, carbon substrates that are synthesized via electrochemical conversion of CO2. To improve growth on the CO2 producing substrate formic acid and for direct integration of ISRU CO2, a synthetic Calvin-Benson-Bassam cycle was designed for use in Escherichia coli. Multiplex genetic modification in E. coli was facilitated by a tailored CRISPR/Cas9 and λ red recombineering two-vector system. For expression of CA, a blue light regulated T7 promoter was employed for dynamic and small molecule free induction. Efficient bioproduction through a fed-batch exponential feeding strategy was determined via mass balance analysis from ISRU substrates to biomass and CA yield. Flux balance analysis was used to model ISRU substrate metabolism and metabolic pathway engineering in candidate organisms under cultivation strategy conditions for both metabolism reconstruction and pathway design optimization. Finally, a small-scale, disposable bag bioreactor for use in the NASA Bioculture System infrastructure was designed to enable CO2-based CA biomanufacturing in reduced-gravity environments.

biomanufacturing↗
NASA NTRS1999

Fabrication and Performance of Zirconia Electrolysis Cells for Carbon Dioxide Reduction for Mars In Situ Resource Utilization Applications

The use of the Martian atmosphere (95% CO2) to produce oxygen (for propellant and life support) can significantly lower the required launch mass and dramatically reduce the total cost for Mars missions. Zirconia electrolysis cells are one of the technologies being considered for oxygen generation from carbon dioxide in Mars In Situ Resource Utilization (ISRU) production plants. The attractive features of the zirconia cell for this application include simple operation and lightweight, low volume system.

Minh, N. Q.↗
NASA NTRS2015

Characterization of Carbon Particulates in the Exit Flow of a Plasma Pyrolysis Assembly (PPA) Reactor

The ISS presently recovers oxygen from crew respiration via a Carbon Dioxide Reduction Assembly (CRA) that utilizes the Sabatier chemical process to reduce captured carbon dioxide to methane (CH4) and water. In order to recover more of the hydrogen from the methane and increase oxygen recovery, NASA Marshall Space Flight Center (MSFC) is investigating a technology, plasma pyrolysis, to convert the methane to acetylene. The Plasma Pyrolysis Assembly (or PPA), achieves 90% or greater conversion efficiency, but a small amount of solid carbon particulates are generated as a side product and must be filtered before the acetylene is removed and the hydrogen-rich gas stream is recycled back to the CRA. In this work, we present the experimental results of an initial characterization of the carbon particulates in the PPA exit gas stream. We also present several potential options to remove these carbon particulates via carbon traps and filters to minimize resupply mass and required downtime for regeneration.

Methane pyrolysis↗
NASA NTRS2015

Optimization of the Carbon Dioxide Removal Assembly (CDRA-4EU) in Support of the International Space System and Advanced Exploration Systems

The Life Support Systems Project (LSSP) under the Advanced Exploration Systems (AES) program builds upon the work performed under the AES Atmosphere Resource Recovery and Environmental Monitoring (ARREM) project focusing on the numerous technology development areas. The Carbon Dioxide (CO2) removal and associated air drying development efforts are focused on improving the current state-of-the-art system on the International Space Station (ISS) utilizing fixed beds of sorbent pellets by seeking more robust pelletized sorbents, evaluating structured sorbents, and examining alternate bed configurations to improve system efficiency and reliability. A component of the CO2 removal effort utilizes a virtual Carbon Dioxide Removal Assembly, revision 4 (CDRA-4) test bed to test a large number of potential operational configurations with independent variations in flow rate, cycle time, heater ramp rate, and set point. Initial ground testing will provide prerequisite source data and provide baseline data in support of the virtual CDRA. Once the configurations with the highest performance and lowest power requirements are determined by the virtual CDRA, the results will be confirmed by testing these configurations with the CDRA-4EU ground test hardware. This paper describes the initial ground testing of select configurations. The development of the virtual CDRA under the AES-LSS Project will be discussed in a companion paper.

Knox, James C.↗
NASA NTRS2015

Double-Pulse Two-Micron IPDA Lidar Simulation for Airborne Carbon Dioxide Measurements

An advanced double-pulsed 2-micron integrated path differential absorption lidar has been developed at NASA Langley Research Center for measuring atmospheric carbon dioxide. The instrument utilizes a state-of-the-art 2-micron laser transmitter with tunable on-line wavelength and advanced receiver. Instrument modeling and airborne simulations are presented in this paper. Focusing on random errors, results demonstrate instrument capabilities of performing precise carbon dioxide differential optical depth measurement with less than 3% random error for single-shot operation from up to 11 km altitude. This study is useful for defining CO2 measurement weighting, instrument setting, validation and sensitivity trade-offs.

Refaat, Tamer F.↗
NASA NTRS2008

Solid-State 2-Micron Laser Transmitter Advancement for Wind and Carbon Dioxide Measurements From Ground, Airborne, and Space-Based Lidar Systems

NASA Langley Research Center has been developing 2-micron lidar technologies over a decade for wind measurements, utilizing coherent Doppler wind lidar technique and carbon dioxide measurements, utilizing Differential Absorption Lidar (DIAL) technique. Significant advancements have been made towards developing state-of-the-art technologies towards laser transmitters, detectors, and receiver systems. These efforts have led to the development of solid-state lasers with high pulse energy, tunablility, wavelength-stability, and double-pulsed operation. This paper will present a review of these technological developments along with examples of high resolution wind and high precision CO2 DIAL measurements in the atmosphere. Plans for the development of compact high power lasers for applications in airborne and future space platforms for wind and regional to global scale measurement of atmospheric CO2 will also be discussed.

Singh, Upendra N.↗
NASA NTRS1972

A continuous physiological data collector

COP-DAC system utilizes oxygen and carbon dioxide analyzers, gas-flow meter, gas breathe-through system, analog computer, and data storage system to provide actual rather than average measurements of physiological and metabolic functions.

Bush, J. C.↗
NASA NTRS2005

Sabatier Methanation Reactor for Space Exploration

The Sabatier Methanation Reactor technology is of vital importance to the success of the human and robotic exploration program. In order to achieve an affordable program, the logistics supply to support the mission must be minimized to the fullest extent possible. One area of potential reduction with high return on investment is the closure of life support loops, particularly oxygen and water. The Sabatier system accomplishes this by utilizing hydrogen and carbon dioxide, waste products from the life support system, to produce water and methane. The recovered water is then recycled back into the life support system to provide oxygen; while the methane can be used for propulsion, or can be broken down further to recover the hydrogen. This technology is applicable not only to transit phases of exploration, but surface habitats as well as in-situ propellant production. The Sabatier Reactor system has been developed for ground based demonstration experiments extensively over the past 30 years. Over the past three years, NASA has funded development of the Sabatier Carbon Dioxide Reduction Assembly (CRA) for use on the ISS. Currently this system is at TRL 5 and it is expected that the system will be flown on the ISS as a flight experiment, The purpose of the flight experiment is to integrate the Sabatier CRA into a synchronized system with the oxygen generation system and the carbon dioxide concentrator. The flight experiment will verify the integration of the different systems working together plus it will verify the capability of the system to operate, and effectively separate its products in a micro-gravity environment. Subsequent to design validation, the flight experiment can remain onboard the ISS providing valuable water to offset logistics re-supply requirements. Some of the challenges facing the development of the Sabatier system include handling vibration induced particulates, microgravity phase separation and containment of hazardous gases. Plans for adequately addressing these issues will be presented. The Sabatier carbon dioxide reduction process will greatly benefit any of the extended duration human exploration missions because of the tremendous savings of consumables realized. Any of these mission scenarios, be they transit or surface based, must consider closing the life support loops in order to make the mission achievable, let alone affordable. Carbon dioxide reduction technology will be necessary for future outpost habitats, and the technology needs to be proven viable in a space application. The Sabatier methanation reaction is also a desirable method for producing propellant from the Mars atmosphere. The common system could be designed to accept carbon dioxide from an indoor air revitalization loop concentrator, or from an outdoor atmosphere compressor. Carbon dioxide reduction validation is but one step in the spiral development of the in-situ propellant production system desired for future planetary exploration.

Murdoch, Karen↗
NASA NTRS1973

Chemical pump study for Pioneer Venus program

Two chemical pumps were designed for the Pioneer Venus large probe mass spectrometer. Factors involved in the design selection are reviewed. One pump is designed to process a sample of the Venus atmosphere to remove the major component, carbon dioxide, so that the minor, inert components may be measured with greater sensitivity. The other pump is designed to promote flow of atmospheric gas through a pressure reduction inlet system. This pump, located downstream from the mass spectrometer sampling point, provides the pressure differential required for flow through the inlet system. Both pumps utilize the reaction of carbon dioxide with lithium hydroxide. The available data for this reaction was reviewed with respect to the proposed applications, and certain deficiencies in reaction rate data at higher carbon dioxide pressures noted. The chemical pump designed for the inert gas experiment has an estimated volume of 30 cu cm and weight of 80 grams, exclusive of the four valves required for the operation. The chemical pump for the pressure reduction inlet system is designed for a total sample of 0.3 bar liter during the Venus descent.

Rotheram, M.↗
NASA NTRS2000

Separation of Carbon Monoxide and Carbon Dioxide for Mars ISRU-Concepts

Solid oxide electrolyzers, such as electrolysis cells utilizing yttria-stabilized zirconia, can produce oxygen from Mars atmospheric carbon dioxide and reject carbon monoxide and unreacted carbon dioxide in a separate stream. The oxygen-production process has been shown to be far more efficient if the high-pressure, unreacted carbon dioxide can be separated and recycled back into the feed stream. Additionally, the mass of the adsorption compressor can be reduced. Also, the carbon monoxide by-product is a valuable fuel for space exploration and habitation, with applications from fuel cells to production of hydrocarbons and plastics. In our research, we will design, construct, and test an innovative, robust, low mass, low power separation device that can recover carbon dioxide and carbon monoxide for Mars ISRU. Such fundamental process technology, involving gas-solid phase separation in a reduced gravitational environment, will help to enable Human Exploration and Development of Space. The separation device will be scaled to operate with a CO2 sorption compressor and a zirconia electrolysis device built at the NASA Ames Research Center and the University of Arizona, respectively. In our research, we will design, construct, and test an innovative, robust, low mass, low power separation device that can recover carbon dioxide and carbon monoxide for Mars ISRU, Such fundamental process technology, involving gas-solid phase separation in a reduced gravitational environment, will help to enable Human Exploration and Development of Space. The separation device will be scaled to operate with a CO2 sorption compressor and a zirconia electrolysis device built at the NASA Ames Research Center and the University of Arizona, The separation device will be scaled to operate with a CO2 sorption compressor and a zirconia electrolysis device built at the NASA Ames Research Center and the University of Arizona, Research needs for the design shown are as follows: (1) The best adsorbent for the process must be determined. (2) Adsorption isotherms must be measured, both for pure components and mixtures. (3) Mathematical modeling must be performed to provide a solid framework for design. (4) The separation system must be constructed and tested. (5) System integration must be studied.

LeVan, M. Douglas↗
NASA NTRS1993

The 1992-1993 advanced design program. Part 1: The Mars methane engine project. Part 2: The Mars oxygen processor new furnace

Three constituents of the Martian atmosphere, methane, carbon dioxide, and oxygen, can be used for internal combustion in engines utilized for future space exploration on Mars. These three gases, considered as the test case in this research, will be examined to determine required flow rates needed for combustion and optimization of engine performance. Results of the test case are examined in relation to a base case of methane and air for comparative purposes. Testing of exhaust temperatures, cylinder pressure, and exhaust gas analysis were performed for the base case and test case. Also described is a study utilizing a zirconia cell to convert carbon dioxide into usable oxygen to help support future Mars missions.

Lauer, Stephen↗
NASA NTRS2017

Novel Liquid Sorbent C02 Removal System for Microgravity Applications

Removing Carbon Dioxide (CO2) from a spacecraft environment for deep space exploration requires a robust system that is low in weight, power, and volume. Current state-of-the-art microgravity compatible CO2 removal systems, such as the carbon dioxide removal assembly (CDRA), utilize solid sorbents that demand high power usage due to high desorption temperatures and a large volume to accommodate for their comparatively low capacity for CO2. Additionally, solid sorbent systems contain several mechanical components that significantly reduce reliability and contribute to a large overall mass. A liquid sorbent based system has been evaluated as an alternative is proposed to consume 65% less power, weight, and volume than solid based CO2 scrubbers. This paper presents the design of a liquid sorbent CO2 removal system for microgravity applications.

Rogers, Tanya↗
NASA NTRS2022

Plasma Activated Water for Crewed Transit and Planetary Habitation: A Study of Gas Type, Electrode Material, and Power Supply Selection and the Impact on the Final Frontier - FY21 CIF

An in-depth study of plasma activated water (PAW) generation was conducted to link changes in power supply, electrode material, input gas, and treatment time to the resulting reaction chemistry. These changes in chemistry can help tailor PAW for different space applications. An AC, DC, and nanosecond (ns) pulsed power supply were each used to generate PAW with stainless steel, copper, tungsten, or platinum (Pt) electrodes while utilizing air, nitrogen (N2), carbon dioxide (CO2), helium (He), or argon (Ar) as the feed gas. Tap or deionized (DI) water was treated for 1 to 15 minutes, and the generated PAW was tested for changes in pH, conductivity, oxidation reduction potential, nitrates (NO3-), ammonium (NH4+), and peroxide. Calculations showed that the production of reactive nitrogen species was the leading cause of pH and conductivity changes. The DC generated air plasma was able to reduce the pH of DI water and generate NO3‑. The pulsed supply, operating at 20% of the input power of the DC supply, lowered the pH generated NO3‑. When a simulated Martian gas mixture of 95% CO2 and 5% N2 was used as the feed gas, NO3‑ was generated with the DC and pulsed supplies, respectively. Mixing PAW with plasma generated ash from inedible biomass allowed pH control, thus enhancing PAW’s potential use for sanitation applications. The large shift in pH was used to study sanitation effects of Escherichia coli (E. coli) reduction and Staphylococcus aureus (S. aureus), in which log reductions were found to be negligible. Additionally, the plasma generated ash in combination with PAW was also implemented in 10-day microgreen growth trials, in which PAW and ash resulted in quicker emergence of the microgreens compared to the standard growth conditions and comparable dry masses to Hoagland’s nutrient solution treated samples.

plasma activated water (PAW)↗
NASA NTRS1999

Fabrication and Performance of Zirconia Electrolysis Cells for Cabon Dioxide Reduction for Mars In Situ Resource Utilization Applications

Use of the Martian atmosphere (95% CO2) to produce oxygen (for propellant and life support) can significantly lower the required launch mass and dramatically reduce the total cost for Mars missions. Zirconia electrolysis cells are one of the technologies being considered for oxygen generation from carbon dioxide in Mars In Situ Resource Utilization (ISRU) production plants. The attractive features of the zirconia cell for this application include simple operation and lightweight, low volume system. A zirconia electrolysis cell is an all-solid state device, based on oxygen-ion conducting zirconia electrolytes, that electrochemically reduces carbon dioxide to oxygen and carbon monoxide. The cell consists of two porous electrodes (the anode and cathode) separated by a dense zirconia electrolyte. Typical zirconia cells contain an electrolyte layer which is 200 to 400 micrometer thick. The electrical conductivity requirement for the electrolyte necessitates an operating temperature of 9000 to 10000C. Recently, the fabrication of zirconia cells by the tape calendering has been evaluated. This fabrication process provides a simple means of making cells having very thin electrolytes (5 to 30 micrometers). Thin zirconia electrolytes reduce cell ohmic losses, permitting efficient operation at lower temperatures (8000C or below). Thus, tape-calendered cells provides not only the potential of low temperature operation but also the flexibility in operating temperatures. This paper describes the fabrication of zirconia cells by the tape calendering method and discusses the performance results obtained to date.

Minh, N. Q.↗
NASA NTRSDate not supplied

Bosch Carbon Catalyst Regeneration in Water I: Bosch Carbon Removal from Reacted Beads Utilizing Mechanical Agitation

The ability to recover oxygen from metabolic carbon dioxide is crucial for crewed long duration missions in which the atmosphere must be recycled. Two physiochemical methods are primarily employed for this purpose: the Bosch process and the Sabatier reaction. This paper focuses on the Bosch process. It utilizes hydrogen in the presence of a catalyst to form water and solid carbon out of metabolic carbon dioxide. The solid carbon product deposits onto the catalyst and eventually causes reactor over pressurization issues. Multiple methods are currently being investigated to regenerate the catalyst’s surface and break up the pressure causing carbon clogs. This paper explores whether water and mechanical abrasion would work to remove Bosch carbon by testing multiple washing conditions. The different washing conditions involved agitation intensity, heating, duration, and volume of water. It was found that it is possible to break up the clumps of carbon formed in the reactor through agitation with room temperature water in one hour and shows promise for completely cleaning the carbon off the beads’ surface.

Agitation↗