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NASA NTRS2015

Increased Oxygen Recovery from Sabatier Systems Using Plasma Pyrolysis Technology and Metal Hydride Separation

State-of-the-art life support carbon dioxide (CO2) reduction technology is based on the Sabatier reaction where less than 50% of the oxygen required for the crew is recovered from metabolic CO2. The reaction produces water as the primary product and methane as a byproduct. Oxygen recovery is constrained by the limited availability of reactant hydrogen. This is further exacerbated when Sabatier methane (CH4) is vented as a waste product resulting in a continuous loss of reactant hydrogen. Post-processing methane with the Plasma Pyrolysis Assembly (PPA) to recover hydrogen has the potential to dramatically increase oxygen recovery and thus drastically reduce the logistical challenges associated with oxygen resupply. The PPA decomposes methane into predominantly hydrogen and acetylene. Due to the highly unstable nature of acetylene, a separation system is necessary to purify hydrogen before it is recycled back to the Sabatier reactor. Testing and evaluation of a full-scale Third Generation PPA is reported and investigations into metal hydride hydrogen separation technology is discussed.

Zachary W Greenwood↗
NASA NTRSDate not supplied

Comparison of Exploration Oxygen Recovery Technology Options Using ESM and LSMAC

In preparation for long duration manned space flight, numerous technology development efforts are ongoing in the area of environmental control and life support (ECLS). In cooperation with international, industry, and academic partners, NASA seeks to leverage the International Space Station as a testbed for technologies targeted for Exploration-class missions. In recent years, Equivalent Systems Mass (ESM) analyses have been conducted to evaluate the relative breakeven points and to compare technologies as part of ECLS architectural trades. While these studies have provided important data pertaining to key engineering metrics, additional considerations are important to more fully understand the potential impacts and costs associated with selecting a specific architecture. A tool, called the Life Support Multi-Dimensional Assessment Criteria (LSMAC), was recently proposed by Sierra Nevada Corporation in an attempt to incorporate influences of these additional considerations including Maintainability, Risk Analysis, Technology Readiness Level, Radiation Impacts, Manufacturing Costs, Reliability, Human Factors, and Un-Crewed Operations. As a first step toward evaluating and implementing this tool, LSMAC was used to revisit the ISS oxygen recovery trade from the 1990’s wherein Sabatier was selected over Bosch technology. Second, the tool was used to compare oxygen recovery developmental technologies currently in work. The results of these studies as well as a comparison with standalone ESM analyses are reported. Further, a discussion of the potential application of the tool across the ECLS portfolio and its potential use in future technology selection for ISS flight demonstrations is provided.

Morgan B Abney↗
NASA NTRS2020

Developmental Efforts of an Electrochemical Oxygen Recovery System for Advanced Life Support

The current State of Art (SOA) Environmental Control and Life Support System (ECLSS) oxygen recovery system onboard the International Space Station (ISS) is complex, heavy, and power consuming system that recovers approximately 50% of the oxygen (O2) from metabolic carbon dioxide (CO2). For future long-duration missions, O2 recovery systems will need to be highly reliable, efficient, and recover maximum metabolic CO2. A minimum of 75% O2 recovery is required for future O2 recovery systems. Investigations into various technologies to help meet these requirements for exploration are ongoing; however, most of these proposed technologies ultimately result in a more complex system. A Macrofluidic Electrochemical Reactor (MFECR) is one proposed technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) that has the potential to significantly reduce the complexity of ECLSS O2 recovery system. The MFECR operates at standard conditions, giving it an advantage over other technologies being investigated, which require high temperatures resulting in heavy reactors and high power consumption. The MFECR would replace three pieces of hardware for future ECLSS architectures: the current Carbon Dioxide Reduction Assembly (Sabatier reactor), the Plasma Pyrolysis Assembly (PPA), and the Oxygen Generation Assembly (OGA). It is designed to interface directly with the Carbon Dioxide Removal Assembly (CDRA) and the Water Processor Assembly (WPA). This allows for a less complex system and higher reliability than the current SOA as well as reduced power, weight and H2O consumption of ECLSS. Here, we will discuss the current technology development efforts of the MFECR and how this technology may aide in the advancement of future long-duration life support systems.

Brown, Brittany R.↗
NASA NTRSDate not supplied

Developmental Efforts of an Electrochemical Oxygen Recovery System for Advanced Life Support

The current State of Art (SOA) Environmental Control and Life Support System (ECLSS) oxygen recovery system onboard the International Space Station (ISS) is a complex, heavy, and power consuming system that recovers approximately 50% of the oxygen (O2) from metabolic carbon dioxide (CO2). For future long-duration missions, O2recovery systems will need to be highly reliable, efficient, and recover maximum metabolic CO2. Investigations into various technologies to help meet these requirements for exploration are ongoing; however, most of these proposed technologies ultimately result in a more complex system. A Macrofluidic Electrochemical Reactor (MFECR) is one proposed technology development effort currently underway at NASA Marshall Space Flight Center (MSFC) that has the potential to significantly reduce the complexity of ECLSSO2recovery system. The MFECR operates at standard conditions, giving it an advantage over other technologies being investigated, which require high temperatures resulting in heavy reactors and high power consumption. The MFECR would replace three pieces of hardware for future ECLSS architectures: the current Carbon Dioxide Reduction Assembly (Sabatier reactor), the Plasma Pyrolysis Assembly (PPA), and the Oxygen Generation Assembly(OGA). It is designed to interface directly with the Carbon Dioxide Removal Assembly (CDRA) and the Water Processor Assembly (WPA). This allows for a less complex system and higher reliability than the current SOA as well as reduced power, weight and H2Oconsumption of ECLSS. Here, we will discuss the current development efforts of the MFECR and how this technology may aide in the advancement of future long-duration life support systems.

Brittany R Brown↗
NASA NTRSDate not supplied

Development of Electrolytic Oxygen Recovery System for Advanced Life Support

The oxygen (O2) recovery system for the International Space Station (ISS) can recover approximately 50 percent of O2 from metabolic carbon dioxide (CO2). Increasing the O2 recovery rate and closing the open loop for future long duration crewed missions in space beyond Low Earth Orbit (LEO) is essential. There are several developmental efforts underway to increase the recovery rate. However, most of these technologies result in a complex, heavy, and power consuming system. The desired exploration O2 recovery system would be reliable and efficient with maximum O2 recovery. Marshall Space Flight Center (MSFC) is currently investigating an electrolytic O2 recovery approach that will increase the O2 recovery to greater than 70 percent as well as lowering the complexity, mass, and power consumption than most other technologies currently under development. The electrolytic O2 recovery system consists of a Microfluidic Electrochemical Reactor (MFECR) that is based on the electrochemical reduction of CO2 to O2 and ethylene (C2H4) using water (H2O) as precursor and operates at standard condition with a theoretical recovery rate of 73 percent. In 2016, NASA’s Game Changing Development Program awarded the University of Texas Arlington (UTA) a grant to initiate the development of the MFECR. Since 2019, MSFC and UTA have been collaborating with the current goals of increasing the O2 recovery efficiency, advancing the technology readiness to a Technology Readiness Level (TRL) 4, and maturing the system to process CO2 of one crew-member. Based on the results from UTA’s initial efforts, the following were identified as key areas of improvement in order to maximize O2 recovery for the system: further development of the anode material and cathode catalyst, model-based cell design optimization, and the addition of a separation system and fuel cell. This paper will present the current developmental efforts of the electrolytic system including MFECR design and overall system enhancements as well as results from single cell stack testing.

Brittany R Brown↗
NASA NTRS2016

Game Changing Development Program - Next Generation Life Support Project: Oxygen Recovery From Carbon Dioxide Using Ion Exchange Membrane Electrolysis Technology

This report summarizes the Phase I research and development work performed during the March 13, 2015 to July 13, 2016 period. The proposal for this work was submitted in response to NASA Research Announcement NNH14ZOA001N, "Space Technology Research, Development, Demonstration, and Infusion 2014 (SpaceTech-REDDI-2014)," Appendix 14GCD-C2 "Game Changing Development Program, Advanced Oxygen Recovery for Spacecraft Life Support Systems Appendix" The Task Agreement for this Phase I work is Document Control Number: GCDP-02-TA-15015. The objective of the Phase I project was to demonstrate in laboratories two Engineering Development Units (EDU) that perform critical functions of the low temperature carbon dioxide electrolysis and the catalytic conversion of carbon monoxide into carbon and carbon dioxide. The low temperature carbon dioxide electrolysis EDU was built by the University of Delaware with Dr. Feng Jiao as the principal investigator in charge of this EDU development (under NASA Contract NNC15CA04C). The carbon monoxide catalytic conversion EDU was built by the NASA Glenn Research Center with Kenneth Burke as the principal investigator and overall project leader for the development of both EDUs. Both EDUs were successfully developed and demonstrated the critical functions for each process. The carbon dioxide electrolysis EDU was delivered to the NASA Johnson Space Center and the carbon monoxide catalytic conversion EDU was delivered to the NASA Marshall Spaceflight Center.

Oxygen Recovery↗
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

An Approach for Hydrogen Recycling in a Closed-loop Life Support Architecture to Increase Oxygen Recovery Beyond State-of-the-Art

State‐of‐the‐art atmosphere revitalization life support technology on the International Space Station is theoretically capable of recovering 50% of the oxygen from metabolic carbon dioxide via the Carbon Dioxide Reduction Assembly (CRA). When coupled with a Plasma Pyrolysis Assembly (PPA), oxygen recovery increases dramatically, thus drastically reducing the logistical challenges associated with oxygen resupply. The PPA decomposes methane to predominantly form hydrogen and acetylene. Because of the unstable nature of acetylene, a down‐stream separation system is required to remove acetylene from the hydrogen stream before it is recycled to the CRA. A new closed‐loop architecture that includes a PPA and downstream Hydrogen Purification Assembly (HyPA) is proposed and discussed. Additionally, initial results of separation material testing are reported.

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 NTRS1973

Cost analysis of oxygen recovery systems

The design and development of equipment for flight use in earth-orbital programs, when optimally approached cost effectively, proceed through the following logical progression: (1) bench testing of breadboard designs, (2) the fabrication and evaluation of prototype equipment, (3) redesign to meet flight-imposed requirements, and (4) qualification and testing of a flight-ready system. Each of these steps is intended to produce the basic design information necessary to progress to the next step. The cost of each step is normally substantially less than that of the following step. An evaluation of the cost elements involved in each of the steps and their impact on total program cost are presented. Cost analyses of four leading oxygen recovery subsystems which include two carbon dioxide reduction subsystem, Sabatier and Bosch, and two water electrolysis subsystems, the solid polymer electrolyte and the circulating KOH electrolyte are described.

Yakut, M. M.↗
NASA NTRS2016

A Discussion of Oxygen Recovery Definitions and Key Performance Parameters for Closed-Loop Atmosphere Revitalization Life Support Technology Development

Over the last 55 years, NASA has evolved life support for crewed space exploration vehicles from simple resupply during Project Mercury to the complex and highly integrated system of systems aboard the International Space Station. As NASA targets exploration destinations farther from low Earth orbit and mission durations of 500 to 1000 days, life support systems must evolve to meet new requirements. In addition to having more robust, reliable, and maintainable hardware, limiting resupply becomes critical for managing mission logistics and cost. Supplying a crew with the basics of food, water, and oxygen become more challenging as the destination ventures further from Earth. Aboard ISS the Atmosphere Revitalization Subsystem (ARS) supplies the crew's oxygen demand by electrolyzing water. This approach makes water a primary logistics commodity that must be managed carefully. Chemical reduction of metabolic carbon dioxide (CO2) provides a method of recycling oxygen thereby reducing the net ARS water demand and therefore minimizing logistics needs. Multiple methods have been proposed to achieve this recovery and have been reported in the literature. However, depending on the architecture and the technology approach, "oxygen recovery" can be defined in various ways. This discontinuity makes it difficult to compare technologies directly. In an effort to clarify community discussions of Oxygen Recovery, we propose specific definitions and describe the methodology used to arrive at those definitions. Additionally, we discuss key performance parameters for Oxygen Recovery technology development including challenges with comparisons to state-of-the-art.

Abney, Morgan B.↗
NASA NTRS2003

Status of the Node 3 Regenerative Environmental Cpntrol& Life Support System Water Recovery & Oxygen Generation Systems

NASA s Marshall Space Flight Center is providing three racks containing regenerative water recovery and oxygen generation systems (WRS and OGS) for flight on the lnternational Space Station s (ISS) Node 3 element. The major assemblies included in these racks are the Water Processor Assembly (WPA), Urine Processor Assembly (UPA), Oxygen Generation Assembly (OGA), and the Power Supply Module (PSM) supporting the OGA. The WPA and OGA are provided by Hamilton Sundstrand Space Systems lnternational (HSSSI), while the UPA and PSM are being designed and manufactured in-house by MSFC. The assemblies are currently in the manufacturing and test phase and are to be completed and integrated into flight racks this year. This paper gives an overview of the technologies and system designs, technical challenges encountered and solved, and the current status.

Carrasquillo, Robyn L.↗
NASA NTRS2004

Experimental Simulation of Turbine-Exhaust Oxygen Recovery

In some liquid-propellant rocket engines, the liquid-oxygen boost pump is driven by a turbine that is powered by high-pressure gaseous oxygen. Once it exits the turbine, this gaseous oxygen can be salvaged by injecting it into the subcooled liquid oxygen exiting the boost pump. If the main LOX pump is to function correctly under these circumstances, complete condensation of the gaseous oxygen must quickly follow its injection into the boost-pump discharge. The current investigation uses steam and water in a simple rig that allows the condensation process to be visualized and quantified. This paper offers dimensionless-parameter correlations of the data and trends observed.

Clark, Jim A.↗
NASA NTRS1996

Integrated Oxygen-Recovery System

System for revitalizing breathing air in enclosed environment converts carbon dioxide and water to oxygen and methane. Chemical conversions take place in reactor module containing solid-metal-cathode water electrolyzer integrated with Sabatier reactor. According to design estimates, fully developed version of system sized to maintain breathable air for four persons, occupies 67 percent less volume, weighs 60 percent less, and consumes 3.4 percent less power than system of same capacity in which electrolyzer and Sabatier reactor are distinct components. Although oxygen primary desired end product in system originally contemplated, product methane also of value in industrial version of system.

Schubert, F. H.↗
NASA NTRS2002

Solid-State Compressor for Space Station Oxygen Recovery

At present, the life support system on the International Space Station Alpha vents overboard the carbon dioxide (CO2) produced by the crew members. Recovering the oxygen contained in the CO2 has the potential to reduce resupply mass by 2000 pounds per year or more, a significant weight that could be used for experimental payloads and other valuable items. The technologies used to remove CO2 from the air and to recover O2 from CO2 are flight-ready; however, the interface between the devices is a problem for the Space Station system. Ames Research Center has developed a new technology that solves the interface issue, possibly allowing closure of the oxygen loop in a spacecraft for the first time. CO2 produced by the crew is removed in the Carbon Dioxide Removal Assembly (CDRA). This device effectively produces a pure CO2 stream, but at a very low pressure. Elsewhere, the oxygen generation system which makes O2 by electrolyzing water produces a hydrogen stream. In principle the CO2 and H2 can react to form methane and water over a suitable catalyst. Water produced in this methane-formation reactor can be returned to the water electrolyzer, where the O2 can be returned to the cabin; however, the methane-formation reactor requires CO2 at a much higher pressure than that produced by the CDRA. Furthermore, the CO2 and H2 are often not available at the same time, due to power management and scheduling on the space station. In order to get the CO2 to the reactor at the right pressure and at the right time, a device or assembly that functions as a vacuum pump, compressor, and storage tank is required.

Finn, John E.↗
NASA NTRS1973

Spacecraft oxygen recovery system

A system which uses an electrochemical carbon dioxide concentrator to remove carbon dioxide from the cabin atmosphere and a Sabatier reactor to reduce carbon dioxide with hydrogen to form methane and water is described. Oxygen is recovered from water by means of a static-feed water electrolysis system. The hydrogen thus generated is reused in the carbon dioxide concentrator. The methane is a system byproduct. The CO2 removal reactions and the implementation of the CO2 concentration concept are discussed, and test results are examined.

Quattrone, P. D.↗
DOE OSTI2023

Identifying High-Performance Metal–Organic Frameworks for Low-Temperature Oxygen Recovery from Helium by Computational Screening

Metal–organic frameworks (MOFs) are an important class of porous crystalline materials for applications ranging from gas adsorption and separation to catalysis. There are thousands of potential MOFs available for separation applications. Here, we developed a computational approach to screen MOFs for the separation of oxygen–helium mixtures at low temperatures (100–200 K), conditions that were motivated by issues associated with propulsion in space-based settings. We used detailed molecular simulations for a small number of MOFs to develop screening methods that were then used to estimate the optimum temperatures for separations using pressure swing adsorption for 2932 MOFs from the CoRE MOF database and the swing capacity and oxygen–helium selectivity at these temperatures. We used the stability of the best-performing structures in the presence of moisture as a means to provide a short list of high-performance materials. In addition to identifying specific materials for oxygen–helium separations, this approach could prove useful for selecting adsorbents for other gas separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗