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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 NTRS2003

Experiences with Lab-on-a-chip Technology in Support of NASA Supported Research

Under the auspices of the Microgravity Sciences and Application Department at Marshall Space Flight Center, we have custom designed and fabricated a lab-on-a-chip (LOC) device, along with Caliper Technologies, for macromolecular crystal growth. The chip has been designed to deliver specified proportions of up-to five various constituents to one of two growth wells (on-chip) for crystal growth. To date, we have grown crystals of thaumatin, glucose isomerase and appoferitin on the chip. The LOC approach offered many advantages that rendered it highly suitable for space based hardware to perform crystal growth on the International Space Station. The same hardware that was utilized for the crystal growth investigations, has also been used by researchers at Glenn Research Center to investigate aspects of microfluidic phenomenon associated with two-phase flow. Additionally, our LOCAD (Lab-on-a-chip Application Development) team has lent its support to Johnson Space Center s Modular Assay for Solar System Exploration project. At present, the LOCAD team is working on the design and build of a unique lab-on-a-chip breadboard control unit whose function is not commercially available. The breadboard can be used as a test bed for the development of chip size labs for environmental monitoring, crew health monitoring assays, extended flight pharmacological preparations, and many more areas. This unique control unit will be configured for local use and/or remote operation, via the Internet, by other NASA centers. The lab-on-a-chip control unit is being developed with the primary goal of meeting Agency level strategic goals.

Monaco, Lisa↗
NASA NTRS1991

Two-Phase Bidirectional Heat Exchanger

Heat exchanger transfers heat from one two-phase thermal loop to another. Condenses vapor in one loop while evaporating liquid in other. Transfers heat with very small drops in temperature and pressure, and efficiently joins heat pipes thermally without mixing of their working fluids. Several such heat exchangers used to build long, complex multiloop heat-control systems. Exchanger bidirectional: transfers heat in reverse, condensing on normally evaporating side, and vice versa. Can warm equipment it normally cools, without using auxiliary heater. In reverse transfer, wicks on evaporating side supply liquid continuously by capillary action; reverse-flow pump not needed. Design modified for other working fluids and larger heat-transfer rates.

Kroliczek, Edward↗
NASA NTRS1987

Development of a prototype two-phase thermal bus system for Space Station

This paper describes the basic elements of a pumped two-phase ammonia thermal control system designed for microgravity environments, the development of the concept into a Space Station flight design, and design details of the prototype to be ground-tested in the Johnson Space Center (JSC) Thermal Test Bed. The basic system concept is one of forced-flow heat transport through interface heat exchangers with anhydrous ammonia being pumped by a device expressly designed for two-phase fluid management in reduced gravity. Control of saturation conditions, and thus system interface temperatures, is accomplished with a single central pressure regulating valve. Flow control and liquid inventory are controlled by passive, nonelectromechanical devices. Use of these simple control elements results in minimal computer controls and high system reliability. Building on the basic system concept, a brief overview of a potential Space Station flight design is given. Primary verification of the system concept will involve testing at JSC of a 25-kW ground test article currently in fabrication.

Myron, D. L.↗
DOE OSTI2025

Population Balance Models for Catalytic Depolymerization: From Elementary Steps to Multiphase Reactors

Here, the ongoing accumulation of plastic waste in landfills and in the environment is driving research on chemical processes and catalysts to recycle polymers. Traditional modeling strategies are not applicable to these processes because they involve too many reactants and intermediates, one for each molecular weight and each functionalization. To model the kinetics, we have developed population balance models (PBMs) that account for macromolecular reactants in the bulk and macromolecular catalytic intermediates. These PBMs couple to each other through polymer adsorption and desorption models and to traditional rate equations for small molecule products and co-reactants (like hydrogen or ethylene). The models, in combination with experimental data, are being used in many ways: (i) to test mechanistic hypotheses, (ii) to extract rate parameters, (iii) to quantitatively compare catalyst activities, (iv) to account for mass transfer and vapor–liquid partitioning in two-phase reactors, and (v) to design novel support architectures and catalysts that mimic the processive action of natural depolymerization enzymes. Some key theoretical advances allow PBMs to be constructed from elementary rates and mechanisms, as opposed to traditional formulations with pseudoelementary rate parameters invoked as fitting parameters. We discuss ways to build these models “bottom-up” from first-principles calculations and ways to extract model parameters from “top down” analyses of rate data. The combination provides a quantitative bridge between first-principles calculations and the kinetics of complex macromolecular transformations for polymer upcycling and beyond.

Manis, Lela K. [University of Illinois at Urbana-C↗
NASA NTRS2011

Validation and Simulation of Ares I Scale Model Acoustic Test - 3 - Modeling and Evaluating the Effect of Rainbird Water Deluge Inclusion

The Ares I Scale Model Acoustics Test (ASMAT) is a series of live-fire tests of scaled rocket motors meant to simulate the conditions of the Ares I launch configuration. These tests have provided a well documented set of high fidelity measurements useful for validation including data taken over a range of test conditions and containing phenomena like Ignition Over-Pressure and water suppression of acoustics. Building on dry simulations of the ASMAT tests with the vehicle at 5 ft. elevation (100 ft. real vehicle elevation), wet simulations of the ASMAT test setup have been performed using the Loci/CHEM computational fluid dynamics software to explore the effect of rainbird water suppression inclusion on the launch platform deck. Two-phase water simulation has been performed using an energy and mass coupled lagrangian particle system module where liquid phase emissions are segregated into clouds of virtual particles and gas phase mass transfer is accomplished through simple Weber number controlled breakup and boiling models. Comparisons have been performed to the dry 5 ft. elevation cases, using configurations with and without launch mounts. These cases have been used to explore the interaction between rainbird spray patterns and launch mount geometry and evaluate the acoustic sound pressure level knockdown achieved through above-deck rainbird deluge inclusion. This comparison has been anchored with validation from live-fire test data which showed a reduction in rainbird effectiveness with the presence of a launch mount.

Strutzenberg, Louise L.↗
NASA NTRS1990

An investigation of messy genetic algorithms

Genetic algorithms (GAs) are search procedures based on the mechanics of natural selection and natural genetics. They combine the use of string codings or artificial chromosomes and populations with the selective and juxtapositional power of reproduction and recombination to motivate a surprisingly powerful search heuristic in many problems. Despite their empirical success, there has been a long standing objection to the use of GAs in arbitrarily difficult problems. A new approach was launched. Results to a 30-bit, order-three-deception problem were obtained using a new type of genetic algorithm called a messy genetic algorithm (mGAs). Messy genetic algorithms combine the use of variable-length strings, a two-phase selection scheme, and messy genetic operators to effect a solution to the fixed-coding problem of standard simple GAs. The results of the study of mGAs in problems with nonuniform subfunction scale and size are presented. The mGA approach is summarized, both its operation and the theory of its use. Experiments on problems of varying scale, varying building-block size, and combined varying scale and size are presented.

Goldberg, David E.↗
NASA NTRS2018

Thermal Modeling of Zero Boil Off Tank Experiment

Understanding fluid behavior in microgravity environments is essential to further development of cryogenic storage in space environments. The Zero Boil Off Tank (ZBOT) experiment was designed to investigate two-phase pressurization and depressurization of a tank in a microgravity environment. The test fluid was the refrigerant Perfluoro-normal-Pentane (PNP). Thermal modeling for the ZBOT model was conducted using Thermal Desktop and SINDA/FLUINT. The temperature distribution within the fluid of the tank is of particular interest. This particular work is centered on ascertaining the thermal behavior of the refrigerant in order to build more complete models of fluid in microgravity. Separate cases were run modeling experiments that were conducted both on the ground and on the International Space Station (ISS) to compare 1g and microgravity environments. The microgravity modeling cases consisted of a fluid lump representing the vapor ullage suspended in a solid to represent the liquid. Mass flow between the liquid and vapor was modeled using the Schrage equation for mass flow. Initial results indicate that the pressure rise and temperature increase within the fluid closely align with the experimental data by matching initial conditions of the experiment. This work is ongoing and will yield further insights into the thermal behavior of fluid mixing in microgravity.

low-gravity fluid modeling↗
DOE OSTI2023

Asymptotic hydrogen redistribution analysis in yttrium-hydride-moderated heat-pipe-cooled microreactors using DireWolf

Yttrium hydride (YH x ) is one of the materials being considered for moderating thermal and epithermal nuclear microreactors. One potential issue with YH x use is that the hydrogen redistributes in the hydride when thermal and concentration gradients are present. This hydrogen redistribution leads to spatial gradients in the hydrogen concentration, thus affecting neutron transport in the reactor. Here, by building upon observations in prior works, this paper aims to gain a better understanding of the reactivity feedback associated with such hydrogen redistributions. In particular, we wish to understand the sign (+/–) of the hydrogen redistribution neutronic feedback, its order of magnitude, and its underlying physical causes. To achieve this goal, the DireWolf multiphysics software driver was used to solve the coupled radiation transport, heat transfer, heat pipe two-phase flow, and hydrogen redistribution equations for the Simplified Microreactor Benchmark Assessment (SiMBA) problem, a full-core microreactor numerical benchmark developed at Idaho National Laboratory.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2022

Embedding Climate Change in Urban Planning and Urban Design in New York City

Confronting the challenges of a rapidly urbanizing world threatened by climate change requires expanding the traditional influence and capabilities of urban planning and urban design, integrating climate science, natural systems and compact urban form to configure dynamic, desirable and healthy communities. Cost-effective planning and design measures that help mitigate emissions while bringing adaptive benefits should be prioritized. The chapter draws from the publication Climate Change and Cities (Cambridge University Press 2018) by the Urban Climate Change Research Network (UCCRN). The two-phase New York City case study by the Urban Design Climate Lab at the New York Institute of Technology and a team of international urban design climate experts illustrates how this emerging expertise can be replicated and implemented worldwide. Its focus on configuring people-centered public spaces that enhance energy efficiency and improve public health draws from four urban climate factors: improving efficiency of urban systems, both in energy and transportation; optimizing the form and layout of urban districts to enhance ventilation; promoting appropriate building materials with high reflectivity; and increasing green and blue urban infrastructure. The chapter highlights a set of tools and methods to measure success.

Resiliency↗
DOE OSTI2025

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗
NASA NTRSDate not supplied

Designing the Imaging and Breadboard System for FBCE-TL Project

This presentation outlines the support work done on designing the imaging and breadboard system of the Transfer Line (TL) project, which is the third module for the Flow Boiling and Condensation Experiment (FBCE) operating in the Fluids Integrated Rack on-board the International Space Station (ISS). The goal of the FBCE is to serve as a facility for flow boiling and condensation investigating two-phase flow and heat transfer data in microgravity. The TL module aims use existing FBCE hardware to study cryogenic chilldown, a large component of cryogenic propellant tank transfer research. The TL test module will perform chilldown studies with normal-perfluorohexane (nPFH), a cryogenic simulant, flowing through a super-heated line, which is heated through the process of Joule-heating. SolidWorks and Creo were used to create electrically conductive pipe junctions that connect and seal several Indium Tin Oxide (ITO) coated sapphire tube sections together to allow for low leak probability fluid flow and circumferentially uniform electrical current density. It is necessary to understand and calculate the thermal expansion of the tubing sections such that the junctions would not leak at anticipated operating temperatures and pressures, would maintain electrical contact, and not crack the crystalline tubes. Optical imaging techniques were used to build an experimentally validated image remapping process for flight-like setups of cylindrical tubes. Then MATLAB was used to create an algorithm that distorts an image based on the refraction of light passing through the mediums we were imaging through to accurately visualize the cryogenic chilldown that is of scientific interest. This research will assist NASA to move forward with long-duration spaceflight missions where knowledge of efficient heat transfer processes becomes more critical.

imaging system↗
DOE OSTI2023

A renewable lignin-based thermoplastic adhesive for steel joining

Adhesive bonding of metals has become increasingly relevant in recent years due to the demand for reducing weight and improving performance in structural applications such as automobiles and aerospace. We developed renewable thermoplastic adhesives from technical organosolv lignin isolated from hardwood biomass and acrylonitrile butadiene co-polymer rubber (NBR) for joining steel substrates. NBR33, NBR41 and NBR51 with acrylonitrile molar ratios of 33, 41 and 51%, respectively, were blended with lignin to form two-phase thermoplastic adhesives, and their adhesion, viscoelastic and surface properties were measured. Lignin content in the compositions were varied, ranging from 40% to 80% (w/w), to alter toughness, stiffness, and surface energy characteristics of the material. Better interaction or reactivity between the lignin and NBR phases was observed with greater nitrile content in NBR, leading to greater modulus and stiffness of the adhesive. Simultaneously, increasing the proportion of lignin reduced toughness and improved stiffness, with the highest adhesive strength of 13.1 MPa measured in a 60% lignin loading ratio with NBR51. Surface energy measurements revealed that total surface energy (sum of polar and dispersive surface energy) raised with lignin loading, suggesting that both surface energy and matrix strength play a critical role in the adhesive properties of the synthesized materials. A finite element-based cohesive zone model (CZM) was developed and implemented to study the failure strength of the adhesively bonded joint. Here, this study demonstrates the viability of lignin as a valuable building block for adhesives, not only due to its inherent chemical structure and rigidity, but also for its surface energy characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Holistic energy analysis method for thermal management architectures of data centers

Modern high-performance computing (HPC) data centers (DCs), particularly those supporting energy-intensive artificial intelligence (AI) workloads, face escalating thermal management challenges that degrade performance through thermal throttling and drive up cooling power consumption and operational costs. To address this challenge, many have developed a wide variety of thermal management solutions (single-phase, two-phase, direct, indirect, hybrid, and more) which attempt to cool HPC DCs effectively while attempting to minimize overall system power consumption. However, the analysis of these solutions and methods to effectively compare one with another is lacking. Overall power usage effectiveness (PUE) and total-power usage effectiveness (TUE) provide a metric to quantify power consumption but fail to identify components in the system which require further optimization. To address this, we propose a holistic analytical framework – the waterfall diagram (WFD) – which leverages a waterfall chart methodology, offering a comprehensive visualization of both the thermal management system loop and heat flow pathways from individual server components to the outdoor ambient. Use of the WFD enables graphical estimations of power efficiency and cooling performance across each component of a DC cooling system and complements Sankey-style energy flow visualizations by additionally resolving stage-wise temperature changes and incremental TUE contributions. The framework is used in conjunction with simulation-based approaches, to conduct a detailed pressure drop and flow distribution analysis aimed at identifying the optimal coolant distribution architecture for a single-phase direct-to-chip water-cooled DC, which serves as the baseline for subsequent WFD analysis. Among the evaluated architectures, the 3 U modular coolant distribution architecture is found to demonstrate the best performance, considering minimal pressure drop and uniform flow distribution. In addition, TUE is calculated for each cooling loop component based on its associated pressure drop and corresponding pumping power, which are integrated into the WFD. This correlation between TUE and local temperature offers immediate insight into the power efficiency and thermal performance contributions of individual components, facilitating further development and optimization. Examples of WFD applications are presented under varying thermal loads and ambient conditions, demonstrating reasonable cooling strategies. Notably, the 3 U modular architecture maintains a consistent chip case temperature of 85°C, achieving a TUE of 1.016 at ambient temperature of 47°C, and a TUE of 1.026 at ambient temperature of 52°C. The WFD methodology provides an efficient, holistic, and streamlined framework for DC thermal management architecture assessment and enables design optimization which is important for addressing the thermal-fluidic energy challenges of current and next-generation DCs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Constraining the release of Sn to the ambient melting point following shock loading using time-resolved x-ray diffraction

The formation of liquid following release from a shocked state governs the transition from spall to cavitation and the formation of ejecta in metals. In order to build physics-based models of these processes, it is necessary to critically evaluate the relative importance of kinetics and entropy generation during the release along with the accuracy of multiphase equations of state. Tin (Sn) has served as a testbed for a variety of experiments examining strength and ejecta due to its accessible melt boundary and solid–solid phase transitions. This work presents experiments examining the phase evolution of high purity Sn following the shock and release to ambient stress near the melting point. Sn is found to release to states between its ambient solidus and liquidus from approximately 19 to 33 GPa under uniaxial loading, with the two-phase region being characterized by a reduction in the intensity of the (220), (211) β -Sn doublet. Jetting experiments performed at 27–28 GPa exhibit comparable diffraction patterns with what is observed following the uniaxial release. The solid fractions of β-Sn in the ambient mixed phase region are found to decrease linearly with increasing shock stress as increasing liquid Sn is formed. Here, the results provide much needed information for interpreting measurements of dynamic strength at a high strain rate and experiments examining cavitation and shallow bubble collapse in Sn.

, spall↗
DOE OSTI2024

Simulation of Particulate Transport for Delivery of Solid Amendments into the Subsurface: FY24 Status Report

For particulate-based amendments to be viable for field-scale remediation at the Hanford Site (e.g., 200 DV-1 Operable Unit), particles need to be delivered a sufficient radial distance from an injection well and retained at concentrations high enough for effective treatment. An accurate description of the particle radius of influence (ROI) is critical for developing an overall remediation strategy. However, field-scale particle simulations are currently limited due to insufficient simulation capabilities and a lack of experimental data to validate and parameterize particle transport models. To help build toward field-scale deployment, this fiscal year (FY) we have (1) developed a pre screening tool to estimate particle transport, (2) implemented particle transport models within PFLOTRAN, and (3) conducted preliminary estimations of particle ROI. While field-scale numerical simulations will ultimately be necessary before remedy design and field implementation, we have developed a pre-screening tool that offers valuable estimations of expected particle injectability and ROI in a 1-D system. The advantage of the tool is that it does not require extensive laboratory experiments and instead makes predictions based solely on routine laboratory measurements. This tool can assist in down-selection and decision-making by identifying which particle amendment systems are worth pursuing in future laboratory experiments, such as 1-D column tests and beyond. With any system, scaling up from the lab to the field presents challenges. Currently, there is no field data available for model calibration or validation. However, the theoretical particle models being developed herein are the best tools available to guide progress toward field deployment. To help bridge this gap and verify model predictions, larger-scale lab experiments are being proposed. To advance simulation capabilities, six particle transport models are being integrated into the reactive transport simulator PFLOTRAN. These include colloid filtration theory (CFT) and five additional particle transport models (M1-M5). Each model, from M1 to M5, progressively incorporates additional particle transport and retention processes. Ultimately, the simplest model capable of accurately describing 1-D column data will be selected and parameterized. During FY24, the CFT and M1 model have been fully implemented within PFLOTRAN. Using an existing 1 D column experiment, the two currently implemented particle transport models (CFT and M1), and associated parameters, were fit to this experiment. While simpler model formulations are helpful for estimations, these formulations could not fully describe particle transport and retention behavior in the previous 1-D column experiment. Thus, additional complexities will need to be considered, which will be accounted for in the M2-M5 model formulations. Additionally, because a viscous, shear thinning fluid was required to keep particles in suspension, considerations for flow will also need to also be accounted for. Therefore, a new immiscible two-phase flow mode is currently being implemented in PFLOTRAN. With some modifications, this new flow module could also support simulation of non-Newtonian liquid amendments, foams, and emulsions. We also estimated the expected ROI of solid amendments using 1-D simulations. The average predicted ROI was approximately 15 ft for micron-sized zero valent iron (mZVI) suspended in xanthan gum (XG). Using the pre screening tool and ROI estimates, additional amendment-delivery laboratory characterization and experiments are proposed. The results from additional experiments can be used to validate and parametrize particulate transport model formulations, which will ultimately provide predictive capabilities for field amendment-delivery systems.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1992

Ignition and combustion characteristics of metallized propellants

During this reporting period, theoretical work on the secondary atomization process was continued and the experimental apparatus was improved. A one-dimensional model of a rocket combustor, incorporating multiple droplet size classes, slurry combustion, secondary atomization, radiation heat transfer, and two-phase slip between slurry droplets and the gas flow was derived and a computer code was written to implement this model. The STANJAN chemical equilibrium solver was coupled with this code to yield gas temperature, density, and composition as functions of axial location. Preliminary results indicate that the model is performing correctly, given current model assumptions. Radiation heat transfer in the combustion chamber is treated as an optically-thick participating media problem requiring a solution of the radiative transfer equation. A cylindrical P sub 1 approximation was employed to yield an analytical expression for chamber-wall heat flux at each axial location. The code exercised to determine the effects of secondary atomization intensity, defined as the number of secondary drops produced per initial drop, on chamber burnout distance and final Al2O3 agglomerate diameter. These results indicate that only weak secondary atomization is required to significantly reduce these two parameters. Stronger atomization intensities were found to yield decreasing marginal benefits. The experimental apparatus was improved to reduce building vibration effects on the optical system alignment. This was accomplished by mounting the burner and the transmitting/receiving optics on a single frame supported by vibration-isolation legs. Calibration and shakedown tests indicate that vibration problems were eliminated and that the system is performing correctly.

Mueller, D. C.↗
NASA NTRS2018

Overview of NASA's Air Traffic Management - eXploration (ATM-X) Project

Projected increases in new vehicle types, new missions, and the continual growth in traditional (e.g., airlines, general aviation) aviation will require changes to the current air traffic system, particularly to accommodate the desire of operators to be more involved in air traffic decisions. To address these challenges, the National Airspace System needs to undergo a transformation to a more scalable, flexible, user-focused system that addresses safety and security requirements and resiliency for current and new users. A system designed to integrate modular software services, provided by users, third parties and government for air traffic management functions, will be scalable and more easily allow modernization and for collaboration between users and service providers. ATM-X is responding to NASA's pivot towards integrating projected new, diverse entrants into the NAS, while also leveraging NASA's prior ATM achievements that continue to improve traditional airspace operations. This project is a two-phased approach to conduct research and focused evaluations to assess the feasibility of a service-based approach and to identify critical design considerations to enable airspace access for new entrants, integrated with current traditional operations. Phase 1 research will be conducted to determine what is needed to reach the ATM-X goals based on specific use-cases to enable large-scale, passenger-carrying Urban Air Mobility operations in a metroplex environment, and also to improve traditional operations in the Northeast Region leveraging mature NASA technologies. Some of these evaluations will be conducted in simulations and field activities. Phase 2 will build upon Phase 1 towards more defined, focused research and field demonstrations in real-world environments to integrate multiple elements of a scalable, service-based ATM-X concept.

air traffic management↗
NASA NTRSDate not supplied

Modeling Electrolytic O2 Recovery from Metabolic CO2 for Advanced Closed Loop Life Support Systems in Extraterrestrial Human Missions

The International Space Station (ISS) is currently equipped with a complex, heavy, and power consuming system that recovers approximately 50% of O2 from metabolic CO2. Future long duration human missions to the Moon and Mars will necessitate a sustainable and highly efficient metabolic oxygen recovery system capable of yielding a minimum of 75% O2 recovery. A Macrofluidic Electrochemical Reactor (MFECR) technology development effort is currently underway at NASA Marshall Space Flight Center (MSFC) to significantly increase current metabolic O2 recovery efficiency, expand mission sustainability, and reduce complexity of the system. The novel design combines CO2 conversion to O2 along with C2H4 as byproduct and water electrolysis (currently conducted in two separate units) into a single compact unit that runs at standard conditions and is theoretically capable of generating O2 with a theoretical maximum metabolic CO2 conversion of 73% while consuming less than metabolic water. This paper presents a comprehensive multi-physic 3D model developed at MSFC on CO2 conversion to O2 and C2H4 at standard conditions via MFECR. The 3D spatial domain of the model is a replica of the actual MFECR’s 3D drawing generated for the MFECR fabrication and operated to recover O2 from CO2 yielding C2H4 as byproduct. Electrochemical (EC) physics that includes EC multicomponent reaction mechanisms, mass transport, and electrical current density distributions is coupled in the model with all the other physics phenomena involved in the MFECR’s process, such as two-phase flow, free and porous fluid regimes, multicomponent mass transfer, heat transfer, and DC electrical current generation along with Joule heating effect. The EC reaction sections of the MFECR consists of two porous gas diffusion electrodes (GDE) and an electrolyte serpentine channel sandwiched in the middle. The CO2 feeds the cathode serpentine channel and part of the O2 product is fed back to the anode serpentine chamber. An alkaline solution feeds the electrolyte serpentine chamber wetting the GDEs of both, the anode and cathode allowing the OH- ionic transport between them. The EC reactions in the cathode’s GDE yield C2H4 from CO2 and H2 from water while the EC reaction in the anode’s GDE yields O2. The authors will present in this paper the validation of the model using experimental data and the utilization of the validated model in building a reliable simulator that will not only assist the authors on the MFECR design but also the optimization of its operation in the ISS and future spatial human missions.

Jesus A Dominguez↗