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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Kiloton Class ISRU Systems for LO2/LCH4 Propellant Production on the Mars Surface

As part of the 2023 strategic analysis cycle to explore the trade space, the NASA Mars Architecture Team wanted to explore what it takes to produce in situ on Mars many hundreds of tons of propellants for a large all-chemical transportation system. The conceptual operations and design of the LO 2 /LCH 4 in situ resource utilization (ISRU) water acquisition, propellant production and liquification system was assigned to the NASA Compass concurrent engineering team with support from various NASA ISRU, cryogenic fluid management, and surface power experts. The conceptual point design examined one case producing 300 t of LO 2 /LCH 4 from the Mars atmosphere and delivered water in 20 months and storing the liquified propellants in a to-be-reused lander. Several of these large single-stage, all-chemical class large vertical landers would deliver the required ISRU equipment. The required 150 t of water stock for the ISRU system was traded between three options: delivered, pumped from subsurface ice deposits or extracted from surface soils. The large propellant production systems consist of atmospheric CO 2 collection scroll pumps, a combined solid oxide electrolysis and methanation system to convert the CO 2 and water into gaseous O 2 and CH 4 , and various dryers, scrubbers, and separators to remove the excess water, CO 2 and H 2 . The liquefaction system consisted of 90 K cryocoolers to provide cold Ne to the launch vehicle tanks to liquify these CH 4 and O 2 gases and store them as rocket propellants. The systems are deployed using a 6 t (payload) capable chassis derived from conceptual pressurized rover designs. In total, the propellant production and liquefaction systems required three propellant production pallets, two liquefaction pallets, two water tankers, and six 40 kW-fission surface power systems (FSPS) with cabling. All this equipment was found to notionally fit inside two- 75 metric ton payload capacity Mars ascent and landing vehicles (MALV). For the case where 150 t of water delivered from Earth, four cargo MALVs are required for the full system. The same is true when the 150 t of water is extracted through surface mining. For the borehole system, only 3 cargo MALVs are necessary. A comparison of approaches in terms of number of landers, number and type of elements, power and time is made.

ISRU↗
NASA NTRSDate not supplied

System Engineering & Integration (SE&I) In-Situ Resource Utilization (ISRU) Modeling and Analysis (SIMA) Tool for Subsystem Integration into Full-Scale Architectures

In situ resource utilization (ISRU) is the practice of producing mission consumables from local lunar/planetary resources, thereby minimizing system launch mass requirements, mainly through the production of propellant fuel components and life support resources. Modeling full ISRU technology architectures significantly impacts the design and optimization of individual unit processes and facilitates their introduction into service with the Science Technology Mission Directorate (STMD) logistical planning and operation space. The Mission Analysis and Integration Tool (MAIT) is a modeling framework that connects individual ISRU subsystem models for the purposes of technology down select, scaling & optimization, and end-to-end process planning. The development project team seeks to address specific STMD capability gaps by simulating ISRU systems in MAIT. The goal is to produce system architectures for the Moon and Mars that are linked to Key Performance Parameters (KPP) and environmental requirements. To that end, the framework is adaptive, flexible, and suitable for collaboration among government, private sector, and international entities. Our approach currently provides conventional outputs, such as mass, power, and volume, to analyze whole system trade spaces. However, the framework was designed to validate current breadboard subsystems, simulate future process design capacity, and allow flexibility to any external developer-driven subsystem model that is in a state of evolution.

SE&I↗
NASA NTRSDate not supplied

A Comparative Assessment of Evolvable Martian ISRU Propellant Production for Future Human Missions

In 2022, NASA released its “Moon to Mars Strategy and Objectives Development” document, containing top-level goals and objectives designed to create a blueprint for sustained human presence and exploration throughout the solar system. One objective in this “blueprint” calls for the demonstration of “…Mars ISRU capabilities to support an initial human Mars exploration campaign.” NASA is looking at both the benefits and liens of this concept, as one of several trade space aspects under consideration, for inclusion in the overall architecture of the human exploration of Mars. This paper summarizes results from a series of Martian ISRU-focused trade studies from 2023 and 2024. These studies cover five different approaches to providing propellants for returning crew and equipment from the surface of Mars, using several different combinations of propellants delivered (from Earth) and produced from Martian feedstock material. For comparison purposes, the same ISRU infrastructure elements were used across all options wherever possible. The equipment mass, power, operational complexity, and time needed to produce some or all of these propellants have been quantified and compared when used in a common mission scenario. Analysis results for each option are discussed. Performance parameters for these options are compared side-by-side and observations made, including the positive and negative aspects of each case. The possibility of evolving from a simpler ISRU case to more complex cases that would potentially lead to more sustainable operations are also discussed. While no single case emerged as “better” in all aspects when compared to the others, there are distinct advantages and disadvantages that did emerge when comparing the results generated from a common set of assumptions for all cases. Consequently, specific mission objectives may determine which of these advantages or disadvantages are important for choosing among the cases that could benefit any particular mission or campaign.

Mars↗
NASA NTRSDate not supplied

A Comparative Assessment of Evolvable Martian ISRU Propellant Production for Future Human Missions

In 2022, NASA released its “Moon to Mars Strategy and Objectives Development” document, containing top-level goals and objectives designed to create a blueprint for sustained human presence and exploration throughout the solar system. One objective in this “blueprint” calls for the demonstration of “…Mars ISRU capabilities to support an initial human Mars exploration campaign.” NASA is looking at both the benefits and liens of this concept, as one of several trade space aspects under consideration, for inclusion in the overall architecture of the human exploration of Mars. This paper summarizes results from a series of Martian ISRU-focused trade studies from 2023 and 2024. These studies cover five different approaches to providing propellants for returning crew and equipment from the surface of Mars, using several different combinations of propellants delivered (from Earth) and produced from Martian feedstock material. For comparison purposes, the same ISRU infrastructure elements were used across all options wherever possible. The equipment mass, power, operational complexity, and time needed to produce some or all of these propellants have been quantified and compared when used in a common mission scenario. Analysis results for each option are discussed. Performance parameters for these options are compared side-by-side and observations made, including the positive and negative aspects of each case. The possibility of evolving from a simpler ISRU case to more complex cases that would potentially lead to more sustainable operations are also discussed. While no single case emerged as “better” in all aspects when compared to the others, there are distinct advantages and disadvantages that did emerge when comparing the results generated from a common set of assumptions for all cases. Consequently, specific mission objectives may determine which of these advantages or disadvantages are important for choosing among the cases that could benefit any particular mission or campaign.

Propellant↗
NASA NTRS2008

In-situ Resource Utilization (ISRU) to Support the Lunar Outpost and the Rationale for Precursor Missions

One of the ways that the Constellation Program can differ from Apollo is to employ a live-off-the-land or In-Situ Resource Utilization (ISRU) supported architecture. The options considered over the past decades for using indigenous materials have varied considerably in terms of what resources to attempt to acquire, how much to acquire, and what the motivations are to acquiring these resources. The latest NASA concepts for supporting the lunar outpost have considered many of these plans and compared these options to customers requirements and desires. Depending on the architecture employed, ISRU technologies can make a significant contribution towards a sustainable and affordable lunar outpost. While extensive ground testing will reduce some mission risk, one or more flight demonstrations prior to the first crew's arrival will build confidence and increase the chance that outpost architects will include ISRU as part of the early outpost architecture. This presentation includes some of the options for using ISRU that are under consideration for the lunar outpost, the precursor missions that would support these applications, and a notional timeline to allow the lessons learned from the precursor missions to support outpost hardware designs.

Simon, Thomas M.↗
NASA NTRS2010

Evolution of Regolith Feed Systems for Lunar ISRU 02 Production Plants

The In-Situ Resource Utilization (ISRU) project of the NASA Constellation Program, Exploration Technology Development Program (ETDP) has been engaged in the design and testing of various Lunar ISRU O2 production plant prototypes that can extract chemically bound oxygen from the minerals in the lunar regolith. This work demands that lunar regolith (or simulants) shall be introduced into the O2 production plant from a holding bin or hopper and subsequently expelled from the ISRU O2 production plant for disposal. This sub-system is called the Regolith Feed System (RFS) which exists in a variety of configurations depending on the O2 production plant oxygen being used (e.g. Hydrogen Reduction, Carbothermal, Molten Oxide Electrolysis). Each configuration may use a different technology and in addition it is desirable to have heat recuperation from the spent hot regolith as an integral part of the RFS. This paper addresses the various RFS and heat recuperation technologies and system configurations that have been developed under the NASA ISRU project since 2007. In addition current design solutions and lessons learned from reduced gravity flight testing will be discussed.

Mueller, Robert P.↗
NASA NTRS2007

Oxygen production System Models for Lunar ISRU

In-Situ Resource Utilization (ISRU) seeks to make human space exploration feasible; by using available resources from a planet or the moon to produce consumables, parts, and structures that otherwise would be brought from Earth. Producing these in situ reduces the mass of such that must be launched and doing so allows more payload mass' for each mission. The production of oxygen from lunar regolith, for life support and propellant, is one of the tasks being studied under ISRU. NASA is currently funding three processes that have shown technical merit for the production of oxygen from regolith: Molten Salt Electrolysis, Hydrogen Reduction of Ilmenite, and Carbothermal Reduction. The ISRU program is currently developing system models of, the , abovementioned processes to: (1) help NASA in the evaluation process to select the most cost-effective and efficient process for further prototype development, (2) identify key parameters, (3) optimize the oxygen production process, (4) provide estimates on energy and power requirements, mass and volume.of the system, oxygen production rate, mass of regolith required, mass of consumables, and other important parameters, and (5) integrate into the overall end-to-end ISRU system model, which could be integrated with mission architecture models. The oxygen production system model is divided into modules that represent unit operations (e.g., reactor, water electrolyzer, heat exchanger). Each module is modeled theoretically using Excel and Visual Basic for Applications (VBA), and will be validated using experimental data from on-going laboratory work. This modularity (plug-n-play) feature of each unit operation allows the use of the same model on different oxygen production systems simulations resulting in comparable results. In this presentation, preliminary results for mass, power, volume will be presented along with brief description of the oxygen production system model.

Santiago-Maldonado, Edgardo↗
NASA NTRS2016

Martian Atmospheric Dust Mitigation for ISRU Intakes via Electrostatic Precipitation

The Mars 2020 and Mars Sample Return missions expected to fly to Mars within the next ten years will each include an In Situ Resource Utilization (ISRU) system. They convert carbon dioxide in the Martian atmosphere into consumable oxygen at 1% and 20% of the rate required by a full scale human exploration Mars mission, respectively. The ISRU systems will need to draw in the surrounding atmosphere at a rate of 110L/min and 550L/min, respectively, in order to meet their oxygen production goals. Over the duration of each respective mission, a total atmospheric dust mass of 4.86g and 243g will be drawn into each system, respectively. Ingestion of large quantities of dust may interfere with ISRU operations, so a dust mitigation device will be required. The atmospheric volume and dust mass flow rates above will be utilized to simulate Martian environmental conditions in a laboratory electrostatic precipitator being developed to provide active dust mitigation support for atmospheric ISRU systems such as these.

In-situ resource utilization↗
NASA NTRS2015

Sustaining Human Presence on Mars Using ISRU and a Reusable Lander

This paper presents an analysis of the impact of ISRU (In-Site Resource Utilization), reusability, and automation on sustaining a human presence on Mars, requiring a transition from Earth dependence to Earth independence. The study analyzes the surface and transportation architectures and compared campaigns that revealed the importance of ISRU and reusability. A reusable Mars lander, Hercules, eliminates the need to deliver a new descent and ascent stage with each cargo and crew delivery to Mars, reducing the mass delivered from Earth. As part of an evolvable transportation architecture, this investment is key to enabling continuous human presence on Mars. The extensive use of ISRU reduces the logistics supply chain from Earth in order to support population growth at Mars. Reliable and autonomous systems, in conjunction with robotics, are required to enable ISRU architectures as systems must operate and maintain themselves while the crew is not present. A comparison of Mars campaigns is presented to show the impact of adding these investments and their ability to contribute to sustaining a human presence on Mars.

Arney, Dale C.↗
NASA NTRS2017

An ISRU Propellant Production System to Fully Fuel a Mars Ascent Vehicle

In-Situ Resource Utilization (ISRU) will enable the long term presence of humans beyond low earth orbit. Since 2009, oxygen production from the Mars atmosphere has been baselined as an enabling technology for Mars human exploration by NASA. However, using water from the Martian regolith in addition to the atmospheric CO2 would enable the production of both liquid Methane and liquid Oxygen, thus fully fueling a Mars return vehicle. A case study was performed to show how ISRU can support NASA's Evolvable Mars Campaign (EMC) using methane and oxygen production from Mars resources. A model was built and used to generate mass and power estimates of an end-to-end ISRU system including excavation and extraction water from Mars regolith, processing the Mars atmosphere, and liquefying the propellants. Even using the lowest yield regolith, a full ISRU system would weigh 1.7 mT while eliminating the need to transport 30 mT of ascent propellants from earth.

Mars Surface↗
NASA NTRS2017

An ISRU Propellant Production System to Fully Fuel a Mars Ascent Vehicle

ISRU of Mars resources was base lined in 2009 Design Reference Architecture (DRA) 5.0, but only for Oxygen production using atmospheric CO2The Methane (LCH4) needed for ascent propulsion of the Mars Ascent Vehicle (MAV) would need to be brought from Earth. HOWEVER: Extracting water from the Martian Regolith enables the production of both Oxygen and Methane from Mars resources Water resources could also be used for other applications including: Life support, radiation shielding, plant growth, etc. Water extraction was not base lined in DRA5.0 due to perceived difficulties and complexity in processing regolith. The NASA Evolvable Mars Campaign (EMC) requested studies to look at the quantitative benefits and trades of using Mars water ISRU Phase 1: Examined architecture scenarios for regolith water retrieval. Completed October 2015Phase 2: Deep dive of one architecture concept to look at end-to-end system size, mass, power of a LCH4LO2 ISRU production system.Evolvable Mars CampaignPre-deployed Mars ascent vehicle (MAV)4 crew membersPropellants: Oxygen MethaneGenerate a system model to roll up mass power of a full ISRU system and enable parametric trade studies. Leverage models from previous studies and technology development programs Anchor with mass power performance from existing hardware. Whenever possible used reference-able (published) numbers for traceability.Modular approach to allow subsystem trades and parametric studies. Propellant mass needs taken from most recently published MAV study:Polsgrove, T. et al. (2015), AIAA2015-4416MAV engines operate at mixture ratios (oxygen: methane) between 3:1 and 3.5:1, whereas the Sabatier reactor produces at a 4:1 ratio. Therefore:Methane production is the driving requirement-Excess Oxygen will be produced.

Mars surface↗
NASA NTRSDate not supplied

Case Studies for Lunar ISRU Systems Utilizing Polar Water

In-Situ Resource Utilization (ISRU) is key to long term presence at any extraterrestrial destination. Current NASA direction is to achieve a sustainable presence on the lunar surface by 2028. Mission plans currently target the lunar South Pole to leverage the extended periods of solar illumination and allows for potential access to water ice in the permanently shadowed areas around the poles. With water, it is possible to produce both fuel and oxidizer to fully refuel a vehicle. In order to address ISRU infusion into mission planning, a study of an end-to-end ISRU propellant production system was initiated to assess ISRU architectures and obtain mass and power estimates for each. The results of these case studies will be presented.

In situ Resource Utilization↗
NASA NTRSDate not supplied

ISRU Evaluation of Artemis Campaign Sites: Considerations and Methodology

The Artemis campaign has stated goals of ‘sustainable exploration’ [1] which includes In-Situ Resource Utilization (ISRU). The selection of the lunar polar region for Artemis was in part due to the identification of water in permanently shadowed regions (PSRs) which is of both scientific and exploration interest. The potential use of this water (as is, or as oxygen/hydrogen) for NASA and commercial applications, such as refueling vehicles, for power systems, or supplying life support consumables, is reflected in NASA’s Moon to Mars objectives (LI-7) [2]. These objectives also specify the need to locate and characterize the lunar water such that a water ‘reserve’ can be identified (AS-3). While infusion of ISRU capabilities is not planned for Artemis III, it is an opportunity to collect information to identify water reserves for later Artemis and commercial use. Selection of an Artemis III site with ISRU consideration will help advance the infusion of ISRU into later missions.

In situ resource utilization↗
NASA NTRSDate not supplied

Analysis of Oxygen Liquefaction with Transient Flow Rates for ISRU Systems

Human occupation of lunar and Martian surfaces requires in-situ resource utilization (ISRU) to create a sustainable environment with the limited resources available in space. Fuel and oxidizer generation is essential for developing a refueling capability for spacecraft, significantly reducing the propellant mass required for landing. Liquefaction systems are a key step in producing and storing cryogenic liquids such as oxygen, hydrogen, and methane. All those fluids are critical to propulsion, life support, and other spacecraft systems. NASA has previously confirmed the presence of water on the Moon and an electrolysis process can be used to separate the oxygen from the hydrogen molecules. Oxygen has also been found within lunar regolith and can be separated through ISRU processes. The extracted oxygen gas can then be liquefied inside a storage tank with tube-on-tank heat exchangers for future use as an oxidizer for propellants. While steady state liquefaction performance is easy to model, power limitations and cyclical environments caused by the change in Sun exposure between day and night periods potentially call for transient operations. The following analysis was performed using the Thermal Desktop software to investigate how various transient gaseous oxygen (GOX) flow rates impact the production and storage of liquid oxygen (LOX) in a 1-g liquefaction system. Variations of sinusoidal and exponential step functions were selected to model potential GOX flow rates that could be experienced by ISRU systems on lunar or Martian surfaces. This early computational analysis provides some insight on how transient operations impact oxygen liquefaction systems and helps illustrate operational questions to explore experimentally throughout the design process.

Cryogenic Fluid Management↗
NASA NTRSDate not supplied

Evaluating Lunar Water Processing System Model Configurations for Small Scale Oxygen and Hydrogen Production Within JAXA’s ISRU Technology Demonstration Plant

In-Situ Resource Utilization (ISRU) refers to novel methods of extracting and processing local resources for use in life support and propulsion systems, reducing or eliminating the required consumables to be transferred from Earth. Current estimates of water-ice availability embedded in regolith within the Moon’s permanently shadowed regions (PSR’s)range between 1-5% by weight. However, the composition and characteristics of the “wet” regolith is unknown. Alternate ISRU excavation techniques and Concept of Operations (ConOps) must be explored to optimize surface system operations based on these factors. To assess the feasibility of different ISRU subsystem technologies and compare system architecture configurations, an interchangeable system model was generated to incorporate technologies spanning excavation of raw materials to storage of products and determine optimal arrangement of total system processing needs. Total Mass, Volume, and Power (M/V/P) requirements were computed for 168 design iterations of this water processing plant.

ISRU↗
NASA NTRS2010

Mauna Kea, Hawaii as an Analogue Site for Future Planetary Resource Exploration: Results from the 2010 ILSO-ISRU Field-Testing Campaign

Within the framework of the International Lunar Surface Operation - In-Situ Resource Utilization Analogue Test held on January 27 - February 11, 2010 on the Mauna Kea volcano in Hawaii, a number of scientific instrument teams collaborated to characterize the field site and test instrument capabilities outside laboratory environments. In this paper, we provide a geological setting for this new field-test site, a description of the instruments that were tested during the 2010 ILSO-ISRU field campaign, and a short discussion for each instrument about the validity and use of the results obtained during the test. These results will form a catalogue that may serve as reference for future test campaigns. In this paper we provide a description and regional geological setting for a new field analogue test site for lunar resource exploration, and discuss results obtained from the 2010 ILSO-ISRU field campaign as a reference for future field-testing at this site. The following instruments were tested: a multispectral microscopic imager, MMI, a Mossbauer spectrometer, an evolved gas analyzer, VAPoR, and an oxygen and volatile extractor called RESOLVE. Preliminary results show that the sediments change from dry, organic-poor, poorly-sorted volcaniclastic sand on the surface, containing basalt, iron oxides and clays, to more water- and organic-rich, fine grained, well-sorted volcaniclastic sand, primarily consisting of iron oxides and depleted of basalt and clays. Furthermore, drilling experiments showed a very close correlation between drilling on the Moon and drilling at the test site. The ILSO-ISRU test site was an ideal location for testing strategies for in situ resource exploration at the lunar or martian surface.

ten Kate, I. L.↗
NASA NTRSDate not supplied

ISRU Pilot Excavator: Bucket Drum Scaling Experimental Results

NASA’s Space Technology Mission Directorate (STMD) is funding the development of a robotic excavator called the “ISRU Pilot Excavator” which will be a technology demonstration of excavating and transporting 10 metric tons of lunar regolith on the surface of the moon with a 30k-class robotic excavator. ISRU Pilot Excavator will be the next generation of robotic excavator to use bucket drums as excavation tools. This is an evolution of the Regolith Advanced Surface Systems Operations Robot (RASSOR) developed at NASA’s Kennedy Space Center. Bucket drums are hollow cylinders with regularly spaced scoops around the perimeter. The drums rotate in one direction to collect regolith with the scoops. The regolith slides down an internal baffling system inside the drum which prevents the regolith from falling back out of the scoops. The captured regolith can then be transported while held in the drum and then deposited by rotating the drum in the opposite direction allowing the regolith to slide back down the baffling and out of the excavation scoops. Bucket drums were developed by Lockheed Martin in 2008 and used on multiple robotic excavator prototypes ever since. However the forces on a bucket drum and considerations for scaling have not been measured in detail. Bucket drums are challenging to model using classical blade\bucket equations because of their unique geometry. Therefore this experiment was performed to measure the forces on three bucket drums of the same geometry at different scales. Small: 9.4” (239mm) dia. x 8.1” (206mm) width, Medium: 11.6” (294mm) dia. x 10” (254mm) width, and Large: 17” (432mm) dia. x 14.1”(358mm) width. The test stand consisted of an actuated gantry with controlled motion in the vertical (Z) and horizontal (X) axes and a single rotation axis (R). The bucket drums were individually mounted to the rotary axis of the test stand and translated across a prepared bed of BP-1 lunar regolith simulant at a specified linear speed and cutting depth. The test stand was outfitted with a torque sensor in line with the rotation of the drum (R) and a 3 axis (X, Y, and Z) load cell. In addition to the three sizes of bucket drums the linear excavation speed and cutting depth were test variables. The results of these experiments show the relationship between the three scales of bucket drums for factors such as: excavation force, torque due to regolith rotation inside the drum, excavation energy, time to fill, etc. and will be discussed in detail in this paper. This fundamental data will be used in the design of the ISRU Pilot Excavator and can inform the design of future bucket drum excavators.

Jason Michael Schuler↗