NASA Hydrogen and Fuel Cell Perspectives
This presentation provides a brief overview of Hydrogen and Fuel Cell technologies for space applications and current NASA activities involving these technologies.
Fuel cells↗
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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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NASA Universal Waste Management System and Toilet Integration Hardware Operations on ISS – Issues, Modifications and Accomplishments
The Universal Waste Management System (UWMS), which has the ISS operational nomenclature “Toilet”, was initially installed on the International Space Station (ISS) in 2020 with final installation completed in 2021. Although technical issues were encountered that delayed installation and operations, progress was made towards the objectives of the project. Technical issue work-arounds resulted in operation of the Toilet with use by male and female crew members in a controlled extended checkout. This paper will summarize operations of the Toilet and Toilet Integration Hardware in this limited configuration, problems encountered during installation and checkout, the modifications made to allow further usage on ISS, and the future modifications planned for nominal use. It will also describe the portions of the technology demonstration that were completed and the benefits from that work and how that knowledge informs the Orion-installed UWMS unit and future manifesting of consumables for both Orion and ISS.
Toilet↗
Trade Study Analysis of a Cryogenic Oxygen Architecture for Lunar Outpost Life Support
A trade study was performed to compare the use of cryogenic liquid oxygen (LOX) with high pressure gaseous oxygen (GOX) and electrolysis approaches for Lunar outpost life support, which consists of a surface habitat and pressurized rover. This study presents the mission details pertaining to a Lunar outpost architecture, discusses the viable concept of operations for each architecture, and compares the equivalent system mass (ESM) of the cryogenic LOX, high pressure GOX, and electrolysis approaches across different parameter trades, e.g. mission duration or extravehicular activity frequency, for the single and 10-year mission architectures. For a single nominal mission, high pressure GOX is favored for short missions (< 50 days); cryogenic LOX is favored for a wide-range of mission durations (50 – 270 days); and the electrolysis approach is favored for long missions (> 270 days). However, when considering a 10-year mission architecture, each additional resupply negatively impacts cryogenic LOX due to the additional replacement tankage. Thus, over a 10-year mission, an electrolysis approach, which can provide all life support O2 utilizing solely recovered H2O, appears to be favored over cryogenic LOX. However, a real electrolysis system may need resupplied H2O due to incomplete closure of the air revitalization loop. Thus, the cryogenic LOX approach was compared with the electrolysis approaches utilizing 100% resupplied or 100% recovered H2O to approximate the resupplied to recovered H2O ratio, i.e. the degree of loop closure, where one approach trades over the other. Additionally, gaps were identified, which are expected to affect the viability and trade of cryogenic LOX. These include the development of cryogenic pumps and vaporizers to generate high pressure GOX from LOX as well as understanding payload limitations which can affect O2 resupply.
ECLSS↗
Status of the Advanced Oxygen Generation Assembly Design
Future Exploration missions will require an Oxygen Generation Assembly (OGA) to electrolyze water to supply oxygen for crew metabolic consumption. The system design will be based on the International Space Station (ISS) OGA but with added improvements based on lessons learned during ISS operations and technological advances since the original OGA was designed and built. The goal of these improvements will be to reduce system weight, crew maintenance time and spares mass while increasing reliability. Over the past year, the team has performed additional design reviews, testing and analysis in an effort to optimize upgrade efforts and achieve the best value that meets Exploration mission requirements. Upgrades that will be incorporated include: redesign of the electrolysis cell stack, redesign of the hydrogen dome, replacement of the hydrogen sensors, redesign of the recirculation loop deionizing bed, and incorporation of recirculation loop nitrogen purging and water flushing. The ISS OGA will be upgraded to an Advanced OGA (AOGA) configuration and its operation demonstrated in a relevant flight environment.
Oxygen Generation Assembly↗
Environmental Control and Life Support (ECLS) System Options for Mars Transit and Mars Surface Missions
The NASA led Artemis campaign will take humanity back to the Moon and serve as an analog for continued deep space exploration to Mars. Artemis utilizes crewed vehicles and habitats on both the Lunar surface and in Lunar orbit. The exploration of the Lunar surface and buildup of a basecamp is meant to be a “Mars forward” approach to testing and refining new technologies and techniques for living and working far outside of Low Earth Orbit (LEO) and preparing for future Mars missions. The Lunar Surface Habitat is planned as a primary element for long duration crew habitation on the Moon and will be the primary testbed for ECLS system hardware in a partial gravity environment. The Mars Transit Habitat will be the crew vehicle for the roundtrip from Earth to Mars and spend a significant amount of time docked to the Gateway outfitting and testing its systems prior to making the first Mars mission transit. The Mars Transit Habitat will utilize closed loop ECLS system technologies while a Mars Surface Habitat could use either open loop, closed loop, or a mix of both. Better understanding the needs of both these system architectures operating for extended periods in the Lunar environment and outside LEO will help to establish the ECLS system architecture for the future Mars surface mission. There are many aspects to consider such as length of crew stay, level of autonomy and dormancy between crewed missions, power requirements, system mass, and overall system reliability and maintainability. Other considerations will include Mars gravity vs. Lunar gravity, Mars atmospheric pressure vs. hard vacuum, and possible use of in-situ resource utilization.
ECLSS↗
Status of the Advanced Oxygen Generation Assembly
Future Exploration missions will require an Oxygen Generation Assembly (OGA) to electrolyze water to supply oxygen for crew metabolic consumption. The system design will be based on the International Space Station (ISS) OGA but with added improvements based on lessons learned during ISS operations and technological advances since the original OGA was designed and built. The goal of these improvements will be to reduce spares mass and crew maintenance time while increasing reliability. Over the past year, the team has performed additional design reviews, testing and analysis in an effort to optimize upgrade efforts and achieve the best value that meets Exploration mission requirements. Upgrades that will be incorporated include: redesign of the electrolysis cell stack, redesign of the hydrogen dome, replacement of the hydrogen sensors, redesign of the recirculation loop deionizing bed, and incorporation of recirculation loop nitrogen purging and water flushing. The ISS OGA will be upgraded to an Advanced OGA (AOGA) configuration and its operation demonstrated in a relevant flight environment.
ECLSS↗
Environmental Control and Life Support (ECLS) System Options for Mars Transit and Mars Surface Missions
The NASA led Artemis campaign will take humanity back to the Moon and serve as an analog for continued deep space exploration to Mars. Artemis utilizes crewed vehicles and habitats on both the Lunar surface and in Lunar orbit. The exploration of the Lunar surface and buildup of a basecamp is meant to be a “Mars forward” approach to testing and refining new technologies and techniques for living and working far outside of Low Earth Orbit (LEO) and preparing for future Mars missions. The Lunar Surface Habitat is planned as a primary element for long duration crew habitation on the Moon and will be the primary testbed for ECLS system hardware in a partial gravity environment. The Mars Transit Habitat will be the crew vehicle for the roundtrip from Earth to Mars and spend a significant amount of time docked to the Gateway outfitting and testing its systems prior to making the first Mars mission transit. The Mars Transit Habitat will utilize closed loop ECLS system technologies while a Mars Surface Habitat could use either open loop, closed loop, or a mix of both. Better understanding the needs of both these system architectures operating for extended periods in the Lunar environment and outside LEO will help to establish the ECLS system architecture for the future Mars surface mission. There are many aspects to consider such as length of crew stay, level of autonomy and dormancy between crewed missions, power requirements, system mass, and overall system reliability and maintainability. Other considerations will include Mars gravity vs. Lunar gravity, Mars atmospheric pressure vs. hard vacuum, and possible use of in-situ resource utilization.
ECLSS↗
Stress Corrosion Evaluation of NiTiHf Alloy for the International Space Station Environmental Control and Life Support System
A stress corrosion evaluation was performed on NiTiHf alloy because this material is considered a bearing material candidate for the Environmental Control and Life Support System. Stressed round tensile specimens survived exposures to alternate pretreat, alternate brine, baseline pretreat, baseline brine, and 3.5% NaCl alternate immersion. Metallographic evaluations did not detect stress corrosion on exposed samples. The ultimate tensile strength values varied significantly for this material, which is common for bearing materials. This variation was observed on both, exposed and nonexposed specimens. The results of this work indicate that this material has potential applications as a bearing material.
International Space Station (ISS)↗
Supercritical Water Oxidation and a Preliminary Concept for Lunar Application
Abstract: Water is a critical resource for crewed space exploration missions and reclamation of aqueous waste streams presents the only long-term viable option. Although early Artemis missions are considering water as part of the payload manifest, it would be extremely advantageous if follow-on missions were supplied—either in total or in part—by a reclamation technology that would operate autonomously between missions. An attractive technology is currently under ongoing research at NASA Glenn Research Center (GRC) that employs a Supercritical Water Oxidation (SCWO) process to destroy all hydrocarbons in the waste stream. Testing of an aqueous waste stream simulant, typical of what is generated on the International Space Station (ISS), has shown reductions in Total Organic Carbon (TOC) of greater than 99% with reactor residence times less than 30 s. Recent effort has been directed toward developing a conceptual design based on the current tubular reactor used in the evaluation of the conversion of SCWO. This conceptual design along with the results of recent SCWO conversion experiments will be presented. Recent design enhancements to achieve shorter residence times along with “production simulation” tests will be presented. The diagnostics used in assessing the extent of the waste conversion include a total organic carbon (TOC) analysis, Raman analyses, and measurements of pH, turbidity, and conductivity. Results obtained from the modified reactor configuration will also be compared to those of the Phase I configuration presented in earlier work.
SCWO↗
Update to Developing a Multi-bioreactor Test Stand for the Evaluation of Biofilm Mitigation Technologies
Biofilm formation in spacecraft wastewater systems is a complex and impactful problem. Biomass flowing in these wastewater systems can cause clogging, higher differential pressures, and flow restrictions impacting equipment reliability and function. To explore this issue, the Marshall Space Flight Center’s biofilm test stand was created and has been utilized to examine multiple biofilm mitigation techniques over a long duration test time. This paper is an update to a previous paper, ICES-2021-122, and will serve to discuss the modifications and enhancements to the biofilm test stand. While the previous configuration tested heat treatments and coatings, this phase of testing will examine differing materials, competing bacteria provided by an external bioreactor, a prototype phytoremediation unit, and additional testing with a nutrient filter. Configuration changes include the addition of float switches, adjustment of the drain assembly architecture and additional support hardware for the competing bacteria bioreactor and phytoremediation units.
ECLSS↗
Stress Corrosion Evaluation of Inconel X-750 for the International Space Station Environmental Control and Life Support System
Inconel X-750 alloy was evaluated for stress corrosion in support of the International Space Station Environmental Control and Life Support System. Round tensile specimens that were obtained from 0.25 in thick material successfully completed 365 days of exposure to baseline pretreat, baseline brine, alternate pretreat, alternate brine, and 3.5% NaCl alternate immersion without any failures at stresses of up to 90% of the yield strength. Posttest evaluations consisting of metallography and tensile testing did not indicate stress corrosion susceptibility.
International Space Station↗
Kinetic Model Development of the Carbon Vapor Deposition Reactor to Predict Performance Versus Design
To enable complete closure of a Sabatier-based atmosphere revitalization system where oxygen recovery is predicated by carbon dioxide reduction to methane and water, there must be a means of recovering the hydrogen from the byproduct methane. Honeywell’s carbon vapor deposition (CVD) reactor is a potential technology that provides a thermochemical means by which methane decomposes at high temperatures (> 1,000 °C) into hydrogen, solid carbon, and a small percentage of hydrocarbons. This advanced methane pyrolysis reactor utilizes a carbon fiber substrate to capture and immobilize the solid pyrolytic carbon rather than allowing continuation toward undesirable soot. The CVD reactor is a highly dynamic system whose characteristic geometry changes while operating. The reactor model was developed to provide predictive performance assessment capabilities at different operating conditions, geometries, and configurations to aid in technology development. Modeling of the CVD reactor considered the multitude of simultaneous and interdependent physicochemical processes that are entailed, including: (1) the homogeneous gas-phase pyrolysis reactions, (2) the heterogeneous deposition reactions, and (3) the transport of gaseous species in the reactor domains. A 1-D CVD reactor model was developed based on a general packed-bed, axial-dispersion plug flow reactor model with a solid substrate balance to account for carbon deposition. The model includes 59 species and 243 reactions constituting the methane pyrolysis reaction network, carbon deposition, and interconversions of oxygenate species. The reactor model was compared to brassboard test data, where it was shown to be able to capture the pertinent physicochemical phenomena as evidenced by its agreement with short-duration run data (i.e., looking at different temperature and flow rate conditions), as well as trend agreement with the brassboard reactor’s long-duration test data. Recommendations are provided on further model development steps as well as its use cases.
Air Revitalization↗
Integrated Simulations of the Sabatier and Carbon Vapor Deposition Reactor to Understand Its Impacts to Operations and Performance
The carbon vapor deposition (CVD) reactor is a technology developed by Honeywell Aerospace to convert methane, at high temperatures, into hydrogen and solid carbon. This element is coupled with a Sabatier reactor to support a closed-loop environmental control and life support system with the aim of achieving nearly complete oxygen recovery (> 95%). Initial open-loop, brassboard CVD reactor tests and simulations have shown the CVD’s ability to achieve moderately high methane conversion and high hydrogen selectivity. However, in an integrated system, additional deficiencies are expected due to recycling of unreacted or extraneous species from the Sabatier reactor (e.g., carbon dioxide, hydrogen, water) and CVD reactor (e.g., hydrocarbons, methane, etc.). Sabatier and CVD reactor models were integrated and simulated to predict potential impacts to individual reactors’ and the overall system’s performance. The simulations showed that increasing the recycle of the CVD effluent hydrogen combined with decreasing the system inlet hydrogen flow rate (i.e., drawing a stoichiometric flow rate from an electrolyzer) can lead to an oxygen recovery of > 95%. However, system integration comes at a detriment to the individual reactors. The simulations show the initial conversion from the integrated system (Sabatier = 87% and CVD = 59%) to be lower than the standalone systems (Sabatier = 91% and CVD = 69%). Furthermore, transient simulations show substrate densification, leading to worsening methane conversion coupled with increasing acetylene production, which is commensurate with soot formation. Simulations predict a shortening of the maintenance interval (i.e., time until CVD methane conversion drops below 50%) in the integrated system, which would increase the consumable substrate mass. These analyses highlight the importance of long-duration, integrated tests to corroborate these findings as well as suggest potential modifications (e.g., intermediate gas separations) to improve performance.
Air Revitalization↗
Update to Developing a Multi-bioreactor Test Stand for the Evaluation of Biofilm Mitigation Technologies
Biofilm formation in spacecraft wastewater systems is a complex and impactful problem. Biomass flowing in these wastewater systems can cause clogging, higher differential pressures, and flow restrictions impacting equipment reliability and function. To explore this issue, the Marshall Space Flight Center’s biofilm test stand was created and has been utilized to examine multiple biofilm mitigation techniques over a long duration test time. This paper is an update to a previous paper, ICES-2021-122, and will serve to discuss the modifications and enhancements to the biofilm test stand. While the previous configuration tested heat treatments and coatings, this phase of testing will examine differing materials, competing bacteria provided by an external bioreactor, a prototype phytoremediation unit, and additional testing with a nutrient filter. Configuration changes include the addition of float switches, adjustment of the drain assembly architecture and additional support hardware for the competing bacteria bioreactor and phytoremediation units.
ECLSS↗
Design of an Adsorption Bed for Exploration Trace Contaminant Control
The state-of-the-art in long mission duration spacecraft trace contaminant control processes relies on physical and chemical adsorption for contaminant removal. Target species for adsorption include low and semivolatile organic compounds while chemisorption is utilized for metabolic ammonia control. When adsorption is employed in conjunction with a high temperature oxidation process, a complementary impact on cabin air quality may be realized. The adsorption bed also serves to guard the downstream oxidation catalyst from foulants and potential poisons which may decrease its lifetime and activity. To this end, a packed adsorption guard-bed was sized to control a statistical contaminant load model over a simulated Mars transit mission duration. The updated load model incorporates flight air-quality data and contemporary metabolic source emission literature. The guard-bed was operated in tandem with an exploration prototype thermal catalytic oxidizer. The exploration guard-bed prototype included design considerations from recent flight technology demonstrations and changes intended to improve compatibility with enriched oxygen exploration cabin environments as compared to the prior-art of contaminant control system design.
Trace Contaminant Control↗
Ground Test Validations for Uncrewed Dormancy Preparation and Recovery
Explore the source record for details and available documents.
ECLSS↗
Comprehensive Evaluation of Electrochemical Hydrogen Separator as Hydrogen Recovery Solution for Plasma Pyrolysis Assembly
Explore the source record for details and available documents.
Skyre↗
Update to Developing a Multi-bioreactor Test Stand for the Evaluation of Biofilm Mitigation Technologies
Biofilm formation in spacecraft wastewater systems is a complex and impactful problem. Biomass flowing in these wastewater systems can cause clogging, higher differential pressures, and flow restrictions impacting equipment reliability and function. To explore this issue, the Marshall Space Flight Center’s biofilm test stand was created and has been utilized to examine multiple biofilm mitigation techniques over a long duration test time. This paper is an update to a previous paper, ICES-2021-122, and will serve to discuss the modifications and enhancements to the biofilm test stand. While the previous configuration tested heat treatments and coatings, this phase of testing will examine differing materials, competing bacteria provided by an external bioreactor, a prototype phytoremediation unit, and additional testing with a nutrient filter. Configuration changes include the addition of float switches, adjustment of the drain assembly architecture and additional support hardware for the competing bacteria bioreactor and phytoremediation units.
ECLSS↗