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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 NTRS1992

Propellant production and useful materials: Hardware data from components and the systems

During the past year significant progress included: a major breakthrough in oxygen production through discs (instead of tubes) that resulted in two orders-of-magnitude increase in the yield rates, proving that oxygen production from any iron-bearing silicate (avoiding costly beneficiation) in lunar in-situ resource utilization (ISRU); construction of a half-scale robotic soil processor; production of melt-spun fibers in a solar furnace; and the culmination of first-stage research in the construction (and delivery to NASA LaRC) of a self-contained portable oxygen plant that incorporates the first generation ISRU technologies developed at UA SERC. In addition, further reductions in mass and power needs were achieved in two smaller oxygen plants, which, however, have far greater production rates. SERC continued to attract bright students both at the undergraduate and graduate levels, and several area high school students through the Professional Internship Program (PIP) administered by the local school district. Invited lectures at elementary schools continue to draw enthusiastic response. Another important first was the creation of the Freshman Colloquium, 'Space in Our Future, and Our Future in Space,' geared toward women and minority students. This course proved to be a success, with more than one-half of the enrollment composed of women. In recognition of these important contributions, the author was appointed to the NRC Committee on Space Science Technologies.

Ramohalli, Kumar↗
NASA NTRS1992

Propellant production and useful materials: Hardware data from components and the systems

Research activities at the University of Arizona/NASA Space Engineering Research Center are described; the primary emphasis is on hardware development and operation. The research activities are all aimed toward introducing significant cost reductions through the utilization of resources locally available at extraterrestrial sites. The four logical aspects include lunar, Martian, support, and common technologies. These are described in turn. The hardware realizations are based upon sound scientific principles which are used to screen a host of interesting and novel concepts. Small scale feasibility studies are used as the screen to allow only the most promising concepts to proceed. Specific examples include: kg/day-class oxygen plant that uses CO2 as the feed stock, spent stream utilization to produce methane and 'higher' compounds (using hydrogen from a water electrolysis plant), separation of CO from the CO2, reduction of any iron bearing silicate (lunar soils), production of structural components, smart sensors and autonomous controls, and quantitative computer simulation of extraterrestrial plants. The most important feature of all this research continues to be the training of high-quality students for our future in space.

Ramohalli, Kumar↗
NASA NTRS1993

Comment on 'Propellant production from the Martian atmosphere'

The optimism of the Tauber et al. (1992) note on photosynthetic production of spacecraft fuels from Martian atmospheric gases is presently noted, in conjunction with the need for prior missions' verification of such a system. Two of the original authors reply that their solar cell array assumptions are conservative in light of plausible performance projections for 2010-decade technology.

Ruppe, H. O.↗
NASA NTRS2019

Study of Sabatier Catalyst Performance for a Mars ISRU Propellant Production Plant

NASA is currently developing technologies for use in the field of in-situ resource utilization (ISRU). One of the technologies being advanced is the Sabatier, or methanation, reactor which converts carbon dioxide and hydrogen into methane gas and water at high temperatures. This paper discusses the catalyst life and performance issues for these reactors that would be expected on Mars and describes the test methods employed and observed results. The various catalysts were tested in their capacity for the continuous production of methane gas via the Sabatier reaction and the possible effects of launch vibration loads, exposure to liquid water, particulate contamination, and chemical contamination to the overall observed reaction efficacy of the catalysts evaluated.

Franco, Carolina↗
NASA NTRS2019

Study of Sabatier Catalyst Performance for a Mars ISRU Propellant Production Plant

NASA is currently developing technologies for use in the field of in-situ resource utilization (ISRU). One of the technologies being advanced is the Sabatier, or methanation, reactor which converts carbon dioxide and hydrogen into methane gas and water at high temperatures. This paper discusses the catalyst life and performance issues for these reactors that would be expected on Mars and describes the test methods employed and observed results. The various catalysts were tested in their capacity for the continuous production of methane gas via the Sabatier reaction and the possible effects of launch vibration loads, exposure to liquid water, particulate contamination, and chemical contamination to the overall observed reaction efficacy of the catalysts evaluated.

Franco, Carolina↗
NASA NTRS1990

Autonomous production of propellants

The autonomous production of propellants is addressed. Since 80 to 90 percent of a spacecraft's mass is typically propellants, it is advantageous to produce propellants in strategic locations en route to, and at, the desired mission destination. This reduces the weight of the spacecraft and the cost of each mission. Since one of the primary goals of the space program is safety, a totally automated propellant production system is desirable. This system would remove, from hostile, high-risk extraterrestrial environments, the constant human intervention currently required in the production of many propellants. This enables the exploration of space to be more than the search for and production of fuel. As a proof-of-concept demonstration, one specific case was chosen for this study. That case was a composite propellant processor (the principle is more important than the application), and the specific processor used saved SERC the considerable cost of acquiring a new liquid propellant processor that would also have required similar automation.

Ramohalli, Kumar↗
NASA NTRS1991

Conceptual study of on orbit production of cryogenic propellants by water electrolysis

The feasibility is assessed of producing cryogenic propellants on orbit by water electrolysis in support of NASA's proposed Space Exploration Initiative (SEI) missions. Using this method, water launched into low earth orbit (LEO) would be split into gaseous hydrogen and oxygen by electrolysis in an orbiting propellant processor spacecraft. The resulting gases would then be liquified and stored in cryogenic tanks. Supplying liquid hydrogen and oxygen fuel to space vehicles by this technique has some possible advantages over conventional methods. The potential benefits are derived from the characteristics of water as a payload, and include reduced ground handling and launch risk, denser packaging, and reduced tankage and piping requirements. A conceptual design of a water processor was generated based on related previous studies, and contemporary or near term technologies required. Extensive development efforts would be required to adapt the various subsystems needed for the propellant processor for use in space. Based on the cumulative results, propellant production by on orbit water electrolysis for support of SEI missions is not recommended.

Moran, Matthew E.↗
NASA NTRS1991

Conceptual study of on orbit production of cryogenic propellants by water electrolysis

The feasibility is assessed of producing cryogenic propellants on orbit by water electrolysis in support of NASA's proposed Space Exploration Initiative (SEI) missions. Using this method, water launched into low earth orbit (LEO) would be split into gaseous hydrogen and oxygen by electrolysis in an orbiting propellant processor spacecraft. The resulting gases would then be liquified and stored in cryogenic tanks. Supplying liquid hydrogen and oxygen fuel to space vehicles by this technique has some possible advantages over conventional methods. The potential benefits are derived from the characteristics of water as a payload, and include reduced ground handling and launch risk, denser packaging, and reduced tankage and piping requirements. A conceptual design of a water processor was generated based on related previous studies, and contemporary or near term technologies required. Extensive development efforts would be required to adapt the various subsystems needed for the propellant processor for use in space. Based on the cumulative results, propellant production by on orbit water electrolysis for support of SEI missions is not recommended.

Moran, Matthew E.↗
NASA NTRS1993

Mars rover sample return mission utilizing in situ production of the return propellants

This paper presents an unmanned Mars sample return mission that utilizes propellants manufactured in situ from the Martian atmosphere for the return trip. A key goal of the mission is to demonstrate the considerable benefits that can be realized through the use of indigenous resources and to test the viability of this approach as a precursor to manned missions to Mars. Two in situ propellant combinations, methane/oxygen and carbon monoxide/oxygen, are compared to imported terrestrial hydrogen/oxygen within a single mission architecture, using a single Earth launch vehicle. The mission is assumed to be launched from Earth in 2003. Upon reaching Mars, the landing vehicle aerobrakes, deploys a small satellite, and lands on the Martian surface. Once on the ground, the propellant production unit is activated, and the product gases are liquefied and stored in the empty tanks of the Earth Return Vehicle (ERV). Power for these activities is provided by a dynamic isotope power system. A semiautonomous rover, powered by the indigenous propellants, gathers between 25 and 30 kg of soil and rock samples which are loaded aboard the ERV for return to Earth. After a surface stay time of approximately 1.5 years, the ERV leaves Mars for the return voyage to Earth. When the vehicle reaches the vicinity of Earth, the sample return capsule detaches, and is captured and circularized in LEO via aerobraking maneuvers.

Bruckner, A. P.↗
NASA NTRS2017

Robust Exploration and Commercial Missions to the Moon Using NTR LANTR Propulsion and Lunar-Derived Propellants

The nuclear thermal rocket (NTR) has frequently been identified as a key space asset required for the human exploration of Mars. This proven technology can also provide the affordable access through cislunar space necessary for commercial development and sustained human presence on the Moon. In his post-Apollo Integrated Space Program Plan (1970-1990), Wernher von Braun, proposed a reusable nuclear thermal propulsion stage (NTPS) to deliver cargo and crew to the Moon to establish a lunar base before undertaking human missions to Mars. The NTR option was selected by von Braun because it was a demonstrated technology capable of generating both high thrust and high specific impulse (Isp 900 s) twice that of todays best chemical rockets. In NASAs Mars Design Reference Architecture (DRA) 5.0 study, the crewed Mars transfer vehicle used three 25 klbf Pewee engines the smallest and highest performing engine tested in the Rover program along with graphite composite fuel. Smaller, lunar transfer vehicles consisting of a NTPS using three approximately 16.5 klbf Small Nuclear Rocket Engines (SNREs), an in-line propellant tank, plus the payload can enable a variety of reusable lunar missions. These include cargo delivery and crewed lunar landing missions. Even weeklong tourism missions carrying passengers into lunar orbit for a day of sightseeing and picture taking are possible. The NTR can play an important role in the next phase of lunar exploration and development by providing an affordable in-space lunar transportation system (LTS) that can allow initial outposts to evolve into settlements supported by a variety of commercial activities such as in-situ propellant production used to supply strategically located propellant depots and transportation nodes. The utilization of iron-rich volcanic glass or lunar polar ice (LPI) deposits (each estimated at billions of metric tons) for propellant production can significantly reduce the launch mass requirements from Earth and can enable reusable, surface-based lunar landing vehicles (LLVs) using liquid oxygen/hydrogen (LOX/LH2) chemical rocket engines. Afterwards, LOX/LH2 propellant depots can be established in lunar equatorial and polar orbits to supply the LTS. At this point a modified version of the conventional NTR called the LOX-augmented NTR, or LANTR would be introduced into the LTS allowing bipropellant operation and leveraging the mission benefits of refueling with lunar-derived propellants for Earth return. The bipropellant LANTR engine utilizes the large divergent section of its nozzle as an afterburner into which oxygen is injected and supersonically combusted with nuclear preheated hydrogen emerging from the engines choked sonic throat essentially scramjet propulsion in reverse. By varying the oxygen-to-hydrogen mixture ratio, LANTR engines can operate over a range of thrust and Isp values while the reactor core power level remains relatively constant. Eventually, a LANTR-based LTS can enable a rapid commuter shuttle with one-way trip times to and from the Moon ranging from 36 to 24 hours. Even if only 1 of the extracted propellant from identified volcanic glass and polar ice deposits were available for use in lunar orbit, such a supply could support daily commuter flights to the Moon for many thousands of years! An evolutionary mission architecture is outlined and a variety of lunar missions and transfer vehicle designs are examined, along with the increasing demands on propellant production as mission complexity increases. A comparison of vehicle features and engine operating characteristics, for both NTR and LANTR engines, is also provided along with a brief discussion on the propellant production issues associated with using volcanic glass and LPI as source material.

Spacecraft design↗
NASA NTRS1989

Extraction of volatiles and metals from extraterrestrial ores

Extraterrestrial materials, processes, and products were identified which are associated with the production of propellants in space, including the most complete possible conversion of the feedstocks for propellant production into useful products with the minimum feasible expenditure of energy. Laboratory research was identified and begun on several processes that promise very large increases in the mass of useful products at the cost of only modest increases in energy consumption. Processes for manufacturing propellants then become processes for making propellants plus metals and refractories. It is the overall yield of useful materials per unit expended energy that matters, not simply the yield of propellants. Three tasks have been undertaken to date: (1) Literature search and compilation of a dBase 3 data base on space materials processing; (2) Gaseous carbonyl extraction and purification of ferrous metals; and (3) Characterization of lunar ilmenite and its simulants.

Lewis, John S.↗
NASA NTRS1989

Lunar resources - Toward living off the lunar land

An overview is presented of possibilities for the exploitation of lunar materials already proven to exist by Apollo experience. It is noted that lunar soils contain various materials required for life support, construction, and transportation, but that the high cost of lifting material from the earth's surface suggests that, in the near term, lunar material should be considered for use both on the moon and in LEO. Lunar water production, farming, propellant production, and the production of glass, iron, aluminum, and silicon to be used in lunar construction are discussed. The role of solar power and the possibility of electrolysis of molten silicate as a means of producing oxygen and metals for use on the moon and in near-earth space are examined. The benefits of immediate investment in developmental technology (given extensive project lead times) are stressed.

Haskin, Larry A.↗
NASA NTRS2017

Robust Exploration and Commercial Missions to the Moon Using LANTR Propulsion and In-Situ Propellants Derived from Lunar Polar Ice (LPI) Deposits

The nuclear thermal rocket (NTR) has frequently been identified as a key space asset required for the human exploration of Mars. This proven technology can also provide the affordable access through cislunar space necessary for commercial development and sustained human presence on the Moon. It is a demonstrated technology capable of generating both high thrust and high specific impulse (Isp 900 s) twice that of todays best chemical rockets. Nuclear lunar transfer vehicles consisting of a propulsion stage using three approx.16.5 klbf "Small Nuclear Rocket Engines (SNREs)", an in-line propellant tank, plus the payload can enable a variety of reusable lunar missions. These include cargo delivery and crewed lunar landing missions. Even weeklong "tourism" missions carrying passengers into lunar orbit for a day of sightseeing and picture taking are possible. The NTR can play an important role in the next phase of lunar exploration and development by providing a robust in-space lunar transportation system (LTS) that can allow initial outposts to evolve into settlements supported by a variety of commercial activities such as in-situ propellant production used to supply strategically located propellant depots and transportation nodes. The processing of LPI deposits (estimated to be approx. 2 billion metric tons) for propellant production - specifically liquid oxygen (LO2) and hydrogen (LH2) can significantly reduce the launch mass requirements from Earth and can enable reusable, surface-based lunar landing vehicles (LLVs) using LO2/LH2 chemical rocket engines. Afterwards, LO2/LH2 propellant depots can be established in lunar polar and equatorial orbits to supply the LTS. At this point a modified version of the conventional NTR called the LO2-augmented NTR, or LANTR would be introduced into the LTS allowing bipropellant operation and leveraging the mission benefits of refueling with lunar-derived propellants (LDPs) for Earth return. The bipropellant LANTR engine utilizes the large divergent section of its nozzle as an afterburner into which oxygen is injected and supersonically combusted with nuclear preheated hydrogen emerging from the engines choked sonic throat essentially scramjet propulsion in reverse. By varying the oxygen-to-hydrogen mixture ratio, LANTR engines can operate over a range of thrust and Isp values while the reactor core power level remains relatively constant. A LANTR-based LTS offers unique mission capabilities including short transit time crewed cargo transports. Even a commuter shuttle service may be possible allowing one-way trip times to and from the Moon on the order of 36 hours or less. If only 1 of the postulated water ice trapped in deep shadowed craters at the lunar poles were available for use in lunar orbit, such a supply could support daily commuter flights to the Moon for many thousands of years! The proposed paper outlines an evolutionary mission architecture and examines a variety of mission types and transfer vehicle designs, along with the increasing demands on LDP production as mission complexity and delta V requirements increase. A comparison of vehicle features and engine operating characteristics are also provided together with a discussion of the propellant production and mining requirements, and issues, associated with using LPI as the source material.

Nuclear Thermal Propulsion↗
NASA NTRS2016

Solar vs. Fission Surface Power for Mars

A multi-discipline team of experts from the National Aeronautics and Space Administration (NASA) developed Mars surface power system point design solutions for two conceptual missions. The primary goal of this study was to compare the relative merits of solar- versus fission-powered versions of each surface mission. First, the team compared three different solar power options against a fission power system concept for a sub-scale, uncrewed demonstration mission. The 4.5 meter (m) diameter pathfinder lander's primary mission would be to demonstrate Mars entry, descent, and landing techniques. Once on the Martian surface, the lander's In Situ Resource Utilization (ISRU) payload would demonstrate liquid oxygen propellant production using atmospheric resources. For the purpose of this exercise, location was assumed to be at the Martian equator. The three solar concepts considered included a system that only operated during daylight hours (at roughly half the daily propellant production rate of a round-the-clock fission design), a battery-augmented system that operated through the night (matching the fission concept's propellant production rate), and a system that operated only during daylight, but at a higher rate (again, matching the fission concept's propellant production rate). Including 30% mass growth allowance, total payload masses for the three solar concepts ranged from 1,116 to 2,396 kg, versus the 2,686 kg fission power scheme. However, solar power masses are expected to approach or exceed the fission payload mass at landing sites further from the equator, making landing site selection a key driver in the final power system decision. The team also noted that detailed reliability analysis should be performed on daytime-only solar power schemes to assess potential issues with frequent ISRU system on/off cycling. Next, the team developed a solar-powered point design solution for a conceptual four-crew, 500-day surface mission consisting of up to four landers per crewed expedition mission. Unlike the demonstration mission, a lengthy power outage due to the global dust storms that are known to occur on Mars would pose a safety hazard to a crewed mission. A similar fission versus solar power trade study performed by NASA in 2007 concluded that fission power was more reliable-with a much lower mass penalty-than solar power for this application. However, recent advances in solar cell and energy storage technologies and changes in operational assumptions prompted NASA to revisit the analysis. For the purpose of this exercise a particular landing site at Jezero Crater, located at 18o north latitude, was assumed. A fission power system consisting of four each 10 kW Kilopower fission reactors was compared to a distributed network of Orion-derived Ultraflex solar arrays and Lithium ion batteries mounted on every lander. The team found that a solar power system mass of about 9,800 kg would provide the 22 kilowatts (kW) keep-alive power needed to survive a dust storm lasting up to 120-days at average optical depth of 5, and 35 kW peak power for normal operations under clear skies. Although this is less than half the mass estimated during the 2007 work (which assumed latitudes up to 30o) it is still more than the 7,000 kg mass of the fission system which provides full power regardless of dust storm conditions.

Rucker, Michelle A.↗
NASA NTRS2016

Solar Versus Fission Surface Power for Mars

A multi-discipline team of experts from the National Aeronautics and Space Administration (NASA) developed Mars surface power system point design solutions for two conceptual missions to Mars using In-situ resource utilization (ISRU). The primary goal of this study was to compare the relative merits of solar- versus fission-powered versions of each surface mission. First, the team compared three different solar-power options against a fission power system concept for a sub-scale, uncrewed demonstration mission. This “pathfinder” design utilized a 4.5 meter diameter lander. Its primary mission would be to demonstrate Mars entry, descent, and landing techniques. Once on the Martian surface, the lander’s ISRU payload would demonstrate liquid oxygen propellant production from atmospheric resources. For the purpose of this exercise, location was assumed to be at the Martian equator. The three solar concepts considered included a system that only operated during daylight hours (at roughly half the daily propellant production rate of a round-the-clock fission design), a battery-augmented system that operated through the night (matching the fission concept’s propellant production rate), and a system that operated only during daylight, but at a higher rate (again, matching the fission concept’s propellant production rate). Including 30% mass growth allowance, total payload masses for the three solar concepts ranged from 1,128 to 2,425 kg, versus the 2,751 kg fission power scheme. However, solar power masses increase as landing sites are selected further from the equator, making landing site selection a key driver in the final power system decision. The team also noted that detailed reliability analysis should be performed on daytime-only solar power schemes to assess potential issues with frequent ISRU system on/off cycling.

Rucker, Michelle A.↗
NASA NTRS2010

Liquid Oxygen Propellant Densification Production and Performance Test Results With a Large-Scale Flight-Weight Propellant Tank for the X33 RLV

This paper describes in-detail a test program that was initiated at the Glenn Research Center (GRC) involving the cryogenic densification of liquid oxygen (LO2). A large scale LO2 propellant densification system rated for 200 gpm and sized for the X-33 LO2 propellant tank, was designed, fabricated and tested at the GRC. Multiple objectives of the test program included validation of LO2 production unit hardware and characterization of densifier performance at design and transient conditions. First, performance data is presented for an initial series of LO2 densifier screening and check-out tests using densified liquid nitrogen. The second series of tests show performance data collected during LO2 densifier test operations with liquid oxygen as the densified product fluid. An overview of LO2 X-33 tanking operations and load tests with the 20,000 gallon Structural Test Article (STA) are described. Tank loading testing and the thermal stratification that occurs inside of a flight-weight launch vehicle propellant tank were investigated. These operations involved a closed-loop recirculation process of LO2 flow through the densifier and then back into the STA. Finally, in excess of 200,000 gallons of densified LO2 at 120 oR was produced with the propellant densification unit during the demonstration program, an achievement that s never been done before in the realm of large-scale cryogenic tests.

Tomsik, Thomas M.↗
NASA NTRS2018

Robust Exploration and Commercial Missions to the Moon Using Nuclear Thermal Rocket Propulsion and In Situ Propellants Derived from Lunar Polar Ice Deposits

The nuclear thermal rocket (NTR) has frequently been identified as a key space asset required for the human exploration of Mars. This proven technology can also provide the affordable “access through cislunar space” necessary for commercial development and sustained human presence on the Moon. It is a demonstrated technology capable of generating both high thrust and high specific impulse (I(sub sp) ~900 s)— twice that of today’s best chemical rockets. Nuclear lunar transfer vehicles—consisting of a propulsion stage using three ~16.5-klb(sub f) small nuclear rocket engines (SNREs), an in-line propellant tank, plus the payload—can enable a variety of reusable lunar missions. These include cargo delivery and crewed lunar landing missions. Even weeklong “tourism” missions carrying passengers into lunar orbit for a day of sightseeing and picture taking are possible. The NTR can play an important role in the next phase of lunar exploration and development by providing a robust in-space lunar transportation system (LTS) that can allow initial outposts to evolve into settlements supported by a variety of commercial activities such as in situ propellant production used to supply strategically located propellant depots and transportation nodes. The processing of lunar polar ice (LPI) deposits (estimated to be ~2 billion metric tons) for propellant production—specifically liquid oxygen (LO(sub 2)) and hydrogen (LH(sub 2))—can significantly reduce the launch mass requirements from Earth and can enable reusable, surface-based lunar landing vehicles (LLVs) using LO(sub 2)/LH(sub 2) chemical rocket engines. Afterwards, LO(sub 2)/LH(sub 2) propellant depots can be established in lunar polar and equatorial orbits to supply the LTS. At this point a modified version of the conventional NTR called the LO(sub 2)-augmented NTR, or LANTR, would be introduced into the LTS, allowing bipropellant operation and leveraging the mission benefits of refueling with lunar-derived propellants (LDPs) for Earth return. The bipropellant LANTR engine utilizes the large divergent section of its nozzle as an “afterburner” into which oxygen is injected and supersonically combusted with nuclear preheated hydrogen emerging from the engine’s choked sonic throat—essentially “scramjet propulsion in reverse.” By varying the oxygen-to-hydrogen mixture ratio, LANTR engines can operate over a range of thrust and I(sub sp) values while the reactor core power level remains relatively constant. A LANTR-based LTS offers unique mission capabilities including short transit time crewed cargo transports. Even a “commuter” shuttle service may be possible, allowing “one-way” trip times to and from the Moon on the order of 36 hr or less. If only 1% of the postulated trapped water ice were available for use in lunar orbit, such a supply could support routine commuter flights to the Moon for many thousands of years. This report outlines an evolving LTS architecture that uses propellants derived from LPI and examines a variety of mission types and transfer vehicle designs along with their operating characteristics and increasing demands on LDP production as mission complexity and velocity change ΔV requirements increase. A comparison of the LDP production and mining requirements using LPI and volcanic glass to produce lunar-derived liquid oxygen (LUNOX) via the hydrogen reduction process is included, and the synergy with an evolving helium-3 mining industry is also discussed.

Borowski, Stanley K.↗