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NASA NTRS1998

Human Mars Mission: Transportation Assessment

The first Human Mars Mission is being projected to take place during the 2011 and 2013 / 2014 Mars opportunities. Two cargo flights will leave for Mars during the first opportunity, one to Mars orbit and the second to the surface, to prepare the descent transportation, landing site reconnaissance, and ascent vehicle and propellant for the crew arriving during the following opportunity. Each trans-Mars injection (TMI) stack will consist of a payload portion (currently coming in at 60 to 84 metric tonnes) and a TMI propulsion stage (currently coming in at 68-156 mt loaded with propellant) for performing the departure ΔVs for the appropriate Mars trajectories. Three different options are being considered for the system(s) that will comprise the TMI stage for each stack and will perform ΔVs that range from 848 meters/second (m/sec) to 4232 m/sec as required by the trajectory (with gravity losses and various performance margins included). Liquid oxygen (LOx) / liquid hydrogen (LH 2 ) and LOx / liquid methane (LCH 4 ) are the propellant options for other transportation elements utilized for descent, ascent, and trans-Earth injection (TEI) in these Mars architectures. This paper will discuss the current applications of the necessary transportation stages to a human Mars mission and project the implications these various options have on an exploration visit to Mars.

Mars Missions↗

NASA NTRS2015

Characterization of Carbon Particulates in the Exit Flow of a Plasma Pyrolysis Assembly (PPA) Reactor

The ISS presently recovers oxygen from crew respiration via a Carbon Dioxide Reduction Assembly (CRA) that utilizes the Sabatier chemical process to reduce captured carbon dioxide to methane (CH4) and water. In order to recover more of the hydrogen from the methane and increase oxygen recovery, NASA Marshall Space Flight Center (MSFC) is investigating a technology, plasma pyrolysis, to convert the methane to acetylene. The Plasma Pyrolysis Assembly (or PPA), achieves 90% or greater conversion efficiency, but a small amount of solid carbon particulates are generated as a side product and must be filtered before the acetylene is removed and the hydrogen-rich gas stream is recycled back to the CRA. In this work, we present the experimental results of an initial characterization of the carbon particulates in the PPA exit gas stream. We also present several potential options to remove these carbon particulates via carbon traps and filters to minimize resupply mass and required downtime for regeneration.

Methane pyrolysis↗

NASA NTRS2010

The Reduction of Lunar Regolith by Carbothermal Processing Using Methane

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans currently being developed by NASA. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source so that a small zone of molten regolith is established. A continuous flow of methane is maintained over the molten regolith zone. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. It is further processed downstream to ultimately produce oxygen.

Balasubramaniam, R.↗

NASA NTRS2010

The Reduction of Lunar Regolith by Carbothermal Processing Using Methane

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans Currently being developed by NASA. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source so that a small zone of molten regolith is established. A continuous flow of methane is maintained over the molten regolith zone. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. It is further processed downstream to ultimately produce oxygen.

Balasubramaniam, R.↗

DOE OSTI2025

Potential Risks Associated with Short-Term Hydrogen Storage in Methane Reservoirs

Hydrogen (H2) has been identified as a flexible energy carrier with zero emissions. It is possible to utilize H2 by storing Hyblend, or H2 blended with CH4, in existing natural gas infrastructure. However, the compatibility of adapting the current CH4 storage strategies to include H2 injection has not been fully demonstrated. It is essential that we understand the impact of H2 gas on the naturally occurring microbial community of subsurface storage reservoirs before deploying large-scale H2-CH4 storage. We designed a series of experiments that allowed us to identify potential challenges of HyBlend Storage in existing methane reservoirs (Figure 1). First, we characterized two field fluid samples from a methane reservoir located in Western United States. Next, we used these samples to complete a series of short-term reactor experiments at reservoir conditions for a natural gas (100% CH4) and HyBlend (80% CH4/20% H2) storage environment.

geomicrobiology↗

DOE OSTI2025

Efficient Synthetic Natural Gas Production from Direct Air Capture Using Titania-Based Dual Function Materials

Converting atmospheric CO2 into methane offers a compelling pathway to store intermittent renewable electricity and enhance energy security using existing natural gas infrastructure. However, current CO2 utilization approaches remain energy- and capital-intensive, largely due to the need for separate capture, purification, and conversion steps. Integrating CO2 capture with catalytic methanation represents a transformative strategy for process intensification on both the unit operation and molecular levels. We report a series of Ru-Na/TiO2 dual function materials (DFMs) for a reactive carbon capture (RCC) process consisting of simulated direct air capture and subsequent CO2 methanation (DACM). Superior methane desorption purity was observed on TiO2-based DFMs (>94 %) relative to state-of-the-art Al2O3-supported DFMs (77 %). Modifying the process to begin CO2 adsorption immediately following the methanation stage, rather than beginning adsorption near ambient temperature, resulted in >97 % methane desorption purity, suitable for injection into the natural gas pipeline without additional CO2 separation steps.

organic↗

DOE OSTI2024

Reactive Carbon Capture: Cooperative and Bifunctional Adsorbent-Catalyst Materials and Process Integration for a New Carbon Economy

To say the least, releasing CO 2 into the atmosphere is reaping undue environmental consequences given the ever-present increase in severe global weather events over the past five years. However, it can be argued that–at least in the confines of current technological capabilities–the atmospheric release of CO 2 is somewhat unavoidable given that even shifting toward clean energy sources–such as solar, nuclear, wind, battery, or H 2 power–incurs an initial carbon requirement by way of manufacturing the very production abilities through which “clean” energy is generated. Even years from now, experts agree that energy production will be diversified and–as the global population continues to drive the growth of global energy consumption–thermal power derived from carbon combustion is likely to remain one intrinsic energetic source, of which CO 2 will always be a byproduct. In this context, it is the responsibility of the scientific community to devise improved pathways of carbon management such that (i) the consequences of combustion on the global environment are reduced and (ii) carbon fuels can be leveraged in a sustainable fashion. In this Account, we discuss a pivotal perspective shift on CO 2 emissions derived from a considerable breakthrough in material science from our work on shape engineering of nanoporous adsorbents and catalysts. This account details the development of materials which no longer vilify CO 2 emissions as a valueless combustion byproduct, instead providing a path for them to become a potential feedstock. In more specific terms, this work details the development of structured, cooperative “bifunctional” materials (BFMs) comprised of (i) a high-temperature adsorbent and (ii) a heterogeneous catalyst that enable single-bed CO 2 capture and utilization in oxidative ethane dehydrogenation (ODHE), oxidative propane dehydrogenation (ODHP), and dry methane reforming (DMR) processes. This Account begins with the conceptual development of the BFMs in the powdered state, followed by detailing the first-ever reports of structuring the materials into facile honeycomb contactors by 3D printing. The Account then summarizes the impressive performance of the 3D-printed BFMs, specifically focusing on how their catalysts (metal oxides and perovskites) influence their reactive CO 2 capture performances in ODHE, ODHP, and DMR processes. Such promise of CO 2 -as-fuel offers a glimpse into the future of a diversified energy economy, in which CO 2 /fuel looping can play an important role. A major factor in achieving this future is, of course, developing an appropriately active catalyst; an account of whose first breakthroughs in material science are detailed herein.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Fermi-Based Kinetic Model for the Sabatier Reaction: Sabatier Principle and Beyond It

The CO 2 methanation reaction (aka the Sabatier reaction) is one of the important carbon utilization technologies to reduce atmospheric greenhouse gases. In this study, kinetic modeling of the Sabatier reaction proceeding via the CO route has been presented by considering weak and strong chemisorption concepts rooted in electronic theory. Based on the single-route mechanism of the Sabatier reaction, the dependence of the reaction rate on the position of the catalyst Fermi level with respect to the antibonding states of the reagent (CO 2 ) and the product (CH 4 ), is demonstrated with the classic Sabatier volcano-shape. Furthermore, the model was applied to explain experimental results of reaction rates for Ni- and Ru-based catalytic systems and to understand origin of enhancement of turnover frequencies established for dynamic catalysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1989

Instrumentation systems for the Langley Research Center 8-foot high temperature tunnel

A description is presented of the 8-foot high-temperature tunnel, a Mach 7 blowdown-type facility in which methane is burned in air under pressure, with the resulting combustion products utilized as the test medium. The instrumentation environment and requirements are identified, and instrumentation design, including wiring, sensors, and data acquisition system are described. The design and installation of a fast oxygen monitoring system to maintain the partial pressure of oxygen at 21 percent in the tunnel test section is included. Also, the new data acquisition system hardware details and data-reduction capabilities are defined.

Walsh, James J., Jr.↗

NASA NTRS2012

Using Pyrolysis and its Bioproducts to Help Close the Loop in Sustainable Life Support Systems

The next step in human exploration of space is beyond low Earth orbit and possibly to sites such as the Moon and Mars. Resupply of critical life support components for missions such as these are difficult or impossible. Life support processes for closing the loop of water, oxygen and carbon have to be identified .. Currently, there are many technologies proposed for terrestrial missions for waste, water, air processing and the creation of consumables. There are a variety of different approaches, but few address all of these issues simultaneously. One candidate is pyrolysis; a method where waste streams can be heated in the absence of oxygen to undergo a thermochemical conversion producing a series of bioproducts. Bioproducts like biochar made from non-edible biomass and human solid waste can possibly provide valuable benefits such as waste reduction, regolith fertilization for increased food production, and become a consumable for water processing and air revitalization systems. Syngas containing hydrogen, carbon monoxide and c~bon dioxide, can be converted to methane and dimethyl ether to create propellants. Bio-oils can be utilized as a heating fuel or fed to bioreactors that utilize oil-eating microbes. Issues such as carbon sequestration and subsequent carbon balance of the closed system and identifying ideal process methods to achieve the highest quality products, whilst being energy friendly, will also be addressed.

McCoy, LaShelle E.↗

NASA NTRS2013

A Review: Using Pyrolysis and its Bioproducts to Help Close the Loop in Sustainable Life Support Systems

The next step in human exploration of space is beyond low Earth orbit and possibly to sites such as the Moon and Mars. Resupply of critical life support components for missions such as these are difficult or impossible. Life support processes for closing the loop of water, oxygen and carbon have to be identified. Currently, there are many technologies proposed for terrestrial missions for waste, water, air processing. and the creation of consumables. There are a variety of different approaches, but few address all of these issues simultaneously. One candidate is pyrolysis; a method where waste streams can be heated in the absence of oxygen to undergo a thermochemical conversion producing a series of bioproducts. Bioproducts like biochar made from non-edible biomass and human solid waste can possibly provide valuable benefits such as waste reduction, regolith fertilization for increased food production, and become a consumable for water processing and air revitalization systems. Syngas containing hydrogen, carbon monoxide and carbon dioxide, can be converted to methane and dimethyl ether to create propellants. Bio-oils can be utilized as a heating fuel or fed to bioreactors that utilize oil-eating microbes.

McCoy, LaShelle E.↗

NASA NTRS2018

Dust Mitigation on Mars Using an Electrostatic Precipitator

The Martian atmosphere contains large amounts of dust, which are lofted by dust devils and dust storms. Some of this dust, particles on the order of 2-4 m, never settle and are constantly present in the atmosphere. Therefore, in order to utilize the planet's atmosphere for production of consumables, like oxygen and methane, this dust must be removed before the commodity production can begin. The electrostatic precipitator is currently being studied at Kennedy Space Center as a realistic option for removing this dust. This project covers the results, to date, of the dust flow initiation, control, and analysis inside the electrostatic precipitator, which is to be modelled after various dusty Martian atmospheric conditions.

electrostatic precipitator↗

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

Franco, Carolina↗

NASA NTRS2010

Creating Methane from Plastics: Recycling at a Lunar Outpost

The high cost of re-supply from Earth demands resources to be utilized to the fullest extent for exploration missions. Recycling is a key technology that maximizes the available resources by converting waste products into useful commodities. One example of this is to convert crew member waste such as plastic packaging, food scraps, and human waste, into fuel. The ability to refuel on the lunar surface would reduce the vehicle mass during launch and provide excess payload capability. The goal of this project is to determine the feasibility of recycling waste into methane on the lunar outpost by performing engineering assessments and lab demonstrations of the technology. The first goal of the project was to determine how recycling could influence lunar exploration. Table I shows an estimation of the typical dried waste stream generated each day for a crew of four. Packaging waste accounts for nearly 86% of the dry waste stream and is a significant source of carbon on the lunar surface. This is important because methane (CH4) can be used as fuel and no other source of carbon is available on the lunar surface. With the initial assessment indicating there is sufficient resources in the waste stream to provide refueling capabilities, the project was designed to examine the conversion of plastics into methane.

Captain, Janine↗

NASA NTRS2008

Carbothermal Processing of Lunar Regolith Using Methane

The processing of lunar regolith for the production of oxygen is a key component of the In-Situ Resource Utilization plans currently being developed by NASA. Among various candidate processes, the modeling of oxygen production by hydrogen reduction, molten salt electrolysis, and carbothermal processing are presently being pursued. In the carbothermal process, a portion of the surface of the regolith in a container is heated by exposure to a heat source such as a laser beam or a concentrated solar heat flux, so that a small zone of molten regolith is established. The molten zone is surrounded by solid regolith particles that are poor conductors of heat. A continuous flow of methane is maintained over the molten regolith zone. Our model is based on a mechanism where methane pyrolyzes when it comes in contact with the surface of the hot molten regolith to form solid carbon and hydrogen gas. Carbon is deposited on the surface of the melt, and hydrogen is released into the gas stream above the melt surface. We assume that the deposited carbon mixes in the molten regolith and reacts with metal oxides in a reduction reaction by which gaseous carbon monoxide is liberated. Carbon monoxide bubbles through the melt and is released into the gas stream. Oxygen is produced subsequently by (catalytically) processing the carbon monoxide downstream. In this paper, we discuss the development of a chemical conversion model of the carbothermal process to predict the rate of production of carbon monoxide.

Balasubramaniam, R.↗

NASA NTRS2009

Carbothermal Processing of Lunar Regolith Using Methane

Balasubramaniam, R.↗

NASA NTRS2010

Creating Methane from Plastic: Recycling at a Lunar Outpost

The high cost of re-supply from Earth demands resources to be utilized to the fullest extent for exploration missions. The ability to refuel on the lunar surface would reduce the vehicle mass during launch and provide excess payload capability. Recycling is a key technology that maximizes the available resources by converting waste products into useful commodities. One example of this is to convert crew member waste such as plastic packaging, food scraps, and human waste into fuel. This process thermally degrades plastic in the presence of oxygen producing CO2 and CO. The CO2 and CO are then reacted with hydrogen over catalyst (Sabatier reaction) producing methane. An end-to-end laboratory-scale system has been designed and built to produce methane from plastic, in this case polyethylene. This first generation system yields 12-16% CH4 by weight of plastic used.

Santiago-Maldonado, Edgardo↗