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NASA NTRS1994

An unmanned mission to Mars with sample collection and in-situ resource utilization

The design for the Mars Analysis and Return Vehicle with In-Situ Resource Utilization (MARVIN) project is outlined. The MARVIN mission is designed to collect samples of the Martian environment; to produce fuel from local Martian resources; and to use the fuel produced to return the samples to earth. It uses only existing technologies. Exploratory Technologies' mission-design efforts have focused on methods of orbit determination, sample collection, fuel production, power, communications, control, and structural design. Lambert Targeting provided Delta-V's, launch dates, and travel times. The landing site is the Tharsis Plateau, to the southeast of Olympus Mons, chosen for its substantial scientific value. Samples of soil, dust, and atmosphere are collected with lander-based collection devices: the soil sample, with a robotic arm similar to those used in the Viking missions; the atmospheric sample, from a bleed line to the compressor in the fuel-production facility; a dust sample, from the dust-collection container in the fuel-production facility; and a redundant dust sample, with a with a passive filter system, which relies upon neither a power source nor other collection methods. The sample-return capsule (SRC) houses these samples, which are triply contained to prevent contamination. Proven technology can be used to produce methane and oxygen for fuel with relative ease at the landing site: the Sabatier reactor produces methane and water by combining carbon dioxide and hydrogen (brought from earth); the Reverse Water-Gas Shift unit combines carbon dioxide and hydrogen to form carbon monoxide and water; a water-electrolysis unit splits the water into hydrogen and oxygen. The Mars-lander vehicle (MLV) transports the equipment from earth to Mars. The Mars-ascent vehicle (MAV) contains the SRC and the engine, which is the same for both the MLV and the MAV. All equipment that is unnecessary for the Mars-Earth trajectory remains on Mars. This report presents detailed sizing information, for which a spreadsheet has been developed. The trends suggest possibilities for expansion, and suggestions for future work in these areas are offered.

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NASA NTRS1995

Mars Sample Return mission utilizing in-situ propellant production

This report presents the results of a study examining the potential of in-situ propellant production (ISPP) on Mars to aid in achieving a low cost Mars Sample Return (MSR) mission. Two versions of such a mission were examined: a baseline version employing a dual string spacecraft, and a light weight version employing single string architecture with selective redundancy. Both systems employed light weight avionics currently being developed by Lockheed Martin, Jet Propulsion Lab and elsewhere in the aerospace community, both used a new concept for a simple, light weight parachuteless sample return capsule, both used a slightly modified version of the Mars Surveyor lander currently under development at Lockheed Martin for flight in 1998, and both used a combination of the Sabatier-electrolysis and reverse water gas shift ISPP systems to produce methane/oxygen propellant on Mars by combining a small quantity of imported hydrogen with the Martian CO2 atmosphere. It was found that the baseline mission could be launched on a Delta 7925 and return a 0.5 kg sample with 82 percent mission launch margin;over and beyond subsystem allocated contingency masses . The lightweight version could be launched on a Mid-Lite vehicle and return a 0.25 kg sample with 11 percent launch margin, over and above subsystem contingency mass allocations.

Zubrin, Robert↗

NASA NTRS1997

In-Situ Propellant Production on Mars: A Sabatier/Electrolysis Demonstration Plant

An efficient, reliable propellant production plant has been developed for use on Mars. Using a Sabatier reactor in conjunction with a water electrolysis system, a complete demonstration plant has produced methane and liquid oxygen from simulated Martian atmosphere. The production plant has demonstrated high efficiency, extended duration production and autonomous operations. This paper presents the results and conclusions relating to eventual use in a Mars sample return mission. This work was funded by the Jet Propulsion Laboratory (JPL). The production plant was built and tested at the Propulsion Center of Lockheed Martin at the Denver Colorado facility.

Clark, David L.↗

NASA NTRS1999

Methane Pyrolysis and Disposing Off Resulting Carbon

Sabatier/Electrolysis (S/E) is a leading process for producing methane and oxygen for application to Mars ISPP. One significant problem with this process is that it produces an excess of methane for combustion with the amount of oxygen that is produced. Therefore, one must discard roughly half of the methane to obtain the proper stoichiometric methane/oxygen mixture for ascent from Mars. This is a waste of hydrogen, which must be brought from Earth and is difficult to transport to Mars and store on Mars. To reduce the problem of transporting hydrogen to Mars, the S/E process can be augmented by another process which reduces overall hydrogen requirement. Three conceptual approaches for doing this are (i) recover hydrogen from the excess methane produced by the S/E process, (ii) convert the methane to a higher hydrocarbon or other organic with a lower H/C ratio than methane, and (iii) use a separate process (such as zirconia or reverse water gas shift reaction) to produce additional oxygen, thus utilizing all the methane produced by the Sabatier process. We report our results here on recovering hydrogen from the excess methane using pyrolysis of methane. Pyrolysis has the advantage that it produces almost pure hydrogen, and any unreacted methane can pass through the S/E process reactor. It has the disadvantage that disposing of the carbon produced by pyrolysis presents difficulties. The goals of a research program on recovery of hydrogen from methane are (in descending priority order): 1) Study the kinetics of pyrolysis to arrive at a pyrolysis reactor design that produces high yields in a confined volume at the lowest possible operating temperature; 2) Study the kinetics of carbon burnoff to determine whether high yields can be obtained in a confined volume at acceptable operating temperatures; and 3) Investigate catalytic techniques for depositing carbon as a fine soot which can be physically separated from the reactor. In the JPL program, we have made significant measurements in regard to goal 1, cursory measurements in regard to goal 2, and would plan to pursue goal 3 if additional resources are secured.

Sharma, P. K.↗

NASA NTRS1999

Methane Pyrolysis and Disposing Off Resulting Carbon

Sabatier/Electrolysis (S/E) is a leading process for producing methane and oxygen for application to Mars ISPP. One significant problem with this process is that it produces an excess of methane for combustion with the amount of oxygen that is produced. Therefore, one must discard roughly half of the methane to obtain the proper stoichiometric methane/oxygen mixture for ascent from Mars. This is wasteful of hydrogen, which must be brought from Earth and is difficult to transport to Mars and store on Mars. To reduced the problem of transporting hydrogen to Mars, the S/E process can be augmented by another process which reduces overall hydrogen requirement. Three conceptual approaches for doing this are (1) recover hydrogen from the excess methane produced by the S/E process, (2) convert the methane to a higher hydrocarbon or other organic with a lower H/C ratio than methane, and (3) use a separate process (such as zirconia or reverse water gas shift reaction) to produce additional oxygen, thus utilizing all the methane produced by the Sabatier process. We report our results here on recovering hydrogen from the excess methane using pyrolysis of methane. Pyrolysis has the advantage that it produces almost pure hydrogen, and any unreacted methane can pass through the S/E process reactor. It has the disadvantage that disposing of the carbon produced by pyrolysis presents difficulties. Hydrogen may be obtained from methane by pyrolysis in the temperature range 10000-12000C. The main reaction products are hydrogen and carbon, though very small amounts of higher hydrocarbons, including aromatic hydrocarbons are formed. The conversion efficiency is about 95% at 12000C. One needs to distinguish between thermodynamic equilibrium conversion and conversion limited by kinetics in a finite reactor.

Sharma, P. K.↗

NASA NTRS2000

The DORIS Data Center at the CDDIS

The DORIS system (Doppler Orbitography and Radio positioning Integrated by Satellite) was designed and developed by CNES, the National Geographic Institute, IGN (Institut G6ographique National), and the Space Geodesy Research Group, GRGS (Groupe de Recherches de Geodesie Spatiale - CNES/CNRS/Universite Paul Sabatier) to meet new needs for the precise determination of satellite positions on their orbits and for precise positioning of terrestrial beacons. This system has been carried since 1990 on the French SPOT 2 satellite, since 1992 on the French/American satellite TOPEX/POSEIDON, and since 1998 on the French SPOT 4 satellite. It will be part of the JASON (CNES/NASA) and ENVISAT (ESA) altimetric missions and also the SPOT follow-on Earth observation missions. DORIS is a radio-electrical system which takes Doppler measurements between a satellite in low orbit and a permanent global network for the purpose, on the one hand, of determining the satellite's position in orbit, and on the other hand, of locating ground beacons with a high degree of precision.

Noll, Carey E.↗

NASA NTRS2000

Microreactor System Design for a NASA In Situ Propellant Production Plant on Mars

The NASA In Situ Resource Utilization (ISRU) program is planning near-term missions to Mars that will include chemical processes for converting the carbon dioxide (CO2) and possibly water from the Martian environment to propellants, oxygen, and other useful chemicals. The use of indigenous resources reduces the size and weight of the payloads from Earth significantly, representing enormous cost savings that make human exploration of Mars affordable. Extraterrestrial chemical processing plants will need to be compact, lightweight, highly efficient under reduced gravity, and extraordinarily reliable for long periods. Microchemical and thermal systems represent capability for dramatic reduction in size and weight, while offering high reliability through massive parallelization. In situ propellant production (ISPP), one aspect of the ISRU program, involves collecting and pressurizing atmospheric CO2, conversion reactions, chemical separations, heat exchangers, and cryogenic storage. A preliminary system design of an ISPP plant based on microtechnology has demonstrated significant size, weight, and energy efficiency gains over the current NASA baseline. Energy management is a strong driver for Mars-based processes, not only because energy is a scarce resource, but because heat rejection is problematic; the low pressure environment makes convective heat transfer ineffective. Energy efficiency gains are largely achieved in the microchemical plant through extensive heat recuperation and energy cascading, which has a small size and weight penalty because the added micro heat exchangers are small. This leads to additional size and weight gains by reducing the required area of waste heat radiators. The microtechnology-based ISPP plant is described in detail, including aspects of pinch analysis for optimizing the heat exchanger network. Three options for thermochemical compression Of CO2 from the Martian atmosphere, adsorption, absorption, and cryogenic freezing, are presented, as well as three options for water decomposition, low temperature electrolysis, high temperature electrolysis, and thermochemical decomposition. Other elements of the plant include Sabatier and reverse water gas shift reactors, water recovery, chemical separations, and cryogenic storage. Data are presented supporting preliminary sizing of components, and results of the system design are compared to the existing NASA baseline that is based on conventional technologies.

TeGrotenhuis, W. E.↗

NASA NTRS2001

A Survey of Alternative Oxygen Production Technologies

Utilization of the Martian atmosphere for the production of fuel and oxygen has been extensively studied. The baseline fuel production process is a Sabatier reactor, which produces methane and water from carbon dioxide and hydrogen. The oxygen produced from the electrolysis of the water is only half of that needed for methane-based rocket propellant, and additional oxygen is needed for breathing air, fuel cells and other energy sources. Zirconia electrolysis cells for the direct reduction of CO2 arc being developed as an alternative means of producing oxygen, but present many challenges for a large-scale oxygen production system. The very high operating temperatures and fragile nature of the cells coupled with fairly high operating voltages leave room for improvement. This paper will survey alternative oxygen production technologies, present data on operating characteristics, materials of construction, and some preliminary laboratory results on attempts to implement each. Our goal is to significantly improve upon the characteristics of proposed zirconia cells for oxygen production. To achieve that goal we are looking at electrolytic systems that operate at significantly lower temperatures, preferably below 31C to allow the incorporation of liquid CO2 in the electrolyte. Our preliminary results indicate that such a system will have much higher current densities and have simpler cathode construction than a porous gas feed electrode system. Such a system could be achieved based on nonaqueous electrolytes or ionic liquids. We are focusing our research on the anode reaction that will produce oxygen from a product generated at the cathode using CO2 as the feed. Operation at low temperatures also will open up the full range of polymer and metal materials, allowing a more robust system design to withstand the rigors of flight, landing, and long term unattended operation on the surface of Mars.

Lueck, Dale E.↗

NASA NTRS2000

A Survey of Alternative Oxygen Production Technologies

Lueck, Dale E.↗

NASA NTRS2001

Performance Testing of a Lightweight, High Efficiency 95 K Cryocooler

Performance data are presented for a flight-like, lightweight, high efficiency pulse tube cryogenic cooler. The cooler has a mass of less than 4.0 kg, and an efficiency of 12 W/W, which is 18% of Carnot at 95 K, nearly double the efficiency of previous cooler designs, The mass of the cooler has been reduced by approximately a factor of three. The design point cooling power is 10 watts at 95 K at a heat rejection temperature of 300 K. The no-load temperature is 45 K. The compressor is built by Hymatic Engineering, UK, and is of a horizontally opposed piston design using flexure bearings. The vertical pulse tube is built by TRW with the heat exchanger or cold block located approximately mid-way along the tube. The final assembly and integration is also performed by TRW. The inertance tube and dead volume are contained within one of the compressor end caps. The cooler was developed by TRW under a joint NASA-DOD program, and has a goal of 10 yr operating lifetime. Potential NASA applications will focus on using coolers of this type in Zero boil off (ZBO) cryogen storage topologies for next generation launch vehicles. Zero boil off systems will feature significant reductions in tank size and Initial Mass to Low Earth Orbit (IMLEO), thereby significantly reducing the cost of access to space, and enabling future missions. The coolers can be used directly in liquid oxygen (LOx) or liquid methane ZBO systems, as shield coolers in liquid hydrogen tanks, or as first stage coolers in two-stage liquid hydrogen (LH2) ZBO cooler systems. Finally, the coolers could find applications in exploration missions where either propellants or breathable oxygen are extracted from the planetary atmosphere using a Sabatier or similar process. The gases could then be liquefied for storage either directly in return vehicle propellant tanks or on the planetary surface. Data presented were taken with the cooler operating in a vacuum of 10 (exp -5) torr, at controlled rejection temperatures from 300 K down to 275 K using a cold water heat exchanger bolted to the cooler. Heat loads were varied between 0.5 W and 15 W by supplying current to a 50 omega resistor mounted on a copper cold plate which was bolted to the cooler cold block. Silicon diodes mounted on both the cold plate and the heat exchanger provided accurate temperature measurement to within plus or minus 0.25 K and plus or minus 0.5 K respectively, up to 100 K with plus or minus 1% accuracy above 100 K. Input power to the compressor was limited to 180 W, corresponding to a maximum stroke of 80%.

Salerno, Lou↗

NASA NTRS2003

An Introduction to Mars ISPP Technologies

This viewgraph presentation provides information on potential In Situ Propellant Production (ISPP) technologies for Mars. The presentation discusses Sabatier reactors, water electrolysis, the advantages of methane fuel, oxygen production, PEM cell electrolyzers, zirconia solid electrolyte cells, reverse water gas shift (RWGS), molten carbonate electrolysis, liquid CO2, and ionic liquids.

Lueck, Dale E.↗

NASA NTRS2003

CO2 Acquisition Membrane (CAM)

The objective of CAM is to develop, test, and analyze thin film membrane materials for separation and purification of carbon dioxide (CO2) from mixtures of gases, such as those found in the Martian atmosphere. The membranes are targeted toward In Situ Resource Utilization (ISRU) applications that will operate in extraterrestrial environments and support future unmanned and human space missions. A primary application is the Sabatier Electrolysis process that uses Mars atmosphere CO2 as raw material for producing water, oxygen, and methane for rocket fuel and habitat support. Other applications include use as an inlet filter to collect and concentrate Mars atmospheric argon and nitrogen gases for habitat pressurization, and to remove CO2 from breathing gases in Closed Environment Life Support Systems (CELSS). CAM membrane materials include crystalline faujasite (FAU) zeolite and rubbery polymers such as silicone rubber (PDMS) that have been shown in the literature and via molecular simulation to favor adsorption and permeation of CO2 over nitrogen and argon. Pure gas permeation tests using commercial PDMS membranes have shown that both CO2 permeance and the separation factor relative to other gases increase as the temperature decreases, and low (Delta)P(Sub CO2) favors higher separation factors. The ideal CO2/N2 separation factor increases from 7.5 to 17.5 as temperature decreases from 22 C to -30 C. For gas mixtures containing CO2, N2, and Ar, plasticization decreased the separation factors from 4.5 to 6 over the same temperature range. We currently synthesize and test our own Na(+) FAU zeolite membranes using standard formulations and secondary growth methods on porous alumina. Preliminary tests with a Na(+) FAU membrane at 22 C show a He/SF6 ideal separation factor of 62, exceeding the Knudsen diffusion selectivity by an order of magnitude. This shows that the membrane is relatively free from large defects and associated non-selective (viscous flow) transport mechanisms. The Membrane Test Facility (MTF) has been developed to measure membrane permeance over a wide range of temperature and pressure. The facility uses two volume compartments separated by the membrane that are instrumented to measure temperature, delta pressure across the membrane, and gas composition. A thermal shroud supports and encloses the membrane, and provides temperature control. Methods were developed to determine membrane permeance using the first order decay of the pressure difference between the sealed compartments, using the total pressure for pure gases, and partial pressure of each species in gas mixtures. The technique provides an end-to-end measurement of gas permeance that includes concentration polarization effects. Experiments have shown that in addition to membrane permeance properties, the geometry and design of associated structures play an important role in how membrane systems will function on Mars.

Mason, Larry W.↗

NASA NTRS2002

Oxygen Penalty for Waste Oxidation in an Advanced Life Support System: A Systems Approach

Oxidation is one of a number of technologies that are being considered for waste management and resource recovery from waste materials generated on board space missions. Oxidation processes are a very effective and efficient means of clean and complete conversion of waste materials to sterile products. However, because oxidation uses oxygen there is an "oxygen penalty" associated either with resupply of oxygen or with recycling oxygen from some other source. This paper is a systems approach to the issue of oxygen penalty in life support systems and presents findings on the oxygen penalty associated with an integrated oxidation-Sabatier-Oxygen Generation System (OGS) for waste management in an Advanced Life Support System. The findings reveal that such an integrated system can be operated to form a variety of useful products without a significant oxygen penalty.

Pisharody, Suresh↗

NASA NTRS2004

Past, Present and Future Advanced ECLS Systems for Human Exploration of Space

This paper will review the historical record of NASA's regenerative life support systems flight hardware with emphasis on the complexity of spiral development of technology as related to the International Space Station program. A brief summary of what constitutes ECLSS designs for human habitation will be included and will provide illustrations of the complex system/system integration issues. The new technology areas which need to be addressed in our future Code T initiatives will be highlighted. The development status of the current regenerative ECLSS for Space Station will be provided for the Oxygen Generation System and the Water Recovery System. In addition, the NASA is planning to augment the existing ISS capability with a new technology development effort by Code U/Code T for CO2 reduction (Sabatier Reactor). This latest ISS spiral development activity will be highlighted in this paper.

Mitchell, Kenny↗

NASA NTRS2004

Past, Present and Future Advanced ECLS Systems for Human Exploration of Space

Mitchell, Kenny↗

NASA NTRS2005

Development of a Low-Power CO2 Removal and Compression System for Closed-Loop Air Revitalization in Future Spacecraft

The current CO2 removal technology of NASA is very energy intensive and contains many non-optimized subsystems. This paper discusses the design and prototype development of a two-stage CO2 removal and compression system that will utilize much less power than NASA s current CO2 removal technology. This integrated system contains a Nafion membrane followed by a residual water adsorber that performs the function of the desiccant beds in the four-bed molecular sieve (4BMS) system of the International Space Station (ISS). The membrane and the water adsorber are followed by a two-stage CO2 removal and compression subsystem that satisfies the operations of the CO2 adsorbent beds of the 4BMS aid the interface compressor for the Sabatier reactor connection. The two-stage compressor will utilize the principles of temperature-swing adsorption (TSA) compression technology for CO2 removal and compression. The similarities in operation and cycle times of the CO2 removal (first stage) and compression (second stage) operations will allow thermal coupling of the processes to maximize the efficiency of the system. In addition to the low-power advantage, this processor will maintain a lower CO2 concentration in the cabin than that can be achieved by the existing CO2 removal systems. The compact, consolidated, configuration of membrane gas dryer and CO2 separator and compressor will allow continuous recycling of humid air in the cabin and supply of compressed CO2 to the reduction unit for oxygen recovery. The device has potential application to the International Space Station and future, long duration, transit, and planetary missions.

Mulloth, Lila M.↗

NASA NTRS2005

In-situ Production of High Density Polyethylene and Other Useful Materials on Mars

This paper describes a revolutionary materials structure and power storage concept based on the in-situ production of abiotic carbon 4 compounds. One of the largest single mass penalties required to support the human exploration of Mars is the surface habitat. This proposal will use physical chemical technologies to produce high density polyethylene (HDPE) inflatable structures and construction materials from Mars atmospheric CO2. The formation of polyethylene from Mars CO2 is based on the use of the Sabatier and modified Fischer Tropsch reactions. The proposed system will fully integrate with existing in-situ propellant production concepts. The technology will also be capable of supplementing human caloric requirements, providing solid and liquid fuels for energy storage, and providing significant reduction in mission risk. The NASA Mars Reference Mission Definition Team estimated that a conventional Mars surface habitat structure would weigh 10 tonnes. It is estimated that this technology could reduce this mass by 80%. This reduction in mass will significantly contribute to the reduction in total mission cost need to make a Mars mission a reality. In addition the potential reduction of risk provided by the ability to produce C4 and potentially higher carbon based materials in-situ on Mars is significant. Food, fuel, and shelter are only three of many requirements that would be impacted by this research.

Flynn, Michael↗

NASA NTRS2006

Closure of Regenerative Life Support Systems: Results of the Lunar-Mars Life Support Test Project

Future long duration human exploration missions away from Earth will require closed-loop regenerative life support systems to reduce launch mass, reduce dependency on resupply and increase the level of mission self sufficiency. Such systems may be based on the integration of biological and physiocochemical processes to produce potable water, breathable atmosphere and nutritious food from metabolic and other mission wastes. Over the period 1995 to 1998 a series of ground-based tests were conducted at the National Aeronautics and Space Administration, Johnson Space Center, to evaluate the performance of advanced closed-loop life support technologies with real human metabolic and hygiene loads. Named the Lunar-Mars Life Support Test Project (LMLSTP), four integrated human tests were conducted with increasing duration, complexity and closure. The first test, LMLSTP Phase I, was designed to demonstrate the ability of higher plants to revitalize cabin atmosphere. A single crew member spent 15 days within an atmospherically closed chamber containing 11.2 square meters of actively growing wheat. Atmospheric carbon dioxide and oxygen levels were maintained by control of the rate of photosynthesis through manipulation of light intensity or the availability of carbon dioxide and included integrated physicochemical systems. During the second and third tests, LMLSTP Phases II & IIa, four crew members spent 30 days and 60 days, respectively, in a larger sealed chamber. Advanced physicochemical life support hardware was used to regenerate the atmosphere and produce potable water from wastewater. Air revitalization was accomplished by using a molecular sieve and a Sabatier processor for carbon dioxide absorption and reduction, respectively, with oxygen generation performed by water hydrolysis. Production of potable water from wastewater included urine treatment (vapor compression distillation), primary treatment (ultrafiltration/reverse osmosis and multi-filtration) and post processing. For the Phase II test the water recovery rate ranged from 95 to 98%, depending on the processor. LMLSTP Phase III, the fourth test of the series, had a duration of 91 days and included four crew members. The test demonstrated an integration of physicochemical and biological technologies for air revitalization, water recovery and waste processing. Wheat supplemented the physicochemical air revitalization systems by providing approximately 25% of the oxygen required for the 4-person crew. The water recovery system included immobilized cell and trickling filter bioreactors for primary water treatment, reverse osmosis and air evaporation systems for secondary water treatment, followed by post processing. The 8 day initial supply of water was recycled through the chamber and crew 10 times over the course of the test. Grain from the wheat together with fresh lettuce from a small growth chamber within the crew chamber provided supplementation to the stored food system, but at a level less than 5% of the crew s caloric requirement. An incinerator was used to demonstrate mineralization of the crew s solid waste, with the combustion products (mainly carbon dioxide) returned to the wheat for conversion to oxygen.

Barta, Daniel↗