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Continuous-duty hydrogen sorption cryocoolers are being developed for the European Space Agency (ESA) Planck mission. To achieve an acceptable level of performance and robust operation with these hydride refrigerators during flight, detailed investigations have been performed on the sorbent materials and on critical hardware components.
NASA is developing a next-generation CO2 removal system, the Four Bed Carbon Dioxide Scrubber (4BCO2), which will use the International Space Station (ISS) as a testbed. A key component of both the existing and the new system is the blower that provides the airflow through the CO2 sorbent beds. To improve performance and reliability, magnetic bearings will be used in lieu of more conventional bearings (e.g. ball bearings or hydrodynamicbearings) to improve resistance to contaminants and enable extensibility with regards to blower speed, pressure rise and mass flow rate. The new blower features a high-efficiency permanent magnet motor, a five-axis, active magnetic bearing system, and a compact controller containing both a variable speed drive and magnetic bearing controller. The blower uses a centrifugal impeller to pull air from the inlet port and drive it through an annular space around the motor and magnetic bearing components to the exhaust port. Technical challenges of the blower and controller development include survival of the blower system under launch random vibration loads, operation in microgravity, packaging under strict size and weight requirements, and successful operation during 4BCO2 operational changeovers. Each serial build of the blower must pass a severe random vibration test to prove it will survive launch conditions. This paper discusses the vibration test requirements and provides details of a simulation performed to estimate the peak backup bearing displacements and loads. Results from the successful random vibration testing of the prototype build are discussed and compared to the simulation.
The Rapid Cycle Amine (RCA) 3.0 system is currently under development by NASA, the Lyndon B. Johnson Space Center (JSC) in conjunction with United Technologies Corporation Aerospace Systems (UTAS). The RCA technology is a new carbon dioxide (CO2) and humidity removal system that has been baselined for the Advanced Extravehicular Mobility Unit (AEMU) Portable Life Support System. The evolution of the RCA development has progressed through several iterations of technology readiness levels including RCA 1.0, RCA 2.0, and RCA 3.0 test articles. The RCA is an advancement over currently technologies due to its unique regeneration capability. The RCA is capable of simultaneously removing CO2 and humidity from an influent air steam and subsequent regeneration when exposed to a vacuum source. The RCA technology uses two solid amine sorbent beds in an alternating fashion to adsorb CO2 and water (uptake mode) and desorb CO2 and water (regeneration mode) at the same time. The two beds operate in an efficient manner so that while one bed is in the uptake mode, the other is in the regeneration mode, thus continuously providing an on-service sorbent bed by which CO2 and humidity may be removed. The RCA 2.0 and 3.0 test articles were designed with a novel valve assembly which allows for switching between uptake and regeneration modes with only one moving part while minimizing gas volume losses to the vacuum source by means of an internal pressure equalization step during actuation. The RCA technology also is low power, small, and has performed extremely well in all development testing thus far. A final design was selected for the RCA 3.0, fabricated, assembled, and performance tested in 2014 with delivery to NASAJSC in January 2015. This paper will provide an overview on the RCA 3.0 system design and results of pre-delivery testing with references to the development of RCA 1.0 and RCA 2.0.
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Under a cooperative agreement with NASA, Hamilton Sundstrand has successfully designed, fabricated, tested and delivered three, state-of-the-art, solid amine prototype systems capable of continuous CO2 and humidity removal from a closed, habitable atmosphere. Two prototype systems (CAMRAS #1 and #2) incorporated a linear spool valve design for process flow control through the sorbent beds, with the third system (CAMRAS #3) employing a rotary valve assembly that improves system fluid interfaces and regeneration capabilities. The operational performance of CAMRAS #1 and #2 has been validated in a relevant environment, through both simulated human metabolic loads in a closed chamber and through human subject testing in a closed environment. Performance testing at Hamilton Sundstrand on CAMRAS #3, which incorporates a new valve and modified canister design, showed similar CO2 and humidity removal performance as CAMRAS #1 and #2, demonstrating that the system form can be modified within certain bounds with little to no effect in system function or performance. Demonstration of solid amine based CO2 and humidity control is an important milestone in developing this technology for human spaceflight. The systems have low power requirements; with power for air flow and periodic valve actuation and indication the sole requirements. Each system occupies the same space as roughly four shuttle non-regenerative LiOH canisters, but have essentially indefinite CO2 removal endurance provided a regeneration pathway is available. Using the solid amine based systems to control cabin humidity also eliminates the latent heat burden on cabin thermal control systems and the need for gas/liquid phase separation in a low gravity environment, resulting in additional simplification of vehicle environmental control and life support system process requirements.
A new compressor with no moving parts has been developed which is able to supply a source of high-pressure gas to a Joule-Thompson based cryogenic refrigerator. The compressor relies on a newly implemented combination of high-surface-area Saran carbon (sorbent) and krypton gas (working fluid). In addition, an integral gas-gap heat switch is used to provide improved overall efficiency. A prototype compressor has been designed, built, and tested as a part of the Jet Propulsion Laboratory effort in sorption refrigeration. Performance data from the prototype unit described here demonstrate successful compressor performance and good agreement with theoretical predictions.
The removal of atmospheric CO2 from a spacecraft is of particular importance to NASA’s mission, and is an area of continual study and technological advancement. One of the more recent advancements has been with reusable sorbents being regenerated with a combination of heat and vacuum. One such technology is the Thermal Amine Scrubber (TAS) flight experiment on the ISS, though several others are currently flying or preparing to fly. A model was created of the TAS to predict chemical performance, using fundamental chemistry and physics based on principles rather than empirical relations. Since the physical laws are true across all conditions, such a model enables greater model accuracy outside the bounds of test data, and allows for virtual testing of the hardware at conditions that are prohibitively difficult or expensive to actually test. This paper details the model’s development, operation, and correlation to data from the flight unit. The model is then compared to a data set taken from the flight unit under different flow, CO2 partial pressure, and bed configuration conditions, resulting in only a 2% error. The equations and principles laid forth in this paper are applicable to a wide range of thermally regenerated sorbents, and additional models of a similar nature would allow for potentially the most straightforward and direct method of comparison of technologies available to date.
The analytical and experimental studies are described which were directed toward the acquisition of basic information on utilizing a liquid amine sorbent for in use in a CO2 removal system for manned spacecraft. Liquid amine systems are successfully used on submarines for control of CO2 generated by the crew, but liquid amines were not previously considered for spacecraft applications due to lack of development of satisfactory rotary phase separators. Developments in this area now make consideration of liquid amines practical for spacecraft system CO2 removal. The following major tasks were performed to evaluate liquid amine systems for spacecraft: (1) characterization, through testing, of the basic physical and thermodynamic properties of the amine solution; (2) determination of the dynamic characteristics of a cocurrent flow absorber; and (3) evaluation, synthesis, and selection of a liquid amine system concept oriented toward low power requirements. A low weight, low power system concept was developed. Numerical and graphical data are accompanied by pertinent observations.
This system is a re-design of NASA’s previously developed Thermally Coupled Temperature Swing Adsorption and Compression (TC-TSAC) systems, providing an air revitalization alternative to assist in the agency’s Moon to Mars exploration objectives. The system consists of two half-cycles whereby packed beds of regenerable bulk sorbents and heat cycles simultaneously adsorb and compress carbon dioxide. The team designed the adsorption and compression beds in a cylindrical shape to maximize airflow. A desiccant bed helps lower humidity and the sorbent Zeolite 13X is used to capture carbon dioxide. Both are monitored by sensors. There is a custom heater within the system that lies in the adsorption bed to regenerate the sorbent, and there is a cooler around the compression bed. The system produced for NASA modeling, experimental test results, and operational results to be able to be scaled up to 4kg CO2 removal per day. The system was found to be 1/16 scale for 1kg of CO2 removal per day. The adsorption and desorption processes were successful, however issues with making the compression bed airtight resulted in an inability to demonstrate full compression. The team provided design suggestions and alternative solutions given these results. This paper describes the final design, fabrication, assembly, and testing of the TC-TSAC re-design.
The Volatile Organics Concentrator (VOC) system, designed to attach to a gas chromatograph/mass spectrometer (GC/MS) for the analyses of volatile organic compounds in water on Space Station Freedom, is described. Organic volatiles are collected and concentrated in the VOC by means of two primary solid sorbent tubes and desorbed into the GC/MS system. The paper describes the results of testing the VOC breadboard using a GC/MS system. Evaluations performed on 39 organic compounds recovered from water samples were compared with data for these compounds using direct injection/GC/MS and purge and trap/GC/MS procedures. The results demonstrate that the VOC/GC/MS system's detection limits for the 39 compounds analyzed are comparable to those of the EPA Method 524.2, and for many compounds reaching a factor of 5 lower.
The Fire Cartridge is a packed bed air filter with two different and separate layers of media designed to provide respiratory protection from combustion products after a fire event on the International Space Station (ISS). The first layer of media is a carbon monoxide catalyst and the second layer of media is universal carbon. During development of Fire Cartridge prototypes, the two media beds were noticed to have shifted inside the cartridge. The movement of media within the cartridge can cause mixing of the bed layers, air voids, and channeling, which could cause preferential air flow and allow contaminants to pass through without removal. An optimally packed bed mitigates these risks and ensures effective removal of contaminants from the air. In order to optimally pack each layer, vertical, horizontal, and orbital agitations were investigated and a packed bulk density was calculated for each method. Packed bulk density must be calculated for each media type to accommodate variations in particle size, shape, and density. Additionally, the optimal vibration parameters must be re-evaluated for each batch of media due to variations in particle size distribution between batches. For this application it was determined that orbital vibrations achieve an optimal pack density and the two media layers can be packed by the same method. Another finding was media with a larger size distribution of particles achieve an optimal bed pack easier than media with a smaller size distribution of particles.
Studies have shown that frequent extravehicular activities planned for future space missions will require regenerable life support systems. The oxides of magnesium, zinc, and silver were tested for their ability to react with CO2 to form the corresponding carbonates, and subsequent thermal regeneration to the oxides. Catalysts and binders were investigated to enhance CO2 sorption rates and structural integrity. A silver oxide formulation was developed which rapidly absorbs 95% of its theoretical capacity and has shown no degradation through 28 regenerations.
Design information was obtained for a new, regenerable carbon dioxide control system for extravehicular activity life support systems. Solid potassium carbonate was supported in a thin porous sheet form and fabricated into carbon dioxide absorber units. Carbon dioxide and water in the life support system atmosphere react with the potassium carbonate and form potassium bicarbonate. The bicarbonate easily reverts to the carbonate by heating to 150 deg C. The methods of effectively packing the sorbent material into EVA-sized units and the effects of inlet concentrations, flowrate, and temperature upon performance were investigated. The cycle life of the sorbent upon the repeated thermal regenerations was demonstrated through 90 cycles.
The Air Revitalization Labs at NASA Ames Research Center (ARC) is investigating liquid amines to for their performance removing spacecraft carbon dioxide (CO2) for crewed space missions. Development of the current one-crew scale amine test stand stems from several modifications to a test stand initially built at NASA Johnson Space Center (JSC) This sub-scale system has been modified to incorporate a flow spreader for the inlet air stream, an updated contactor design for CO2 capture, a degasser to regenerate the liquid sorbent and recover the captured CO2, and a condenser to reduce water loss. Results from the existing integrated liquid amine test stand have provided valuable insight, but continued performance optimization requires design and build of a new integrated test system. New design concepts will institute a modular configuration to allow for interfacing with novel contactor and degasser architecture, parallel or series flow pathways for the air stream and liquid sorbent, and scaling up to a 4-crew CO2 removal system.
This paper describes an advanced regenerable carbon dioxide (CO2) and humidity control system being developed for the NASA Johnson Space Center. The system offers substantial weight advantages in comparison with the baseline Shuttle Orbiter expendable, lithium hydroxide CO2 removal system for extended missions beyond the nominal design of 4 men for 7 days. The regenerable system offers a potential weight savings of 431 kg for a 7-man 30-day mission. A regenerable sorbent material designated as HS-C coadsorbs CO2 and water vapor from the cabin atmosphere and desorbs the CO2 and H2O vapor overboard when exposed to the space vacuum. In addition to a comparison of the regenerable system with the baseline Shuttle expendable system, HS-C mission simulation test results and the flight prototype regenerable system currently being fabricated are presented. The paper shows the integration of the system into the Shuttle Orbiter vehicle; exclusive of cryogenic fuel-cell power expendables, the available packaging envelope is sufficient to stow all expendables necessary for HS-C operation on 30-day extended missions.
The International Space Station Water Processor Assembly provides contaminant control and deionization to the Water Recovery System. The Water Processor Assembly presently utilizes sorbent-based Multifiltration Beds and a downstream Catalytic Reactor for these operations. Upgrades and process improvements are desired to improve performance, increase reliability, and decrease consumable resupply. To this end, reverse osmosis membrane separation technologies were evaluated to reduce influent contaminant loads, candidate additives to inhibit wastewater biofilm formation were studied, and life stability testing was completed for a recently developed high-activity catalyst. Evaluation of an adsorption media integration concept was also completed. The performance and applicability of these new technologies within the Water Processor Assembly, as well as their suitability for exploration missions, are discussed herein.
Portable life support equipment was studied for meeting the requirements of extravehicular activities. Previous studies indicate that the most promising method for performing the CO2 removal function removal function were metallic oxides and/or metallic hydroxides. Mgo, Ag2, and Zno metallic oxides and Mg(OH)2 and Zn(OH)2 metallic hydroxides were studied, by measuring sorption and regeneration properties of each material. The hydroxides of Mg and Zn were not regenerable and the zinc oxide compounds showed no stable form. A silver oxide formulation was developed which rapidly absorbs approximately 95% of its 0.19 Kg CO2 Kg oxide and has shown no sorption or structural degeneration through 22 regenerations. It is recommended that the basic formula be further developed and tested in large-scale beds under simulated conditions.
Simple heating and cooling of chemisorption and physisorption compressors provide high pressure gas, which, when expanded through a Joule-Thomson (J- T) valve, can provide cooling from 0.3 to 200 K depending on the sorbent/gas combination. System life tests are under way on Pr(1-n)Ce(n)O(x)/O2 (PCO/O2) chemisorption compressors for 65-80 K cooling and on carbon/krypton (C/Kr) physisorption compressors for 120-140 K cooling. Investigations have been initiated to examine reliability physics issues related to critical compressor components such as sorbents, container materials and electrical heaters.