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NASA NTRS2013

Aerospace Fuels From Nonpetroleum Raw Materials

Recycling human metabolic and plastic wastes minimizes cost and increases efficiency by reducing the need to transport consumables and return trash, respectively, from orbit to support a space station crew. If the much larger costs of transporting consumables to the Moon and beyond are taken into account, developing waste recycling technologies becomes imperative and possibly mission enabling. Reduction of terrestrial waste streams while producing energy and/or valuable raw materials is an opportunity being realized by a new generation of visionary entrepreneurs; several relevant technologies are briefly compared, contrasted and assessed for space applications. A two-step approach to nonpetroleum raw materials utilization is presented; the first step involves production of supply or producer gas. This is akin to synthesis gas containing carbon oxides, hydrogen, and simple hydrocarbons. The second step involves production of fuel via the Sabatier process, a methanation reaction, or another gas-to-liquid technology, typically Fischer-Tropsch processing. Optimization to enhance the fraction of product stream relevant to transportation fuels via catalytic (process) development at NASA Glenn Research Center is described. Energy utilization is a concern for production of fuels whether for operation on the lunar or Martian surface, or beyond. The term green relates to not only mitigating excess carbon release but also to the efficiency of energy usage. For space, energy usage can be an essential concern. Another issue of great concern is minimizing impurities in the product stream(s), especially those that are potential health risks and/or could degrade operations through catalyst poisoning or equipment damage; technologies being developed to remove heteroatom impurities are discussed. Alternative technologies to utilize waste fluids, such as a propulsion option called the resistojet, are discussed. The resistojet is an electric propulsion technology with a powered thruster to vaporize and heat a propellant to high temperature, hot gases are subsequently passed through a converging-diverging nozzle expanding gases to supersonic velocities. A resistojet can accommodate many different fluids, including various reaction chamber (by-)products.

Palaszewski, Bryan A.↗

NASA NTRS2013

Trash to Gas: Converting Space Waste into Useful Supply Products

The cost of sending mass into space with current propulsion technology is very expensive, making every item a crucial element of the space mission. It is essential that all materials be used to their fullest potential. Items like food, packaging, clothing, paper towels, gloves, etc., normally become trash and take up space after use. These waste materials are currently either burned up upon reentry in earth's atmosphere or sent on cargo return vehicles back to earth: a very wasteful method. The purpose of this project was to utilize these materials and create useful products like water and methane gas, which is used for rocket fuel, to further supply a deep space mission. The system used was a thermal degradation reactor with the configuration of a down-draft gasifier. The reactor was loaded with approximately 100g of trash simulant and heated with two external ceramic heaters with separate temperature control in order to create pyrolysis and gasification in one zone and incineration iri a second zone simultaneously. Trash was loaded into the top half of the reactor to undergo pyrolysis while the downdraft gas experienced gasification or incineration to treat tars and maximize the production of carbon dioxide. Minor products included carbon monoxide, methane, and other hydrocarbons. The carbon dioxide produced can be sent to a Sabatier reactor to convert the gas into methane, which can be used as rocket propellant. In order to maximize the carbon dioxide and useful gases produced, and minimize the unwanted tars and leftover ashen material, multiple experiments were performed with altered parameters such as differing temperatures, flow rates, and location of inlet air flow. According to the data received from these experiments, the process will be further scaled up and optimized to ultimately create a system that reduces trash buildup while at the same time providing enough useful gases to potentially fill a methane tank that could fuel a lunar ascent vehicle or other deep space mission.

Tsoras, Alexandra↗

NASA NTRS2013

Atmospheric Processing Module for Mars Propellant Production

The multi-NASA center Mars Atmosphere and Regolith COllector/PrOcessor for Lander Operations (MARCO POLO) project was established to build and demonstrate a methane/oxygen propellant production system in a Mars analog environment. Work at the Kennedy Space Center (KSC) Applied Chemistry Laboratory is focused on the Atmospheric Processing Module (APM). The purpose of the APM is to freeze carbon dioxide from a simulated Martian atmosphere containing the minor components nitrogen, argon, carbon monoxide, and water vapor at Martian pressures (~8 torr) by using dual cryocoolers with alternating cycles of freezing and sublimation. The resulting pressurized CO2 is fed to a methanation subsystem where it is catalytically combined with hydrogen in a Sabatier reactor supplied by the Johnson Space Center (JSC) to make methane and water vapor. We first used a simplified once-through setup and later employed a HiCO2 recycling system to improve process efficiency. This presentation and paper will cover (1) the design and selection of major hardware items, such as the cryocoolers, pumps, tanks, chillers, and membrane separators, (2) the determination of the optimal cold head design and flow rates needed to meet the collection requirement of 88 g CO2/hr for 14 hr, (3) the testing of the CO2 freezer subsystem, and (4) the integration and testing of the two subsystems to verify the desired production rate of 31.7 g CH4/hr and 71.3 g H20/hr along with verification of their purity. The resulting 2.22 kg of CH4/O2 propellant per 14 hr day (including O2 from electrolysis of water recovered from regolith, which also supplies the H2 for methanation) is of the scale needed for a Mars Sample Return mission. In addition, the significance of the project to NASA's new Mars exploration plans will be discussed.

Muscatello, Anthony↗

NASA NTRS2013

Advanced Exploration Systems Logistics Reduction and Repurposing Trash-to-Gas and Heat Melt Compactor KSC

Topics covered: 1. Project Structure 2. "Trash to Gas" 3. "Smashing Trash! The Heat Melt Compactor" 4. "Heat Melt Compaction as an Effective Treatment for Eliminating Microorganisms from Solid Waste" Thermal degradation of trash reduces volume while creating water, carbon dioxide and ash. CO2 can be fed to Sabatier reactor for CH4 production to fuel LOX/LCH4 ascent vehicle. Optimal performance: HFWS, full temperature ramp to 500-600 C. Tar challenges exist. Catalysis: Dolomag did eliminate allene byproducts from the product stream. 2nd Gen Reactor Studies. Targeting power, mass, time efficiency. Gas separation, Catalysis to reduce tar formation. Microgravity effects. Downselect in August will determine where we should spend time optimizing the technology.

Caraccio, Anne J.↗

NASA NTRS2013

Trash-to-Gas: Using Waste Products to Minimize Logistical Mass During Long Duration Space Missions

Just as waste-to-energy processes utilizing municipal landftll and biomass wastes are finding increased terrestrial uses, the Trash-to-Gas (TtG) project seeks to convert waste generated during spaceflight into high value commodities. These include methane for propulsion and water for life support in addition to a variety of other gasses. TtG is part of the Logistic Reduction and Repurposing (LRR) project under the NASA Advanced Exploration Systems Program. The LRR project will enable a largely mission-independent approach to minimize logistics contributions to total mission architecture mass. LRR includes technologies that reduce the amount of consumables that need to be sent to space, repurpose items sent to space, or convert wastes to commodities. Currently, waste generated on the International Space Station is stored inside a logistic module which is de-orbited into Earth's atmosphere for destruction. The waste consists of food packaging, food, clothing and other items. This paper will discuss current results on incineration as a waste processing method. Incineration is part of a two step process to produce methane from waste: first the waste is converted to carbon oxides; second, the carbon oxides are fed to a Sabatier reactor where they are converted to methane. The quantities of carbon dioxide, carbon monoxide, methane and water were measured under the different thermal degradation conditions. The overall carbon conversion efficiency and water recovery are discussed.

Hintze, Paul. E.↗

NASA NTRS2013

Trash-to-Gas: Using Waste Products to Minimize Logistical Mass During Long Duration Space Missions

Hintze, Paul E.↗

NASA NTRS2013

Aerospace Fuels from Nonpetroleum Raw Materials

Recycling human metabolic and plastic wastes minimizes cost and increases efficiency by reducing the need to transport consumables and return trash, respectively, from orbit to support a space station crew. If the much larger costs of transporting consumables to the Moon and beyond are taken into account, developing waste recycling technologies becomes imperative and possibly mission enabling. Reduction of terrestrial waste streams while producing energy and/or valuable raw materials is an opportunity being realized by a new generation of visionary entrepreneurs; several relevant technologies are briefly compared, contrasted and assessed for space applications. A two-step approach to nonpetroleum raw materials utilization is presented; the first step involves production of supply or producer gas. This is akin to synthesis gas containing carbon oxides, hydrogen, and simple hydrocarbons. The second step involves production of fuel via the Sabatier process, a methanation reaction, or another gas-to-liquid technology, typically Fischer- Tropsch processing. Optimization to enhance the fraction of product stream relevant to transportation fuels via catalytic (process) development at NASA GRC is described. Energy utilization is a concern for production of fuels whether for operation on the lunar or Martian surface, or beyond. The term "green" relates to not only mitigating excess carbon release but also to the efficiency of energy usage. For space, energy usage can be an essential concern. Other issues of great concern include minimizing impurities in the product stream(s), especially those that are potential health risks and/or could de-grade operations through catalyst poisoning or equipment damage; technologies being developed to remove heteroatom impurities are discussed. Alternative technologies to utilize waste fluids, such as a propulsion option called the resistojet, are discussed. The resistojet is an electric propulsion technology with a powered thruster to vaporize and heat a propellant to high temperature, hot gases are subsequently passed through a converging-diverging nozzle expanding gases to supersonic velocities. A resistojet can accommodate many different fluids, including various reaction chamber (by-)products.

Palaszewski, B. A.↗

NASA NTRS2014

Atmospheric Processing Module for Mars Propellant Production

The multi-NASA center Mars Atmosphere and Regolith COllectorPrOcessor for Lander Operations (MARCO POLO) project was established to build and demonstrate a methaneoxygen propellant production system in a Mars analog environment. Work at the Kennedy Space Center (KSC) Applied Chemistry Laboratory is focused on the Atmospheric Processing Module (APM). The purpose of the APM is to freeze carbon dioxide from a simulated Martian atmosphere containing the minor components nitrogen, argon, carbon monoxide, and water vapor at Martian pressures (8 torr) by using dual cryocoolers with alternating cycles of freezing and sublimation. The resulting pressurized CO(sub 2) is fed to a methanation subsystem where it is catalytically combined with hydrogen in a Sabatier reactor supplied by the Johnson Space Center (JSC) to make methane and water vapor. We first used a simplified once-through setup and later employed a H(sub 2)CO(sub 2) recycling system to improve process efficiency. This presentation and paper will cover (1) the design and selection of major hardware items, such as the cryocoolers, pumps, tanks, chillers, and membrane separators, (2) the determination of the optimal cold head design and flow rates needed to meet the collection requirement of 88 g CO(sub 2) hr for 14 hr, (3) the testing of the CO(sub 2) freezer subsystem, and (4) the integration and testing of the two subsystems to verify the desired production rate of 31.7 g CH(sub 4) hr and 71.3 g H(sub 2)O hr along with verification of their purity. The resulting 2.22 kg of CH(sub 2)O(sub 2) propellant per 14 hr day (including O(sub 2) from electrolysis of water recovered from regolith, which also supplies the H(sub 2) for methanation) is of the scale needed for a Mars Sample Return mission. In addition, the significance of the project to NASAs new Mars exploration plans will be discussed.

waste treatment↗

NASA NTRS2014

Novel Catalysts and Processing Technologies for Production of Aerospace Fuels from Non-Petroleum Raw Materials

Transportation fuels production (including aerospace propellants) from non-traditional sources (gases, waste materials, and biomass) has been an active area of research and development for decades. Reducing terrestrial waste streams simultaneous with energy conversion, plentiful biomass, new low-cost methane sources, and/or extra-terrestrial resource harvesting and utilization present significant technological and business opportunities being realized by a new generation of visionary entrepreneurs. We examine several new approaches to catalyst fabrication and new processing technologies to enable utilization of these nontraditional raw materials. Two basic processing architectures are considered: a single-stage pyrolysis approach that seeks to basically re-cycle hydrocarbons with minimal net chemistry or a two-step paradigm that involves production of supply or synthesis gas (mainly carbon oxides and H2) followed by production of fuel(s) via Sabatier or methanation reactions and/or Fischer-Tröpsch synthesis. Optimizing the fraction of product stream relevant to targeted aerospace (and other transportation) fuels via modeling, catalyst fabrication and novel reactor design are described. Energy utilization is a concern for production of fuels for either terrestrial or space operations; renewable sources based on solar energy and/or energy efficient processes may be mission enabling. Another important issue is minimizing impurities in the product stream(s), especially those potentially posing risks to personnel or operations through (catalyst) poisoning or (equipment) damage. Technologies being developed to remove (and/or recycle) heteroatom impurities are briefly discussed as well as the development of chemically robust catalysts whose activities are not diminished during operation. The potential impacts on future missions by such new approaches as well as balance of system issues are addressed.

space processing↗

NASA NTRS2014

Atmospheric Processing Module for Mars Propellant Production

The multi-NASA center Mars Atmosphere and Regolith COllector/PrOcessor for Lander Operations (MARCO POLO) project was established to build and demonstrate a methaneoxygen propellant production system in a Mars analog environment. Work at the Kennedy Space Center (KSC) Applied Chemistry Laboratory is focused on the Atmospheric Processing Module (APM). The purpose of the APM is to freeze carbon dioxide from a simulated Martian atmosphere containing the minor components nitrogen, argon, carbon monoxide, and water vapor at Martian pressures (approx. 8 torr) by using dual cryocoolers with alternating cycles of freezing and sublimation. The resulting pressurized CO(sub 2) is fed to a methanation subsystem where it is catalytically combined with hydrogen in a Sabatier reactor supplied by the Johnson Space Center (JSC) to make methane and water vapor. We first used a simplified once-through setup and later employed a H(sub 2)CO(sub 2) recycling system to improve process efficiency. This presentation and paper will cover (1) the design and selection of major hardware items, such as the cryocoolers, pumps, tanks, chillers, and membrane separators, (2) the determination of the optimal cold head design and flow rates needed to meet the collection requirement of 88 g CO(sub 2) hr for 14 hr, (3) the testing of the CO(sub 2) freezer subsystem, and (4) the integration and testing of the two subsystems to verify the desired production rate of 31.7 g CH(sub 4) hr and 71.3 g H(sub 2)O hr along with verification of their purity. The resulting 2.22 kg of CH(sub 2)O(sub 2) propellant per 14 hr day (including O(sub 2) from electrolysis of water recovered from regolith, which also supplies the H(sub 2) for methanation) is of the scale needed for a Mars Sample Return mission. In addition, the significance of the project to NASAs new Mars exploration plans will be discussed.

hydrocarbon fuel production↗

NASA NTRS2014

Novel Catalysts and Processing Technologies for Production of Aerospace Fuels from Non-Petroleum Raw Materials

Transportation fuels production (including aerospace propellants) from non-traditional sources (gases, waste materials, and biomass) has been an active area of research and development for decades. Reducing terrestrial waste streams simultaneous with energy conversion, plentiful biomass, new low-cost methane sources, and/or extra-terrestrial resource harvesting and utilization present significant technological and business opportunities being realized by a new generation of visionary entrepreneurs. We examine several new approaches to catalyst fabrication and new processing technologies to enable utilization of these non-traditional raw materials. Two basic processing architectures are considered: a single-stage pyrolysis approach that seeks to basically re-cycle hydrocarbons with minimal net chemistry or a two-step paradigm that involves production of supply or synthesis gas (mainly carbon oxides and hydrogen) followed by production of fuel(s) via Sabatier or methanation reactions and/or Fischer-Tropsch synthesis. Optimizing the fraction of product stream relevant to targeted aerospace (and other transportation) fuels via modeling, catalyst fabrication and novel reactor design are described. Energy utilization is a concern for production of fuels for either terrestrial or space operations; renewable sources based on solar energy and/or energy efficient processes may be mission enabling. Another important issue is minimizing impurities in the product stream(s), especially those potentially posing risks to personnel or operations through (catalyst) poisoning or (equipment) damage. Technologies being developed to remove (and/or recycle) heteroatom impurities are briefly discussed as well as the development of chemically robust catalysts whose activity are not diminished during operation. The potential impacts on future missions by such new approaches as well as balance of system issues are addressed.

propellants↗

NASA NTRS2015

Advanced Oxygen Recovery via Series-Bosch Technology

Oxygen recovery from metabolically-produced carbon dioxide (CO2) is of critical importance for long-duration manned space missions beyond low Earth orbit. On the International Space Station (ISS), oxygen is provided to the crew through electrolysis of water in the Oxygen Generation Assembly (OGA). Prior to 2011, this water was entirely resupplied from Earth. A CO2 Reduction Assembly based on the Sabatier reaction (1) was developed by Hamilton Sundstrand and delivered to ISS in 2010. The unit recovers oxygen by reducing metabolic CO2 with diatomic hydrogen (H2) to produce methane and product water. The water is cleaned by the Water Purification Assembly and recycled to the OGA for continued oxygen production. The methane product is vented overboard.

Abney, Morgan B.↗

NASA NTRS2015

Upgrades to the ISS Water Recovery System

The ISS Water Recovery System (WRS) includes the Water Processor Assembly (WPA) and the Urine Processor Assembly (UPA). The WRS produces potable water from a combination of crew urine (first processed through the UPA), crew latent, and Sabatier product water. The WRS has been operational on ISS since November 2008, producing over 21,000 L of potable water during that time. Though the WRS has performed well during this time, several modifications have been identified to improve the overall system performance. These modifications can reduce resupply and improve overall system reliability, which is beneficial for the ongoing ISS mission as well as for future NASA manned missions. The following paper lists these modifications, how they improve WRS performance, and a status on the ongoing development effort.

Pruitt, Jennifer M.↗

NASA NTRS2016

Assessment of the Impacts of ACLS on the ISS Life Support System Using Dynamic Simulations in V-HAB

The Advanced Closed Loop System (ACLS) is currently under development by Airbus Defense and Space and is slated for launch to the International Space Station (ISS) in 2017. The addition of new hardware into an already complex system such as the ISS life support system (LSS) always poses operational risks. It is therefore important to understand the impacts ACLS will have on the existing systems to ensure smooth operations for the ISS. This analysis can be done by using dynamic computer simulations and one possible tool for such a simulation is the Virtual Habitat (V-HAB). Based on MATLAB, V-HAB has been under development at the Institute of Astronautics of the Technical University of Munich (TUM) since 2004 and in the past has been successfully used to simulate the ISS life support systems. The existing V-HAB ISS simulation model treated the interior volume of the space station as one large, ideally-stirred container. This model was improved to allow the calculation of the atmospheric composition inside individual modules of the ISS by splitting it into twelve distinct volumes. The virtual volumes are connected by a simulation of the inter-module ventilation flows. This allows for a combined simulation of the LSS hardware and the atmospheric composition aboard the ISS. A dynamic model of ACLS is added to the ISS Simulation and several different operating modes for both ACLS and the existing ISS life support systems are studied and the impacts of ACLS on the rest of the system are determined. The results suggest that the US, Russian and ACLS CO2 systems can operate at the same time without impeding each other. Furthermore, based on the results of this analysis, the US and ACLS Sabatier systems can be operated in parallel as well to a achieve a very low CO2 concentration in the cabin atmosphere.

Putz, Daniel↗

NASA NTRS2011

Advanced Life Support Technologies and Scenarios

As NASA looks beyond the International Space Station toward long-duration, deep space missions away from Earth, the current practice of supplying consumables and spares will not be practical nor affordable. New approaches are sought for life support and habitation systems that will reduce dependency on Earth and increase mission sustainability. To reduce launch mass, further closure of Environmental Control and Life Support Systems (ECLSS) beyond the current capability of the ISS will be required. Areas of particular interest include achieving higher degrees of recycling within Atmosphere Revitalization, Water Recovery and Waste Management Systems. NASA is currently investigating advanced carbon dioxide reduction processes that surpass the level of oxygen recovery available from the Sabatier Carbon Dioxide Reduction Assembly (CRA) on the ISS. Improving the efficiency of the recovery of water from spacecraft solid and liquid wastes is possible through use of emerging technologies such as the heat melt compactor and brine dewatering systems. Another significant consumable is that of food. Food production systems based on higher plants may not only contribute significantly to the diet, but also contribute to atmosphere revitalization, water purification and waste utilization. Bioreactors may be potentially utilized for wastewater and solid waste management. The level at which bioregenerative technologies are utilized will depend on their comparative requirements for spacecraft resources including mass, power, volume, heat rejection, crew time and reliability. Planetary protection requirements will need to be considered for missions to other solar system bodies.

Barta, Daniel J.↗

NASA NTRS2016

Resource Tracking Model Updates and Trade Studies

The Resource tracking model has been updated to capture system manager and project manager inputs. Both the Trick/GUNNS RTM simulator and the RTM mass balance spreadsheet have been revised to address inputs from system managers and to refine the way mass balance is illustrated. The revisions to the RTM included addition of a Plasma Pyrolysis Assembly (PPA) to recover hydrogen from Sabatier reactor methane which was vented in the prior version of the RTM. The effect of the PPA on the overall balance of resources in an exploration vehicle is illustrated in the increased recycle of vehicle oxygen. Additionally simulation of EVAs conducted from the exploration module was added. Since the focus of the exploration module is to provide a habitat during deep space operations the EVA simulation approach to EVA is based on ISS EVA protocol and processes. Case studies have been run to show the relative effect of performance changes on vehicle resources.

Chambliss, Joe↗

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 NTRS2015

Space Technology Game Changing Development- Next Generation Life Support: Spacecraft Oxygen Recovery (SCOR)

The Next Generation Life Support Spacecraft Oxygen Recovery (SCOR) project element is dedicated to developing technology that enables oxygen recovery from metabolically produced carbon dioxide in space habitats. The state-of-the-art system on the International Space Station uses Sabatier technology to recover (is) approximately 50% oxygen from carbon dioxide. The remaining oxygen required for crew respiration is supplied from Earth. For long duration manned missions beyond low-Earth orbit, resupply of oxygen becomes economically and logistically prohibitive. To mitigate these challenges, the SCOR project element is targeting development of technology to increase the recovery of oxygen to 75% or more, thereby reducing the total oxygen resupply required for future missions.

Abney, Morgan↗