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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

4BCO2 Model Validation and Comparisons Between Simulation and Ground and ISS Telemetry Data

The 4-bed CO2Scrubber (4BCO2), used to remove carbon dioxide from the atmosphere of the International Space Station(ISS), was built to improve upon its predecessors to meet the air revitalization needs of future missions. During this internship session, a Matlab wrapper of COMSOL models used to simulate the operation of the 4BCO2 unit was improved upon and validated against both ground test data and flight test data from the currently operating 4BCO2 unit. This presentation details the results of the activities and exercises performed during this internship session, such as the discussion on the plots generated from least squares minimization of the simulation linear driving force and sorbent bed dispersion correction factor multiplier. Plots derived from the collection and processing of telemetry data from the 4BCO2 unit aboard the ISS are discussed in relation to the work processing work performed, and comparisons between real-time CO2 removal rates and simulation removal rates are also discussed.

Larissa Lagria↗
NASA NTRSDate not supplied

Thermal Design Challenges Posed by the Four Bed CO2 Scrubber COTS Air-Save Pump

The Four Bed Carbon Dioxide (4BCO2) scrubber Air-Save Pump (ASP) operates as part of the adsorbent bed regeneration cycle. The ASP removes residual air from the bed for return to the cabin prior to heat and vacuum exposure which drives out the CO2 regenerating the bed. 4BCO2 employs a Commercial Off-the-Shelf (COTS) scroll type air pump, repackaged in an acoustically insulated enclosure to reduce noise and mounted to a cold plate. The International Space Station (ISS) Low Temperature Loop (LTL) flow (operating between 38°F and 50°F) first cools the process air, and then flows through the cold plate, cooling the pump. This results in competing ASP thermal design goals: (1) to keep the pump and motor sufficiently cool and (2) to avoid forming condensation due to over-cooling. Surfaces below 60°F typically warrant careful consideration of condensation. A test-calibrated thermal model demonstrates such a balanced design is feasible with temperatures above 60°F. A separate, coupled fluid model predicts the potential for condensation formation, allowing risk assessment of flying with the unmodified design.

Daniel P Popok↗
NASA NTRSDate not supplied

Optimization of the 4-Bed CO2 Scrubber Performance Based on Ground Tests

Testing of ground hardware closely matching the flight design for the 4-Bed CO2Scrubber (4BCO2) has provided a wealth of information about the complex and highly coupled batch process. The 4BCO2 process is a Thermal and Vacuum Swing Adsorption (TVSA) cycle with recirculating flows. The ability to measure CO2concentration at intermediate points in this architecture is new to this ground test system and has revealed a better understanding of system performance and its dependence on system design, operational parameters, and boundary conditions. This paper will discuss a statistical analysis performed to identify significant correlations between performance factors and operational parameters. Using these new insights on the highly coupled system physics, means for improvements to system performance are proposed.

CO2 Removal↗
NASA NTRSDate not supplied

Random Vibration Simulation and Testing of a Compact, Magnetic Bearing Supported Blower for Space Applications

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.

bearings↗
NASA NTRS2019

CO2 Removal Onboard the International Space Station – Material Selection and System Design

The previous three years of efforts have focused on the study of the sorbent materials available for use in a 4-bed molecular sieve system. The accumulation of knowledge has been invaluable for further decisions and for reflecting on the conclusions of past decisions. The goal of the next system is perfect uptime for nearly 20,000 hours of operation, but no complex life support system has yet reached this lofty goal. In addition to reliability, CO2 removal performance improvements have been intensively studied. The achievements toward this end include highly detailed isotherm measurements which drive system simulations as well as testing physical design improvements. Looking back on the successes and failures of past systems, correlating tests with long-duration data, and carefully projecting the future are all needed for the success of the next system. This work intends to reveal the path we have taken and illuminate the steps to come for CO2 removal life support with the 4BCO2 flight demonstration.

Cmarik, Gregory E.↗
NASA NTRS2019

CO2 Removal for the International Space Station – 4-Bed Molecular Sieve Material Selection and System Design

Efforts over the past three years have focused on the study of candidate sorbent materials for use in a 4BMS molecular sieve system. The accumulation of knowledge has been invaluable for further decisions and for reflecting on the conclusions of past decisions. The goal of the next generation CO2 removal system is continuous, failure-free operation for nearly 20,000 hours, but no complex life support system has yet reached this lofty goal. In addition to reliability, CO2 removal performance improvements have been intensively studied. The achievements toward this end include highly detailed isotherm measurements which drive system simulations as well as testing physical design improvements. Looking back on the successes and failures of past systems, correlating data from long-duration tests, and carefully projecting future results are all needed for the success of the next system. This work intends to reveal the path we have taken and illuminate the steps to come for CO2 removal life support with the 4BCO2 flight demonstration.

Cmarik, Gregory E.↗
NASA NTRSDate not supplied

Performance of the Four Bed Carbon Dioxide Scrubber ISS Technology Demonstration

The Four Bed Carbon Dioxide Scrubber technology demonstration is presently operating onboard the International Space Station after being launched in August of 2021and activated in October. This work describes the ground and flight performance of the 4BCO2 and the methods used to determine performance on the ISS where limited sensor data is available.

Life Support↗
NASA NTRS2026

Equivalent System Mass Comparison of ECLSS CO2 Removal Technologies

This project employs equivalent system mass (ESM) analyses to evaluate and compare state-of-the-art spacecraft CO2 removal systems. The ESM methodology converts sizing characteristics such as volume, power, and cooling requirements into a unified metric of mass, allowing for simple quantitative comparison of equipment impacts on a system level. Comparison of six high TRL technologies – the Carbon Dioxide Removal System (CDRS), Thermal Amine Scrubber (TAS), Carbon Dioxide Removal Assembly (CDRA), Four-Bed CO2 Scrubber (4BCO2), CO2 and Humidity Control Swing Bed (CHC), and the Carbon Dioxide Removal by Ionic Liquid Sorbent (CDRILS) – was achieved using an existing ESM spreadsheet tool that formerly ranked such technologies for consideration on Gateway. Fidelity of the tool was increased through revision with the most up-to-date sizing and performance data for each technology. ESM values were then estimated using NASA-supplied Lunar, Martian, and low-Earth orbit habitat infrastructure costs. This paper details the ESM approach used, lists major performance variables for each CO2 removal option, and summarizes conclusions of the technology comparison. The results are intended to act as a guide to assist programs in their selection of CO2 technologies best suited for a specific vehicle or mission.

Madeleine C Oliver↗
NASA NTRS2026

Equivalent System Mass Comparison of ECLSS CO 2 Removal Technologies

This project employs equivalent system mass (ESM) analyses to evaluate and compare state-of-the-art spacecraft CO 2 removal systems. The ESM methodology converts sizing characteristics such as volume, power, and cooling requirements into a unified metric of mass, allowing for simple quantitative comparison of equipment impacts on a system level. Comparison of six high TRL technologies – the Carbon Dioxide Removal System (CDRS), Thermal Amine Scrubber (TAS), Carbon Dioxide Removal Assembly (CDRA), Four-Bed CO 2 Scrubber (4BCO2), CO 2 and Humidity Control Swing Bed (CHC), and the Carbon Dioxide Removal by Ionic Liquid Sorbent (CDRILS) – was achieved using an existing ESM spreadsheet tool that formerly ranked such technologies for consideration on Gateway. Fidelity of the tool was increased through revision with the most up-to-date sizing and performance data for each technology. ESM values were then estimated using NASA-supplied Lunar, Martian, and low-Earth orbit habitat infrastructure costs. This paper details the ESM approach used, lists major performance variables for each CO 2 removal option, and summarizes conclusions of the technology comparison. The results are intended to act as a guide to assist programs in their selection of CO 2 technologies best suited for a specific vehicle or mission.

Madeleine Oliver↗
NASA NTRSDate not supplied

4-Bed CO2 Scrubber – From Design to Build

Four-bed technology is an International Space Station (ISS) mainstay for metabolic Carbon Dioxide (CO2) removal and crew life support. The current generation is known as the Carbon Dioxide Removal Assembly (CDRA) and has a long history of unplanned maintenance as well as obsolete core components. The 4-bed CO2 Scrubber was commissioned to operate with no unplanned maintenance for 3 years while removing 4 crew-equivalents of CO2 at a target inlet concentration of 2 torr CO2. This work goes into detail of the various design aspects that have been undertaken to ensure a successful project design and successful build leading to an upcoming flight. This work will discuss the compromises caught both early and late in the design cycle and the adaptations in response. Finally, the expected performance of the system once launched will be discussed based on summaries of data from the testbed.

Carbon Dioxide↗
NASA NTRSDate not supplied

Progress of Four Bed Carbon Dioxide Scrubber

The Four Bed Carbon Dioxide Scrubber flight demonstration is presently operating onboard the International Space Station. After being launched in August of 2021 and installed in October, the system has been removing metabolic CO2 from the cabin as a supplement and replacement for other CO2 systems, specifically the two Carbon Dioxide Removal Assemblies. This work describes the conclusion of the ground integration and testing campaign and the start of on orbit operations. Additionally, performance, reliability, and forward works will be summarized. Interactions of the software with off-nominal events will be discussed and how the system will be reconfigured to sustain operations.

4BCO2↗