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NASA NTRSDate not supplied

System Modeling of a Lunar Molten Regolith Electrolysis Plant

Introduction: In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO2, MgO, Al2O3) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The System Engineering and Integration (SE&I) ISRU Modeling and Analysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) [1] as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant. System Model: Figure 1: MRE Plant Block Diagram The regolith excavation model determines the mass and power needed to excavate sufficient regolith. The preheating auger initiates the regolith heating process before regolith enters the MRE re-actor to reduce the energy required to turn the solid into a molten liquid. The MRE reactor is modeled in COMSOL Multiphysics and based on the research by Dominguez, Sibille, and Schreiner [2, 3, 4]. This preliminary reactor model provides an accurate calculation of thermal equilibrium during electrochemical operation of the reactor system to assess the optimal mass and power required to process the inlet flow of regolith. The model also computes the outlet flowrates of oxygen and molten products. For this analysis, the primary components of the metal alloy considered were iron and silicon. The oxygen is then purified using an Yttrium Stabilized Zirconia (YSZ) electrode, followed by liquefaction using a 90K cryocooler to be stored as liquid oxygen in insulated cylindrical tanks. In future iterations of the system model, the molten metal tapped from the MRE reactor will undergo additional processing or refinement. However, downstream handling of metals is currently a technology gap that is missing a high TRL subsystem model. Therefore, for this analysis, the accumulated metal alloy stream terminates after leaving the MRE reactor. Study Goals: This analysis investigates multiple input variables to the system to determine the sensitivity of a (near) complete plant at full-scale. This preliminary investigation ran parametric sweeps on the MRE reactor geometry, electrical current supply, layers of multi-layer insulation (MLI) on the reactor, size of the electrodes in the oxygen purification model, and regolith composition (based on landing site location). Three production targets of oxygen (1,000, 10,000, and 50,000 kg/yr) were investigated for this analysis. The parametric sweeps conducted in this analysis provide valuable insight into the expected impact of the various model inputs on plant size. This information can be used to identify the most critical components of the plant and guide future decisions on allocating funding for research and development, providing subsystem developers with appropriate interfaces with downstream and upstream processes, and assessing the overall feasibility of MRE when compared to other ISRU plants. References: [1] Carlson, A. et al. (2024) ICES, ICES-2024-53. [2] Dominguez, D.A., and Sibille, L. (2011) AIAA, AIAA-2011-700. [3] Schreiner, S.S. (2015) MIT, Dissertation. [4] Schreiner, S.S. et al. (2016) ASR, 57(7), pp.1585-1603.

ISRU↗
NASA NTRS2024

System Modeling of a Lunar Molten Regolith Electrolysis Plant

In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO 2 , MgO, Al 2 O 3 ) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The S ystem Engineering and Integration ( S E&I) I SRU M odeling and A nalysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant.

In-Situ Resource Utilization↗
NASA NTRS2023

Galvanic Protected Anode Materials for Molten Regolith Electrolysis

This effort aimed to explore the use of refractory alloys as long-lifetime electrode materials for use in a molten regolith electrolysis (MRE) reactor, a technology that can produce oxygen (O2) from regolith. To find a material capable of withstanding the high temperatures and corrosive nature of molten regolith, first-principles thermodynamic calculations were performed on platinum group metals in the presence of iron (Fe) and silicon (Si) to determine favorable compositions for resisting unwanted secondary phases that could form on the surface of the material. As a result of these first-principles calculations, the kinetic properties of elements such as aluminum (Al), Fe, and Si can be more easily derived, which would provide insight into the longevity of such a material when used in an MRE reactor. The effort funded by this CIF project mapped the entire phase diagram of platinum group metals, which is beneficial not only to MRE where high temperatures and molten material are present, but also aerospace applications like turbine materials, terrestrial metal processing techniques, and energy storage applications. This project narrowed a broad spectrum of refractory metals down to a small list of alloys that would be able to survive not only the high temperatures of an MRE reactor, but also the thermodynamic forces that would cause inferior alloys to form secondary phases, which would ultimately consume the electrodes of the reactor. This research needs to be followed up with experimental demonstrations of these alloys in an MRE environment.

Kevin Grossman↗
NASA NTRS2010

Acceleration of Magnetospheric Relativistic Electrons by Ultra-Low Frequency Waves: A Comparison between Two Cases Observed by Cluster and LANL Satellites

Understanding the origin and acceleration of magnetospheric relativistic electrons (MREs) in the Earth's radiation belt during geomagnetic storms is an important subject and yet one of outstanding questions in space physics. It has been statistically suggested that during geomagnetic storms, ultra-low-frequency (ULF) Pc-5 wave activities in the magnetosphere are correlated with order of magnitude increase of MRE fluxes in the outer radiation belt. Yet, physical and observational understandings of resonant interactions between ULF waves and MREs remain minimum. In this paper, we show two events during storms on September 25, 2001 and November 25, 2001, the solar wind speeds in both cases were > 500 km/s while Cluster observations indicate presence of strong ULF waves in the magnetosphere at noon and dusk, respectively, during a approx. 3-hour period. MRE observations by the Los Alamos (LANL) spacecraft show a quadrupling of 1.1-1.5 MeV electron fluxes in the September 25, 2001 event, but only a negligible increase in the November 2.5, 2001 event. We present a detailed comparison between these two events. Our results suggest that the effectiveness of MRE acceleration during the September 25, 2001 event can be attributed to the compressional wave mode with strong ULF wave activities and the physical origin of MRE acceleration depends more on the distribution of toroidal and poloidal ULF waves in the outer radiation belt.

Shao, X.↗
NASA NTRS2009

A New Blind Pointing Model Improves Large Reflector Antennas Precision Pointing at Ka-Band (32 GHz)

The National Aeronautics and Space Administration (NASA), Jet Propulsion Laboratory (JPL)-Deep Space Network (DSN) subnet of 34-m Beam Waveguide (BWG) Antennas was recently upgraded with Ka-Band (32-GHz) frequency feeds for space research and communication. For normal telemetry tracking a Ka-Band monopulse system is used, which typically yields 1.6-mdeg mean radial error (MRE) pointing accuracy on the 34-m diameter antennas. However, for the monopulse to be able to acquire and lock, for special radio science applications where monopulse cannot be used, or as a back-up for the monopulse, high-precision open-loop blind pointing is required. This paper describes a new 4th order pointing model and calibration technique, which was developed and applied to the DSN 34-m BWG antennas yielding 1.8 to 3.0-mdeg MRE pointing accuracy and amplitude stability of 0.2 dB, at Ka-Band, and successfully used for the CASSINI spacecraft occultation experiment at Saturn and Titan. In addition, the new 4th order pointing model was used during a telemetry experiment at Ka-Band (32 GHz) utilizing the Mars Reconnaissance Orbiter (MRO) spacecraft while at a distance of 0.225 astronomical units (AU) from Earth and communicating with a DSN 34-m BWG antenna at a record high rate of 6-megabits per second (Mb/s).

DSN↗
NASA NTRS2017

Oxygen Extraction from Minerals

Oxygen, whether used as part of rocket bipropellant or for astronaut life support, is a key consumable for space exploration and commercialization. In Situ Resource Utilization (ISRU) has been proposed many times as a method for making space exploration more cost effective and sustainable. On planetary and asteroid surfaces the presence of minerals in the regolith that contain oxygen is very common, making them a potential oxygen resource. The majority of research and development for oxygen extraction from minerals has been for lunar regolith although this work would generally be applicable to regolith at other locations in space. This presentation will briefly survey the major methods investigated for oxygen extraction from regolith with a focus on the current status of those methods and possible future development pathways. The major oxygen production methods are (1) extraction from lunar ilmenite (FeTiO3) with either hydrogen or carbon monoxide, (2) carbothermal reduction of iron oxides and silicates with methane, and (3) molten regolith electrolysis (MRE) of silicates. Methods (1) and (2) have also been investigated in a two-step process using CO reduction and carbon deposition followed by carbothermal reduction. All three processes have byproducts that could also be used as resources. Hydrogen or carbon monoxide reduction produce iron metal in small amounts that could potentially be used as construction material. Carbothermal reduction also makes iron metal along with silicon metal and a glass with possible applications. MRE produces iron, silicon, aluminum, titanium, and glass, with higher silicon yields than carbothermal reduction. On Mars and possibly on some moons and asteroids, water is present in the form of mineral hydrates, hydroxyl (-OH) groups on minerals, andor water adsorbed on mineral surfaces. Heating of the minerals can liberate the water which can be electrolyzed to provide a source of oxygen as well. The chemistry of these processes, some key development and demonstration projects, the challenges remaining to be overcome, and possible future directions will be discussed with a goal of increased understanding of these important ISRU technologies and their potential applications to space exploration and settlement.

propellant production↗
NASA NTRSDate not supplied

Development of a Cold-Walled Molten Regolith Electrolysis Reactor for Lunar Oxygen Production

On the lunar surface, production of commodi-ties to support human presence, such as water, food and oxygen, and sustain the growth of a per-manent outpostwill likely require the use oflocal resources. The moon is covered almost entirely withfragmented oxide minerals known as regolithhundreds of meter thick.As a resource, it is rich in oxygen (> 42 wt.%) bound in a solid state with a variety of metals. The molten regolith electrolysis (MRE)reactor is a promising technology for the production of gaseous oxygen from the lunar reg-olithin a simple, single-stepreaction that requires minimalconsumable materials, produces oxygen and metals with high electrical efficiency and high yields from any regolithcomposition.This process involvesmelting regolith to~1600°C then electro-lyzing the molten pool to separate metal and oxy-gen ions that are then collected as liquid metal and gaseous oxygen at the respective electrodes. Lab-scale demonstrations of the MRE technology have previously reliedon external heating sources to bring the entirety of the reactor up to the operating temperaturewhich creates corrosive interfaces be-tween the molten regolith and the containment ma-terial in the reactor, limiting the overall lifespan of a reactor[1]. The Gaseous Lunar Oxygen from Regolith Electrolysis (GaLORE) project is focused on the development of a “cold-walled” or “Joule-heated” reactor design in which an internal heating source is used to selectively melt a pool of regolith between the electrodes of the reactor, leaving a shell of solidified regolith between the molten pool and the containment vessel of the reactor. This next generation reactor concept has been under development as molten oxide electrolysis (MOE) by MIT and Boston Metal for the production of iron from pure ores for terrestrial application [2]. The GaLORE project in engaged in early development of the technology for use with varying lunar regolith compositionsin the lunar environment. Thermal modelling of a proposed cold-walledreac-tor design were used as a scaffold to develop pa-rameters for a feasible reactor shape and size as well as target energy consumption[3]. The current development effort for the cold-walled reactor de-sign will be presented as a trade study of the most promising techniques for melting regolithwithin the constraints imposed by the lunar environment.Heater devices are designed to accommodate lim-ited electrical power availabilityon the moon, a wide range of regolith compositions that may be seen on the moon, limited metals available for re-placing consumed parts,and the low thermal con-ductivity of granular regolith in vacuum.Heater de-vices will be down-selectedbased on performance measurements within the above operationalcon-straints,and selected devices will be integrated into a reactor with electrodes to begin producing oxygen. [1]Sibille,L.,Sadoway, D.R.,Sirk, A., Tripathy,P.,Melendez, O., Standish, E., Dominguez, J. A., Stefanescu, D.M.,Curreri, P.A., Poizeau,S.,2009. “Recent Advancesin Scale-up Development of Molten Regolith Electrolysis for Oxygen Production in support of a Lunar Base.”AIAA 2009-659, 47th AIAA Aerospace Sciences Meeting, 5 -8 January 2009, Orlando, FL. [2] Boston Metal, https://www.boston-metal.com/moe-technology/#moe-process[3]Schreiner, S.S.,Sibille, L., Dominguez, J.A., Hoffman, J.A., 2016. "A parametric sizing model for Molten Regolith Electrolysis reactors to pro-duce oxygen on the Moon." Advances in Space Research 57.,7,1585-1603.

K D Grossman↗
NASA NTRSDate not supplied

Gaseous By-Product of Thermal Vacuum Processing of Lunar Highland Simulant

Scientists at Kennedy Space Center are advancing technologies to achieve oxygen extraction on the Lunar surface. One such technology is Molten Regolith Electrolysis (MRE) in which regolith simulant is melted under high temperatures to perform oxygen extraction through electrolysis of the melt pool. A study was conducted to understand the molten formation and proper-ties of Lunar Highlands Simulants (LHS-1) under high vacuum environments ranging between 10-6 Torr. These studies include investigating the regolith melt behavior and by-product gas analysis systems to prepare for pilot plant development and operations. The off-gassing rates and pressure build-up, gaseous compounds, and material compatibility may be a risk to MRE systems. The KSC findings are reported here for inclusion into future mis-sion architecture and operational planning. The four stages of the experiment were vacuum, resistive heating, regolith melt and gas detection. The regolith mass of 70 g was melted in a 40 cm tall x 50 cm diameter vacuum chamber at temperature increase rate 47 ℃ /min and ramp rate of 1 ampere/3 min up to an 18-amp maximum. The test is conducted for about 60 minutes and the constituent gases produced during heating of regolith is monitored with a re-sidual gas analyzer. During the molten formation, primary off-gassing volatiles included water vapor (18 amu), a peak at 44 amu (FeO2 – expected), and atomic oxygen (16 amu), among a series of other compounds that could create compatibility issues such as magnesium, chlorine, and silicon oxide. These results add to the knowledge required for successful oxygen extraction on the moon.

Molten Regolith Electrolysis↗
NASA NTRS2024

NIAC Phase I Final Report Lunar South Pole Oxygen Pipeline (LSPOP)

The Lunar South Pole Oxygen Pipeline (LSPOP) Phase I NIAC, is to analyze the feasibility of constructing a pipeline at the Moon’s South Pole for transporting gaseous oxygen from point of generation to point of use. A lunar pipeline has never been pursued and will revolutionize lunar surface operations for the Artemis program and reduce cost and risk. Our starting concept is for a 5 km pipeline to transport oxygen gas from an oxygen production source, for example from our molten regolith electrolysis (MRE, currently at TRL 5, see references[1],[2],[3],[4],[5],[6] for technical discussions of the MRE process) extraction site, or any other source, to an oxygen storage/liquification plant near a lunar base. The pipeline is designed to: 1) be constructed robotically from regolith-derived metals with minimal material transferred from Earth, 2) be repairable robotically, 3) have an oxygen flow rate of ~2 kg/hour, which is commensurate with the NASA initial projected need of 10,000 kg/year, 4) operate with minimal power over the lifetime of the pipeline, with a goal of high operational reliability and the ability to survive in the lunar environment for > 10 years. We compare this concept to a pipeline concept with pipe produced on Earth and then transported to and assembled on the Moon. Both approaches will use earth-based compressors, valves, and fittings which are integrated into the pipeline on the Moon.

NIAC Phase I↗
NASA NTRS2005

A Hexapod Robot to Demonstrate Mesh Walking in a Microgravity Environment

The JPL Micro-Robot Explorer (MRE) Spiderbot is a robot that takes advantage of its small size to perform precision tasks suitable for space applications. The Spiderbot is a legged robot that can traverse harsh terrain otherwise inaccessible to wheeled robots. A team of Spiderbots can network and can exhibit collaborative efforts to SUCCeSSfUlly complete a set of tasks. The Spiderbot is designed and developed to demonstrate hexapods that can walk on flat surfaces, crawl on meshes, and assemble simple structures. The robot has six legs consisting of two spring-compliant joints and a gripping actuator. A hard-coded set of gaits allows the robot to move smoothly in a zero-gravity environment along the mesh. The primary objective of this project is to create a Spiderbot that traverses a flexible, deployable mesh, for use in space repair. Verification of this task will take place aboard a zero-gravity test flight. The secondary objective of this project is to adapt feedback from the joints to allow the robot to test each arm for a successful grip of the mesh. The end result of this research lends itself to a fault-tolerant robot suitable for a wide variety of space applications.

Foor, David C.↗
NASA NTRS2012

Joule-Heated Molten Regolith Electrolysis Reactor Concepts for Oxygen and Metals Production on the Moon and Mars

The maturation of Molten Regolith Electrolysis (MRE) as a viable technology for oxygen and metals production on explored planets relies on the realization of the self-heating mode for the reactor. Joule heat generated during regolith electrolysis creates thermal energy that should be able to maintain the molten phase (similar to electrolytic Hall-Heroult process for aluminum production). Self-heating via Joule heating offers many advantages: (1) The regolith itself is the crucible material, it protects the vessel walls (2) Simplifies the engineering of the reactor (3) Reduces power consumption (no external heating) (4) Extends the longevity of the reactor. Predictive modeling is a tool chosen to perform dimensional analysis of a self-heating reactor: (1) Multiphysics modeling (COMSOL) was selected for Joule heat generation and heat transfer (2) Objective is to identify critical dimensions for first reactor prototype.

Sibille, Laurent↗
NASA NTRS2019

ASCot, the NASA Analogy Software Cost Tool Suite: expanding our estimation horizons

The NASA Analogy Software Costing Tool Suite (ASCoT) consists of a cluster-based analogy estimator for estimating software development effort, a K-Nearest Neighbors (KNN) analogy estimator for estimating effort and delivered lines of code, a simple regression-based cost estimating relationship (CER) model that estimates cost in dollars, and a probabilistic version of COCOMO II. In this paper we document the analogy algorithms as well as summarize the results of the performance of the KNN and the principle components (PCA) cluster analogy models. KNN performance is assessed by varying the number of inputs and number of neighbors. Four different clustering methods: K-means, Spectral Clustering, Hierarchical Clustering, and Principle Components Analysis (PCA), and their respective evaluation criterion are described in detail. The comparative performance of all four estimation models is assessed using magnitude of relative error (MRE) measurements.

Menzies, Tim↗
NASA NTRSDate not supplied

Advanced Metal Separation (AMS) via Marangoni Effect-driven Separation

For practical, economical, and sustainable human missions to the Moon, processing of lunar regolith and metal oxides is necessary for localized production of oxygen (O2) and metals that can be repurposed as rocket propellant, life support O2, and in-space manufactured parts. The primary candidates for in-situ resource utilization (ISRU) regolith processing are carbothermic reductions and molten regolith electrolysis (MRE) which both produce oxygen and a reduced, deoxygenated metallic slag. A metal separation technique is still required to capture and purify metals from the deoxygenated slag for reuse in areas such as metallic part fabrication, structural or design frameworks, and metal catalyst production. The Marangoni Effect is best explained as mass transfer along an interface driven by surface tension gradients induced by temperature and concentration differences. Due to the temperature gradients, molten metal can be transported in this fashion to create thin films. This method can transport molten metal in the absence of gravity or mechanical motion and greatly increases the available surface area for a vacuum fractional separation process. In this study, a novel vacuum furnace induces the Marangoni Effect to fractionally decompose and separate valuable metals (e.g., aluminum) from thin films of molten metal via vacuum distillation. The proposed work will examine lunar regolith, metal-based recycling feedstocks, and metallic slags produced from the carbothermal reduction of regolith. Data and observations from this study could produce a simple yet effective method of refining lunar derived metals by taking advantage of the high vacuum environment present on the lunar surface.

ISRU↗
NASA NTRSDate not supplied

Manufacturing and Metal Extraction Lunar Technology (MMELT)

Extraction processes of oxygen from regolith under development include carbothermal, molten regolith electrolysis (MRE), ionic liquids, and others, all of which result in a metal slag byproduct. The separation of some of these metals from the slag byproduct have been accomplished on small scales. However, no system currently exists that can extract aluminum, from these processes at scale, to create suitable feedstocks for manufacturing. Funding for MMELT will be used to develop a demonstration of the first end-to-end process to additively manufacture aluminum wire from lunar regolith in a simulated environment.

Manufacturing↗
NASA NTRS2024

Making Rocket Fuel from Moon Rocks: Silicon-Liquid Oxygen (SiLOX) as a Hybrid Propellant

The research team at KSC explored the controlled passivation and burning of Lunar soil constituents in an oxygen combustion vessel for use as an in-space resource. Technologies such as carbothermal reduction (CaRD) and molten regolith electrolysis (MRE) are being developed to remove the oxygen for use and leave constituents in an enriched state. This leaves behind reduced compounds that can react with oxygen for heat generation. The team at KSC looked to explore the feasibility of controlling such reactions in a pure oxygen environment for potential technology integrations. Our proof-of-concept demonstrations have given promise to many potential applications for the controlled burning or combustion of nano- and porous silicon for silicon based, Lunar economy applications. The team at KSC was able to control the burn rate and total energy released effectively via pre-treatment of the nano-silicon in a muffle furnace at varying temperatures at one-hour durations. We created a new capability at KSC with the supporting safety documentation and procedural writeup. Our work highlights the need for greater investigation to understand the regenerative properties of the proposed porous silicon discs, and its viability of a thermal and electrical energy source. This work has demonstrated the proof-of-concept that elemental silicon is able to be combusted with gaseous and liquid oxygen in a controlled manner. This report provides such evidence as well as theoretical calculations and assumptions made for technologies that would be useful in Lunar surface operations with in-situ resources. The concepts are based on the assumption that oxygen extraction technologies from Lunar regolith processing will result in enriched silicon that may be adapted for the presented use cases. Additionally, the energy storage concept is able to be adapted for terrestrial use and integrated into already existing infrastructure.

Kenneth Engeling↗