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NASA NTRS2004

Sabatier Carbon Dioxide Reduction Assembly Development for Closed Loop Water Recovery

The Sabatier Carbon Dioxide Reduction System (CRA) offers water recovery on a long duration space mission to reduce water resupply. Currently, NASA Johnson Space Center (JSC), NASA Marshall Space Flight Center (MSFC), Hamilton Sundstrand Space Systems International, Inc. (HSSSI), and Southwest Research Institute (SWRI) are working together to develop a Sabatier CRA for the International Space Station (ISS). This effort is being funded by the Office of Biological and Physical Research (Code U)/Advanced Life Support program which is administered by NASA JSC. The Sabatier CRA is the next step in closing the oxygen life support loop on future space missions. The Sabatier reaction combines the waste carbon dioxide (recovered from crew metabolism) with waste hydrogen (a byproduct of electrolysis to produce oxygen) to produce water and methane (CH4). On ISS, the methane would be vented overboard, however the methane can be utilized for propulsion during a planetary exploration mission. Based on a crew size of 7-equivalent people, the Sabatier CRA can produce as much a 2000 lb/year water. Use of the Sabatier CRA will significantly reduce the amount of water that needs to be resupplied to the ISS on a yearly basis, at a tremendous cost saving to the program. Additionally, by recycling this additional water, the Sabatier CRA enables additional launch capacity for science experiments to be brought up to the ISS. The NASA/Industry team noted above has been working to reduce technical risks associated with the Sabatier CRA system. To date the technical risks have been considerably reduced, bringing the Technology Readiness Level (TRL) from TRL 4 to TRL 5/6. In doing so, the team has developed the system schematic, system models, control scheme, produced engineering development unit (EDU) hardware, performed limited integration testing of the EDU's and verified system modeling through testing. Additionally, the system schematic has been evaluated for failure modes and hazards and had a successful technical review by the NASA Safety Board. The current focus is now related to development of the water/methane phase separator, liquid sensor and CO2 compressor piston seal life. The overall goal of the current effort is to bring the system up to a TRL6 by the end of GFY04. Although the Sabatier CRA is not currently baselined for use on the ISS, its benefits are significant enough such that volume within the Oxygen Generation System rack has been reserved for future installation. The value of the water the CRA recover will allow NASA the additional crew time and payload needed to pursue its mission of scientific research.

Smith, Frederick↗

NASA NTRS2005

Sabatier Methanation Reactor for Space Exploration

The Sabatier Methanation Reactor technology is of vital importance to the success of the human and robotic exploration program. In order to achieve an affordable program, the logistics supply to support the mission must be minimized to the fullest extent possible. One area of potential reduction with high return on investment is the closure of life support loops, particularly oxygen and water. The Sabatier system accomplishes this by utilizing hydrogen and carbon dioxide, waste products from the life support system, to produce water and methane. The recovered water is then recycled back into the life support system to provide oxygen; while the methane can be used for propulsion, or can be broken down further to recover the hydrogen. This technology is applicable not only to transit phases of exploration, but surface habitats as well as in-situ propellant production. The Sabatier Reactor system has been developed for ground based demonstration experiments extensively over the past 30 years. Over the past three years, NASA has funded development of the Sabatier Carbon Dioxide Reduction Assembly (CRA) for use on the ISS. Currently this system is at TRL 5 and it is expected that the system will be flown on the ISS as a flight experiment, The purpose of the flight experiment is to integrate the Sabatier CRA into a synchronized system with the oxygen generation system and the carbon dioxide concentrator. The flight experiment will verify the integration of the different systems working together plus it will verify the capability of the system to operate, and effectively separate its products in a micro-gravity environment. Subsequent to design validation, the flight experiment can remain onboard the ISS providing valuable water to offset logistics re-supply requirements. Some of the challenges facing the development of the Sabatier system include handling vibration induced particulates, microgravity phase separation and containment of hazardous gases. Plans for adequately addressing these issues will be presented. The Sabatier carbon dioxide reduction process will greatly benefit any of the extended duration human exploration missions because of the tremendous savings of consumables realized. Any of these mission scenarios, be they transit or surface based, must consider closing the life support loops in order to make the mission achievable, let alone affordable. Carbon dioxide reduction technology will be necessary for future outpost habitats, and the technology needs to be proven viable in a space application. The Sabatier methanation reaction is also a desirable method for producing propellant from the Mars atmosphere. The common system could be designed to accept carbon dioxide from an indoor air revitalization loop concentrator, or from an outdoor atmosphere compressor. Carbon dioxide reduction validation is but one step in the spiral development of the in-situ propellant production system desired for future planetary exploration.

Murdoch, Karen↗

NASA NTRS2014

CO2 Reduction Assembly Prototype Using Microlith-Based Sabatier Reactor for Ground Demonstration

The utilization of CO2 to produce life support consumables, such as O2 and H2O, via the Sabatier reaction is an important aspect of NASA's cabin Atmosphere Revitalization System (ARS) and In-Situ Resource Utilization (ISRU) architectures for both low-earth orbit and long-term manned space missions. Carbon dioxide can be reacted with H2, obtained from the electrolysis of water, via Sabatier reaction to produce methane and H2O. Methane can be stored and utilized as propellant while H2O can be either stored or electrolyzed to produce oxygen and regain the hydrogen atoms. Depending on the application, O2 can be used to replenish the atmosphere in human-crewed missions or as an oxidant for robotic and return missions. Precision Combustion, Inc. (PCI), with support from NASA, has previously developed an efficient and compact Sabatier reactor based on its Microlith® catalytic technology and demonstrated the capability to achieve high CO2 conversion and CH4 selectivity (i.e., ≥90% of the thermodynamic equilibrium values) at high space velocities and low operating temperatures. This was made possible through the use of high-heat-transfer and high-surface-area Microlith catalytic substrates. Using this Sabatier reactor, PCI designed, developed, and demonstrated a stand-alone CO2 Reduction Assembly (CRA) test system for ground demonstration and performance validation. The Sabatier reactor was integrated with the necessary balance-of-plant components and controls system, allowing an automated, single "push-button" start-up and shutdown. Additionally, the versatility of the test system prototype was demonstrated by operating it under H2-rich (H2/CO2 of >4), stoichiometric (ratio of 4), and CO2-rich conditions (ratio of <4) without affecting its performance and meeting the equilibrium-predicted water recovery rates. In this paper, the development of the CRA test system for ground demonstration will be discussed. Additionally, the performance results from testing the system at various operating conditions and the results from durability testing will be presented.

Junaedi, Christian↗

NASA NTRS2024

Integrated Simulations of the Sabatier and Carbon Vapor Deposition Reactor to Understand Its Impacts to Operations and Performance

The carbon vapor deposition (CVD) reactor is a technology developed by Honeywell Aerospace to convert methane, at high temperatures, into hydrogen and solid carbon. This element is coupled with a Sabatier reactor to support a closed-loop environmental control and life support system with the aim of achieving nearly complete oxygen recovery (> 95%). Initial open-loop, brassboard CVD reactor tests and simulations have shown the CVD’s ability to achieve moderately high methane conversion and high hydrogen selectivity. However, in an integrated system, additional deficiencies are expected due to recycling of unreacted or extraneous species from the Sabatier reactor (e.g., carbon dioxide, hydrogen, water) and CVD reactor (e.g., hydrocarbons, methane, etc.). Sabatier and CVD reactor models were integrated and simulated to predict potential impacts to individual reactors’ and the overall system’s performance. The simulations showed that increasing the recycle of the CVD effluent hydrogen combined with decreasing the system inlet hydrogen flow rate (i.e., drawing a stoichiometric flow rate from an electrolyzer) can lead to an oxygen recovery of > 95%. However, system integration comes at a detriment to the individual reactors. The simulations show the initial conversion from the integrated system (Sabatier = 87% and CVD = 59%) to be lower than the standalone systems (Sabatier = 91% and CVD = 69%). Furthermore, transient simulations show substrate densification, leading to worsening methane conversion coupled with increasing acetylene production, which is commensurate with soot formation. Simulations predict a shortening of the maintenance interval (i.e., time until CVD methane conversion drops below 50%) in the integrated system, which would increase the consumable substrate mass. These analyses highlight the importance of long-duration, integrated tests to corroborate these findings as well as suggest potential modifications (e.g., intermediate gas separations) to improve performance.

Air Revitalization↗

NASA NTRS2017

Mars Atmospheric Conversion to Methane and Water: An Engineering Model of the Sabatier Reactor with Characterization of Ru/Al2O3 for Long Duration Use on Mars

The Atmospheric Processing Module (APM) is a Mars In-Situ Resource Utilization (ISRU) technology designed to demonstrate conversion of the Martian atmosphere into methane and water. The Martian atmosphere consists of approximately 95 carbon dioxide (CO2) and residual argon and nitrogen. APM utilizes cryocoolers for CO2 acquisition from a simulated Martian atmosphere and pressure. The captured CO2 is sublimated and pressurized as a feedstock into the Sabatier reactor, which converts CO2 and hydrogen to methane and water. The Sabatier reaction occurs over a packed bed reactor filled with Ru/Al2O3 pellets. The long duration use of the APM system and catalyst was investigated for future scaling and failure limits. Failure of the catalyst was detected by gas chromatography and temperature sensors on the system. Following this, characterization and experimentation with the catalyst was carried out with analysis including x-ray photoelectron spectroscopy and scanning electron microscopy with elemental dispersive spectroscopy. This paper will discuss results of the catalyst performance, the overall APM Sabatier approach, as well as intrinsic catalyst considerations of the Sabatier reactor performance incorporated into a chemical model.

Ru/Al2O3 Catlayst↗

NASA NTRS2012

Compact, Lightweight Adsorber and Sabatier Reactor for CO2 Capture and Reduction for Consumable and Propellant Production

The utilization of CO2 to produce (or recycle) life support consumables, such as O2 and H2O, and to generate propellant fuels is an important aspect of NASA's concept for future, long duration planetary exploration. One potential approach is to capture and use CO2 from the Martian atmosphere to generate the consumables and propellant fuels. Precision Combustion, Inc. (PCI), with support from NASA, continues to develop its regenerable adsorber technology for capturing CO2 from gaseous atmospheres (for cabin atmosphere revitalization and in-situ resource utilization applications) and its Sabatier reactor for converting CO2 to methane and water. Both technologies are based on PCI's Microlith(R) substrates and have been demonstrated to reduce size, weight, and power consumption during CO2 capture and methanation process. For adsorber applications, the Microlith substrates offer a unique resistive heating capability that shows potential for short regeneration time and reduced power requirements compared to conventional systems. For the Sabatier applications, the combination of the Microlith substrates and durable catalyst coating permits efficient CO2 methanation that favors high reactant conversion, high selectivity, and durability. Results from performance testing at various operating conditions will be presented. An effort to optimize the Sabatier reactor and to develop a bench-top Sabatier Development Unit (SDU) will be discussed.

Junaedi, Christian↗

NASA NTRS2017

Mars Atmospheric Conversion to Methane and Water: An Engineering Model of the Sabatier Reactor with Characterization of Ru/Al2O3 for Long Duration Use on Mars

Catlayst↗

NASA NTRS2018

Sabatier System Design Study for a Mars ISRU Propellant Production Plant

As NASA looks towards human missions to Mars, an effort has started to advance the technology of a Mars in situ resource utilization (ISRU) Propellant Production Plant to a flight demonstration. This paper will present a design study of the Sabatier subsystem. The Sabatier subsystem receives carbon dioxide, CO2, and hydrogen, H2, and converts them to methane, CH4, and water, H2O. The subsystem includes the Sabatier reactor, condenser, thermal management, and a recycling system (if required). This design study will look at how the choice of reactor thermal management, number of reactors, and recycling system affect the performance of the overall Sabatier system. Different schemes from the literature involving single or cascading reactors will be investigated to see if any provide distinct advantages for a Mars propellant production plant.

Hintze, Paul E.↗

NASA NTRS2006

Integrated Testing of a 4-Bed Molecular Sieve, Air-Cooled Temperature Swing Adsorption Compressor, and Sabatier Engineering Development Unit

Accumulation and subsequent compression of carbon dioxide that is removed from the space cabin are two important processes involved in a closed-loop air revitalization scheme of the International Space Station (ISS). The 4-Bed Molecular Sieve (4BMS) of ISS currently operates in an open loop mode without a compressor. The Sabatier Engineering Development Unit (EDU) processes waste CO2 to provide water to the crew. This paper reports the integrated 4BMS, air-cooled Temperature Swing Adsorption Compressor (TSAC), and Sabatier EDU testing. The TSAC prototype was developed at NASA Ames Research Center (ARC). The 4BMS was modified to a functionally flight-like condition at NASA Marshall Space Flight Center (MSFC). Testing was conducted at MSFC. The paper provides details of the TSAC operation at various CO2 loadings and corresponding performance of the 4BMS and Sabatier.

Knox, James C.↗

NASA NTRS2010

Sabatier Reactor System Integration with Microwave Plasma Methane Pyrolysis Post-Processor for Closed-Loop Hydrogen Recovery

The Carbon Dioxide Reduction Assembly (CRA) designed and developed for the International Space Station (ISS) represents the state-of-the-art in carbon dioxide reduction (CDRe) technology. The CRA produces water and methane by reducing carbon dioxide with hydrogen via the Sabatier reaction. The water is recycled to the Oxygen Generation Assembly (OGA) and the methane is vented overboard resulting in a net loss of hydrogen. The proximity to earth and the relative ease of logistics resupply from earth allow for a semi-closed system on ISS. However, long-term manned space flight beyond low earth orbit (LEO) dictates a more thoroughly closed-loop system involving significantly higher recovery of hydrogen, and subsequent recovery of oxygen, to minimize costs associated with logistics resupply beyond LEO. The open-loop ISS system for CDRe can be made closed-loop for follow-on missions by further processing methane to recover hydrogen. For this purpose, a process technology has been developed that employs a microwave-generated plasma to reduce methane to hydrogen and acetylene resulting in 75% theoretical recovery of hydrogen. In 2009, a 1-man equivalent Plasma Pyrolysis Assembly (PPA) was delivered to the National Aeronautics and Space Administration (NASA) for technical evaluation. The PPA has been integrated with a Sabatier Development Unit (SDU). The integrated process configuration incorporates a sorbent bed to eliminate residual carbon dioxide and water vapor in the Sabatier methane product stream before it enters the PPA. This paper provides detailed information on the stand-alone and integrated performance of both the PPA and SDU. Additionally, the integrated test stand design and anticipated future work are discussed.

Abney, Morgan B.↗

NASA NTRS2010

Analyses of the Integration of Carbon Dioxide Removal Assembly, Compressor, Accumulator and Sabatier Carbon Dioxide Reduction Assembly

A tool has been developed by the Sabatier Team for analyzing/optimizing CO2 removal assembly, CO2 compressor size, its operation logic, water generation from Sabatier, utilization of CO2 from crew metabolic output, and Hz from oxygen generation assembly. Tests had been conducted using CDRA/Simulation compressor set-up at MSFC in 2003. Analysis of test data has validated CO2 desorption rate profile, CO2 compressor performance, CO2 recovery and CO2 vacuum vent in CDRA desorption. Optimizing the compressor size and compressor operation logic for an integrated closed air revitalization system Is being conducted by the Sabatier Team.

Jeng, Frank F.↗

NASA NTRS2011

Compact and Lightweight Sabatier Reactor for Carbon Dioxide Reduction

The utilization of CO2 to produce life support consumables, such as O2 and H2O, via the Sabatier reaction is an important aspect of NASA s cabin Atmosphere Revitalization System and In-Situ Resource Utilization architectures for both low-earth orbit and long-term manned space missions. In the current International Space Station (ISS) and other low orbit missions, metabolically-generated CO2 is removed from the cabin air and vented into space, resulting in a net loss of O2. This requires a continuous resupply of O2 via water electrolysis, and thus highlights the need for large water storage capacity. For long-duration space missions, the amount of life support consumables is limited and resupply options are practically nonexistent, thus atmosphere resource management and recycle becomes crucial to significantly reduce necessary O2 and H2O storage. Additionally, the potential use of the Martian CO2-rich atmosphere and Lunar regolith to generate life support consumables and propellant fuels is of interest to NASA. Precision Combustion, Inc. (PCI) has developed a compact, lightweight Microlith(Registered TradeMark)-based Sabatier (CO2 methanation) reactor which demonstrates the capability of achieving high CO2 conversion and near 100% CH4 selectivity at space velocities of 30,000-60,000 hr-1. The combination of the Microlith(Registered TradeMark) substrates and durable, novel catalyst coating permitted efficient Sabatier reactor operation that favors high reactant conversion, high selectivity, and long-term durability. This paper presents the reactor development and performance results at various operating conditions. Additionally, results from 100-hr durability tests and mechanical vibration tests are discussed.

Junaedi, Christian↗

NASA NTRS2015

Increased Oxygen Recovery from Sabatier Systems Using Plasma Pyrolysis Technology and Metal Hydride Separation

State-of-the-art life support carbon dioxide (CO2) reduction technology is based on the Sabatier reaction where less than 50% of the oxygen required for the crew is recovered from metabolic CO2. The reaction produces water as the primary product and methane as a byproduct. Oxygen recovery is constrained by the limited availability of reactant hydrogen. This is further exacerbated when Sabatier methane (CH4) is vented as a waste product resulting in a continuous loss of reactant hydrogen. Post-processing methane with the Plasma Pyrolysis Assembly (PPA) to recover hydrogen has the potential to dramatically increase oxygen recovery and thus drastically reduce the logistical challenges associated with oxygen resupply. The PPA decomposes methane into predominantly hydrogen and acetylene. Due to the highly unstable nature of acetylene, a separation system is necessary to purify hydrogen before it is recycled back to the Sabatier reactor. Testing and evaluation of a full-scale Third Generation PPA is reported and investigations into metal hydride hydrogen separation technology is discussed.

Zachary W Greenwood↗

NASA NTRS2005

Rotary Drum Separator and Pump for the Sabatier Carbon Dioxide Reduction System

A trade study conducted in 2001 selected a rotary disk separator as the best candidate to meet the requirements for an International Space Station (ISS) Carbon Dioxide Reduction Assembly (CRA). The selected technology must provide micro-gravity gasfliquid separation and pump the liquid from 10 psia at the gasfliquid interface to 18 psia at the wastewater bus storage tank. The rotary disk concept, which has pedigree in other systems currently being built for installation on the ISS, failed to achieve the required pumping head within the allotted power. The separator discussed in this paper is a new design that was tested to determine compliance with performance requirements in the CRA. The drum separator and pump @SP) design is similar to the Oxygen Generator Assembly (OGA) Rotary Separator Accumulator (RSA) in that it has a rotating assembly inside a stationary housing driven by a integral internal motor. The innovation of the DSP is the drum shaped rotating assembly that acts as the accumulator and also pumps the liquid at much less power than its predecessors. In the CRA application, the separator will rotate at slow speed while accumulating water. Once full, the separator will increase speed to generate sufficient head to pump the water to the wastewater bus. A proof-of- concept (POC) separator has been designed, fabricated and tested to assess the separation efficiency and pumping head of the design. This proof-of-concept item was flown aboard the KC135 to evaluate the effectiveness of the separator in a microgravity environment. This separator design has exceeded all of the performance requirements. The next step in the separator development is to integrate it into the Sabatier Carbon Dioxide Reduction System. This will be done with the Sabatier Engineering Development Unit at the Johnson Space Center.

Holder, Don↗

NASA NTRS2013

Sabatier Catalyst Poisoning Investigation

The Carbon Dioxide Reduction Assembly (CRA) on the International Space Station (ISS) has been operational since 2010. The CRA uses a Sabatier reactor to produce water and methane by reaction of the metabolic CO2 scrubbed from the cabin air and the hydrogen byproduct from the water electrolysis system used for metabolic oxygen generation. Incorporating the CRA into the overall air revitalization system has facilitated life support system loop closure on the ISS reducing resupply logistics and thereby enhancing longer term missions. The CRA utilizes CO2 which has been adsorbed in a 5A molecular sieve within the Carbon Dioxide Removal Assembly, CDRA. There is a potential of compounds with molecular dimensions similar to, or less than CO2 to also be adsorbed. In this fashion trace contaminants may be concentrated within the CDRA and subsequently desorbed with the CO2 to the CRA. Currently, there is no provision to remove contaminants prior to entering the Sabatier catalyst bed. The risk associated with this is potential catalyst degradation due to trace organic contaminants in the CRA carbon dioxide feed acting as catalyst poisons. To better understand this risk, United Technologies Aerospace System (UTAS) has teamed with MSFC to investigate the impact of various trace contaminants on the CRA catalyst performance at relative ISS cabin air concentrations and at about 200/400 times of ISS concentrations, representative of the potential concentrating effect of the CDRA molecular sieve. This paper summarizes our initial assessment results.

Nallette, Tim↗

NASA NTRS2017

Modeling a Packed Bed Reactor Utilizing the Sabatier Process

A numerical model is being developed using Python which characterizes the conversion and temperature profiles of a packed bed reactor (PBR) that utilizes the Sabatier process; the reaction produces methane and water from carbon dioxide and hydrogen. While the specific kinetics of the Sabatier reaction on the RuAl2O3 catalyst pellets are unknown, an empirical reaction rate equation1 is used for the overall reaction. As this reaction is highly exothermic, proper thermal control is of the utmost importance to ensure maximum conversion and to avoid reactor runaway. It is therefore necessary to determine what wall temperature profile will ensure safe and efficient operation of the reactor. This wall temperature will be maintained by active thermal controls on the outer surface of the reactor. Two cylindrical PBRs are currently being tested experimentally and will be used for validation of the Python model. They are similar in design except one of them is larger and incorporates a preheat loop by feeding the reactant gas through a pipe along the center of the catalyst bed. The further complexity of adding a preheat pipe to the model to mimic the larger reactor is yet to be implemented and validated; preliminary validation is done using the smaller PBR with no reactant preheating. When mapping experimental values of the wall temperature from the smaller PBR into the Python model, a good approximation of the total conversion and temperature profile has been achieved. A separate CFD model incorporates more complex three-dimensional effects by including the solid catalyst pellets within the domain. The goal is to improve the Python model to the point where the results of other reactor geometry can be reasonably predicted relatively quickly when compared to the much more computationally expensive CFD approach. Once a reactor size is narrowed down using the Python approach, CFD will be used to generate a more thorough prediction of the reactors performance.

Reactor↗

NASA NTRS2019

Study of Sabatier Catalyst Performance for a Mars ISRU Propellant Production Plant

NASA is currently developing technologies for use in the field of in-situ resource utilization (ISRU). One of the technologies being advanced is the Sabatier, or methanation, reactor which converts carbon dioxide and hydrogen into methane gas and water at high temperatures. This paper discusses the catalyst life and performance issues for these reactors that would be expected on Mars and describes the test methods employed and observed results. The various catalysts were tested in their capacity for the continuous production of methane gas via the Sabatier reaction and the possible effects of launch vibration loads, exposure to liquid water, particulate contamination, and chemical contamination to the overall observed reaction efficacy of the catalysts evaluated.

Franco, Carolina↗

NASA NTRS2019

Study of Sabatier Catalyst Performance for a Mars ISRU Propellant Production Plant

Franco, Carolina↗