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Numerous studies suggest that local feedback of evaporation on precipitation, or recycling, is a significant source of water for precipitation. Quantitative results on the exact amount of recycling have been difficult to obtain in view of the inherent limitations of diagnostic recycling calculations. The current study describes a calculation of the amount of local and remote sources of water for precipitation, based on the implementation of passive constituent tracers of water vapor (termed water vapor tracers, WVT) in a general circulation model. In this case, the major limitation on the accuracy of the recycling estimates is the veracity of the numerically simulated hydrological cycle, though we note that this approach can also be implemented within the context of a data assimilation system. In this approach, each WVT is associated with an evaporative source region, and tracks the water until it precipitates from the atmosphere. By assuming that the regional water is well mixed with water from other sources, the physical processes that act on the WVT are determined in proportion to those that act on the model's prognostic water vapor. In this way, the local and remote sources of water for precipitation can be computed within the model simulation, and can be validated against the model's prognostic water vapor. Furthermore, estimates of precipitation recycling can be compared with bulk diagnostic approaches. As a demonstration of the method, the regional hydrologic cycles for North America and India are evaluated for six summers (June, July and August) of model simulation. More than 50% of the precipitation in the Midwestern United States came from continental regional tracers, and the local source was the largest of the regional tracers (14%). The Gulf of Mexico and Atlantic 2 regions contributed 18% of the water for Midwestern precipitation, but further analysis suggests that the greater region of the Tropical Atlantic Ocean may also contribute significantly. In general, most North American land regions showed a positive correlation between evaporation and recycling ratio (except the Southeast United States) and negative correlations of recycling ratio with precipitation and moisture transport (except the Southwestern United States). The Midwestern local source is positively correlated with local evaporation, but it is not correlated with water vapor transport. This is contrary to bulk diagnostic estimates of precipitation recycling. In India, the local source of precipitation is a small percentage of the precipitation owing to the dominance of the atmospheric transport of oceanic water. The southern Indian Ocean provides a key source of water for both the Indian continent and the Sahelian region.
This report describes a flexible, reliable, deep space life support system design approach that uses either storage or recycling or both together. The design goal is to provide the needed life support performance with the required ultra reliability for the minimum Equivalent System Mass (ESM). Recycling life support systems used with multiple redundancy can have sufficient reliability for deep space missions but they usually do not save mass compared to mixed storage and recycling systems. The best deep space life support system design uses water recycling with sufficient water storage to prevent loss of crew if recycling fails. Since the amount of water needed for crew survival is a small part of the total water requirement, the required amount of stored water is significantly less than the total to be consumed. Water recycling with water, oxygen, and carbon dioxide removal material storage can achieve the high reliability of full storage systems with only half the mass of full storage and with less mass than the highly redundant recycling systems needed to achieve acceptable reliability. Improved recycling systems with lower mass and higher reliability could perform better than systems using storage.
NASA’s In-Space Manufacturing (ISM) project seeks to develop the materials, processes, and manufacturing technologies needed to provide an on-demand manufacturing capability for deep space exploration missions. The ability to manufacture and recycle some parts on demand rather than launch them from earth has the potential to reduce logistics requirements on long duration missions and enhance crew safety. With the launch of the first 3D printer (built and operated by Made in Space through a Small Business Innovative Research – SBIR -- contract) to the International Space Station (ISS) in 2014, the ISM project demonstrated the feasibility of operating an on-demand manufacturing system in a microgravity environment. This paper will provide an update on recent advancements in ISM under three key technology areas: manufacturing, recycling, and development of a design database. ISM continues to pursue development of manufacturing technologies for space applications and use the ISS as a critical test bed to prove out these technologies before deploying them on next generation exploration systems. Activities under this focus area include: characterization of materials manufactured using the Additive Manufacturing Facility (AMF), the second generation commercial 3D-printer on ISS, also owned and operated by Made in Space; development of prototype payloads for metal manufacturing through phase II SBIR contracts with Tethers Unlimited, Made in Space, and Ultra Tech Machinery; development of a multi-material fabrication laboratory capable of processing metals and providing inspection of manufactured parts through a Broad Agency Announcement (Techshot, Interlog, and Tethers Unlimited); an in-line sensing system for ISM platforms; and development of higher strength feedstocks for 3D polymer printers. In the area of recycling, the Tethers Unlimited Refabricator payload (an integrated 3D printer and recycler for ULTEM 9085) launched to ISS in November 2018 and began operating in early 2019. This payload represents the first demonstration of on-orbit recycling; down massed specimens will assess material degradation in the polymer over multiple recycling cycles to define limits on material re-use. Other work in the recycling area includes development of common use materials intended to be reused and recycled on space missions (Tethers Unlimited and Cornerstone Research Group) and a sterilization capability for multiple-use materials (ERASMUS from Tethers Unlimited). Concurrent with manufacturing technology and materials development work is creation of a design database, a curated list of parts that can be manufactured using the suite of In-Space Manufacturing capabilities.
Most human missions in space have been brief, lasting only days or weeks, and they have taken all the materials they need. Using the alternate method, the International Space Station recycles water and oxygen, and it is often assumed that future Moon and Mars missions should also recycle their life support materials. The “take or make” decision is primarily based on cost, and making or recycling material on longer space missions can sometimes be less expensive than taking it. Longer missions favor recycling over resupply when the initial cost to provide recycling equipment is less than the cost to provide resupply. Recycling was clearly cheaper than taking material to the space station in the space shuttle era when launch costs were very high. Launch costs have decreased and the take or make decision point has changed. The recent reduction in launch cost by a factor of about twenty-five to fifty makes taking material cost less than making or recycling it for much longer missions. The cost breakeven point when making rather than taking material is less expensive is now much farther out in time than before. Material recycling or in situ production no longer saves cost except for very large or very long missions.
Most human missions in space have been brief, lasting only days or weeks, and they have taken all the materials they need. Using the alternate method, the International Space Station recycles water and oxygen, and it is often assumed that future Moon and Mars missions should also recycle their life support materials. The “take or make” decision is primarily based on cost, and making or recycling material on longer space missions can sometimes be less expensive than taking it. Longer missions favor recycling over resupply when the initial cost to provide recycling equipment is less than the cost to provide resupply. Recycling was clearly cheaper than taking material to the space station in the space shuttle era when launch costs were very high. Launch costs have decreased and the take or make decision point has changed. The recent reduction in launch cost by a factor of about twenty-five to fifty makes taking material cost less than making or recycling it for much longer missions. The cost breakeven point when making rather than taking material is less expensive is now much farther out in time than before. Material recycling or in situ production no longer saves cost except for very large or very long missions.
Recycling space life support systems have been built and tested since the 1960s and have operated on the International Space Station (ISS) since the mid 2000s. The development of space life support has been guided by a general consensus focused on two important related goals, increasing system closure and reducing launch mass. High closure is achieved by recycling crew waste products such as carbon dioxide and condensed humidity. Recycling directly reduces the mass of oxygen and water for the crew that must be launched from Earth. The launch mass of life support can be further reduced by developing recycling systems with lower hardware mass and reduced power. The life support consensus has also favored using biological systems. The goal of increasing closure using biological systems suggests that food should be grown in space and that biological processors be used for air, water, and waste recycling. The goal of reducing launch mass led to use of Equivalent System Mass (ESM) in life support advocacy and technology selection. The recent consensus assumes that the recycling systems architecture developed in the 1960s and implemented on ISS will be used on all future long missions. NASA and other project organizations use the standard systems engineering process to guide hardware development. The systems process was used to develop ISS life support, but it has been less emphasized in planning future systems for the moon and Mars. Since such missions are far in the future, there has been less immediate need for systems engineering analysis to consider trade-offs, reliability, and Life Cycle Cost (LCC). Preliminary systems analysis suggests that the life support consensus concepts should be revised to reflect systems engineering requirements.
A sustained presence in any extra-terrestrial environment will require the capability to generate materials, goods, and ultimately vehicles, construction supplies and habitats to be tenable. As an example, NASA, in collaboration with Made In Space, Inc., recently reported the results of extensive research toward enabling3D printing in space. The extensive characterization and comparison of 3D printed articles suggested that, overall, articles generated in the International Space Station microgravity environment were comparable to those generated on Earth. The benefit of in-space manufacturing can be increased through utilization of recyclable materials. A recent analysis of a hypothetical 1,100 day round trip mission to Mars determined that significant mass savings and increase in mission probability of success could be achieved through in-space manufacturing with recyclable materials. NASA’s project ESPUR (Enabling Sustained Presence Using Recyclables), through support from NASA Langley’s Innovative Research and Development Fund, is investigating novel, polymer-coated, epoxy microparticle systems as an enabling technology to realize in-space manufacturing using recyclable feedstocks. Building from previously reported results, further progress toward synthesis of the polymer coating containing click chemical functionalities will be described here. Finite elemental analysis (FEA) has been utilized, in light of scale-free/small world considerations in an effort to identify compositions most likely to yield robust macroscopic geometries. Initial results will be described here. Finally, potential mass savings and life cycle of this recyclable materials technology will be discussed.
Development of Controlled Ecological Life Support System (CELSS) technology is inevitable for future long duration stays of human beings in space, for lunar base construction and for manned Mars flight programs. CELSS functions can be divided into 2 categories, Environmental Control and Material Recycling. Temperature, humidity, total atmospheric pressure and partial pressure of oxygen and carbon dioxide, necessary for all living things, are to be controlled by the environment control function. This function can be performed by technologies already developed and used as the Environment Control Life Support System (ECLSS) of Space Shuttle and Space Station. As for material recycling, matured technologies have not yet been established for fully satisfying the specific metabolic requirements of each living thing including human beings. Therefore, research activities for establishing CELSS technology should be focused on material recycling technologies using biological systems such as plants and animals and physico-chemical systems, for example, a gas recycling system, a water purifying and recycling system and a waste management system. Japanese research activities were conducted and will be continued accordingly.
The requirements for a human life support system for long-duration space missions are reviewed. The system design of a controlled ecological life support system is briefly described, followed by a more detailed account of the study of the conceptual design of a Lunar Based CELSS. The latter is to provide a safe, reliable, recycling lunar base life support system based on a hybrid physicochemical/biological representative technology. The most important conclusion reached by this study is that implementation of a completely recycling CELSS approach for a lunar base is not only feasible, but eminently practical. On a cumulative launch mass basis, a 4-person Lunar Base CELSS would pay for itself in approximately 2.6 years relative to a physicochemical air/water recycling system with resupply of food from the Earth. For crew sizes of 30 and 100, the breakeven point would come even sooner, after 2.1 and 1.7 years, respectively, due to the increased mass savings that can be realized with the larger plant growth units. Two other conclusions are particularly important with regard to the orientation of future research and technology development. First, the mass estimates of the Lunar Base CELSS indicate that a primary design objective in implementing this kind of system must be to minimized the mass and power requirement of the food production plant growth units, which greatly surpass those of the other air and water recycling systems. Consequently, substantial research must be directed at identifying ways to produce food more efficiently. On the other hand, detailed studies to identify the best technology options for the other subsystems should not be expected to produce dramatic reductions in either mass or power requirement of a Lunar Base CELSS. The most crucial evaluation criterion must, therefore, be the capability for functional integration of these technologies into the ultimate design of the system. Secondly, this study illustrates that existing or near-term technologies are adequate to implement a Lunar Base CELSS. There are no apparent "show-stoppers" which require the development of new technologies. However, there are several areas in which new materials and technologies could be used for a more efficient implementation of the system, e.g., by decreasing mass or power requirement and increasing recycling efficiency. These areas must be further addressed through research and development. Finally, although this study focused on the development of a Lunar Base CELSS, the same technologies and a nearly identical design would be appropriate for a Mars base. Actually, except for the distance of transportation, the implementation of a CELSS on Mars would even be easier than it would be on the Moon. The presence of atmospheric CO2 on Mars, although in low concentration, coupled with the fact that the day/night cycle on Mars is very similar to that on Earth, makes the use of light-weight, greenhouse-like structures for growing food plants even more feasible than on the Moon. There are some environmental problems, which would have to be dealt with, like dust storms and the large amount of the ultraviolet radiation incident on the planet's surface. However, the materials and methods are largely available today to develop such a life support system for a Mars base.
Methane to aromatics on Mars ( METAMARS ) is the name of a process originally intended as a means of converting Martian atmospheric carbon dioxide to aromatic hydrocarbons and oxygen, which would be used as propellants for spacecraft to return to Earth. The process has been demonstrated on Earth on a laboratory scale. A truncated version of the process could be used on Earth to convert natural gas to aromatic hydrocarbon liquids. The greater (relative to natural gas) density of aromatic hydrocarbon liquids makes it more economically feasible to ship them to distant markets. Hence, this process makes it feasible to exploit some reserves of natural gas that, heretofore, have been considered as being "stranded" too far from markets to be of economic value. In the full version of METAMARS, carbon dioxide is frozen out of the atmosphere and fed to a Sabatier reactor along with hydrogen (which, on Mars, would have been brought from Earth). In the Sabatier reactor, these feedstocks are converted to methane and water. The water is condensed and electrolyzed to oxygen (which is liquefied) and hydrogen (which is recycled to the Sabatier reactor). The methane is sent to an aromatization reactor, wherein, over a molybdenum-on-zeolite catalyst at a temperature 700 C, it is partially converted into aromatic hydrocarbons (specifically, benzene, toluene, and naphthalene) along with hydrogen. The aromatics are collected by freezing, while unreacted methane and hydrogen are separated by a membrane. Most of the hydrogen is recycled to the Sabatier reactor, while the methane and a small portion of the hydrogen are recycled to the aromatization reactor. The partial recycle of hydrogen to the aromatization reactor greatly increases the catalyst lifetime and eases its regeneration by preventing the formation of graphitic carbon, which could damage the catalyst. (Moreover, if graphitic carbon were allowed to form, it would be necessary to use oxygen to remove it.) Because the aromatics contain only one hydrogen atom per carbon atom, METAMARS produces four times as much propellant from a given amount of hydrogen as does a related process that includes the Sabatier reaction and electrolysis but not aromatization. In the terrestrial version of METAMARS, the Sabatier reactor and electrolyzer would be omitted, while the hydrogen/ methane membrane-separating membrane, the aromatization reactor, and the unreacted-gas-recycling subsystem would be retained. Natural gas would be fed directly to the aromatization reactor. Because natural gas consists of higher hydrocarbons in addition to methane, the aromatization subprocess should be more efficient than it is for methane alone.
Recycling is a technology that will be key to creating a self sustaining lunar outpost. The plastics used for food packaging provide a source of material that could be recycled to produce water and methane. The recycling of these plastics will require some additional resources that will affect the initial estimate of starting materials that will have to be transported from earth, mainly oxygen, energy and mass. These requirements will vary depending on the recycling conditions. The degredation products of these plastics will vary under different atmospheric conditions. An estimate of the the production rate of methane and water using typical ISRU processes along with the plastic recycling will be presented.
Water systems for human bases on the moon and Mars will recycle multiple sources of wastewater. Systems for both the moon and Mars will also store water to support and backup the recycling system. Most water system requirements, such as number of crew, quantity and quality of water supply, presence of gravity, and surface mission duration of 6 or 18 months, will be similar for the moon and Mars. If the water system fails, a crew on the moon can quickly receive spare parts and supplies or return to Earth, but a crew on Mars cannot. A recycling system on the moon can have a reasonable reliability goal, such as only one unrecoverable failure every five years, if there is enough stored water to allow time for attempted repairs and for the crew to return if repair fails. The water system that has been developed and successfully operated on the International Space Station (ISS) could be used on a moon base. To achieve the same high level of crew safety on Mars without an escape option, either the recycling system must have much higher reliability or enough water must be stored to allow the crew to survive the full duration of the Mars surface mission. A three loop water system architecture that separately recycles condensate, wash water, and urine and flush can improve reliability and reduce cost for a Mars base.
What water supply method should be used on a trip to Mars? Two alternate approaches are using fuel cell and stored water, as was done for short missions such as Apollo and the Space Shuttle, or recycling most of the water, as on long missions including the International Space Station (ISS). Stored water is inexpensive for brief missions but its launch mass and cost become very large for long missions. Recycling systems have much lower total mass and cost for long missions, but they have high development cost and are more expensive to operate than storage. A Mars transit mission would have an intermediate duration of about 450 days out and back. Since Mars transit is about ten times longer than a brief mission but probably less than one-tenth as long as ISS, it is not clear if stored or recycled water would be best. Recycling system design is complicated because water is used for different purposes, drinking, food preparation, washing, and flushing the urinal, and because wastewater has different forms, humidity condensate, dirty wash water, and urine and flush water. The uses have different requirements and the wastewater resources have different contaminants and processing requirements. The most cost-effective water supply system may recycle some wastewater sources and also provide safety reserve water from storage. Different water supply technologies are compared using mass, cost, reliability, and other factors.
Brief human space missions such as Apollo and shuttle used material storage to provide life support but long missions such as a trip to Mars and back are expected to use a recycling life support system similar to the one on the International Space Station (ISS). Mars transit life support design is investigated considering requirements, performance, reliability, cost, and risk. The launch cost, crew size, and reliability are variable parameters that affect the life support design choice. Greater launch cost and larger crew size tend to make recycling more cost-effective than resupply. A higher reliability requirement tends to favor resupply over recycling. A mixed system combining direct supply of minimal survival materials for very high reliability with additional materials provided by recycling systems seems the best choice.
An improved system for recovery of a liquid hydrocarbon fuel from oil shale is presented. The oil shale pyrolysis system is composed of a retort reactor for receiving a bed of oil shale particules which are heated to pyrolyis temperature by means of a recycled solar heated gas stream. The gas stream is separated from the recovered shale oil and a portion of the gas stream is rapidly heated to pyrolysis temperature by passing it through an efficient solar heater. Steam, oxygen, air or other oxidizing gases can be injected into the recycle gas before or after the recycle gas is heated to pyrolysis temperature and thus raise the temperature before it enters the retort reactor. The use of solar thermal heat to preheat the recycle gas and optionally the steam before introducing it into the bed of shale, increases the yield of shale oil.
Water used during previous space missions has been either carried or made aloft. Future human space endeavors will probably have to utilize some form of water reclamation and recycling. There is little applied experience in either the US or foreign space programs with this technology. Water reclamation and recycling constitutes an engineering challenge of the broadest nature and will require an intensive research and development effort if this technology is to mature in time for practical use on the proposed US spacestation. In order for this to happen, reclaimed/recycled water specification will need to be devised to guide engineering development. Perhaps the most strigent specifications will involve water to be consumed. NASA's present Potable Water Specifications are not applicable to reclaimed or recycled potable water. No specifications for reclaimed or recycled potable water presently exist either inside or outside NASA. NASA's past experience with potable water systems is reviewed, limitations of the present Potable Water Specifications are examined, present world expertise with potable water reclamation/recycling systems and system analogs is reviewed, and an approach to developing pertinent Reclaimed/Recycled Potable Water Specifications for spacecraft is presented.