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Recovery system is comprised of three integrated subsystems: electrochemical carbon dioxide concentrator which removes carbon dioxide from atmosphere, Sabatier reactor in which carbon dioxide is reduced with hydrogen to form methane and water, and static-feed water electrolysis cell to recover oxygen from water.
This report analyzes the reasons for the 2 new ranking of techniques for recovering 0(2) from CO(2). Work recently completed has reversed previous ranking, placing thermal dissociation at reduced pressures at the top of the list. The problem to be solved to make this technique suitable for space flight are also discussed.
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Life support technology requirements for long-term space habitation are identified with emphasis on regeneration capabilities and biological life support systems. Other topics discussed include: water recovery, oxygen recovery, waste management recycle, and a man-made closed ecology with selected biological species.
The state-of-the-art Carbon Dioxide (CO2) Reduction Assembly (CRA) on the International Space Station (ISS) facilitates the recovery of oxygen from metabolic CO2. The CRA utilizes the Sabatier process to produce water with methane as a byproduct. The methane is currently vented overboard as a waste product. Because the CRA relies on hydrogen for oxygen recovery, the loss of methane ultimately results in a loss of oxygen. For missions beyond low earth orbit, it will prove essential to maximize oxygen recovery. For this purpose, NASA is exploring an integrated post-processor system to recover hydrogen from CRA methane. The post-processor, called a Plasma Pyrolysis Assembly (PPA) partially pyrolyzes methane to recover hydrogen with acetylene as a byproduct. In-flight operation of post-processor will require a Methane Purification Assembly (MePA) and an Acetylene Separation Assembly (ASepA). Recent efforts have focused on the design, fabrication, and testing of these components. The results and conclusions of these efforts will be discussed as well as future plans.
Human exploration missions to Mars and other destinations beyond low Earth orbit require highly robust, reliable, and maintainable life support systems that maximize the recovery of oxygen (O2). One process in development and under consideration is the Series-Bosch System (S-Bosch). This system is a two stage reactor process that reduces carbon dioxide (CO2) with hydrogen (H2) to produce water and solid carbon. Theoretically, the Bosch process can recover 100% of the O2 from CO2 in the form of water, making it an attractive option for long duration missions. The Series Bosch system includes a reverse water gas shift (RWGS) reactor, a carbon formation reactor (CFR), a H2 extraction membrane, and a CO2extraction membrane. To further the development of oxygen recovery systems, NASA awarded Phase I contracts to several entities under the Game Changing Development Program addressing Spacecraft Oxygen Recovery (SCOR). Two of the hardware deliverables were integrated into the Carbon Dioxide Reduction Test Stand (CORTS) as carbon formation reactors and performance evaluations were executed at Marshall Space Flight Center. A trade study was performed between these two reactors along with one developed at MSFC. This paper provided the necessary information for the Advanced Exploration Systems/Life Support Systems Project (AES/LSS) managers to select a CFR for further development and discusses the process of selection.
Oxygen recovery from metabolic carbon dioxide is an enabling capability for long-duration manned space flight. Complete recovery of oxygen (100%) involves the production of solid carbon. Catalytic approaches for this purpose, such as Bosch technology, have been limited in trade analyses due in part to the mass penalty for high catalyst resupply caused by carbon fouling of the iron or nickel catalyst. In an effort to mitigate this challenge, several technology approaches have been proposed. These approaches have included methods to prolong the life of the catalysts by increasing the total carbon mass loading per mass catalyst, methods for simplified catalyst introduction and removal to limit the resupply container mass, methods of using in situ resources, and methods to regenerate catalyst material. Research and development into these methods is ongoing, but only use of in situ resources and/or complete regeneration of catalyst material has the potential to entirely eliminate the need for resupply. The use of ionic liquids provides an opportunity to combine these methods in a technology approach designed to eliminate the need for resupply of oxygen recovery catalyst. Here we describe the results of an initial feasibility study using ionic liquids and in situ resources for life support catalyst regeneration, we discuss the key challenges with the approach, and we propose future efforts to advance the technology.
Oxygen recovery from metabolic carbon dioxide is an enabling capability for long-duration manned space flight. Complete recovery of oxygen (100%) involves the production of solid carbon. Catalytic approaches for this purpose, such as Bosch technology, have been limited in trade analyses due in part to the mass penalty for high catalyst resupply caused by carbon fouling of the iron or nickel catalyst. In an effort to mitigate this challenge, several technology approaches have been proposed. These approaches have included methods to prolong the life of the catalysts by increasing the total carbon mass loading per mass catalyst, methods for simplified catalyst introduction and removal to limit the resupply container mass, methods of using in situ resources, and methods to regenerate catalyst material. Research and development into these methods is ongoing, but only use of in situ resources and/or complete regeneration of catalyst material has the potential to entirely eliminate the need for resupply. The use of ionic liquids provides an opportunity to combine these methods in a technology approach designed to eliminate the need for resupply of oxygen recovery catalyst. Here we describe the results of an initial feasibility study using ionic liquids and in situ resources for life support catalyst regeneration, we discuss the key challenges with the approach, and we propose future efforts to advance the technology.
NASA is developing three racks containing regenerative water recovery and oxygen generation systems (WRS and OGS) for deployment on the International Space Station (ISS). The major assemblies included in these racks are the Water Processor Assembly (WPA), Urine Processor Assembly (UPA), Oxygen Generation Assembly (OGA), and the Power Supply Module (PSM) supporting the OGA. The WPA and OGA are provided by Hamilton Sundstrand Space Systems International (HSSSI), Inc., while the UPA and PSM are developed in- house by the Marshall Space Flight Center (MSFC). The assemblies have completed the manufacturing phase and are in various stages of testing and integration into the flight racks. This paper summarizes the status as of April 2005 and describes some of the technical challenges encountered and lessons learned over the past year.
NASA's Marshall Space Flight Center is providing three racks containing regenerative water recovery and oxygen generation systems (WRS and OGS) for flight on the International Space Station's (ISS) Node 3 element. The major assemblies included in these racks are the Water Processor Assembly (WPA), Urine Processor Assembly (UPA), Oxygen Generation Assembly (OGA), and the Power Supply Module (PSM) supporting the OGA. The WPA and OGA are provided by Hamilton Sundstrand Space Systems International (HSSSI), while the UPA and PSM are being designed and manufactured in-house by MSFC. The assemblies are completing the manufacturing phase and are in various stages of ORU and system level testing, to be followed by integration into the flight racks. This paper gives a current status, along with technical challenges encountered and lessons learned.
Current oxygen recovery technology onboard the International Space Station only recovers approximately 50% of the oxygen from metabolic carbon dioxide, thus requiring resupply mass in order to sustain life onboard. Future long duration manned missions will require maximum oxygen recovery in order to reduce resupply mass. Complete recovery of oxygen can be achieved through Bosch technology. The challenge with this technology is that the solid carbon produced during the process results in undesired catalyst resupply mass. Although there have been several approaches to solve this challenge, in order to totally eliminate the need for resupply only one potential process has been identified. This process is a fully-regenerable Ionic Liquid (IL)-based Bosch system that employs in situ resources. In 2016, efforts were made that proved the feasibility of an IL-based Bosch system. ILs were used to electroplate iron onto a copper substrate and to regenerate the iron by extracting the iron from the copper substrate and product carbon. In 2017, efforts were initiated to scale the proposed technology. Here we report the results of those efforts as well as an IL-based Bosch system concept and basic reactor design.
Minimizing resupply from Earth is essential for future long duration manned missions. The current oxygen recovery system aboard the International Space Station is capable of recovering approximately 50% of the oxygen from metabolic carbon dioxide. For long duration manned missions, a minimum of 75% oxygen recovery is targeted with a goal of greater than 90%. Theoretically, the Bosch process can recover 100% of oxygen, making it a promising technology for oxygen recovery for long duration missions. However, the Bosch process produces elemental carbon which ultimately fouls the catalyst. Once the catalyst performance is compromised, it must be replaced resulting in undesired resupply mass. Based on the performance of a Bosch system designed by NASA in the 1990's, a three year Martian mission would require approximately 1315 kg (2850 lbs) of catalyst resupply. It may be possible to eliminate catalyst resupply with a fully regenerable system using an Ionic Liquid (IL)-based Bosch system. In 2016, we reported the feasibility of using ILs to produce an iron catalyst on a copper substrate and to regenerate the iron catalyst by extracting the iron from the copper substrate and product carbon. Additionally, we described a basic system concept for an IL-based Bosch. Here we report the results of efforts to scale catalyst preparation, catalyst regeneration, and to scale the carbon formation processing rate of a single reactor.
Minimizing resupply from Earth is essential for future long duration manned missions. The current oxygen recovery system aboard the International Space Station is capable of recovering approximately 50% of the oxygen from metabolic carbon dioxide. For long duration manned missions, a minimum of 75% oxygen recovery is targeted with a goal of greater than 90%. Theoretically, the Bosch process can recover 100% of oxygen, making it a promising technology for oxygen recovery for long duration missions. However, the Bosch process produces elemental carbon which ultimately fouls the catalyst. Once the catalyst performance is compromised, it must be replaced resulting in undesired resupply mass. Based on the performance of a Bosch system designed by NASA in the 1990's, a three year Martian mission would require approximately 1315 kg (2850 lbs) of catalyst resupply. It may be possible to eliminate catalyst resupply with a fully regenerable system using an Ionic Liquid (IL)-based Bosch system. In 2016, we reported the feasibility of using ILs to produce an iron catalyst on a copper substrate and to regenerate the iron catalyst by extracting the iron from the copper substrate and product carbon. Additionally, we described a basic system concept for an IL-based Bosch. Here we report the results of efforts to scale catalyst preparation, to scale catalyst regeneration, and to scale the carbon formation processing rate of a single reactor.