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A sensitive carbon monoxide detector, developed specifically for spacecraft use, is described. An instrument range of 0 to 60 ppm CO in air was devised. The fuel cell type detector is used as a highly sensitive electrolysis cell for electrochemically detecting gases. The concept of an electrochemical CO detector is discussed and the CO oxidation behavior in phosphoric and sulfuric acid electrolytes is reported.
A hydrazine/water electrolysis process system module design was fabricated and tested to demonstrate component and module performance. This module is capable of providing both the metabolic oxygen for crew needs and the oxygen and nitrogen for spacecraft leak makeup. The component designs evolved through previous R and D efforts, and were fabricated and tested individually and then were assembled into a complete module which was successfully tested for 1000 hours to demonstrate integration of the individual components. A survey was made of hydrazine sensor technology and a cell math model was derived.
The level of proficiency attained by the most effective physical and chemical regenerative processes capable of providing a habitable atmospheric environment in a spacecraft is assessed. It is shown that both the Sabatier and Bosh reactions are in a mature stage of technological readiness and can effectively reduce the carbon dioxide in a spacecraft. An electrochemical method for concentrating CO2 from an air environment offers promise to approach low levels of pCO2 control. Technological advances in the fields of solid polymer electrolytes and oxygen evolution electrocatalysts have led to a water electrolysis system that can maintain efficient performance for several years. Nitrogen supply and control of the composition of the spacecraft atmosphere is effectively provided by the circulating electrolyte technique.
A system which uses an electrochemical carbon dioxide concentrator to remove carbon dioxide from the cabin atmosphere and a Sabatier reactor to reduce carbon dioxide with hydrogen to form methane and water is described. Oxygen is recovered from water by means of a static-feed water electrolysis system. The hydrogen thus generated is reused in the carbon dioxide concentrator. The methane is a system byproduct. The CO2 removal reactions and the implementation of the CO2 concentration concept are discussed, and test results are examined.
Thermochemical processes which lead to the production of hydrogen and oxygen from water without the consumption of any other material have a number of advantages when compared to other processes such as water electrolysis. It is possible to operate a sequence of chemical steps with net work requirements equal to zero at temperatures well below the temperature required for water dissociation in a single step. Various types of procedures are discussed, giving attention to halide processes, reverse Deacon processes, iron oxide and carbon oxide processes, and metal and alkali metal processes. Economical questions are also considered.
Cost estimates for experiments and subsystems flown in the Spacelab were established. Ten experiments were cost analyzed. Estimated cost varied from $650,000 for the hardware development of the SPE water electrolysis experiment to $78,500,000 for the development and operation of a representative life sciences laboratory program. The cost of subsystems for thermal, atmospheric and trace contaminants control of the Spacelab internal atmosphere was also estimated. Subsystem cost estimates were based on the utilization of existing components developed in previous space programs whenever necessary.
A program was successfully completed to analytically and experimentally evaluate the feasibility of using an electrochemical oxygen (O2) concentrator as an O2 compressor. The electrochemical O2 compressor (EOC) compresses 345 kN/sq m (50 psia) O2 generated on board the space vehicle by the water electrolysis subsystem (WES) in a single stage to 20,700 kN/sq m (3000 psia) to refill spent extravehicular equipment O2 bottles and to eliminate the need for high pressure O2 storage. The single cell EOC designed, fabricated, and used for the feasibility testing is capable of being tested at O2 pressures up to 41,400 kN/sq m (6000 psia). A ground support test facility to test the EOC cell was designed, fabricated, and used for the EOC feasibility testing. A product assurance program was established, implemented, and maintained which emphasized safety and materials compatibility associated with high pressure O2 operation. A membrane development program was conducted to develop a membrane for EOC application. Data obtained using a commercially available membrane were used to guide the development of the membranes fabricated specifically for an EOC. A total of 15 membranes were fabricated.
An integrated water vapor electrolysis (WVE) hydrogen depolarized CO2 concentrator (HDC) system sized for one man support over a wide range of inlet air conditions was designed, fabricated, and tested. Data obtained during 110 days of testing verified that this system can provide the necessary oxygen, CO2 removal, and partial humidity control to support one man (without exceeding a cabin partial pressure of 3.0 mmHg for CO2 and while maintaining a 20% oxygen level), when operated at a WVE current of 50 amperes and an HDC current of 18 amperes. An evaluation to determine the physical properties of tetramethylammonium bicarbonate (TMAC) and hydroxide was made. This provides the necessary electrolyte information for designing an HDC cell using TMAC.
Results of an ongoing program set up to evaluate solar terrestrial photovoltaic power sources. The results of this program, which now includes a solar array encapsulant and materials test and a solar-powered buoy study, are updated, and the results of efforts to study the dynamic interaction of a solar photovoltaic array and a water electrolysis system coupled to produce hydrogen are reported for the first time.
Safety, as a major factor in the development of a power economy based on hydrogen produced by nuclear- or solar-energy operated water electrolysis, is considered in terms of the safety problems involved in the production, handling, transportation, and use of liquid and gaseous hydrogen. These problems are reviewed through the records of accidents and incidents that have occurred in the development and operation of NASA's propulsion and power systems. Areas of research and development are suggested for increased safety and for the development of techniques to reduce the consequences of any mishaps.
This paper is a discussion of the safety and cost of underground high-pressure air and gas storage systems based on recent experience with a high-pressure air system installed at Moffett Field, California. The system described used threaded and coupled oil well casings installed vertically to a depth of 1200 ft. Maximum pressure was 3000 psi and capacity was 500,000 lb of air. A failure mode analysis is presented, and it is shown that underground storage offers advantages in avoiding catastrophic consequences from pressure vessel failure. Certain problems such as corrosion, fatigue, and electrolysis are discussed in terms of the economic life of such vessels. A cost analysis shows that where favorable drilling conditions exist, the cost of underground high-pressure storage is approximately one-quarter that of equivalent aboveground storage.
This paper presents and reviews the fundamental thermodynamic principles underlying thermochemical water splitting processes. The overall system is considered first and the temperature limitation in process thermal efficiency is developed. The relationship to an ideal water electrolysis cell is described and the nature of efficient multistage reaction processes is discussed. The importance of the reaction entropy change and the relation of the reaction free energy change to the work of separation is described. A procedure for analyzing thermochemical water splitting processes is presented and its use to calculate individual stage efficiency is demonstrated. A number of processes are used to illustrate the concepts and procedures.
A thermodynamic analysis and state-of-the-art review of three basic schemes for production of hydrogen from water: electrolysis, thermal water-splitting, and multi-step thermochemical closed cycles is presented. Criteria for work-saving thermochemical closed-cycle processes are established, and several schemes are reviewed in light of such criteria. An economic analysis is also presented in the context of energy costs.
A program to characterize a Breadboard of an Electrochemical Air Revitalization System (BEARS) was successfully completed. The BEARS is composed of three components: (1) a water vapor electrolysis module (WVEM) for O2 production and partial humidity control, (2) an electrochemical depolarized carbon dioxide concentrator module (EDCM) for CO2 control, and (3) a power-sharing controller, designed to utilize the power produced by the EDCM to partially offset the WVEM power requirements. It is concluded from the results of this work that the concept of electrochemical air revitalization with power-sharing is a viable solution to the problem of providing a localized topping force for O2 generation, CO2 removal and partial humidity control aboard manned spacecraft. Continued development of the EARS concept is recommended, applying the operational experience and limits identified during the BEARS program to testing of a one-man capacity system and toward the development of advanced system controls to optimize EARS operation for given interfaces and requirements. Successful completion of this development will produce timely technology necessary to plan future advanced environmental control and life support system programs and experiments.
Upgrading metallurgical grade silicon is being pursued in four associated areas in order to improve the purity of the normally 98% material. The first two work areas involve purification of raw materials entering the process in addition to upgrading the arc furnace itself. The second two areas of process upgrading comprise improving the purity of the silicon after it leaves the arc furnace by reactive gas blowing and unidirectional freezing. The best cell produced to date was fabricated from MG-Si that had been blown with an O2-Cl2 mixture, unidirectionally solidified, and 6-float-zone passed (to determine a base boron level of 0.04 ohm/cm). The cell showed a 10.7% AMO efficiency. In the other processes category, the use of silicates as a silicon source and of electrolysis as a process were studied. The best electrolytic process uses a 1000 C fused salt of silica in cryolite.
Future uses of hydrogen and hydrogen production processes that can meet the demand for hydrogen in the coming decades were considered. To do this, a projection was made of the market for hydrogen through the year 2000. Four hydrogen production processes were selected, from among water electrolysis, fossil based and thermochemical water decomposition systems, and evaluated, using a consistent set of ground rules, in terms of relative performance, economics, resource requirements, and technology status.
The state of hydrogen production technology is evaluated. Specific areas discussed include: hydrogen production fossil fuels; coal gasification processes; electrolysis of water; thermochemical production of hydrogen; production of hydrogen by solar energy; and biological production of hydrogen. Supply options are considered along with costs of hydrogen production.
Regenerative processes for the revitalization of spacecraft atmospheres require an Oxygen Reclamation System (ORS) for the collection of carbon dioxide and water vapor and the recovery of oxygen from these metabolic products. Three life support subsystems uniquely qualified to form such an ORS are an Electrochemical CO2 Depolarized Concentrator (EDC), a CO2 Reduction Subsystem (BRS) and a Water Electrolysis Subsystem (WES). A program to develop and test the interface hardware and control concepts necessary for integrated operation of a four man capacity EDC with a four man capacity BRS was successfully completed. The control concept implemented proved successful in operating the EDC with the BRS for both constant CO2 loading as well as variable CO2 loading, based on a repetitive mission profile of the Space Station Prototype (SSP).