Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “ELECTROLYSIS”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,567 records · Page 87
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Lunar Water Pilot Plant Conceptual Design

A study was conducted to determine mass, power, and concept of operations for a polar water pilot plant that can produce 1000 kg of oxygen in a year from 1125 kg of water extracted from the icy regolith in a permanently shadowed region(PSR). Icy regolith in the PSR is excavated and delivered to a stationary dryer that extracts the water which is frozen in an ice tanker and delivered up to the ridge for further processing into oxygen and hydrogen. This study assumed a previously landed nuclear reactor was available in the PSR to provide power for the water extraction, which requires 2.4 kW of power, including a 30 percent margin. At 325 kg, the ISRU system mass in the PSR, including the excavator, should be deliverable by one of the Commercial Lunar Payload Services (CLPS) landers, and the packaging and concept of operations are shown using one specific CLPS lander. The mass and power of the ISRU system components on the ridge for water electrolysis and liquefaction and storage of the oxygen and hydrogen are estimated at 840 kg and 4.3 kW.

Lunar↗
NASA NTRSDate not supplied

Case Study for Lunar ISRU Systems Utilizing Polar Water

In-Situ Resource Utilization (ISRU) is key to long term presence at any extraterrestrial destination. Current NASA direction is to achieve a sustainable presence on the lunar surface by 2028. Mission plans currently target the lunar South Pole to leverage the extended periods of solar illumination and allows for potential access to water ice in the permanently shadowed areas around the poles. With water, it is possible to produce both fuel and oxidizer to fully refuel a vehicle. In order to address ISRU infusion into mission planning, a study of an end-to-end ISRU propellant production system was initiated to assess ISRU architectures and obtain mass and power estimates for each. The results of these case studies will be presented. For this study, The ISRU system architecture involved two sites; the mine site in a shadowed crater where water ice is excavated and extracted from the regolith and the propellant production site at an illuminated ridge where the water is processed into liquefied O2 and H2 propellants. Fixed hardware would be emplaced at each site, with two alternating water tankers to transport water between them. Notional lunar sites were identified for this architecture for baseline environmental parameters. Technology solutions for each subsystem were selected based on those with the highest fidelity models or those that have empirical laboratory data to anchor to. While power needs were identified for each location, a power solution was not prescribed, therefore the masses presented do not include surface power systems. The baseline case in this study assumed that 10 mT of oxygen, along with enough hydrogen to support a propulsion mixture ratio of 6, must be produced in 225 days. Therefore 15 mT of water would need to be collected and processed. The baseline solution resulted in a system mass of5 mT and a total required power of 68kW. The majority of the mass was split between the ridge site system and the two water tankers (2.6 mTand 1.8mTrespectively). The majority of the required power was with three subsystems at approximately 20 kW each: hydrogen liquefaction, electrolysis, and the water extractor subsystem. Trades for four key variables are also presented, namely production rate, water concentration, dry overburden depth, and number of water transport trips. This can be compared to a system that targets oxygen from the minerals in the surface regolith material. A carbothermal reduction reactor system was used for this comparison. The use of direct solar thermal energy to process the regolith and the ease of access of the resource resulted in significantly lower values for the oxygen case: approximately 2.7 mT and 11.8 kW. However, the mass trade would favor the water case over successive missions where the hydrogen up-mass of 2 mT per mission will accrue against the oxygen system.1Aerospace Research Engineer, Chemical and Thermal Propulsion Systems Branch, Senior Member.2Mechanical Engineer, Propulsion and Power Division/Energy Conversion Systems, 2101 Nasa Pkwy/Mailcode EP3 Houston, TX 77058, AIAA member.

Lunar↗
NASA NTRS2021

Software Approach for the Regenerative Fuel Cell Project

The Regenerative Fuel Cell (RFC) project is developing a system that combines a fuel cell subsystem for energy production with an electrolysis subsystem for energy storage. The system is primarily being developed at the Glenn Research Center with support from Johnson Space Center under the Space Technology Mission Directorate / Game Changing Development Program. Currently, the intent is to operate the RFC system in an equivalent environment to a lunar equator location for a period of several lunar day/night cycles with minimal operator input. Demonstrating an automated RFC system in this environment is a step towards showing the extensibility to a flight system. This paper describes the RFC software team’s approach for development of the monitoring and control software that allows for the automated operation of the RFC system. We describe the rationale for the choice of Core Flight System architecture, as well as the plan for software/hardware integration.

Mathew J Mccaskey↗
NASA NTRSDate not supplied

Modeling Electrolytic O2 Recovery from Metabolic CO2 for Advanced Closed Loop Life Support Systems in Extraterrestrial Human Missions

The International Space Station (ISS) is currently equipped with a complex, heavy, and power consuming system that recovers approximately 50% of O2 from metabolic CO2. Future long duration human missions to the Moon and Mars will necessitate a sustainable and highly efficient metabolic oxygen recovery system capable of yielding a minimum of 75% O2 recovery. A Macrofluidic Electrochemical Reactor (MFECR) technology development effort is currently underway at NASA Marshall Space Flight Center (MSFC) to significantly increase current metabolic O2 recovery efficiency, expand mission sustainability, and reduce complexity of the system. The novel design combines CO2 conversion to O2 along with C2H4 as byproduct and water electrolysis (currently conducted in two separate units) into a single compact unit that runs at standard conditions and is theoretically capable of generating O2 with a theoretical maximum metabolic CO2 conversion of 73% while consuming less than metabolic water. This paper presents a comprehensive multi-physic 3D model developed at MSFC on CO2 conversion to O2 and C2H4 at standard conditions via MFECR. The 3D spatial domain of the model is a replica of the actual MFECR’s 3D drawing generated for the MFECR fabrication and operated to recover O2 from CO2 yielding C2H4 as byproduct. Electrochemical (EC) physics that includes EC multicomponent reaction mechanisms, mass transport, and electrical current density distributions is coupled in the model with all the other physics phenomena involved in the MFECR’s process, such as two-phase flow, free and porous fluid regimes, multicomponent mass transfer, heat transfer, and DC electrical current generation along with Joule heating effect. The EC reaction sections of the MFECR consists of two porous gas diffusion electrodes (GDE) and an electrolyte serpentine channel sandwiched in the middle. The CO2 feeds the cathode serpentine channel and part of the O2 product is fed back to the anode serpentine chamber. An alkaline solution feeds the electrolyte serpentine chamber wetting the GDEs of both, the anode and cathode allowing the OH- ionic transport between them. The EC reactions in the cathode’s GDE yield C2H4 from CO2 and H2 from water while the EC reaction in the anode’s GDE yields O2. The authors will present in this paper the validation of the model using experimental data and the utilization of the validated model in building a reliable simulator that will not only assist the authors on the MFECR design but also the optimization of its operation in the ISS and future spatial human missions.

Jesus A Dominguez↗
NASA NTRSDate not supplied

Wastewater Brine Purification and Recovery through Electrodialysis Ion Exchange

Reutilizing resources onboard the International Space Station (ISS) and for future deep space missions are critical for mission longevity and sustainability. Wastewater brine produced from water recovery systems contain chemical species that could be processed into a potential fertilizer for future plant systems. This can be achieved through a process called electrodialysis ion exchange. Wastewater containing inorganic salt components are fed through a series of ion exchange membranes to produce fertilizer (a phosphate rich stream), electrolysis-grade water, and other useful commodities. Electrodialysis cells consisting of anion and cation exchange membranes, monovalent anion exchange membranes, and bipolar membranes were utilized to achieve selective ion exchange. The use of the electrodialysis cells were effective for both water extraction and ion separation. Ions successfully diffused across their respective membranes into the concentrate, acid, and base streams. This resulted in pure water, a phosphate rich stream, and a separate anion/hydrogen and cation/hydroxide stream. However, sulfate and some phosphate ions were able to diffuse through the monovalent anion exchange membrane into the acid stream. This resulted in predominantly phosphate ions remaining in the concentrate. Optimization of the process was accomplished by altering flowrates of each stream and initial volumes, adjusting the power input and resulting current through each cell, and varying the starting parameters by splitting the inorganic waste input into the diluate and the concentrate. As expected, increasing the flowrate and the power input to each cell reduced the overall time of the process. However, mission constraints may require a longer duration process in order to reduce the power consumption. Further analysis will be required to determine the power input necessary to achieve ion diffusion effectively and in a timely manner.

Ion Exchange Membranes↗
NASA NTRSDate not supplied

Status of the Advanced Oxygen Generation Assembly Design

Future Exploration missions will require an Oxygen Generation Assembly (OGA) to electrolyze water to supply oxygen for crew metabolic consumption. The system design will be based on the International Space Station (ISS) OGA but with added improvements based on lessons learned during ISS operations and technological advances since the original OGA was designed and built. The goal of these improvements will be to reduce system weight, crew maintenance time and spares mass while increasing reliability. Over the past year, the team has performed additional design reviews, testing and analysis in an effort to optimize upgrade efforts and achieve the best value that meets Exploration mission requirements. Upgrades that will be incorporated include: redesign of the electrolysis cell stack, redesign of the hydrogen dome, replacement of the hydrogen sensors, redesign of the recirculation loop deionizing bed, and incorporation of recirculation loop nitrogen purging and water flushing. The ISS OGA will be upgraded to an Advanced OGA (AOGA) configuration and its operation demonstrated in a relevant flight environment.

Oxygen Generation Assembly↗
NASA NTRSDate not supplied

Ice Growth Model and Lunar Tanker for Polar Water Extraction

In-Situ Resource Utilization (ISRU) is a major component of sustainable and cost-effective missions to the Moon and beyond. Ever since it has been identified in the Permanently Shadowed Regions (PSRs) of the Moon, water has become a resource of interest for it’s wide range of uses such as life support and hydrogen and oxygen rocket propellant. It is ice-bound in the regolith, so separation typically involves heating to sublimation temperatures and capturing at very low pressure. One option is to then store it in ice form and transport it out of the PSR and into a sunlit ridge. From here, processes such as electrolysis can be performed. An understanding of frost growth dynamics under rarefied conditions is necessary for successful water production, though. An analytical model was developed using a Diffusion-Limited Aggregation (DLA) approach to evaluate bulk thermal conductivity changes of frost under varying conditions. This model will be evaluated using a one-dimensional frost growth experiment on a horizontal, flat plate under vacuum and cryogenic conditions. The tests will measure frost growth rate and bulk density, and the thermal conductivity of the ice layer as a function of thickness for different plate temperatures. The test data will then be used to validate and improve the analytical model.

Lunar water↗
NASA NTRSDate not supplied

Analysis of Oxygen Liquefaction with Transient Flow Rates for ISRU Systems

Human occupation of lunar and Martian surfaces requires in-situ resource utilization (ISRU) to create a sustainable environment with the limited resources available in space. Fuel and oxidizer generation is essential for developing a refueling capability for spacecraft, significantly reducing the propellant mass required for landing. Liquefaction systems are a key step in producing and storing cryogenic liquids such as oxygen, hydrogen, and methane. All those fluids are critical to propulsion, life support, and other spacecraft systems. NASA has previously confirmed the presence of water on the Moon and an electrolysis process can be used to separate the oxygen from the hydrogen molecules. Oxygen has also been found within lunar regolith and can be separated through ISRU processes. The extracted oxygen gas can then be liquefied inside a storage tank with tube-on-tank heat exchangers for future use as an oxidizer for propellants. While steady state liquefaction performance is easy to model, power limitations and cyclical environments caused by the change in Sun exposure between day and night periods potentially call for transient operations. The following analysis was performed using the Thermal Desktop software to investigate how various transient gaseous oxygen (GOX) flow rates impact the production and storage of liquid oxygen (LOX) in a 1-g liquefaction system. Variations of sinusoidal and exponential step functions were selected to model potential GOX flow rates that could be experienced by ISRU systems on lunar or Martian surfaces. This early computational analysis provides some insight on how transient operations impact oxygen liquefaction systems and helps illustrate operational questions to explore experimentally throughout the design process.

Cryogenic Fluid Management↗
NASA NTRSDate not supplied

Ice Growth Model for Polar Water Capture Systems

In-situ resource utilization (ISRU) is essential to NASA’s goal of sustainable and cost-effective missions to the Moon and beyond. Water has become a particular source of interest since its discovery in the permanently shadowed regions (PSRs) of the Moon. This water exists as ice bound within the regolith, so one mode of capture is heating to sublimation temperatures and capturing at very low pressure. It then can be stored in ice form and transported out of the PSR and to a sunlit ridge, where processes such as electrolysis can be performed[2]. An understanding of frost growth dynamics under rarefied conditions is necessary for successful water capture and storage due to transient thermal properties of frost. A Diffusion-Limited Aggregation (DLA) approach was taken to analytically model bulk thermal conductivity changes of the growing frost layer under varying wall temperatures and frost layer porosities. The model utilizes well-known correlations for effective thermal conductivity and records the values as the frost layer thickness increases. This thermal conductivity can be applied to a known temperature change and be used to evaluate heat flux through the combined frost layer and tank wall for either a flat plate or cylindrical geometry. An experiment is described that will evaluate this model using one-dimensional frost growth on a horizontal, flat plate under low-pressure. The ice growth will be measured using a millimeter-scale photogrammetry camera system and a load cell measured transient mass growth.

In situ Resource Utilization↗
NASA NTRSDate not supplied

Ice Growth Model for Polar Water Capture Systems

In-situ resource utilization (ISRU) is essential to NASA’s goal of sustainable and cost-effective missions to the Moon and beyond. Water has become a particular source of interest since its discovery in the permanently shadowed regions (PSRs) of the Moon. This water exists as ice bound within the regolith, so one mode of capture is heating to sublimation temperatures and capturing at very low pressure. It then can be stored in ice form and transported out of the PSR and to a sunlit ridge, where processes such as electrolysis can be performed[2]. An understanding of frost growth dynamics under rarefied conditions is necessary for successful water capture and storage due to transient thermal properties of frost. A Diffusion-Limited Aggregation (DLA) approach was taken to analytically model bulk thermal conductivity changes of the growing frost layer under varying wall temperatures and frost layer porosities. The model utilizes well-known correlations for effective thermal conductivity and records the values as the frost layer thickness increases. This thermal conductivity can be applied to a known temperature change and be used to evaluate heat flux through the combined frost layer and tank wall for either a flat plate or cylindrical geometry. An experiment is described that will evaluate this model using one-dimensional frost growth on a horizontal, flat plate under low-pressure. The ice growth will be measured using a millimeter-scale photogrammetry camera system and a load cell measured transient mass growth.

ice growth↗
NASA NTRS2022

Aerospace Regenerative Fuel Cell Fluidic Component Design Challenges

A discrete regenerative fuel cell (RFC) system is currently under development at the NASA Glenn Research Center and Johnson Space Center. The objective of this activity is to produce an energy storage system with a higher specific energy (W·hr/kg) than the state-of-the-art battery technologies then test that system within an environment simulating the temperatures and pressures expected over a full lunar day cycle on the lunar surface. The system is designed to be as flight-like as possible given resource and commercially available technology limitations. The RFC system is comprised of a fuel cell power system, a high pressure electrolysis system, fluidic and electronic balance of plant systems, avionics, power management and distribution system, and software. This technical memorandum discusses components and subsystems that present challenges in developing flight ready RFCs. To remedy identified issues, functional application test plans are presented for components and subsystems primarily constructed with commercially available options due to the budget and schedule constraints of this ground technology demonstration project.

fuel cell↗
NASA NTRSDate not supplied

Status of ISS Water Management and Recovery

Water management on ISS is responsible for the provision of water to the crew for drinking water, food preparation, and hygiene, to the Oxygen Generation System (OGS) for oxygen production via electrolysis, to the Waste & Hygiene Compartment (WHC) for flush water, and for experiments on ISS. This paper summarizes water management activities on the ISS US Segment as of March 2022 and provides a status of the performance and issues related to the operation of the Water Processor Assembly (WPA) and Urine Processor Assembly (UPA).

Water Recovery System↗
NASA NTRSDate not supplied

Overview of NASA's RESOURCE (Resource Exploration and Science of OUR Cosmic Environment) Project

The RESOURCE(Resource Exploration and Science of OUR Cosmic Environment) project is supported by NASA’s SSERVI (Solar System Exploration Research Virtual Institute) and is led by Principal Investigator (PI) Dr. Jennifer L. Heldmann and Deputy PIs Dr. Matthew Deans and Dr. Alexander Sehlke at NASA Ames Research Center. RESOURCE is focused on enabling In Situ Resource Utilization (ISRU) near the sites of robotic and/or human missions to enable sustainable and affordable exploration of the Moon and near-Earth objects (NEOs). This year RESOURCE has supported the development of a summary of the current state of knowledge regarding lunar polar volatiles as well as a comprehensive catalog and analysis of NEOs. RESOURCE is developing advanced mission capabilities to enable rapid, collaborative operations for lunar resource exploration missions. Hardware testing has been conducted to evaluate potential contaminants released during lunar polar regolith heating. Volatiles and particulates are the two sources of contamination that will affect the requirements of a water cleanup system, and RESOURCE research has identified the requirement for filtration prior to electrolysis for ISRU. RESOURCE also supports development of next-generation planetary drilling systems with integrated instrumentation within the drill. RESOURCE is also deeply committed to sustained efforts to engage educators, students, and broadening participation among under represented groups, and has partnered with Howard University in Washington, DC to foster minoritized students’ interest in STEAMD (science, technology, engineering, arts, math, design) careers through direct and virtual experiences with NASA Subject Matter Experts.

Jennifer L Heldmann↗
NASA NTRSDate not supplied

Fixed-Bed Columns for Adsorption of C2H2 in Metal Organic Frameworks for Hydrogen Recovery in Long-Duration Human Space Flight

To live and work in space, astronauts must have a breathable atmosphere. Current life support system technology utilizes the electrolysis of water to recover O2 as the main method of Oxygen recovery. In addition, the Sabatier Reaction is used to recover H2O from the CO2 produced by human respiration. The current atmosphere revitalization architecture onboard the International Space Station (ISS) has an efficiency of approximately 54% oxygen recovery. Therefore, these systems require substantial resupplies of water to sustain this environment, which make long-duration space flight missions, such as Martian transit, expensive and difficult. In order to support these missions, oxygen recovery must exceed 75-90% efficiency. Additional research has shown that with the addition of a Plasma Pyrolysis system, CH4 produced by the Sabatier reaction may be broken down into H2 and C2H2 and the H2 may be recycled. However, the Hydrogen must be separated from the highly volatile C2H2. There are many potential separation methods. A promising method includes the adsorption of the C2H2 into Metal Organic Frameworks (MOFs) using Vacuum Swing Adsorption. Due to the fragile nature of the MOFs and hazards present in producing C2H2, the columns must have a design that is compatible to both materials and that has the potential to operate in extraterrestrial environments. Successful design and testing of this Hydrogen separation system would allow the PPA to be fully integrated into the current oxygen regeneration system, resulting in a theoretical O2 recovery of 91.3%.

Hannah K Davis↗
NASA NTRSDate not supplied

Status of ISS Water Management and Recovery

Water management on ISS is responsible for the provision of water to the crew for drinking water, food preparation, and hygiene, to the Oxygen Generation System (OGS) for oxygen production via electrolysis, to the Waste & Hygiene Compartment (WHC) for flush water, and for experiments on ISS. This paper summarizes water management activities on the ISS US Segment as of March 2022 and provides a status of the performance and issues related to the operation of the Water Processor Assembly (WPA) and Urine Processor Assembly (UPA).

Water Recovery↗
NASA NTRSDate not supplied

Status of the Advanced Oxygen Generation Assembly

Future Exploration missions will require an Oxygen Generation Assembly (OGA) to electrolyze water to supply oxygen for crew metabolic consumption. The system design will be based on the International Space Station (ISS) OGA but with added improvements based on lessons learned during ISS operations and technological advances since the original OGA was designed and built. The goal of these improvements will be to reduce spares mass and crew maintenance time while increasing reliability. Over the past year, the team has performed additional design reviews, testing and analysis in an effort to optimize upgrade efforts and achieve the best value that meets Exploration mission requirements. Upgrades that will be incorporated include: redesign of the electrolysis cell stack, redesign of the hydrogen dome, replacement of the hydrogen sensors, redesign of the recirculation loop deionizing bed, and incorporation of recirculation loop nitrogen purging and water flushing. The ISS OGA will be upgraded to an Advanced OGA (AOGA) configuration and its operation demonstrated in a relevant flight environment.

ECLSS↗
NASA NTRS2021

Aqua Factorem: Ultra Low Energy Lunar Water Extraction

We propose a new method we call Aqua Factorem to extract lunar water. It will drastically reduce energy and complexity of lunar mining operations helping to establish this industry. Other methods to extract water from the regolith are based on phase change, pumping energy into the regolith to sublimate the ice into vapor, then capturing the vapor, re-freezing it, and hauling the solid ice to a chemical processor where it is converted again into vapor for purification then electrolysis. This requires transporting high power into the permanently shadowed regions (PSRs) not only to vaporize the ice in situ in the soil but to heat the surrounding soil itself, which is wasted energy. Still other methods are based on strip mining and hauling the resource along with slag (the unwanted silicates, which constitutes about 95% of the mass), to a processing unit that is located outside the PSRs. That may be a simpler architecture but is generally not favored because hauling 49,000 t of regolith over many kilometers yearly to produce the projected demand of 2,450 t of propellant would be terribly difficult and expensive with high risk that the vehicles will get stuck driving with such loads across the unprepared regolith. We propose an alternative to both of these approaches, taking advantage of the processing that the unique lunar geology has already performed. Micrometeoroid bombardment has already broken most solid material in the upper part of the regolith into fine grains. This includes solid material of all compositions, including the ice, which is as hard as granite at PSR temperatures and is therefore essentially another type of rock. These ice grains are intermixed with all the other minerals, so a simple, ultra-low-energy grain-sorting process can extract the ice without phase change. As another benefit it can extract the 1 wt% free metal known to be in lunar soil, again with very little energy. The ice can then be hauled to the chemical processing unit in solid phase and converted into rocket propellant. We estimate the 800 kW power needed for thermal extraction can be reduced to less than 100 watts using the new method. This affects the entire architecture of the mining operation producing extensive economic benefit, which we will quantify in this study. We will study it in the context of a mission to mine propellants commercially for space tugs that boost commercial communication satellites from Geosynchronous Transfer Orbit (GTO) to Geostationary Orbit (GEO) then return to the lunar surface for refueling. This simple architecture requires the minimum number of in-space elements, and notably does not require an in-space propellant depot, so it provides the lowest cost and lowest risk startup for a commercial operation. The study will also test the innovative Aqua Factorem process through laboratory experiments, and this will produce basic insights into the handling of lunar resources.

lunar↗
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↗