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NASA NTRSDate not supplied

Status of the Four Bed Carbon Dioxide Scrubber ISS Technology Demonstration

The Four Bed Carbon Dioxide Scrubber flight demonstration is presently operating onboard the International Space Station. After being launched in August and activated in September 2021, the system has been removing metabolic CO2 from the cabin as a supplement and replacement for other CO2 removal systems, specifically the two Carbon Dioxide Removal Assemblies. This paper describes on-orbit operations and changes (including installation of the Calnetix blower) during 2022 and early 2023. Performance of the system especially as affected by changes in the on-orbit configuration will be described. System reliability, software changes, and ongoing efforts will be summarized.

Life Support↗

NASA NTRS2016

Filtration of Carbon Particulate Emissions from a Plasma Pyrolysis Assembly

NASA is investigating plasma pyrolysis as a candidate technology that will enable the recovery of hydrogen from the methane produced by the ISS Sabatier Reactor. The Plasma Pyrolysis Assembly (PPA) is the current prototype of this technology which converts the methane product from the Carbon Dioxide Reduction Assembly (CRA) to acetylene and hydrogen with 90% or greater conversion efficiency. A small amount of solid carbon particulates are generated as a side product and must be filtered before the acetylene is removed and the hydrogen-rich gas stream is recycled back to the CRA. We discuss developmental work on several options for filtering out the carbon particulate emissions from the PPA exit gas stream. The filtration technologies and concepts investigated range from fibrous media to monolithic ceramic and sintered metal media. This paper describes the different developed filter prototypes and characterizes their performance from integrated testing at the Environmental Chamber (E-Chamber) at MSFC. In addition, characterization data on the generated carbon particulates, that help to define filter requirements, are also presented.

methane↗

NASA NTRS2015

Microlith-Based Catalytic Reactor for Air Quality and Trace Contaminant Control Applications

Traditionally, gaseous compounds such as methane, carbon monoxide, and trace contaminants have posed challenges for maintaining clean air in enclosed spaces such as crewed spacecraft cabins as they are hazardous to humans and are often difficult to remove by conventional adsorption technology. Catalytic oxidizers have provided a reliable and robust means of disposing of even trace levels of these compounds by converting them into carbon dioxide and water. Precision Combustion, Inc. (PCI) and NASA - Marshall (MSFC) have been developing, characterizing, and optimizing high temperature catalytic oxidizers (HTCO) based on PCI's patented Microlith® technology to meet the requirements of future extended human spaceflight explorations. Current efforts have focused on integrating the HTCO unit with a compact, simple recuperative heat exchanger to reduce the overall system size and weight while also reducing its energy requirements. Previous efforts relied on external heat exchangers to recover the waste heat and recycle it to the oxidizer to minimize the system's power requirements; however, these units contribute weight and volume burdens to the overall system. They also result in excess heat loss due to the separation of the HTCO and the heat recuperator, resulting in lower overall efficiency. Improvements in the recuperative efficiency and close coupling of HTCO and heat recuperator lead to reductions in system energy requirements and startup time. Results from testing HTCO units integrated with heat recuperators at a variety of scales for cabin air quality control and heat melt compactor applications are reported and their benefits over previous iterations of the HTCO and heat recuperator assembly are quantified in this paper.

Vilekar, Saurabh↗

DOE OSTI2025

Techno-Economic Analysis of Sorbent-Based Direct Air Capture Informed by EPC Input and Recent Technological Advancements

Direct air capture (DAC) technology has been developing at an accelerated rate. Independent, comprehensive, and transparent techno-economic analyses (TEAs) of DAC technologies are required to inform future development. NETL is publishing an update to the 2022 sorbent-based DAC case study report. This manuscript highlights select TEA results that will be presented in the upcoming NETL report. The analysis considers three sorbent-based DAC system configurations (direct steam temperature swing, indirect steam temperature swing, and direct steam temperature/vacuum swing) and two scenarios for providing the required electricity and steam (stand-alone system with a combined heat and power plant generating the required steam and electricity, and a purchased power case utilizing an electric boiler). Detailed sensitivity analyses are included and highlight the impact of external market factors, sorbent performance, and economies of scale. The potential for cost reductions by opting for temperature vacuum swing adsorption is highlighted. More detailed background and TEA results will be presented in the upcoming NETL report titled “Direct Air Capture Case Studies: Sorbent System (Revision 1)”.

carbon dioxide removal↗

NASA NTRS2021

Analytical Methods and Testbeds for Characterizing Adsorbents and Catalysts for Atmosphere Revitalization of Crewed Spacecraft

Spacecraft environmental control and life support systems (ECLSS) include a number of air revitalization (AR) technologies to provide breathable air and a comfortable living environment to the crew. Crew health and comfort is ensured by controlling human produced CO2 (1 kg person-1 day-1) and water vapor (~2 kg person-1 day-1), and by removing trace contaminants (TCs) from cabin air. These life support functions on-board the International Space Station (ISS) are carried out by the Carbon Dioxide Removal Assembly (CDRA), the Water Processor Assembly (WPA), and the trace contaminant control system (TCCS). During the development of the TCCS, new analytical and theoretical methods were developed in the 1970s for characterizing adsorption and desorption characteristics of activated carbons for the purpose of designing suitable AR technologies required for controlling airborne trace contaminants within spacecraft cabins during long exploration missions. The TCCS removes harmful volatile organic compounds and other trace contaminants from the circulating air. It consists of a granular activated carbon (GAC) bed for the removal of high molecular weight contaminants and ammonia followed by a heated catalytic bed for low molecular weight hydrocarbons. The high temperature catalytic oxidizer (HTCO) of the TCCS, which operates at 400°C and requires 120W average power, removes low molecular weight compounds such as carbon monoxide (CO), formaldehyde (CH2O), and methane (CH4), that pass through the GAC bed. The Air Revitalization Laboratory at the Kennedy Space Center (KSC) was established to develop new analytical methods for evaluating emerging ECLSS technologies for use in future AR architectures. General properties of adsorbents and catalysts are required for trace contaminant control system design calculations and vendor-supplied data are seldom available at relevant process conditions of interest to spacecraft cabin applications. To address this shortcoming, appropriate testbeds were developed to measure the desired properties of AR technologies being considered for use in ECLS architectures. Generally, the testbeds developed at KSC challenge the test media (activated carbon, impregnated activated carbon, catalysts, zeolites, solid amines, or pleated filters) with simulated spacecraft gas streams containing representative mixtures of trace contaminants (volatile organic compounds, ammonia, CO, CO2, or siloxanes) at the flow rates, temperatures, and relative humidity that will be encountered within manned spacecraft. Work performed at KSC funded by NASA’s Advanced Exploration (AES) Program has included: Identifying candidate sorbents to replace commercially obsolete impregnated carbons for NH3 control within the TCCS, characterizing their adsorptive capacities using simulated spacecraft gas streams, and ranking their appropriateness in various AR applications; evaluating novel low temperature catalysts for controlling CO and formaldehyde by traditional and photocatalytic methods for trace contaminant control; development of analytical methods to assess regenerable solid amine performance for CO2 control via pressure swing adsorption. The Air Revitalization lab was also funded to study trace contaminant control by other NASA programs. These include: screening of candidate sorbents for the design of new Charcoal HEPA Integrated Particle Scrubber (CHIPS) filters for removing siloxanes from cabin air; characterizing the performance of an impregnated activated carbon at low humidity for use in ORION ECLS; screening of sorbents for protecting the Sabatier 2.0 catalyst from DMSO2, siloxanes, NH3, and solid amine byproducts.

Monje, Oscar↗

NASA NTRSDate not supplied

Status of the Four Bed Carbon Dioxide Scrubber ISS Technology Demonstration 2022-2023

Life Support↗

NASA NTRS2013

Commercial Non-Dispersive Infrared Spectroscopy Sensors for Sub-Ambient Carbon Dioxide Detection

Carbon dioxide produced through respiration can accumulate rapidly within closed spaces. If not managed, a crew's respiratory rate increases, headaches and hyperventilation occur, vision and hearing are affected, and cognitive abilities decrease. Consequently, development continues on a number of CO2 removal technologies for human spacecraft and spacesuits. Terrestrially, technology development requires precise performance characterization to qualify promising air revitalization equipment. On-orbit, instrumentation is required to identify and eliminate unsafe conditions. This necessitates accurate in situ CO2 detection. Recursive compensation algorithms were developed for sub-ambient detection of CO2 with commercial off-the-shelf (COTS) non-dispersive infrared (NDIR) sensors. In addition, the source of the exponential loss in accuracy is developed theoretically. The basis of the loss can be explained through thermal, Doppler, and Lorentz broadening effects that arise as a result of the temperature, pressure, and composition of the gas mixture under analysis. The objective was to develop a mathematical routine to compensate COTS CO2 sensors relying on NDIR over pressures, temperatures, and compositions far from calibration conditions. The routine relies on a power-law relationship for the pressure dependency of the sensors along with an equivalent pressure to account for the composition dependency. A Newton-Raphson iterative technique solves for actual carbon dioxide concentration based on the reported concentration. Moreover, first principles routines were established to predict mixed-gas spectra based on sensor specifications (e.g., optical path length). The first principles model can be used to parametrically optimize sensors or sensor arrays across a wide variety of pressures/temperatures/ compositions. In this work, heuristic scaling arguments were utilized to develop reasonable compensation techniques. Experimental results confirmed this approach and provided evidence that composition broadening significantly alters spectra when pressure is reduced. Consequently, a recursive compensation technique was developed with the Newton-Raphson method, which was subsequently verified through experimentation.

Swickrath, Michael J.↗

NASA NTRS2016

Advanced Supported Liquid Membranes for Carbon Dioxide Control in Cabin Applications

The development of new, robust, life support systems is critical to NASA's continued progress in space exploration. One vital function is maintaining the carbon dioxide (CO2) concentration in the cabin at levels that do not impair the health or performance of the crew. The CO2 removal assembly (CDRA) is the current CO2 control technology on-board the International Space Station (ISS). Although the CDRA has met the needs of the ISS to date, the repeated cycling of the molecular sieve sorbent causes it to break down into small particles that clog filters or generate dust in the cabin. This reduces reliability and increases maintenance requirements. Another approach that has potential advantages over the current system is a membrane that separates CO2 from air. In this approach, cabin air contacts one side of the membrane while other side of the membrane is maintained at low pressure to create a driving force for CO2 transport across the membrane. In this application, the primary power requirement is for the pump that creates the low pressure and then pumps the CO2 to the oxygen recovery system. For such a membrane to be practical, it must have high CO2 permeation rate and excellent selectivity for CO2 over air. Unfortunately, conventional gas separation membranes do not have adequate CO2 permeability and selectivity to meet the needs of this application. However, the required performance could be obtained with a supported liquid membrane (SLM), which consists of a microporous material filled with a liquid that selectively reacts with CO2 over air. In a recently completed Phase II SBIR project, Reaction Systems, Inc. fabricated an SLM that is very close to meeting permeability and selectivity objectives for use in the advanced space suit portable life support system. This paper describes work carried out to evaluate its potential for use in spacecraft cabin application.

Wickham, David T.↗

NASA NTRS1997

Adsorption and Processes in Spacecraft Environmental Control and Life Support Systems

The environmental control and life support system on a spacecraft must maintain a safe and comfortable environment in which the crew can live and work. The system's functions include supplying the crew with oxygen and water, as well as removing carbon dioxide, water vapor, and trace contaminants from cabin air. Although open-loop systems have been used in the past, logistics and safety factors of current and future missions in space make near-complete recycling of the cabin's air and water desirable. The recycling process may include separation and reduction of carbon dioxide, removal of trace gas-phase contaminants, recovery and purification of humidity condensate, purification and polishing of wastewater streams, and other processes. Several of these operations can be performed totally or in part by adsorption processes. Adsorption processes are frequently good candidates for separation and purification in space by virtue of such characteristics as gravity independence, high reliability, relatively high energy efficiency, design flexibility, technological maturity, and regenerability. For these reasons, adsorption has historically played a key role in life support on U.S. and Russian piloted spacecraft. This article focuses on three current spacecraft life support applications that often use adsorption technology: carbon dioxide separation from cabin air, gas-phase trace contaminant control, and potable water recovery from waste streams. In each application, adsorption technology has been selected for use on the International Space Station. The requirements, science, and hardware for each application are discussed. Eventually, human space exploration may lead to construction of planetary habitats. These habitats may have additional applications, such as control of greenhouse gas composition and purification of hydroponic solutions, and may have different requirements and resources available to them, such as gases present in the planetary atmosphere. Adsorption separation and purification processes may continue to fulfill environmental control and life support needs well into the future.

Dall-Bauman, Liese↗

NASA NTRS2007

Application of Vacuum Swing Adsorption for Carbon Dioxide and Water Vapor Removal from Manned Spacecraft Atmospheres

The design and testing of a vacuum-swing adsorption process to remove metabolic 'water and carbon dioxide gases from NASA's Orion crew exploration vehicle atmosphere is presented. For the Orion spacecraft, the sorbent-based atmosphere revitalization (SBAR) system must remove all metabolic water, a technology approach 1Lhathas not been used in previous spacecraft life support systems. Design and testing of a prototype SBAR in sub-scale and full-scale configurations is discussed. Experimental and analytical investigations of dual-ended and single-ended vacuum desorption are presented. An experimental investigation of thermal linking between adsorbing and desorbing columns is also presented.

Knox, J.↗

DOE OSTI2024

Demonstration of a Continuous Motion Direct Air Capture System

Global Thermostat (GT) has developed a process that addresses the primary technical challenges associated with direct air capture (DAC): the ability to process enormous volumetric flowrates of air and provide the energy for regeneration at acceptable cost. However, at current, there is opportunity for improvement in overall capture costs and especially in capital costs. While GT has advanced its base technology to TRL levels supporting commercial deployments, its research strategy includes alternative technology embodiments that enable substantial reductions in the cost per tonne of CO 2 removed. The objective of this project is to advance the most promising of these embodiments, where a DAC plant is operated in a continuous fashion rather than a discrete stepwise fashion (GT’s commercial scale technology approach). The Continuous Motion Direct Air Capture (cDAC) System’s advantages over the GT baseline stepwise DAC platform have been proposed primarily as a reduction in the complexity required for starting and stopping a movement system, relaxing requirements for other components designed for a rapid switching application, and a flattening of the sharp instantaneous fluid flowrates into steady-state mass & energy flows to enable smoother operation and easier heat integration. These advantages can lead to shorter cycle times, greater plant reliability, and lower capital expense. The primary objective of this project is the design, construction, commissioning, and operation of a field-test unit (FTU) at a scale in the range of ~200 tons CO 2 per year. Data generated from the operation campaign would then be used in a prescreening techno-economic analysis (TEA) and life cycle analysis (LCA), allowing this process to be compared to other carbon capture technologies.

42 ENGINEERING↗

DOE OSTI2022

Process Simulations Reveal the Carbon Dioxide Removal Potential of a Process That Mineralizes Industrial Waste Streams via an Ion Exchange-Based Regenerable pH Swing

Not provided.

Chemistry↗

NASA NTRS1982

Advanced CO2 removal process control and monitor instrumentation development

A progam to evaluate, design and demonstrate major advances in control and monitor instrumentation was undertaken. A carbon dioxide removal process, one whose maturity level makes it a prime candidate for early flight demonstration was investigated. The instrumentation design incorporates features which are compatible with anticipated flight requirements. Current electronics technology and projected advances are included. In addition, the program established commonality of components for all advanced life support subsystems. It was concluded from the studies and design activities conducted under this program that the next generation of instrumentation will be greatly smaller than the prior one. Not only physical size but weight, power and heat rejection requirements were reduced in the range of 80 to 85% from the former level of research and development instrumentation. Using a microprocessor based computer, a standard computer bus structure and nonvolatile memory, improved fabrication techniques and aerospace packaging this instrumentation will greatly enhance overall reliability and total system availability.

Heppner, D. B.↗

NASA NTRS2018

Plasma Methane Pyrolysis for Spacecraft Oxygen Loop Closure

Life support is a critical function of any crewed space vehicle or habitat. Human life support systems on the International Space Station (ISS) include a number of atmosphere revitalization (AR) technologies to provide breathable air and a comfortable living environment to the crew. The Trace Contaminant Control System removes harmful volatile organic compounds and other trace contaminants from the circulating air. The Carbon Dioxide Removal Assembly (CDRA) removes metabolic carbon dioxide (CO2) and returns air to the cabin. Humidity is kept at comfortable levels by a number of condensing heat exchangers. The Oxygen Generation Assembly (OGA) electrolyzes water to produce oxygen for the crew and hydrogen (H2) as a byproduct. A Sabatier reaction-based CO2 Reduction Assembly (CRA) was launched to the ISS in 2009 and became fully operational in June 2011.The CRA interfaces with both the OGA and CDRA. Carbon dioxide from the CDRA is compressed and stored in tanks until hydrogen is available from OGA water electrolysis. When the OGA is operational and there is CO2 available, the CRA is activated and produces methane and water via the Sabatier reaction shown in Equation 1... One approach to achieve these higher recovery rates builds upon the ISS AR architecture and includes adding a methane post-processor to recover H2 from CRA methane. NASA has been developing the Plasma Pyrolysis Assembly (PPA) to fill the role of a methane post-processor.

Greenwood, Z. W.↗

DOE OSTI2023

Mission Analysis for Marine Renewable Energy to Provide Power for Marine Carbon Dioxide Removal

The mission of this project was to provide a preliminary feasibility assessment of powering different marine carbon dioxide removal (mCDR), marine carbon capture, and marine carbon sequestration strategies with marine energy. In this report, carbon capture refers to methods that can separate or capture carbon dioxide (CO 2 ) from the air or ocean; carbon sequestration refers to methods that store CO 2 obtained by capture methods out of the atmosphere for long periods of time; and carbon dioxide removal (CDR) refers to methods that do both. The project found that mCDR powered by marine energy and offshore wind energy available in the United States could meet global CDR scales needed by 2040 and 2050 to limit warming to 1.5 degrees C by 2100. Note that this preliminary estimate assumes that it is possible to harvest all the marine and offshore wind resources available in the United States with existing technology options, and it does not account for the power needed for monitoring these methods, as these power needs are not yet well defined and require further research. Additionally, these CDR scales will still require emissions reductions.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Advancing a Low-Temperature, Low-Cost Direct Air Capture System Based on Organic Chemistry

Holocene Climate Corporation (Holocene) partnered with Oak Ridge National Laboratory (ORNL) to conduct bench-scale testing of a new optimized Direct Air Capture (DAC) process to assist the U.S. Department of Energy (DOE) in achieving the Carbon Negative Shot target of under $\$$100/net tonne CO₂ removed by 2031. Holocene’s DAC process for carbon dioxide (CO₂) removal uses amino acids and guanidine compounds, an ORNL-invented chemical process and licensed by Holocene. Holocene will use this novel chemistry to develop a new process and deploy the technology commercially.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Monitoring and control of atmosphere in a closed environment

Applications requiring new technologies for atmosphere monitoring and control in the closed environment and their principal functions aboard the Space Station Freedom are described. Oxygen loop closure, involving the conversion of carbon dioxide to oxygen; carbon dioxide reduction and removal; and monitoring of atmospheric contamination are discussed. The Trace Contaminant Monitor, the Major Constituent Analyzer, the Carbon Dioxide Monitor, and the Particulate Counter Monitor are discussed.

Humphries, R.↗

DOE OSTI2026

A Review on Direct Air Capture of Carbon Dioxide: Sorbent Materials, Process Engineering, Industrial Scale-Up, and Future Perspectives

The relentless accumulation of anthropogenic greenhouse gases has driven atmospheric carbon dioxide concentrations to approximately 426 ppm, necessitating the aggressive deployment of negative-emission technologies to achieve net zero by 2050. Direct air capture (DAC) offers a scalable, location-independent approach to atmospheric carbon removal; however, it is fundamentally constrained by the significant thermodynamic barriers associated with capturing CO 2 from ultradilute ambient conditions, requiring minimum thermodynamic energy inputs substantially higher than those for postcombustion point sources. This comprehensive review critically examines the technological landscape of DAC, focusing on the interdependent triad of sorbent material design, contactor engineering, and regeneration thermodynamics. We evaluate the fundamental boundaries of adsorption, emphasizing that an optimal adsorption enthalpy and isosteric heat of adsorption must balance the high CO 2 uptake capacity with the energetic penalties of sorbent regeneration. A systematic, comparative analysis of state-of-the-art sorbents is presented, encompassing mesoporous silicas, zeolites, carbon-based materials (CBMs), metal−organic frameworks (MOFs), porous organic polymers (POPs), and polymeric membranes. Special attention is devoted to surface functionalization strategies, particularly amine grafting and impregnation, which transition capture mechanisms from physisorption to chemisorption to enhance selectivity under ambient moisture and low partial pressures. Furthermore, we assess the operational merits of various reactor configurations, including gas−solid, gas−liquid, and membrane contactors, alongside regeneration cycles such as temperature, vacuum, pressure, and moisture swing adsorption. Finally, the review bridges fundamental materials science with industrial application by chronicling the scale-up milestones of pioneering entities and providing a strategic roadmap for advancing DAC technology readiness levels toward global deployment.

Adsorption↗