prototype development of an integrated mars atmosphere and soil processing system
DESCRIPTION
NASA multicenter effort to design and build an integrated system for processing representative Martian Atmosphere and Soil. Presented at the Earth & Space 2012 conference in Pasadena CA.TRANSCRIPT
Prototype Development of an Integrated Mars Atmosphere and
Soil Processing System
Michael Interbartolo IIIMARCO POLO Project Manager
NASA - JSC
• Mars Atmosphere and Regolith COllector/PrOcessor for Lander Operations
• First generation integrated Mars soil and atmospheric processing system with mission relevant direct current power– 10 KW Fuel Cell for 14 hrs of daytime operations– 1KW Fuel Cell for 10 hrs of night time operations
• Demonstrates closed loop power production via the combination of a fuel cell and electrolyzer.– The water we make and electrolyze during the day is the
consumables for the 1KW Fuel Cell that night• Planned for remote and autonomous operations
What is MARCO POLO?
• While NASA Design Reference Architecture 5.0 showed that production of propellants and life support consumables was a mission enabling capability, mission planners were hesitant to select the newly proposed water extraction from Mars soil option due to the perceived high risk associated with this approach.
• To overcome resistance in putting ISRU capabilities in the critical path of mission success, NASA ISRU developers have adopted the approach of designing and building hardware into end-to-end systems at representative mission scales and testing these systems under mission relevant conditions at analog field test sites.– In the past used large components that were independently
developed, powered by Alternating current generators and had to be manually controlled.
History of ISRU at NASA
Evolution of the Field Demo
• In May 2011 AES/OCT pulled FY12 funding for Mars ISRU which precluded our ability to attend the 3rd International Hawaii Analogue Field Test in 2012
• Team came up with plan to perform Integrated testing at the JSC Planetary Analog Site using Mars Simulant instead of Tephra from the slopes of Mauna Kea– Can still perform 24 hr operations and utilize Mission control
for remote operations– Fuel Cell consumables is much easier at JSC vs Mauna Kea
due to availability of the tube trailer
Field Demo Location Change
Programmatic Objectivescomparison
JSC Hawaii
Expand NASA and CSA partnership; Include other International
Partners in analogues
YES, nothing preventing CSA from participating
YES
Expand integration of Science & Engineering for exploration, particularly with ISRU
YES continue JSC & KSC institutional ISRU development
YES
Utilize analog activities and operations to develop and enhance mission concepts and integrate new technologies; Improve remote operations and control
YES, YES
Evaluate parallel paths and test hardware under stressful environmental conditions to evolve TRL and improve path to flight
YES YES
Be synergistic with other analogue test activities (past and future) YES YES
Public Outreach, Education, and “Participatory Exploration” YES, could invite local schools to provide excavators
YES
Technical Objectives Comparison
JSC Hawaii
Perform early deployment of advanced and “Game Changing” technologies applicable to multiple destinations before integration into future missions.
YES YES
Increase the fidelity and scope of surface system element integration and operations; continue development and integration of “Space Resource Utilization Mining Cycle“
YES YES
Develop and enhance exploration operation mission concepts YES YES
Improve remote operations & control of hardware for surface exploration and
science
YES YES
Promote use of common software, interfaces, & standards for control and operation YES YES
Focus on interfaces, standards, and requirements YES YES
Focus on modularity and ‘plug n play’ integration YES YES
Lander at Critical Design Review
M. Interbartolo
Atmo Processing Module:•CO2 capture from Mixed Mars atmosphere (KSC)•Sabatier converts H2 and CO2 into Methane and water (JSC)
Water Processing Module: (JSC)•Currently can process 520g/hr of water (max 694 g/hr)
1KW Fuel Cell and consumable storage (JSC & GRC)•Using metal hydride for H2 storage due to available•1KW No Flow Through FC (GRC)•10KW FC not shown (JSC)
Liquefaction Module: (TBD)•Common bulkhead tank for Methane and Oxygen liquid storage
Soil Processing Module:•Soil Hopper handles 30kg (KSC)•Soil dryer uses CO2 sweep gas and 500 deg C to extract water (JSC)
C&DH/PDU Module: (JSC)•Central executive S/W•Power distribution
Water Cleanup Module: (KSC)•Cleans water prior to electrolysis•Provides clean water storage
Life Detection Drill: (ARC-Honeybee) •Replaces excavator mockup•Takes core samples•Provides some feed to Soil Dryer
3m x 3m octagon lander deck
Atmospheric Processing Module
MethaneDryer
Sabatier
MethaneSeparator
CO2 Freezer
Chiller
Mixed Mars Input
Atmospheric Processing Module
CO2 ballast tanks not shown
Atmospheric Processing Operations
Mars Mix
CO2 freezer
Sabatier Reactor(~600 deg C)
Condenser
CH4/H2
SeparatorCH4
Dryer
CH4
storage
88 g/hr CO2
@ 50 PSI
95% CO2, 3% N2, 2% Ar at 10.8 mbar
71.3 g/hr H2O31.7 g/hr CH4
2 g/hr H2
H2OCH4
H2
H2O
16.2 g/hr H2
H2OCH4
CH4
H2O
Electrolysis Stacks
CO2 freezer
2 g/hr H2
Water Processing Module
Water Cleanup Module
Ballast tank
Ballast tank
CO2 Freezer Test Stand
•Several designs of the cold head have been tested
• Ferris wheel design produces the best CO2 for the surface area to mass ratio
• Using a cryocooler to reach the needed 150K (-123C/-190F) at 8 mbar
•Settled on 85 minute cycles of freezing/sublimation to meet the needed 88 grams/hour for the Sabatier Reactor•Will use ballast tanks to capture the CO2 after sublimation to then feed the Sabatier at 50 psi
Sabatier Test Stand•Testing determined that 4.5:1 ratio of H2 to CO2 was optimum for the reaction with the ruthenium catalyst•Uses cold ice bath for condensing instead of the Water Cleanup module•Methane separator is not functional
• Could not keep up with flow rate• Looked at using electrolyzer stack to act as
hydrogen separator, but proved unstable• Could not find replacement COTS version
• Looked into potential of hollow membrane system
•Cryocart team was okay with hydrogen/methane mix
• Would improve thruster performance• They can vent off hydrogen bubble from
methane dewar since it would not liquefy
Soil Processing Module
• SPM Consists of: – Feed System– Dryer System (Dryer + Fluid System)– Electronics/Power
• Objective:– Transfer simulant/soil/regolith – Process simulant/soil/regolith to liberate
water
• Process Overview:– Excavators deposit soil into a hopper– Hopper transfers soil into the dryer– Dryer heats soil and sweeps water into
condenser– Process repeats
Soil Processing Module
FEED SYSTEM
DRYER
DRYER BOP & ELECTRONICS
Soil Processing Module Concept of Operations
SOIL PROCESSING MODULE
FEED SYSTEM
DRYERSYSTEM
WATER CLEANUP MODULE
SOIL COLLECT/ TRANSPORT SOIL
H2O + Sweep Gas
Sweep Gas
18oC < T < 45oC10 psia < P < 14.7 psia
2” Tube @ 0.813 m (32 in)
75oC < T < 110oC5 psig < P < 20 psig¼” Tube @ 0.726 m (30 in)
5 psig < P < 20 psig 15oC < T < 30oC¼” Tube @ any height
18oC < T < 45oC10 psia < P < 14.7 psia
Ground Level
DAQ POWER
DAQ MAIN PDU
SOILSOIL
Three tests to date using Sandman and JSC-Mars-1A Simulant (Batch Size: 6 kg)
Simulant Processing Time (hrs)
Simulant Processing Time (min)
Total Batch Time (min)
Number of Batches per
Day
Water per Batch
(g)
Total Water/Day
(g)1.5 90 2 7 66 4652 120 2.5 6 241 1349
2.5 150 3 5 388 17873 180 3.5 4 512 2050
3.5 210 4 4 616 21564 240 4.5 3 703 2178
4.5 270 5 3 775 21715 300 5.5 3 838 2094
5.5 330 6 2 892 20526 360 6.5 2 943 1980
6.5 390 7 2 992 19857 420 7.5 2 1044 1880
7.5 450 8 2 1102 18738 480 8.5 2 1168 1870
• If dryer feedstock is 6 kg unspent JSC-Mars-1A, operating temperature ~115oC, flow rate ~10 slpm, & pressure ~25 psia
– 3 batches/day (4 hours for processing, 0.5 hours for feed/unload)– ~700 g of water/batch → ~ 2100 g of water/day
(hrs)
– MWE-001: Heated to 500oC• Flow Rate: 20 slpm• Pressure: ~25 psia
– MWE-002: Heated to ~120oC, then ~220oC
• Flow Rate: ~10 slpm• Pressure: ~25 psia
– MWE-003: Not heated, then heated to ~120oC• Flow Rate: ~10 slpm• Pressure: ~25 psia
TEST SETUP
Water Cleanup Module
Water Cleanup Module
Membrane
Clean Water Tank
Dirty Water Tank
Liquid-Liquid HExDI Resin
Condenser
Gas-Gas HEx
Gas-Gas HEx
Freon Reservoir
Coolant Reservoir
Water Clean Up Operations
Water Cleanup
Water/CO2 Inlet
Deionizer Clean water outlet
H2/CH4 Outlet
Fuel Cell Water inlet
Water storage tank
CO2 Outlet
Water/CH4/H2 Inlet
Dirty Water tank
Condenser
Soil Processing Module:• Inlet:
• Up to 20slpm H2O/CO2• ~50psig• ~200degC
• Outlet:• Up to 20slpm CO2-trace H2O• ~45psig (expected pressure drop of 5 psi)• ~5degC
Atmospheric Processing Module:• Inlet:
– ~3 slpm (up to 5slpm) CH4/H2O/trace CO2-H2
– ~50psig– ~200degC
• Outlet:– ~2slpm CH4/trace H2O/trace CO2-
H2– ~48psig (expected pressure drop of
1-2 psi)– ~5degC
Water Processing Module:• Outlet:
• Up to 170ml/min• 85 psig max• 25degC
Water Transfer Plan• Water will be transferred three times a day at approximately 4.5 hrs, 9.0hrs, and 13.5hrs
– Transfer times were used to maintain water level above level sensor immeasurable region and below the separator tank capacity
– Separator tanks will be full and ready for operation at the beginning of each day– No water transfer into the system overnight required
Water Cleanup Module
Water Processing Module
Water Processing Module
Water Processing Module
O2 Drying
H2 Drying
Fork Lift Spaces
Water Loops
Electrical Components/CRIO
Access Doors
Water Processing Operations
Deionizer Hydrogen Dryer
Oxygen Dryer
Hydrogen Outlet
Oxygen OutletCompact Rio
Control Node
Water inlet
Electrolyzer Stacks
H2 Sep Tank
O2 Sep Tank
•Processing 522 g/hr of water @ 3KW of power (max is 695 g/hr @~5KW)•Maximum pressure: 400psig•Temperature range: 5-65°C •Water flow rate range: 3.6-12 LPM/stack•Gas flow rates range:
• H2: 5.4-7.2 SLPM/stack• O2: 2.7-3.6 SLPM/stack
2nd Generation Electrolyzer System
Power Production and storage
•1KW shown•10KW not shown•O2 storage under the lander
Power Production
10KW Fuel Cell (117 cells): Advanced Passive-Flow-Through (PFT) with Ejector/Regulator technology
1KW Fuel Cell (32 cells): Advanced Passive-Flow-Through (PFT) with Ejector/Regulator technology
1KW Fuel Cell (40 cells): Non-Flow-Through (NFT) technology demonstration
Differences between a flow-through and non-flow-through fuel cell system
Power Distribution and Software
Power Distribution
ESTA Modular PDU design
3 200A High Power Distribution Unit (HPDU) 1 50 A Medium Power Distribution Unit (MPDU) 1 7.5A Low Power Distribution Unit (LPDU) Data and Control Unit (lab view controlled) Diode and Fuse box
HPDU
HPDUHPDU
Fuel cell
Ground Power
MPDU
16 channels 50A
LPDU
16 channels 7.5A
High Power Loads
High Power Loads
Fuel cell
Medium Power Loads
Low Power Loads
• Distributed, embedded command, control and communications architecture
• Uses National Instruments CompactRioTM as control node for each module– This will allow for standalone testing as well as
facilitate integrated remote operations• LabVIEWTM will provide the Human/System
Interface
Software
• Hawaii was ruled out last summer with the loss of AES/OCT support• JSC Rockyard was cancelled in January due to insufficient funds to complete
the project– Soil Processing Module not built
• leveraged the Sandman test rig for Mars soil data– Atmospheric Module not built
• CO2 Freezer test stand and Sabatier test stands built– Lander structure not built
• Currently working towards Regen Fuel Cell demonstration with the MMSEV– Will use the core Water Clean up and Water Processing Modules as well as the
PDUs to demonstrate a refueling depot that the MMSEV periodically docks with for resupply
• Long Term Goal to continue to refine the ISRU technologies for potential 2018 robotic mission using a SpaceX ‘Red Dragon’ capsule as part of an Ames lead science effort.
Current Status
MMSEV Demo Concept
Water Processing
Module
Water Clean up Module
Active Umbilical
Plate
Passive Umbilcal
Plate
3KW PFT Fuel Cell
O2 Tank
H2 Tank
Refueling station
Waterstorage
MMSEV PUP
KSC provided Umbilical plates
10KW Fuel Cell
Diode Fuse Box
PDUs distributing power (3HPDU, 1 C&DH)
MMSEV
Any Questions?Ultimate Destination - Mars
Follow us on Facebook:https://www.facebook.com/NASA.ISRU
BACKUP
CO2 Freezer DevelopmentRequirement: 88 g CO2/hr @ 50 psia
Based on Lockheed6” fins~5 g/hr
Cold tip + 1x3/4” rod~60 g/hr
Cold tip + 1x3/4” rod + Al fins~20 g/hr
2x2.5” machined fins~35 g/hr
CO2 Freezer Testing
1.00 1.10 1.20 1.30 1.40 1.50 1.6056.0%
58.0%
60.0%
62.0%
64.0%
66.0%
68.0%
70.0%
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Optimization of Mars Gas Simulant Flow Rate for Ferris Wheel (#2) Configuration Coldhead Design
CO2 Flow Rate (L/min) vs % CO2 Capture Efficiency CO2 Flow Rate (L/min) vs CO2 Collection Rate (g/hr)CO2 Flow Rate (L/min)
% CO2 Capture Efficiency
CO2 Collection Rate (g/hr)
4.00 4.04 4.10 4.15 4.20 4.2592.00%
93.00%
94.00%
95.00%
96.00%
97.00%
98.00%
99.00%
100.00%
Comparison of H2/CO2 Ratio to Reactor EfficiencyRuns 20, 22-26
Reac
tor E
ffici
ency
4.00 4.05 4.10 4.15 4.20 4.25 4.30 4.35 4.40 4.45 4.50
H2/CO2 Ratio
Literature shows that the reaction should have an efficiency greater than 99% when the mole ratio is higher than 4.51
Sabatier TestingMixture Ratio vs. Reactor Efficiency
WCM Build Up
WCM TestingNafion membrane thickness vs. temperature
0.5 1 1.5 2 2.5 3 3.5 4 4.5 50.000
0.005
0.010
0.015
0.020
0.025
0.030
0.035
254um - 20C 254um - 80C 51um - 20C
51um - 80C
Nitrogen Flow Rate (L/min)
Wat
er F
lux
(g/c
m2-
min
)
51 m – 20C
Temperature and membrane thickness effect on water flux versus dry nitrogen flow on the permeate side
WCM testingContamination(chlorine and fluorine) rejection vs. flow
rate and membrane thickness
Ion rejection (i.e., ion in retentate) as a function gas flow rate for two membrane thickness
0.5 1 1.5 2 2.5 3 3.5 4 4.5 560
65
70
75
80
85
90
95
100
51um thickness, Cl-
254um thickness, Cl-
51um thickness, F-
254nm thickness, F-
Nitrogen Flow Rate (L/min)
Ion
Reje
ction
(%)
51 m thickness, Cl-
254 m thickness, Cl-
51 m thickness, F-
Separator Tanks
Air/Liquid HX
Electrolysis Stacks ( 12-cell liquid-anode feed)
DI Beds
Back Pressure Regulators
Sight Glass
Gas Drying
Desiccant Beds
Motorized Ball Valves
Desiccant Beds
Solenoid Valves
Purge Lines
Sweep Gas Vent Lines
Water Loops
WPM detailed CAD
WPM testingRegenerative Dryer concepts
Media Date Gas FR Type of regeneration Energy Heat Up At Temp Cool Down Total Time H2O Removed Amt desiccant N2 RqdSLPM watt-hrs min min min min g g g
Drierite - Du-Cal 5/6/2011 5 N2 Sweep Gas 121.1 32.9 58.3 63.5 154.8 7.7 109.8 569.9Drierite - Du-Cal 5/5/2011 5 N2 Sweep Gas 80.4 27.4 29.4 65.4 122.3 2.7 109.8 355.0Drierite - Du-Cal 5/3/2011 5 N2 Sweep Gas 52.6 28.7 5.5 64.7 98.8 0.4 109.8 213.4Drierite - Du-Cal 4/25/2011 - N2 Sweep Gas 73.6 26.6 23.5 74.9 125.0 3.3 111.0 312.8
average = 81.9 28.9 29.2 67.1 125.2 3.5 110.1 362.8stdev= 28.7 2.8 21.9 5.3 22.9 3.1 0.6 150.3
Drierite - Du-Cal 4/22/2011 - Vacuum 601.0 23.8 59.7 86.3 169.8 3.7 109.0 -Drierite - Du-Cal 5/5/2011 - Vacuum 818.1 24.9 89.3 62.5 176.7 1.9 109.8 -Drierite - Du-Cal 5/3/2011 - Vacuum 525.8 25.8 46.8 47.3 120.0 1.4 109.8 -
average = 648.3 24.9 65.3 65.4 155.5 2.3 109.5 -stdev= 151.8 1.0 21.8 19.6 30.9 1.2 0.5 -
Drierite - Du-Cal 4/12/2011 - Vent 125.8 62.6 27.2 75.6 165.3 0.4 109.0 -Molecular Sieve 13X 4/27/2011 1->5 N2 Sweep Gas 312.5 35.0 239.6 84.0 358.6 7.9 69.1 1715.0Molecular Sieve 13X 4/29/2011 5 N2 Sweep Gas 142.1 63.0 19.9 70.5 153.4 3.7 69.1 517.9Molecular Sieve 13X 5/2/2011 5 N2 Sweep Gas 177.4 79.0 28.1 63.5 170.6 9.4 69.1 668.8
average = 159.7 71.0 24.0 67.0 162.0 6.6 69.1 593.4stdev= 24.9 11.3 5.8 4.9 12.1 4.0 0.0 106.7
Molecular Sieve 13X 4/26/2011 - Vacuum 607.2 38.6 43.5 73.6 155.7 5.1 71.7 -Molecular Sieve 13X 4/28/2011 - Vacuum 794.8 44.7 60.8 63.2 168.7 11.3 69.1 -Molecular Sieve 13X 4/29/2011 - Vacuum 623.9 31.5 52.1 64.8 148.3 1.2 69.1 -
average = 675.3 38.3 52.1 67.2 157.6 5.9 70.0 -stdev= 103.8 6.6 8.7 5.6 10.3 5.1 1.5 -
Soil Dryer Up close
• Design Details– Single Batch Processor– 60o Conical Chamber (From Horizontal)– Helical Agitator– Blanket External Heater – Internal Heaters– Simulant Enters/Exit through Valves– Gas Flow into Bottom through Top– Max Simulant Temperature: 500oC– Max Vessel Pressure: 20 psig
• Mass: 100 kg (220 lbs)
• Vessel Volume: 15863 cm3 (968 in3)
12.4”
17.1”
44.9”
18.0”11.5”
Command, control and communications architecture showing local control nodes and remote user interface
stations.