Browsing by Author "Abney, Morgan B."
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Item Advanced Oxygen Recovery via Series-Bosch Technology(45th International Conference on Environmental Systems, 2015-07-12) Abney, Morgan B.; Mansell, J. Matthew; Atkins, Bobby; Evans, Chris; Nur, Mononita; Beassie, Rockford D.Advanced oxygen recovery life support for Martian transit and surface missions constitutes a variety of possible architectures. Over the last several years, NASA has pursued development of a two-step Bosch-based system called Series-Bosch (S-Bosch) to enable maximum recovery of oxygen from metabolic carbon dioxide. The first step of the process involves the Reverse Water-Gas Shift (RWGS) reaction. Two RWGS reactors, one developed at NASA and the other developed at Precision Combustion, Inc. have been assembled for the S-Bosch. The RWGS reactors were each tested to evaluate and compare general operational performance and fouling resistance. A down-select was completed to identify the reactor to be used in an integrated S-Bosch system. The second step in the S-Bosch process is carbon deposition. A carbon formation reactor (CFR) based on Martian regolith simulant as a catalyst was designed and tested for performance. Because the regolith will only be available once the crew arrives on the Martian surface, a second catalyst was evaluated for transit phases. Finally, integrated testing of an S-Bosch system was completed, leading to a technology readiness level (TRL) advancement of the S-Bosch system to TRL 4. The results of the RWGS down-select, CFR testing, and TRL evaluation are reported and discussed.Item Characterization of carbon particulates in the exit flow of a Plasma Pyrolysis Assembly (PPA) reactor(45th International Conference on Environmental Systems, 2015-07-12) Green, Robert D.; Meyer, Marit E.; Agui, Juan H.; Berger, Gordon M.; Vijayakumar, R.; Abney, Morgan B.; Greenwood, ZacharyThe ISS presently recovers oxygen from crew respiration via a Carbon Dioxide Reduction Assembly (CRA) that utilizes the Sabatier chemical process to reduce captured carbon dioxide to methane (CH4) and water. In order to recover more of the hydrogen from the methane and increase oxygen recovery, NASA Marshall Space Flight Center (MSFC) is investigating a technology, plasma pyrolysis, to convert the methane to acetylene. The Plasma Pyrolysis Assembly (or PPA), achieves 90% or greater conversion efficiency, but 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. In this work, we present the experimental results of an initial characterization of the carbon particulates in the PPA exit gas stream. We also present several potential options to remove these carbon particulates via carbon traps and filters to minimize resupply mass and required downtime for regeneration.Item CO2 Reduction Assembly Prototype using Microlith-based Sabatier Reactor for Ground Demonstration(44th International Conference on Environmental Systems, 2014-07-13) Junaedi, Christian; Hawley, Kyle; Walsh, Dennis; Roychoudhury, Subir; Abney, Morgan B.; Perry, Jay L.The utilization of CO2 to produce life support consumables, such as O2 and H2O, via the Sabatier reaction is an important aspect of NASA’s cabin Atmosphere Revitalization System (ARS) and In-Situ Resource Utilization (ISRU) architectures for both low-earth orbit and long-term manned space missions. Carbon dioxide can be reacted with H2, obtained from the electrolysis of water, via Sabatier reaction to produce methane and H2O. Methane can be stored and utilized as propellant while H2O can be either stored or electrolyzed to produce oxygen and regain the hydrogen atoms. Depending on the application, O2 can be used to replenish the atmosphere in human-crewed missions or as an oxidant for robotic and return missions. Precision Combustion, Inc. (PCI), with support from NASA, has previously developed an efficient and compact Sabatier reactor based on its Microlith® catalytic technology and demonstrated the capability to achieve high CO2 conversion and CH4 selectivity (i.e., ≥90% of the thermodynamic equilibrium values) at high space velocities and low operating temperatures. This was made possible through the use of high-heat-transfer and high-surface-area Microlith catalytic substrates. Using this Sabatier reactor, PCI designed, developed, and demonstrated a stand-alone CO2 Reduction Assembly (CRA) test system for ground demonstration and performance validation. The Sabatier reactor was integrated with the necessary balance-of-plant components and controls system, allowing an automated, single “push–button” start-up and shutdown. Additionally, the versatility of the test system prototype was demonstrated by operating it under H2-rich (H2/CO2 of >4), stoichiometric (ratio of 4), and CO2-rich conditions (ratio of <4) without affecting its performance and meeting the equilibrium-predicted water recovery rates. In this paper, the development of the CRA test system for ground demonstration will be discussed. Additionally, the performance results from testing the system at various operating conditions and the results from durability testing will be presented.Item Electrolyte Membrane Hydrogen Recovery for Advanced Oxygen Recovery Architecture(45th International Conference on Environmental Systems, 2015-07-12) Preston, Joshua S.; Molter, Trent M.; Murdoch, Karen E.; Abney, Morgan B.; Greenwood, ZacharyNASA’s endeavor to further enable long duration manned space exploration requires further closure of the oxygen loop of the life support system than is currently realized aboard the International Space Station. Currently, oxygen is recovered from crew generated carbon dioxide via the use of a Sabatier carbon dioxide reduction system coupled with water electrolysis. Water is electrolyzed to form oxygen for crew consumption as well as hydrogen. The hydrogen is reacted with carbon dioxide forming water and waste methane gas. Since hydrogen is lost from the desired closed loop system in the form of methane, there is insufficient hydrogen available to fully react all of the carbon dioxide, resulting in a net loss of oxygen from the loop. In order to further close the oxygen loop, NASA has been developing an advanced Plasma Pyrolysis technology that further converts the waste methane to higher order hydrocarbons in order to better utilize the hydrogen for oxygen recovery. This Plasma Pyrolysis produces a product gas stream that consists of hydrogen, hydrocarbons, and a significant concentration of carbon monoxide. In order for this Plasma Pyrolysis technology to be feasible, there must be a means to separate the hydrogen from the other compounds for recycle to the Sabatier reactor. Sustainable Innovations’ signature electrochemical cell architecture provides a solution to NASA’s search for regenerative separation technology enabling maximum hydrogen recovery from a stream containing water vapor, carbon monoxide (CO), and hydrocarbons including methane, acetylene, ethane, and ethylene, among others. Separation of hydrogen from mixed gaseous streams presents a significant technical challenge for various NASA applications in addition to posing a significant opportunity for commercial uses. Sustainable Innovations is developing a technology that extracts hydrogen from a mixed stream by electro-oxidization of the hydrogen and subsequent electro-reduction of the resultant protons in a separate chamber. The process, when combined with an electrochemical cell architecture that is engineered to tolerate high differential pressure, can be used to separate and compress hydrogen in a single step. The process is proven to be efficient, quiet, and highly reliable. It requires no reciprocating compressor, so it is largely maintenance free.Item Evaluation of an Atmosphere Revitalization Subsystem for Deep Space Exploration Missions(45th International Conference on Environmental Systems, 2015-07-12) Perry, Jay L.; Abney, Morgan B.; Conrad, Ruth E.; Frederick, Kenneth R.; Greenwood, Zachary W.; Kayatin, Matthew J.; Knox, James C.; Newton, Robert L.; Parrish, Keith J.; Takada, Kevin C.; Miller, Lee A.; Scott, Joseph P.; Stanley, Christine M.An Atmosphere Revitalization Subsystem (ARS) suitable for deployment aboard deep space exploration mission vehicles has been developed and functionally demonstrated. This modified ARS process design architecture was derived from the International Space Station’s (ISS) basic ARS. Primary functions considered in the architecture include trace contaminant control, carbon dioxide removal, carbon dioxide reduction, and oxygen generation. Candidate environmental monitoring instruments were also evaluated. The process architecture rearranges unit operations and employs equipment operational changes to reduce mass, simplify, and improve the functional performance for trace contaminant control, carbon dioxide removal, and oxygen generation. Results from integrated functional demonstration are summarized and compared to the performance observed during previous testing conducted on an ISS-like subsystem architecture and a similarly evolved process architecture. Considerations for further subsystem architecture and process technology development are discussed.Item Hydrogen Purification in Support of Plasma Pyrolysis of Sabatier Derived Methane(45th International Conference on Environmental Systems, 2015-07-12) Holtsnider, John T.; Wheeler, Richard R.; Dewberry, Ross H.; Abney, Morgan B.; Greenwood, Zachary W.The use of microwave regenerative sorption media for purification of hydrogen has been studied. The Sabatier Assembly recovers oxygen from carbon dioxide while consuming hydrogen and producing methane and water. The Plasma Pyrolysis Assembly (PPA) is being developed to recover most of the hydrogen from the methane. Acetylene and smaller amounts of other hydrocarbons are produced as byproducts of PPA operation. The present project is directed toward purifying the hydrogen product gas using sorption media and subsequently thermally regenerating the media using microwave power. The penetrative nature of microwave heating is utilized to efficiently drive gas desorption from the physical sorbents. Microwave heating drives off captured contaminants from a sorbent bed (which is held at relative vacuum) during regeneration. A series of molecular sieves, activated carbons and high surface area forms of alumina and silica were evaluated as candidate sorbent materials. Additionally, water vapor removal with the use of silica gel was evaluated. As a result of this research, hydrogen recovery from Sabatier methane is improved, thereby further closing the air-loop. Such increases in efficiency are necessary for crewed deep space exploration missions.Item Increased Oxygen Recovery from Sabatier Systems Using Plasma Pyrolysis Technology and Metal Hydride Separation(45th International Conference on Environmental Systems, 2015-07-12) Greenwood, Zachary W.; Abney, Morgan B.; Perry, Jay L.; Miller, Lee A.; Dahl, Roger W.; Hadley, Neal M.; Wambolt, Spencer R.; Wheeler, Richard R.State-of-the-art life support carbon dioxide (CO2) reduction technology is based on the Sabatier reaction where less than 50% of the oxygen required for the crew is recovered from metabolic CO2. The reaction produces water as the primary product and methane as a byproduct. Oxygen recovery is constrained by the limited availability of reactant hydrogen. This is further exacerbated when Sabatier methane (CH4) is vented as a waste product resulting in a continuous loss of reactant hydrogen. Post-processing methane with the Plasma Pyrolysis Assembly (PPA) to recover hydrogen has the potential to dramatically increase oxygen recovery and thus drastically reduce the logistical challenges associated with oxygen resupply. The PPA decomposes methane into predominantly hydrogen and acetylene. Due to the highly unstable nature of acetylene, a separation system is necessary to purify hydrogen before it is recycled back to the Sabatier reactor. Testing and evaluation of a full-scale Third Generation PPA is reported and investigations into metal hydride hydrogen separation technology is discussed.Item Next Generation Life Support Project Status(44th International Conference on Environmental Systems, 2014-07-13) Barta, Daniel J.; Chullen, Cinda; Vega, Leticia; Cox, Marlon R.; Aitchison, Lindsay T.; Lange, Kevin E.; Pensinger, Stuart J.; Meyer, Caitlin E.; Flynn, Michael; Richardson, Tra-My Justine; Jackson, W. Andrew; Abney, Morgan B.; Birmele, Michele N.; Lunn, Griffin M.; Wheeler, Raymond M.Next Generation Life Support (NGLS) is one of more than 20 technology development projects sponsored by NASA’s Game Changing Development Program. The NGLS Project develops selected life support technologies needed for humans to live and work productively in space, with focus on technologies for future use in spacecraft cabin and space suit applications. Over the last 3 years, NGLS had five main project elements: Variable Oxygen Regulator (VOR), Rapid Cycle Amine (RCA) swing bed, High Performance Extravehicular Activity (EVA) Glove (HPEG), Alternative Water Processor (AWP) and Series-Bosch Carbon Dioxide Reduction. The RCA swing bed, VOR and HPEG tasks are directed at key technology needs for the Portable Life Support System (PLSS) and pressure garment for an Advanced Extravehicular Mobility Unit (EMU). Focus is on prototyping and integrated testing in cooperation with the Advanced Exploration Systems (AES) Advanced EVA Project. The HPEG Element, new this fiscal year, includes the generation of requirements and standards to guide development and evaluation of new glove designs. The AWP and Bosch efforts focus on regenerative technologies to further close spacecraft cabin atmosphere revitalization and water recovery loops and to meet technology maturation milestones defined in NASA’s Space Technology Roadmaps. These activities are aimed at increasing affordability, reliability, and vehicle self-sufficiency while decreasing mass and mission cost, supporting a capability-driven architecture for extending human presence beyond low-Earth orbit, along a human path toward Mars. This paper provides a status of current technology development activities with a brief overview of future plans.Item Series-Bosch Technology For Oxygen Recovery During Lunar or Martian Surface Missions(44th International Conference on Environmental Systems, 2014-07-13) Abney, Morgan B.; Mansell, J. Matthew; Rabenberg, Ellen; Stanley, Christine M.; Edmunson, Jennifer; Alleman, James E.; Chen, Kevin; Dumez, SamLong-duration surface missions to the Moon or Mars will require life support systems that maximize resource recovery to minimize resupply from Earth. To address this need, NASA previously proposed a Series-Bosch (S-Bosch) oxygen recovery system, based on the Bosch process, which can theoretically recover 100% of the oxygen from metabolic carbon dioxide. Bosch processes have the added benefits of the potential to recover oxygen from atmospheric carbon dioxide and the use of regolith materials as catalysts, thereby eliminating the need for catalyst resupply from Earth. In 2012, NASA completed an initial design for an S-Bosch development test stand that incorporates two catalytic reactors in series including a Reverse Water-Gas Shift (RWGS) Reactor and a Carbon Formation Reactor (CFR). In 2013, fabrication of system components, with the exception of a CFR, and assembly of the test stand was initiated. Stand-alone testing of the RWGS reactor was completed to compare performance with design models. Continued testing of Lunar and Martian regolith simulants provided sufficient data to design a CFR intended to utilize these materials as catalysts. Finally, a study was conducted to explore the possibility of producing bricks from spent regolith catalysts. The results of initial demonstration testing of the RWGS reactor, results of continued catalyst performance testing of regolith simulants, and results of brick material properties testing are reported. Additionally, design considerations for a regolith-based CFR are discussed.Item Third Generation Advanced PPA Development(44th International Conference on Environmental Systems, 2014-07-13) Wheeler, Richard R.; Hadley, Neal M.; Wambolt, Spencer R.; Abney, Morgan B.A Phase 3 advanced development project has culminated in the design and fabrication of a third generation Plasma Pyrolysis Assembly (PPA), recovering up to 75% of the hydrogen currently lost as methane in Sabatier reactor effluent. By doing so, the PPA helps to minimize life support resupply costs for extended duration missions. The 3-year development effort, completed as part of NASA’s Atmosphere Revitalization Resource Recovery task, has resulted in a fully functional stand-alone 5-CM (crew member) capacity PPA prototype. This device, recently delivered to NASA-MSFC, embodies the current state of the art in microwave methane plasma pyrolysis. At 90% single pass conversion the third generation PPA shows a ten-fold increase in processing rate capability over the first generation PPA, improves microwave to chemical energy conversion efficiency by three-fold (to 22%), and maintains a low residual carbon production rate at 0.20% of carbon from converted methane. Additional third generation technology advancements include increased process autonomy, incorporation of a regenerative residual carbon trap and in-situ reactor cleaning using CO2 plasma oxidation. Future development work must focus on fully autonomous operation, increased carbon trap capacity, more complete regeneration and improved process energy efficiency.