Thermal & Fluids Analysis Workshop 2002Thermal & Fluids Analysis Workshop 2002

InIn--Situ Resource Utilization (ISRU) Thermal, Situ Resource Utilization (ISRU) Thermal, Fluid, and Process ModelingFluid, and Process Modeling

NASA-JSCTom Simon281-483-7547tsimon@ems.jsc.nasa.gov

AbstractAbstractIn-Situ Resource Utilization (ISRU) Thermal, Fluid, and Process Modeling

Modeling of In-Situ Resource Utilization technologies and systems have been performed to support trade studies and ground testing. The models are used to determine promising methods and technologies of producing consumables for various missions including both robotic and manned missions to the moon and Mars. Testing of these technologies and overall systems rely on the models to help size components and develop operating procedures for specific production goals. This presentation will focus on the modeling done in support of an ISRU system that is sized for a robotic Mars sample return mission, producing 32 grams/hour ofmethane and 62 grams/hour of oxygen. This paper will cover the water electrolysis subsystem analysis and design, including testing to date.

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Tom Simon NASA JSCTom Simon NASA JSC 2

InIn--Situ Resource Utilization Situ Resource Utilization (ISRU)(ISRU)

Modeling Performed– By NASA and Others– Support Trade Studies– Support Testing

• Component Design• Subsystems• End-to-End Systems

ISRU Background– Living Off The Land– Develop Systems To

Provide Consumables– To Support Robotic

and Human Exploration

– Can Reduce Cost and Increase Safety

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Specific JSC ISRU ModelingSpecific JSC ISRU Modeling

Trade Studies– Determine Systems Best Suited To Meet Goals

Of Missions: Qualitative– Size Systems To Provide Estimate Of System

Parameters: Quantitative

Testing Support– JSC Testing Of Technologies

Requires Design (If JSC Fabricated)Requires System Design and Modeling

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Modeling Supporting JSC TestingModeling Supporting JSC Testing

2nd Generation ISRU System Design & Testing– Main Components

CO2 Freezer (Lockheed Martin)Sabatier Reactor (JSC)Water Electrolysis (Hamilton Sundstrand)Common Bulkhead Cryogenic Storage Tank (Lockheed Martin)

– Sized For Robotic Mars Sample Return Mission32 g/hr of CH4, 62 g/hr of O2

280 kg/yr (618 lb/yr) of CH4, 543 kg/yr (1197 lb/yr) of O2

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Modeling Supporting JSC TestingModeling Supporting JSC Testing

Water Electrolysis Subsystem Design– System Requirements Defined– System Components Designed or Procured To

Support Hamilton Sundstrand Built ElectrolyzerSabatier Reactor Subsystem Design– System Requirements Defined– Sabatier Reactor Model, Design, and Fabrication– System Components Designed or Procured To

Support JSC Built Sabatier Reactor

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MIST Water Electrolysis Unit MIST Water Electrolysis Unit System ConfigurationSystem Configuration

MIST Liquid Anode Feed WEU From Hamilton SundstrandDesign of WEU System Configuration– Mass Flow Rate Calculations– Set Requirements for Hardware– Select Hardware– System Schematic– Pro/Engineer Model

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Where to begin?Where to begin?

Inputs– Recommendations from

Hamilton Sundstrand– Improvements desired

over first ISPP breadboard

Procedure followed– Determine the WEU

requirements– Select components and

configuration of system to meet requirements

– Select miniature, flight like components

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Fluid AnalysisFluid AnalysisCH4 kg/hr

CH4 kg/hr H2O kg/hrH2 kg/hr psia H2 kg/hr

H2O kg/hr CH4 kg/hr Vent H2O kg/hrpsia H2 kg/hr psia

H2O kg/hr H2O kg/hr To Sabatierpsia H2 kg/hr

H2 psia

Separator H2 kg/hrH2O kg/hr

psia

in H2O O2 kg/hrWEU H2O kg/hr

psiain H2O

VentH2O kg/hr O2 kg/hr

psia H2O kg/hrpsia in H2O

H2O kg/hrpsia

200 psia

Water Circulation Pump

Qdot

Water Feed Pump

H2O kg/hrpsia

H2OPS

36.985195

O2/

0.07845

H2/

H2OPS

75

0.0340.0010.00245

ColdPlate

0.001

0.66145

0.585

DIBed

HoldingTank

0.00175

19537.643

0.06500.0033195

0.0080.58575

0.065

0.0090.000475

FromSabatier

0.03440.000945

0.0340.001

Filter

Filter

99

WEU RequirementsWEU RequirementsHydrogen Separator– Methane and Hydrogen go in– Two outlets

MethaneHydrogen

Water Electrolysis Unit– Water goes in– Two outlets

Hydrogen and waterOxygen and water

1010

Selected Components To PurchaseSelected Components To PurchaseFinding the right components– Searching the internet for

miniature components that meet the requirements

– These components include:Water feed pumpWater circulation pumpLatching solenoid valvesDelta pressure transducerFeed line filterCirculation loop filterCheck valvesCold PlateCartridge HeatersMicro Pump Series 120

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Components Designed forComponents Designed forInIn--House FabricationHouse Fabrication

On-site produced hardware– Sizing components to meet our

needs– These components include

Phase Separator Tanks– Three units to separate water

and gasesDeionization bed

– Cation resin bed to remove possible iron, chrome, and platinum ions from water feed line

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1212

Second Generation Breadboard Second Generation Breadboard SchematicSchematic

13

System AssemblySystem Assembly

1414

MIST WEU ConclusionMIST WEU Conclusion

Initial configuration completedMIST hardware scheduled to be delivered in November

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1515

ConclusionConclusion

Detailed Modeling and Analysis Is Required To Transform Theoretical Systems Into Actual Systems– Fabrication and Procurement of Hardware– Operational Procedures For System– Characterization of System For Use In Studies

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