An Advanced In-Situ Resource Utilization (ISRU) Production Plant Design for Robotic and Human Mars Missions

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The ability to produce the necessary consumables, rather than relying solely on what is brought from Earth decreases the launch mass, cost, and risk associated with a Mars mission while providing capabilities that enable the commercial development of space. The idea of using natural resources, or "living off the land", is termed In-Situ Resource Utilization (ISRU). Trade studies have shown that producing and utilizing consumables such as water, breathing oxygen, and propellant can reduce the launch mass for a human or robotic mission to Mars by 20-45%. The Johnson Space Center and Lockheed Martin Astronautics are currently designing and planning assembly of a complete collection-to-storage production plant design for producing methane (fuel), oxygen, and water from carbon dioxide (Martian atmosphere) and hydrogen (electrolyzed Martian water or Earth-originated), based on lessons learned and design enhancements from a 1st generation testbed. The design and testing of the major subsystems incorporated in the 2nd generation system, including a carbon dioxide freezer, Sabatier reactor, water electrolysis unit, and vacuum-jacketed, cryogenic, common-bulkhead storage tank, will be presented in detail with the goal of increasing the awareness of the readiness level of these technologies. These technologies are mass and power efficient as well as fundamentally simple and reliable. These technologies also have potential uses in Environmental Control and Life Support System (ECLSS) applications for removing and recycling crew-exhaled carbon dioxide. Each subsystem is sized for an ISRU-assisted sample return mission, producing in an 8-hour period 0.56 kg water and 0.26 kg methane from the Sabatier reactor and 0.50 kg oxygen from electrolyzed water. The testing of these technologies to date will be discussed as well as plans for integrating the subsystems for a complete end-to-end demonstration at Mars conditions. This paper will also address the history of these subsystem technologies, the issues involved with the interfaces between these subsystems, the storage of the products, and the benefits for the contined study of ISRU related technologies.

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