ISRU in the Context of Future European Human Mars Exploration

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ISRU or In-Situ Resource Utilisation is the use of Martian resources to manufacture, typically, life support consumables (e.g. water, oxygen, breathing buffer gases), and propellant for a return journey to Earth. European studies have shown that some 4kg of reaction mass must be launched to LEO to send 1kg payload to Mars orbit, with landing on the Mars surface reducing payload mass still further. This results in very high transportation costs to Mars, and still higher costs for returning payloads to Earth. There is therefore a major incentive to reduce payload mass for any form of Mars return mission (human or otherwise) by generating consumables on the surface. ESA through its GSTP programme has been investigating the system level design of a number of mission elements as potential European contributions to an international human Mars exploration mission intended for the 2020-2030 timeframe. One of these is an ISRU plant, a small chemical factory to convert feedstock brought from Earth (hydrogen), and Martian atmospheric gases (CO2 and trace quantities of nitrogen and argon) into methane and oxygen propellant for Earth return and life support consumables, in advance of the arrival of astronauts. ISRU technology has been the subject of much investigation around the world, but little detailed research or system level studies have been reported in Europe. Furthermore, the potential applicability of European expertise, technology and sub- system studies to Martian ISRU is not well quantified. Study work covered in this paper has compared existing designs (e.g. NASA's Design Reference Mission, DLR and Mars Society studies) with the latest ESA derived requirements for human Mars exploration, and has generated a system level ISRU design. This paper will review and quantify the baseline chemical reactions essential for ISRU, including CO2 collection and purification, Sabatier reduction of CO2 with hydrogen to methane and water, and electrolysis of water in the context of the latest requirements. In addition, the paper will explore the options for compressing, cooling and storing gaseous products, methods for extracting buffer gases (such as nitrogen), and chemistries for producing additional oxygen. The paper will be written from the viewpoint of what European industry might be able to offer to a future set of Martian ISRU requirements, but in the context of an international human Mars mission. For example, the development of a compact Sabatier reactor for ISS air revitalisation, and high temperature methane cracking reactors by Astrium GmbH are considered. Other, current research has highlighted low temperature catalytic decomposition of methane, under evaluation as means of producing carbon nanofibres; and the photocatalytic reduction of CO2 as relevant technologies. This paper will also consider some key issues in ISRU design which have not yet been widely addressed, including the suitability of an Ar/N2 buffer gas mixture for life support (and the difficulties of its separation from the Martian atmosphere), the transfer of hydrogen feedstock to Mars, the storage of products on the surface, and the thermal balance in an ISRU plant (e.g. the balance of energy required for liquefaction of oxygen, against the heat sink available from the liquid hydrogen feedstock). In addition, this paper will detail the selected reaction chemistries for each required subsystem, giving (where possible) mass, power and volume estimates. These will be drawn together, justified and presented as a system level design for an ISRU plant. Finally, a technology roadmap for ISRU development will be covered, suggesting near term (2002-2006), medium term (2006-2015) and long term (2015-2030) priorities which could enable a European ISRU capability to be qualified for initial human Mars exploration.

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