Laurent Sibille

Direct Electrolysis of Molten Lunar Regolith for the Production of Oxygen and Metals on the Moon

The feasibility of producing oxygen by direct electrolysis of molten lunar regolith at 1600 oC was investigated. Oxygen gas at the anode was generated concomitantly with production of iron and silicon at the cathode from the tightly bound oxide mix. Current efficiencies for oxygen evolution from different melt compositions were determined during the course of electrolysis by on-stream analysis of oxygen gas. Scale-up from thin wire (ca. 0.3 cm 2 ) electrodes to plate and disc electrodes (ca. 10 cm 2 ) was achieved.

Recent Advances in Scale-up Development of Molten Regolith Electrolysis for Oxygen Production in support of a Lunar Base

Previously, we have demonstrated the production of oxygen by electrolysis of molten regolith simulants at temperatures near 1600oC. Using an inert anode and suitable cathode, direct electrolysis (no supporting electrolyte) of the molten silicate is carried out, resulting in the production of molten metallic products at the cathode and oxygen gas at the anode. Initial direct measurements of current efficiency have confirmed that the process offer potential advantages of high oxygen production rates in a smaller footprint facility landed on the moon, with a minimum of consumables brought from Earth. We now report the results of a scale-up effort toward the goal of achieving production rates equivalent to 1 metric ton O2/year, a benchmark established for the support of a lunar base. We previously reported on the electrochemical behavior of the molten electrolyte as dependent on anode material, sweep rate and electrolyte composition in batches of 20-200g and at currents of less than 0.5A. In this paper, we present the results of experiments performed at higher currents (several Amperes) and in larger volumes of regolith simulant (500g) for longer durations of

Preparing for Mars: Evolvable Mars Campaign “Proving Ground” approach

As the National Aeronautics and Space Administration (NASA) prepares to extend human presence beyond Low Earth Orbit, we are in the early stages of planning missions within the framework of an Evolvable Mars Campaign. Initial missions would be conducted in near-Earth cis-lunar space and would eventually culminate in extended duration crewed missions on the surface of Mars. To enable such exploration missions, critical technologies and capabilities must be identified, developed, and tested. NASA has followed a principled approach to identify critical capabilities and a “Proving Ground” approach is emerging to address testing needs. The Proving Ground is a period subsequent to current International Space Station activities wherein exploration-enabling capabilities and technologies are developed and the foundation is laid for sustained human presence in space. The Proving Ground domain essentially includes missions beyond Low Earth Orbit that will provide increasing mission capability while reducing technical risks. Proving Ground missions also provide valuable experience with deep space operations and support the transition from “Earth-dependence” to “Earth-independence” required for sustainable space exploration.

Joule-Heated Molten Regolith Electrolysis Reactor Concepts for Oxygen and Metals Production on the Moon and Mars

The maturation of Molten Regolith Electrolysis (MRE) as a viable technology for oxygen and metals production on explored planets relies on the realization of the self-heating mode for the reactor. Joule heat generated during regolith electrolysis creates thermal energy that should be able to maintain the molten phase (similar to electrolytic Hall-Heroult process for aluminum production). Self-heating via Joule heating offers many advantages: (1) The regolith itself is the crucible material, it protects the vessel walls (2) Simplifies the engineering of the reactor (3) Reduces power consumption (no external heating) (4) Extends the longevity of the reactor. Predictive modeling is a tool chosen to perform dimensional analysis of a self-heating reactor: (1) Multiphysics modeling (COMSOL) was selected for Joule heat generation and heat transfer (2) Objective is to identify critical dimensions for first reactor prototype.

Modeling Joule Heating Effect on Lunar O2 Generation via Electrolytic Reduction.

Kennedy Space Center is leading research work on lunar O2 generation via electrolytic reduction of regolith; the metal oxide present in the regolith is dissociated in oxygen anions and metal cations leading to the generation of gaseous oxygen at the anode and liquid metal at the cathode. Electrical resistance of molten regolith is high, leading to heating of the melt when electrical current is applied between the electrodes (Joule heating). The authors have developed a 3D model using a rigorous approach for two coupled physics (thermal and electrical potential) to not only study the effect of Joule heating on temperature distribution throughout the molten regolith but also to evaluate and optimize the design of the electrolytic cells. This paper presents the results of the thermal analysis performed on the model and used to validate the design of the electrolytic cell.

Additive Construction using Basalt Regolith Fines

Planetary surfaces are often covered in regolith (crushed rock), whose geologic origin is largely basalt. The lunar surface is made of small-particulate regolith and areas of boulders located in the vicinity of craters. Regolith composition also varies with location, reflecting the local bedrock geology and the nature and efficiency of the micrometeorite- impact processes. In the lowland mare areas (suitable for habitation), the regolith is composed of small granules (20 – 100 microns average size) of mare basalt and volcanic glass. Impacting micrometeorites may cause local melting, and the formation of larger glassy particles, and this regolith may contain 10-80% glass. Studies of lunar regolith are traditionally conducted with lunar regolith simulant (reconstructed soil with compositions patterned after the lunar samples returned by Apollo). The NASA Kennedy Space Center (KSC) Granular Mechanics & Regolith Operations ( GMRO) lab has identified a low fidelity but economical geo-technical simulant designated as Black Point-1 (BP-1). It was found at the site of the Arizona Desert Research and Technology Studies (RATS) analog field test site at the Black Point lava flow in adjacent basalt quarry spoil mounds. This paper summarizes activities at KSC regarding the utilization of BP-1 basalt regolith and comparative work with lunar basalt simulant JSC-1A as a building material for robotic additive construction of large structures. In an effort to reduce the import or in-situ fabrication of binder additives, we focused this work on in-situ processing of regolith for construction in a single-step process after its excavation. High-temperature melting of regolith involves techniques used in glassmaking and casting (with melts of lower density and higher viscosity than those of metals), producing basaltic glass with high durability and low abrasive wear. Most Lunar simulants melt at temperatures above 1100°C, although melt processing of terrestrial regolith at 1500°C is not uncommon. These temperatures are achievable by laser heating or by using solar concentrators. Similar to volcanic magma, the cooling rate determines the crystallite size – slower cooling develops larger crystals, and rapid quenching can result in fully amorphous glass.

Opportunities and Strategies for Testing and Infusion of ISRU in the Evolvable Mars Campaign

HE Evolvable Mars Campaign (EMC) is developing the plans and systems needed for a robust, evolutionary strategy to explore cis-lunar space, the Mars sphere of influence (including the moons of Mars), and the surface of Mars. Recently, the emphasis of NASAs plans has changed to focus on the prolonged pioneering of space, rather than focusing on a single crewed mission as the ultimate goal. A sustainable, pioneering vision of space would include in-situ resource utilization (ISRU) in multiple forms and at multiple destinations: atmospheric capture of Mars CO2 and/or volatiles for consumables and propellants, regolith for bulk and refined materials, and in-situ manufacturing at the Moon, Mars, and other bodies. These resources would enable a reduction in the logistical needs from Earth for future missions, thus preparing the way for a sustained presence on Mars. Although the EMC initially relies only on propellant production for the Mars ascent vehicle via ISRU, one of its primary objectives is to prospect at every EMC destination to understand the potential for ISRU; this will permit true pioneering to be enabled after the first crew arrives at Mars. Recent and ongoing analysis has considered the possible prospecting measurements that can be performed at the asteroid returned to cis-lunar space by the Asteroid Robotic Redirect Mission (ARRM), at the lunar surface, at Phobos and Deimos, and on the surface of Mars to identify available resources for future use. These opportunities will be available on missions currently in the Evolvable Mars Campaign construct, and will also facilitate the testing and demonstration of resource acquisition, processing, storage, and useage technologies that can play a role in later missions. This analysis has also led to the identification of several objectives that should be targeted during the missions building up to and including the initial crewed missions. These objectives are mapped to strategies for incorporating ISRU to support resource cycle closure and reduce mass requirements from Earth. This analysis has yielded engineering constraints, based on ISRU, that impact the evaluation of landing sites for missions to the surface of Mars. The terrain of a particular site must be sufficiently flat to permit ISRU systems, as well as ancillary systems such as power and propellant storage tanks, to be landed, moved into position, set up, and operated. Water must be accessible in a form that can be acquired via ISRU, in quantities that align with demands. The chosen method of acquiring and processing water should align with the available resources at a particular site, and that site must have sufficient quantities to meet the requirements (based on crew consumables and propellant demands). Lower altitude landing sites are preferred, as the increase in density can facilitate carbon dioxide acquisition from the atmosphere. Another preference is for sites with a greater ability to move regolith for civil engineering purposes; for example, this would be conducive to both bulk regolith uses (such as the manufacture of berms), and processed regolith uses (such as microwave sintering).

Concepts of Operations for Asteroid Rendezvous Missions Focused on Resources Utilization

Several asteroids are the targets of international robotic space missions currently manifested or in the planning stage. This global interest reflects a need to study these celestial bodies for the scientific information they provide about our solar system, and to better understand how to mitigate the collision threats some of them pose to Earth. Another important objective of these missions is providing assessments of the potential resources that asteroids could provide to future space architectures. In this paper, we examine a series of possible mission operations focused on advancing both our knowledge of the types of asteroids suited for different forms of resource extraction, and the capabilities required to extract those resources for mission enhancing and enabling uses such as radiation protection, propulsion, life support, shelter and manufacturing. An evolutionary development and demonstration approach is recommended within the framework of a larger campaign that prepares for the first landings of humans on Mars. As is the case for terrestrial mining, the development and demonstration approach progresses from resource prospecting (understanding the resource, and mapping the ‘ore body’), mining/extraction feasibility and product assessment, pilot operations, to full in-situ resource utilization (ISRU). Opportunities to gather specific knowledge for ISRU via resource prospecting during science missions to asteroids are also examined to maximize the pace of development of needed ISRU capabilities and technologies for deep space missions.

Regolith-Derived Heat Shield for Planetary Body Entry and Descent System with In Situ Fabrication

In this paper we will discuss a new mass-efficient and innovative way of protecting high-mass spacecraft during planetary Entry, Descent & Landing (EDL). Heat shields fabricated in situ can provide a thermal-protection system (TPS) for spacecraft that routinely enter a planetary atmosphere. By fabricating the heat shield with space resources from regolith materials available on moons and asteroids, it is possible to avoid launching the heat-shield mass from Earth. Three regolith processing and manufacturing methods will be discussed: 1) oxygen & metal extraction ISRU processes produce glassy melts enriched in alumina and titania, processed to obtain variable density, high melting point and heat-resistance; 2) compression and sintering of the regolith yield low density materials; 3) in-situ derived high-temperature polymers created to bind regolith particles together, with a lower energy budget.

Multiphysics modeling for dimensional analysis of a self-heated Molten Regolith Electrolysis reactor for oxygen and metals production from space resources

The technology of direct electrolysis of molten lunar regolith to produce oxygen and molten metal alloys has progressed greatly in the last few years. The development of longlasting inert anodes and cathode designs as well as techniques for the removal of molten products from the reactor has been demonstrated. The containment of chemically aggressive oxide and metal melts is very difficult at the operating temperatures ca. 1600oC. Containing the molten oxides in a regolith shell can solve this technical issue and can be achieved by designing a self-heating reactor in which the electrolytic currents generate enough Joule heat to create a molten bath.