Climate Enhancing Resource Utilization Through Ultra-low-temperature, Electrolytic Carbon Dioxide Valorization on Mars

Supporting human life on long-tern space exploration missions to the surface of Mars requires sustainable in-situ resource utilization with minimal support from Earth. In particular, atmospheric carbon dioxide (CO2), which makes up 95% of the atmosphere on Mars, provides an abundant in-situ resource for human explorers. CO2 can be electrochemically reduced into ethanol, which exists as a liquid on the Martian surface, allowing for relative ease of storage.Ethanol is a critical component for manned missions to exoplanets, as this chemical is a high energy density fuel (30 MJ/kg), is a potent chemical for sterilization of equipment to prevent cross contamination of Earth life and potential Martian life, and can be used as a solvent for a variety of scientific experiments. Phase I demonstrated the feasibility of electrochemical conversion of atmospheric CO2 to ethanol. Ethanol was produced at a rate of 2.2 g per hour, with an energy efficiency of 0.31 g of ethanol per watt-hour and faradic efficiencies of87% and 72% for catalyst and electrochemical cell, respectively. Phase II will include improvement of the catalyzed cathode surface to achieve a faradaic efficiency in the cell of at least 80%, coupled with scaling the cell to increase the ethanol production rate to at least 20 g per hour at an energy efficiency of 0.5 g of ethanol per watt-hour. We will produce ethanol under conditions that are relevant to the surface of Mars (down to -60℃ and 7 mbar), work on purification of the ethanol product, and perform durability testing, catalyst regeneration studies, and operation under various orientations versus gravity. Phase II will include designing an alpha-scale electrochemical cell for testing in later work, with the long term goal of ethanol production rates of 2.8 kg per hour. We will reach out to commercialization partners in the space industry to align the technology transition to their needs. The innovation is an energy efficient, scalable electrochemical apparatus and process for conversion of atmospheric carbon dioxide into ethanol on manned missions to Mars. This will meet NASA’s in-situ resource utilization needs to provide sustainable infrastructure for long-term space exploration with minimal support from Earth, to minimize the cost of escaping Earth’s gravity well. Potential uses for ethanol on Mars include as an energy dense fuel, as a feedstock for manufacturing materials such as polyethylene, as a solvent, and for sterilization of equipment. Phase I demonstrated ethanol production from carbon dioxide at over 2 g per hour, at energy efficiencies of 0.3 g per watt-hour, and faradaic efficiencies of over 70%, exceeding Phase I targets. The long term goal is ethanol production rates of 2.8 kg per hour at energy efficiencies of 1 g per watt-hour. This technology is a scalable production platform with low mass and volume, operational under conditions on the Martian surface, that produces a high-value feedstock with high product selectivity and energy efficiency. The overall objective is the development and scale-up of an energy efficient, durable, scalable manufacturing solution to produce ethanol from atmospheric carbon dioxide on Mars. Phase II Objectives include: Scale up the electrochemical cell for CO2 conversion to ethanol by coupling advanced catalysts with improved cell designs and operational protocols to exceed an ethanol production rate of 20 g per hour, energy efficiency of 0.5 g of ethanol per watt-hour, and cell faradaic efficiency of 80 percent. Separate and purify the ethanol. Demonstrate productivity and energy efficiency of the electrochemical cell under relevant Martian conditions (-60℃, 7 mbar), including operation under various orientations with respect to gravity. Demonstrate durability of cell components over extended periods of time and under relevant conditions. Ensure the catalyst retains 75 percent of ethanol production capacity for 100 hours. Develop catalyst regeneration protocols. Design an alpha-scale electrochemical cell for ethanol production of 200 g per hour, based on modeling and operational data for single cells and a 3-cell stack. Identify a pathway to system scale and implementation on commercial and NASA space missions. Proposed deliverables: All contractually required reports Design of an alpha-scale system for high rate conversion of atmospheric carbon dioxide into ethanol

Production of high-value energy and chemical feedstocks using in-situ resources is critical for success of manned missions to Mars. The proposed technology would support lower launch masses required for escaping Earth’s gravity well and long-term activities on the Martian surface. Ethanol produced using this technology could be used as a fuel source, for disinfection, or as a feedstock for production of materials such as polyethylene. The oxygen produced as a byproduct can be used in life-support systems or an oxidant in propellants. The potential terrestrial customer could be involved in a variety of industries. By far the largest industry for ethanol is the fuel industry, in which ethanol is an additive in gasoline to improve emissions. The ability to produce cleaner burning fuels while also removing greenhouse gases from the atmosphere in the process could be a significant selling point for commercial partnerships.

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