Turbomachinery Liquefaction Demonstration with a Recuperator (TLDR)

Commercial Space Partners are shifting focus to Mars Surface Habitation and are interested in the development of Mars Propellant Production. The Martian atmosphere consists of 95% CO2 and 5% inert gas. CO2 can be collected and reacted with hydrogen (H2) to form CH4. The Sabatier Reaction, an ECLSS technology, has historically utilized H2 (a byproduct from water electrolysis used for oxygen generation) and metabolic CO2 to produce CH4 and additional water to be used in a closed-loop ECLSS water system. This project focuses on purifying the CH4 in the outlet gas stream and cryocooling it to form LNG. A cryocooler is a refrigeration cycle which can cool the working fluid below 120K. A Martian cryocooler system would require long and high life capacity and the ability to interface with broad area cooling heat exchangers in cryogenic propellant tanks. This criterion is satisfied by reverse turbo-Brayton cycle cryocoolers being developed by the CFMPP In-house Cryocooler Activity, which consists of a warm-end compressor and heat rejection system, a counterflow recuperative heat exchanger, and a cold-end turbo-expander and load interface. While a packaged LNG liquefaction costs millions MSFC intends to use this TID to develop the turbo-expander for a 70-120K class cryocooler. The MSFC ECLSS Branch is in possession of a Sabatier Reactor test stand that can be used to produce CH4 from CO2. Conjoining this technology with ER13 turbo-expander technology, we can simulate the quality of fuel that can be produced from Martian Atmosphere Simulant (MAS) gas and H2. There are technologies available to separate Martian atmosphere components, so we are able to test a LNG product produced from pure CO2 as well as a LNG product from MAS gas. This test will also provide preliminary data regarding power and sizing requirements for a pilot plant demonstration on the Mars Surface. This project will also reduce the cost estimate of a pilot plant system by enabling preliminary data collection

NASA will trial production of liquid methane (LNG) fuel using an ECLSS technology that converts carbon dioxide (CO2) to methane (CH4) and water. This project matures cryocooling tech needed to produce and test quality of prototype Mars Surface LNG.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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