Flight-Like Advanced Materials Reactor (FLAMR)

The National Research Council's "NASA Space Technology Roadmaps and Priorities" identified long-duration environmental control and life support systems (ECLSS) as one of the top five areas capable of having the greatest impact on deep space exploration. The capability addressed represents an advanced system to further close the atmosphere revitalization loop on long duration human spacecraft. NASA Space Technology Roadmap TA 6 “Human Health, Life Support and Habitation Systems” established for the technology performance goal of increasing the percentage of oxygen recovered from metabolic carbon dioxide to 75-90%. As future exploration missions extend beyond Low Earth Orbit (LEO), vehicles will require life support systems (LSS) with high reliability and self-sufficiency, as practical opportunities for consumable resupply will not exist. An effective life support system must maintain a safe and habitable atmosphere within a spacecraft by removing contaminants while simultaneously maintaining the proper atmospheric composition and cabin pressure. The goal of this effort is to advance the state-of-the-art of atmospheric revitalization system technologies required to enable NASA’s human exploration missions.

Honeywell International, Inc. developed the Methane Pyrolysis Brassboard between 2017 and 2021 which has an O₂ recovery rate of up to 95%. The Brassboard included metallic reactors.  Due to the high operating temperatures, it was determined that the reactors should be made of advanced materials to extend the operating lifecycle of the system.

Honeywell International Inc. then began further work to provide two Flight-Like Advanced Material reactors (FLAMR) to advance the methane pyrolysis technology. The period of performance of this contract is August 02, 2021 through August 2, 2026. This most recent contract aims to design a low-mass, low-heat-loss flight-like reactor that can withstand the high temperatures required by the Methane Pyrolysis process, with a focus on materials of construction and thermal management.  A 6-month extension of this contract is planned for the end of FY26 through the beginning of FY27. The extension will cover preliminary work towards development of a Flight Prototype. 

There are plans to contract with Honeywell Aerospace, Inc., a recent spin off of Honeywell International, Inc., to develop a Flight Prototype of the system beginning FY27.  The system will include the FLAMR reactors along with the ancillary hardware that make up the system. 

Along with the Sabatier, the CVD/MPS system has a theoretical oxygen (O₂) recovery of 95% from metabolic carbon dioxide (CO₂).This level of O2 recovery could eliminate the need for re-supply of Oxygen/water making long duration flight possible.

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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