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The amount of oxygen consumption for crew extravehicular activity (EVA) in future lunar exploration missions will be significant. Eight technologies to provide high pressure EVA O2 were investigated. They are: high pressure O2 storage, liquid oxygen (LOX) storage followed by vaporization, scavenging LOX from Lander followed by vaporization, LOX delivery followed by sorption compression, water electrolysis followed by compression, stand-alone high pressure water electrolyzer, Environmental Control and Life Support System (ECLSS) and Power Elements sharing a high pressure water electrolyzer, and ECLSS and In-Situ Resource Utilization (ISRU) Elements sharing a high pressure electrolyzer. A trade analysis was conducted comparing launch mass and equivalent system mass (ESM) of the eight technologies in open and closed ECLSS architectures. Technologies considered appropriate for the two architectures were selected and suggested for development.

The development of the Advanced Life Support (ALS) Sizing Analysis Tool (ALSSAT) using Microsoft® Excel was initiated by the Crew and Thermal Systems Division of the NASA Johnson Space Center (JSC) in 1997 to support the ALS and Exploration Offices in Environmental Control and Life Support System (ECLSS) design and studies. It aids the user in performing detailed sizing of the ECLSS for different combinations of Exploration Life Support (ELS) regenerative system technologies. This analysis tool will assist the user in performing ECLSS preliminary design and trade studies as well as system optimization efficiently and economically.

NASA is working to develop a new lunar lander to support lunar exploration. The development process that the Altair project is using for this vehicle is unlike most others. In “Lander Design Analysis Cycle 1” (LDAC-1), a single-string, minimum functionality design concept was developed, including life support systems for different vehicle configuration concepts. The first configuration included an ascent vehicle and a habitat with integral airlocks. The second concept analyzed was a combined ascent vehicle-habitat with a detachable airlock. In LDAC-2, the Altair team took the ascent vehicle-habitat with detachable airlock and analyzed the design for the components that were the largest contributors to the risk of loss of crew (LOC). For life support, the largest drivers were related to oxygen supply and carbon dioxide control. Integrated abort options were developed at the vehicle level.

NASA's Constellation Program, which includes the mission objectives of establishing a permanently-manned lunar Outpost, and the exploration of Mars, poses new and unique challenges for human life support systems that will require solutions beyond the Shuttle and International Space Station state of the art systems. In particular, the requirement to support crews for extended durations at the lunar outpost with limited resource resupply capability will require closed-loop regenerative life support systems with minimal expendables. Planetary environmental conditions such as lunar dust and extreme temperatures, as well as the capability to support frequent and extended-duration Extra-vehicular Activity's (EVA's) will be particularly challenging.

Exploration Life Support (ELS) is a technology development project under the National Aeronautics and Space Administration's (NASA) Exploration Technology Development Program. The ELS Project's goal is to develop and mature a suite of Environmental Control and Life Support System (ECLSS) technologies for potential use on human spacecraft under development in support of U.S. Space Exploration Policy. Technology development is directed at three major vehicle projects within NASA's Constellation Program: the Orion Crew Exploration Vehicle (CEV), the Altair Lunar Lander and Lunar Surface Systems, including habitats and pressurized rovers. The ELS Project includes four technical elements: Atmosphere Revitalization Systems, Water Recovery Systems, Waste Management Systems and Habitation Engineering, and two cross cutting elements, Systems Integration, Modeling and Analysis, and Validation and Testing.

Engineers designing life support systems for NASA's next Lunar Landers face unique challenges. As with any vehicle that enables human spaceflight, the needs of the crew drive most of the lander requirements. The lander is also a key element of the architecture NASA will implement in the Constellation program. Many requirements, constraints, or optimization goals will be driven by interfaces with other projects, like the Crew Exploration Vehicle, the Lunar Surface Systems, and the Extravehicular Activity project. Other challenges in the life support system will be driven by the unique location of the vehicle in the environments encountered throughout the mission. This paper examines several topics that may be major design drivers for the lunar lander life support system. There are several functional requirements for the lander that may be different from previous vehicles or programs and recent experience.

Hamilton Sundstrand has developed a scalable evaporative heat rejection system called the Multi-Fluid Evaporator (MFE). It was designed to support the Orion Crew Module and to support future Constellation missions. The MFE would be used from Earth sea level conditions to the vacuum of space. This system combines the functions of the Space Shuttle flash evaporator and ammonia boiler into a single compact package with improved freeze-up protection. The heat exchanger core is designed so that radial flow of the evaporant provides increasing surface area to keep the back pressure low. The multiple layer construction of the core allows for efficient scale up to the desired heat rejection rate. A full-scale unit uses multiple core sections that, combined with a novel control scheme, manage the risk of freezing the heat exchanger cores. A four-core MFE prototype was built in 2007.

In preparation for the contract award of the Crew Exploration Vehicle (CEV), the National Aeronautics and Space Administration (NASA) produced two design reference missions for the vehicle. The design references used teams of engineers across the agency to come up with two configurations. This process helped NASA understand the conflicts and limitations in the CEV design, and investigate options to solve them.

Hamilton Sundstrand is under contract with the NASA Johnson Space Center to develop a scalable, evaporative heat rejection system called the Multi-Fluid Evaporator (MFE). It is being designed to support the Orion Crew Module and to support future Constellation missions. A MFE would be used from Earth sea level conditions to the vacuum of space. The current Space Shuttle configuration utilizes an ammonia boiler and flash evaporator system to achieve cooling at all altitudes. With the MFE system, both functions are combined into a single compact package with significant weight reduction and improved freeze-up protection. The heat exchanger core is designed so that radial flow of the evaporant provides increasing cross-sectional area to keep the back pressure low. Its multiple layer construction allows for efficient scale up to the desired heat rejection rate.

Selecting the appropriate atmosphere for a spacecraft and mission is a complicated problem. NASA has previously used atmospheres from Earth normal composition and pressure to pure oxygen at low pressures. Future exploration missions will likely strike a compromise somewhere between the two, trying to balance operation impacts on EVA, safety concerns for flammability and health risks, life science and physiology questions, and other issues. Life support systems and internal thermal control systems are areas that will have to respond to changes in the atmospheric composition and pressure away from the Earth-like conditions currently used on the International Space Station. This paper examines life support and internal thermal control technologies currently in use or in development to find what impacts in design, efficiency and performance, or feasibility might be expected.

Sublimators have been used for heat rejection for a variety of space applications including the Apollo Lunar Module and the Extravehicular Mobility Unit (EMU). Sublimators are excellent candidates for heat rejection devices on future vehicles like the Crew Exploration Vehicle (CEV), the Lunar Surface Access Module (LSAM), and future spacesuits. One of the drawbacks of previous designs was sensitivity to contamination in the feedwater. Undissolved contaminants can be removed with filters, but dissolved contaminants would be left in the pores of the porous plates in which the feedwater freezes and sublimates. These contaminants build up and clog the relatively small pores (~3–6 μm), thereby blocking the flow of the feedwater, reducing the available area for freezing and sublimation, and degrading the performance of the sublimator. For the X-38 program, a new sublimator design was developed by NASA-JSC that is less sensitive to contaminants.

The challenges of missions to the Moon and Mars presents NASA with the need for more advanced life support systems, including better technologies for CO2 removal in spacecraft atmospheres and extravehicular mobility units (EMU). Amine-coated single wall carbon nanotubes (SWCNT) have been proposed as a potential solution because of their high surface area and thermal conductivity. Initial research demonstrated the need for functionalization of SWCNT to obtain optimal adherence of the amine to the SWCNT support phase [1]. Recent efforts focus on the development of new methods to chemically bond amines to SWCNT. Synthesis and characterization methods for these materials are discussed and some preliminary materials characterization data are presented. The CO2 adsorption capacity for several versions of SWCNT supported amine-based CO2 scrubber materials is also determined.

For short durations, evaporative heat rejection systems are a very effective way of removing heat from spacecraft. Future NASA vehicles, such as the Crew Exploration Vehicle (CEV), will require non-radiative heat rejection systems during at least a portion of the planned mission, just as their predecessors have. While existing technologies are available to modify, such as Apollo era sublimators, or the Space Shuttle Flash Evaporator System (FES), several new technologies are under development or investigation to progress beyond these existing heat rejection systems. Examples include the Multi-Fluid Evaporator developed by Hamilton Sundstrand, improvements upon the Contaminant Insensitive Sublimator originally developed for the X-38 program, and a Compact Flash Evaporator System. Other possibilities evaluate new ways of operating existing designs.

A cryofreezer system is being evaluated as a new method of compressing and storing carbon dioxide (CO2) in an Advanced Life Support (ALS) Environmental Control and Life Support System (ECLSS). A cryocooler is used to provide cold temperatures and heat removal while CO2 freezes and accumulates around a coldtip. The CO2 can then be stored as a liquid or high-pressure gas after it has been accumulated. This system was originally conceived as an In-Situ Resource Utilization (ISRU) application for collecting CO2 from the Mars atmosphere to be converted to methane fuel with a Sabatier reaction. In the ALS application, this system could collect CO2 from the International Space Station (ISS) Carbon Dioxide Removal Assembly (CDRA) for delivery to the Sabatier reactor. The Sabatier reaction is an important part of proposed Air Revitalization System (ARS) for ALS, and technology sharing is often possible between ISRU and ARS applications in CO2 processing systems.

Technology developers understand the need to optimize technologies for human missions beyond Earth. Greater benefits are achievable when systems that share common interfaces are optimized as an integrated unit, including taking advantage of possible synergies or removing counterproductive efforts at the mission level. Life support, extravehicular activity (EVA), and habitability are three systems that have significant interfaces with the crew, and thus share many common interfaces with each other. Technologies and architectures developed for these systems need to account for the effect that design decisions will have on each of the other systems. Many of these impacts stem from the use of water by the crew and the way that the life support system provides and processes that water. Other resources, especially air-related, can have significant impacts as well.

Biological processes represent a potential primary treatment approach as part of an integrated system for recycling wastewater during long term space missions. The rationale for biological processing lies in the removal of organic and nitrogen contaminants within the wastewater, leading to concomitant reductions in the costs of downstream P/C systems used for production of potable water. Several different general approaches for biological processing are under evaluation; 1) separate versus single reactors for conducting nitrification and denitrification, 2) rotating the membrane unit to enhance the rate of nitrification, 3) integration of alternative electron acceptors (H2 or CH4) for more complete volatilization of nitrogen. Equivalent system mass (ESM analysis) of the different biological reactor configurations was performed to assess design alternatives for both the transit mission and early planetary base (EPB).

Dynamic modeling can be a powerful tool to predict the performance of life support technologies, especially those with strong transient behaviors or those that cycle between on and off states regularly. The Advanced Life Support (ALS) Air Revitalization System (ARS) is an example of a system where detailed integrated simulations can be a useful technique for studying the system behavior. This paper describes the results of integrating models of three components of the ARS: the Carbon Dioxide Removal Assembly (CDRA), Carbon Dioxide Management Subsystem (CMS) made of a mechanical compressor and accumulator, and the Carbon Dioxide Reduction Assembly (CRA). The combination of these systems has been proposed as an upgrade to the International Space Station (ISS) Environmental Control and Life Support System (ECLSS), and is considered a baseline for further ALS studies.

A dynamic simulation of the ISS CDRA hardware was created using the Aspen Custom Modeler software platform. The dynamic model calculates the material and energy balances that describe the system properties. The model was calibrated by comparison to test data results from a flight-like CDRA at NASA Marshall Space Flight Center. While other FORTRAN models of the CDRA already exist, developing an ACM simulation is the first step towards creating a generic tool to simulate larger collections of life support hardware. The ACM tool should make it possible to be very flexible when rearranging these models to simulate possible configurations of the life support subsystems that could be used in the future, especially for advanced life support applications.