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The design and evaluation of a Vacuum-Swing Adsorption (VSA) system to remove metabolic water and metabolic carbon dioxide from a spacecraft atmosphere is presented. The approach for Orion and Altair is a VSA system that removes not only 100 percent of the metabolic CO2 from the atmosphere, but also 100% of the metabolic water as well, a technology approach that has not been used in previous spacecraft life support systems. The design and development of an Orion Crew Exploration Vehicle Sorbent Based Atmosphere Revitalization system, including test articles, a facility test stand, and full-scale testing in late 2008 and early 2009 is discussed.

The design of a vacuum-swing adsorption process to remove metabolic water, metabolic carbon dioxide, and metabolic and equipment generated trace contaminant gases from the Orion Crew Exploration Vehicle (CEV) atmosphere is presented. For Orion, the approach is taken that all metabolic water must be removed by the Sorbent-Based Atmosphere Revitalization System (SBAR), a technology approach that has not been used in previous spacecraft life support systems. Design and development of a prototype SBAR, a facility test stand, and subsequent testing of the SBAR in late 2006 and early 2007 is discussed.

Validation and simulations of a real-time dynamic cabin model were conducted on the sorbent-based atmosphere revitalization system for Orion. The dynamic cabin model, which updates the concentration of H2O and CO2 every second during the simulation, was able to predict the steady state model values for H2O and CO2 for long periods of steady metabolic production for a 4-person crew. It also showed similar trends for the exercise periods, where there were quick changes in production rates. Once validated, the cabin model was used to determine the effects of feed flow rate, cabin volume and column volume. A higher feed flow rate reduced the cabin concentrations only slightly over the base case, a larger cabin volume was able to reduce the cabin concentrations even further, and the lower column volume led to much higher cabin concentrations. Finally, the cabin model was used to determine the effect of the amount of silica gel in the column.

The design of a Vacuum-Swing Adsorption (VSA) system to remove metabolic water and metabolic carbon dioxide from the Orion Crew Exploration Vehicle (CEV) atmosphere is presented. The approach for Orion is a VSA system that removes not only 100 percent of the metabolic CO2 from the atmosphere, but also 100% of the metabolic water as well, a technology approach that has not been used in previous spacecraft life support systems. The design and development of the Sorbent Based Atmosphere Regeneration (SBAR) system, including test articles, a facility test stand, and full-scale testing in late 2007 and early 2008 is discussed.

In NASA's Vision for Space Exploration, humans will once again travel beyond the confines of earth's gravity, this time to remain there for extended periods. These forays will place unprecedented demands on launch systems. They must not only blast out of earth's gravity well as during the Apollo moon missions, but also launch the supplies needed to sustain a larger crew over much longer periods. Thus all spacecraft systems, including those for the separation of metabolic carbon dioxide and water from a crewed vehicle, must be minimized with respect to mass, power, and volume. Emphasis is also placed on system robustness both to minimize replacement parts and ensure crew safety when a quick return to earth is not possible. This paper describes efforts to improve on typical packed beds of sorbent pellets by making use of structured sorbents and alternate bed configurations to improve system efficiency and reliability.

CO2 removal, recovery and reduction are essential processes for a closed loop air revitalization system in a crewed spacecraft. Typically, a compressor is required to recover the low pressure CO2 that is being removed from the spacecraft in a swing bed adsorption system. This paper describes integrated tests of a Temperature-Swing Adsorption Compressor (TSAC) with high-fidelity systems for carbon dioxide removal and reduction assemblies (CDRA and Sabatier reactor). It also provides details of the TSAC operation at various CO2 loadings. The TSAC is a solid-state compressor that has the capability to remove CO2 from a low-pressure source, and subsequently store, compress, and deliver it at a higher pressure. TSAC utilizes the principle of temperature-swing adsorption compression and has no rapidly moving parts.

The design of a vacuum-swing adsorption process to remove metabolic water, metabolic carbon dioxide, and metabolic and equipment generated trace contaminant gases from the crew exploration vehicle (CEV) atmosphere is presented. For the CEV, the sorbent-based atmosphere revitalization (SBAR) system must remove all metabolic water, a technology approach that has not been used in previous spacecraft life support systems. Design and development of a prototype SBAR, a full scale and subscale facility test stand, and other aspects of the SBAR development program is discussed.

A cyclic adsorption process simulator was used to determine preliminary bed size and characteristics for a sorbent-based atmosphere revitalization (SBAR) system being designed by NASA for the Crew Exploration Vehicle. An initial study of a 2-bed 3-step 3-layer, vacuum swing adsorption cycle, utilizing 50% silica gel, 17% 13X zeolite, and 33% 5A zeolite revealed that a 10 L bed could easily meet the CO2 and H2 O removal criteria for a 3 person crew. A parametric study showed that the cycle time, layering percentage of silica gel, and H2 O-silica gel mass transfer coefficient were important parameters in the SBAR design. Increasing the cycle time diminished the CO2 and H2 O removal performances but resulted in less O2 lost to space. The CO2 and H2 O removal performances increased considerably when a silica gel layer was added to the bed, with the above layering percentages being close to optimum. As more silica gel was added to the bed slightly more O2 was lost.

A finite-difference gas adsorption computer model for CO2, H2O, and N2 on zeolite 5A is discussed. It is part of an effort to predict results, via simulation, of changing a spacecraft CO2 removal system's operational configuration. The mathematical and numerical modeling approach, with emphasis on identification and independent verification of important adsorption physics, is described. The apparatus used to obtain single and multicomponent isotherms, and the subscale packed column bench test used to derive transfer coefficients and verify the model are described. The favorable comparison of simulation and test results show the potential for predictive capability with this modeling approach.

An important aspect of air revitalization for life support in spacecraft is the removal of carbon dioxide from cabin air. Several types of carbon dioxide removal systems are in use or have been proposed for use in spacecraft life support systems. These systems rely on various removal techniques that employ different architectures and media for scrubbing CO2, such as permeable membranes, liquid amine, adsorbents, and absorbents. Sorbent systems have been used since the first manned missions. The current state of key technology is the existing International Space Station (ISS) Carbon Dioxide Removal Assembly (CDRA), a system that selectively removes carbon dioxide from the cabin atmosphere. The CDRA system was launched aboard UF-2 in February 2001 and resides in the U.S. Destiny Laboratory module. During the past four years, the CDRA system has experienced operational limitations.

Continuous removal of carbon dioxide is one of the most critical processes in a spacecraft air revitalization system. Recovery of the waste carbon dioxide and its subsequent conversion to oxygen become essential for long-duration human space missions beyond Low-Earth orbit where re-supply of consumables such as oxygen is neither practical nor economical. The current CO2 removal technology employed in the United States Operating Segment (USOS) of the International Space Station (ISS) operates in an open loop mode where the waste CO2 is vented to space. A compressor is required to facilitate CO2 recovery capabilities. The CO2 removal process itself is one of the most energy-intensive processes in the life support system of the ISS due to the water vapor recovery method involved in the process. This paper discusses the design and development of a low-power CO2 removal system that has capabilities to recover and compress the CO2 for recycling oxygen.

An analysis model has been developed for analyzing/optimizing the integration of a carbon dioxide removal assembly (CDRA), CO2 compressor, accumulator, and Sabatier CO2 reduction assembly. The integrated model can be used in optimizing compressor sizes, compressor operation logic, water generation from Sabatier, utilization of CO2 from crew metabolic output, and utilization of H2 from oxygen generation assembly. Tests to validate CO2 desorption, recovery, and compression had been conducted in 2002-2003 using CDRA/Simulation compressor set-up at NASA Marshall Space Flight Center (MSFC). An analysis of test data has validated CO2 desorption rate profile, CO2 compressor performance, CO2 recovery and CO2 vacuum vent in the CDRA model. Analysis / optimization of the compressor size and the compressor operation logic for an integrated closed air revitalization system is currently being conducted

Following a series of anomalies of the carbon dioxide removal assembly (CDRA) on the International Space Station (ISS), a CDRA teardown, test, and evaluation (TT&E) effort found that the sorbent material was not retained as intended by the packed beds and that presence of the sorbent in the check valve and selector valves was the cause of the failure of these components. This paper documents the development of design data for an in-line filter element. The purpose of the in-line filter is to provide temporary protection for on-orbit CDRA hardware until the bed retainment system can be redesigned and replaced.

Accumulation and subsequent compression of carbon dioxide that is removed from the space cabin are two important processes involved in a closed-loop air revitalization scheme of the International Space Station (ISS). The 4-Bed Molecular Sieve (4BMS) of ISS currently operates in an open loop mode without a compressor. This paper reports the integrated 4BMS and liquid-cooled Temperature Swing Adsorption Compressor (TSAC) testing conducted during the period of March 3 to April 18, 2003. The TSAC prototype was developed at NASA Ames Research Center (ARC)1. The 4BMS was modified to a functionally flight-like condition at NASA Marshall Space Flight Center (MSFC)2. Testing was conducted at MSFC. The paper provides details of the TSAC operation at various CO2 loadings and corresponding performance of the 4BMS.

This paper presents and discusses the results of an integrated 4-Bed Molecular Sieve (4BMS), mechanical compressor, and Sabatier Engineering Development Unit (EDU) test. Testing was required to evaluate the integrated performance of these components of a closed loop atmosphere revitalization system together with a proposed compressor control algorithm. A theoretical model and numerical simulation had been used to develop the control algorithm; however, testing was necessary to verify the simulation results and further refine the model. Hardware testing of a fully integrated system also provided a better understanding of the practical inefficiencies and control issues, which are unavailable from a theoretical model.

Performance testing of the International Space Station Carbon Dioxide Removal Assembly flight hardware in the United States Laboratory during 1999 is described. The CDRA exceeded carbon dioxide performance specifications and operated flawlessly. Data from this test is presented.

This paper describes testing of four-bed molecular sieve (4BMS) development hardware in support of future operations of the International Space Station (ISS) Carbon Dioxide Removal Assembly (CDRA). During 1998, testing of a MSFC 4BMS included operations with the 4BMS inlet air drawn directly from the cabin atmosphere instead of the baseline air source downstream of a Condensing Heat Exchanger (CHX), operating with high carbon dioxide (CO2) loading, and long duration operation in a power save mode. Additionally, testing with increased coolant water temperature was performed to determine effects on the systems CO2 removal performance.