[The following is an excerpt from a letter to Allen Meece]
[Updated 6 September 2002]
I'm afraid I must reverse myself on the idea of using solar
power to electrolyse water into oxygen for life support. While water is
the most convenient package for bringing oxygen and hydrogen to the platform,
some examination of how to fit the processing system into the hab reveals
that it is not the most efficient way to deliver oxygen and hydrogen once you
get it there.
Between breathing and power generation, the crew requires
about 2kg of oxygen per man day. Producing this from water also produces
three other products: hydrogen, half of which (the same number of moles as
oxygen produced) is stored for power generation and the other half is sent
directly to the lift cells to replace daily losses due to leaks and diffusion;
water vapor, which must be condensed out and can be returned to the system; and
ozone (a poison), which must be removed by converting it to usable oxygen with a
catalyst, returning it to the system. In addition to a heat exchanger and
catalyst bed, this also requires electrolysers, solar panels to run the
electrolysers, tanks and compressors to store the gas, and regulators &
tubing to distribute the gas to the crew and back to the fuel cell.
We would use two 10kW reversible fuel cells in this
scenario. With two, we can alternate them between producing gas and
producing power. A single reversible fuel cell doesn't have the power
output of other types of fuel cell of the same mass, but does have the same or
better gas output ratio as a dedicated electrolyser of the same size, so
it's better to just use two (or one reversible and one high power fuel
cell) and have the reserve power handy.
We require at least a 24 hour reserve of gas, because we will
be unable to obtain more overnight and must have sufficient reserves to repair a
non-functioning system during the day. Unfortunately, this requires a
large amount of tankage, for at least 1000 moles. Considering
the low rate at which we can expect gas to come out of the electrloyser and feed
through both the catalyst bed and heat exchanger, I don't think we can expect to
achieve high pressure in the tanks if we're using half their contents or
more on a daily basis. Rather than the hundreds of atmospheres found
in industrially bottled oxygen cylinders, I think the most the system will
be capable of is the ten or twenty atmospheres of a garage air
compressor. Unfortunately, it means that the number and volume of all
the tanks required to store all of this gas will be quite large. Though
the walls are thinner on low pressure tanks, there will be more of them and so
they will weigh more than for gas bottled at higher pressure. Chilling the
tanks by storing them outside will reduce their required volume, but
also reduces compressor efficiency and still does not come near the
reduction possible by storing the gas at higher pressure. And storing at
high pressure can only reduce their required mass by about a third. The
tanks will still be heavy because their walls must be thicker.
The mass breakdown for such a system is roughly:
Gas Cylinders
500kg, if stored inside the hab @15atm
400kg, if stored outside @15atm
Two 10kW Fuel
Cells 200kg
to 600kg (Depends on
design)
10kW Vertical Solar Array (180
W/m^2)
500kg
Compressors, regulators, and tubing
<100kg
Water
required 60kg
for 50 man-days
Ozone Catalyst and Heat
Exchanger <10kg
Rough Mass Estimate:
1300kg to 1800kg
This estimate is very imprecise. However, I don't think
there is anything we can do to get it down below 500kg, regardless of materials,
pressurization or anything else.
It is a testimony to the VBP's versatility that 1500kg is
still within our mass budget. However, shipping up enough oxygen on the
elevator for 50 man-days requires just 45kg of oxygen in a 40L dewar for the
crew. One crewman could probably lift each full dewar by himself.
The distribution system for liquid oxygen is relatively simple and light.
Furthermore, it isn't necessary to keep feeding a fuel cell because a fuel cell
isn't necessary. So long as it is recharged daily by the solar
array, a bank of nickel/metal-hydride batteries can do the same work as a
fuel cell at the same weight without requiring a drop of fuel.
(We will not need two, although it is desirable to break a single battery bank
up into parallel.) And halve the size of the solar array, since it no
longer needs to crack water for the crew's air. The entire
system could easily be accomplished with less than 600kg, including
the dewar.
So, rather than introducing an equipment problem to solve a
grocery problem, I recommend we get rid of both problems. Keep shipping up
the oxygen, which has to go up no matter what, only ship it in LOX form which is
immediately usable upon delivery. This way, we will not be limited to a
day's reserve of breathable air. Abandon multiple reversible fuel cells,
and the mass of systems and added fuel that go with them, in favor of
compact banks of metal-hydride batteries that do not require fuel or extensive
maintenance.
This means abandoning the idea of using solar power to crack
oxygen at the hab. But think of all the space you'll save where those
tanks used to go.