Design Status of the Capillary Brine Residual in Containment Water Recovery System

One of the goals of the AES Life Support System (LSS) Project is to achieve 98% water loop closure for long duration human exploration missions beyond low Earth orbit. To meet this objective, the AES LSS Project is developing technologies to recover water from wastewater brine; highly concentrated waste products generated from a primary water recovery system. The state of the art system used aboard the International Space Station (ISS) has the potential to recover up to 85% water from unine wastewater, leaving a significant amounts of water in the waste brine, the recovery of which is a critical technology gap that must be filled in order to enable long duration human exploration. Recovering water from the urine wastewater brine is complicated by the concentration of solids as water is removed from the brine, and the concentration of the corrosive, toxic chemicals used to stabilize the urine which fouls and degrades water processing hardware, and poses a hazard to operators and crew. Brine Residual in Containment (BRIC) is focused on solids management through a process of "in-place" drying - the drying of brines within the container used for final disposal. Application of in-place drying has the potential to improve the safety and reliability of the system by reducing the exposure to crew and hardware to the problematic brine residual. Through a collaboration between the NASA Johnson Space Center and Portland Status University, a novel water recovery system was developed that utilizes containment geometry to support passive capillary flow and static phase separation allowing free surface evaporation to take place in a microgravity environment. A notional design for an ISS demonstration system was developed. This paper describes the concept for the system level design

Honeywell Cascade Distiller System Performance Testing Interim Results

The ability to recover and purify water through physiochemical processes is crucial for realizing long-term human space missions, including both planetary habitation and space travel. Because of their robust nature, distillation systems have been actively pursued as one of the technologies for water recovery. The Cascade Distillation System (CDS) is a vacuum rotary distillation system with potential for greater reliability and lower energy costs than existing distillation systems. The CDS was previously under development through Honeywell and NASA. In 2009, an assessment was performed to collect data to support down-selection and development of a primary distillation technology for application in a lunar outpost water recovery system. Based on the results of this testing, an expert panel concluded that the CDS showed adequate development maturity, TRL-4, together with the best product water quality and competitive weight and power estimates to warrant further development. The Advanced Exploration Systems (AES) Water Recovery Project (WRP) worked to address weaknesses identified by The Panel; namely bearing design and heat pump power efficiency. Testing at the NASA-JSC Advanced Exploration System Water Laboratory (AES Water Lab) using a prototype Cascade Distillation Subsystem (CDS) wastewater processor (Honeywell International, Torrance, Calif.) with test support equipment and control system developed by Johnson Space Center was performed to evaluate performance of the system with the upgrades. The CDS will also have been challenged with ISS analog waste streams and a subset of those being considered for Exploration architectures. This paper details interim results of the AES WRP CDS performance testing

Cascade Distillation System Design for Safety and Mission Assurance

Per the NASA Human Health, Life Support and Habitation System Technology Area 06 report "crewed missions venturing beyond Low-Earth Orbit (LEO) will require technologies with improved reliability, reduced mass, self-sufficiency, and minimal logistical needs as an emergency or quick-return option will not be feasible." To meet this need, the development team of the second generation Cascade Distillation System (CDS 2.0) opted a development approach that explicitely incorporate consideration of safety, mission assurance, and autonomy. The CDS 2.0 prelimnary design focused on establishing a functional baseline that meets the CDS core capabilities and performance. The critical design phase is now focused on incorporating features through a deliberative process of establishing the systems failure modes and effects, identifying mitigative strategies, and evaluating the merit of the proposed actions through analysis and test. This paper details results of this effort on the CDS 2.0 design

Development of an Exploration-Class Cascade Distillation System: Flight Like Prototype Design Status

The ability to recover and purify water through physiochemical processes is crucial for realizing long-term human space missions, including both planetary habitation and space travel. Because of their robust nature, distillation systems have been actively pursued as one of the technologies for water recovery. One such technology is the Cascade Distillation System (CDS) a multi-stage vacuum rotary distiller system designed to recover water in a microgravity environment. The CDS provides a similar function to the state of the art (SOA) vapor compressor distiller (VCD) currently employed on the International Space Station, but its control scheme and ancillary components are judged to be more straightforward and simpler to implement into a more reliable and efficient system. Through the Advanced Exploration Systems (AES) Life Support Systems (LSS) Project, the NASA Johnson Space Center (JSC) in collaboration with Honeywell International is developing a second generation flight forward prototype (CDS 2.0). A preliminary design fo the CDS 2.0 was presented to the project in September 2014. Following this review, detailed design of the system continued. The existing ground test prototype was used as a platform to demonstrate key 2.0 design and operational concepts to support this effort and mitigate design risk. A volumetric prototype was also developed to evaluate the packaging design for operability and maintainability. The updated system design was reviewed by the AES LSS Project and other key stakeholders in September 2015. This paper details the status of the CDS 2.0 design

Development of an Exploration-Class Cascade Distillation Subsystem: Performance Testing of the Generation 1.0 Prototype

The ability to recover and purify water is crucial for realizing long-term human space missions. The National Aeronautics and Space Admininstration and Honeywell co-developed a five-stage vacuum rotary distillation water recovery system referred to as the Cascade Distillation Subsystem (CDS). Over the past three years, NASA's Advanced Exploration Systems (AES) Water Recovery Project (WRP) has been working toward the development of a flight-forward CDS design. In 2012 the original CDS prototype underwent a series of incremental upgrades and tests intened to both demonstrate the feasibility of a on-orbit demonstration of the system and to collect operational and performance data to be used to inform a second generation design. The latest testing of the CDS Generation 1.0 prototype was conducted May 29 through July 2, 2014. Initial system performance was benchmarked by processing deionized water and sodium chloride. Following, the system was challenged with analogue urine waste stream solutions stabilized with an Oxone-based and the two International Space Station baseline and alternative pretreatment solutions. During testing, the system processed more than 160 kilograms of wastewater with targeted water recoveries between 75 and 85% depending on the specific waste stream tested. For all wastewater streams, contaminant removals from wastewater feed to product water distillate, were estimated at greater than 99%. The average specific energy of the system was less than 120 Watt-hours/kilogram. The following paper provides detailed information and data on the performance of the CDS as challenged per the WRP test objectives

Cascade Distillation System Design for Safety and Mission Assurance

Per the NASA Human Health, Life Support and Habitation System Technology Area 06 report "crewed missions venturing beyond Low-Earth Orbit (LEO) will require technologies with improved reliability, reduced mass, self-sufficiency, and minimal logistical needs as an emergency or quick-return option will not be feasible".1 To meet this need, the development team of the second generation Cascade Distillation System (CDS 2.0) chose a development approach that explicitly incorporate consideration of safety, mission assurance, and autonomy. The CDS 2.0 preliminary design focused on establishing a functional baseline that meets the CDS core capabilities and performance. The critical design phase is now focused on incorporating features through a deliberative process of establishing the systems failure modes and effects, identifying mitigation strategies, and evaluating the merit of the proposed actions through analysis and test. This paper details results of this effort on the CDS 2.0 design

Cascade Distillation System Development

NASA's Advanced Exploration Systems (AES) Life Support System (LSS) Project is chartered with de-veloping advanced life support systems that will ena-ble NASA human exploration beyond low Earth orbit (LEO). The goal of AES is to increase the affordabil-ity of long-duration life support missions, and to re-duce the risk associated with integrating and infusing new enabling technologies required to ensure mission success. Because of the robust nature of distillation systems, the AES LSS Project is pursuing develop-ment of the Cascade Distillation Subsystem (CDS) as part of its technology portfolio. Currently, the system is being developed into a flight forward Generation 2.0 design

Cascade Distiller System Performance Testing Interim Results

The Cascade Distillation System (CDS) is a rotary distillation system with potential for greater reliability and lower energy costs than existing distillation systems. Based upon the results of the 2009 distillation comparison test (DCT) and recommendations of the expert panel, the Advanced Exploration Systems (AES) Water Recovery Project (WRP) project advanced the technology by increasing reliability of the system through redesign of bearing assemblies and improved rotor dynamics. In addition, the project improved the CDS power efficiency by optimizing the thermoelectric heat pump (TeHP) and heat exchanger design. Testing at the NASA-JSC Advanced Exploration System Water Laboratory (AES Water Lab) using a prototype Cascade Distillation Subsystem (CDS) wastewater processor (Honeywell d International, Torrance, Calif.) with test support equipment and control system developed by Johnson Space Center was performed to evaluate performance of the system with the upgrades as compared to previous system performance. The system was challenged with Solution 1 from the NASA Exploration Life Support (ELS) distillation comparison testing performed in 2009. Solution 1 consisted of a mixed stream containing human-generated urine and humidity condensate. A secondary objective of this testing is to evaluate the performance of the CDS as compared to the state of the art Distillation Assembly (DA) used in the ISS Urine Processor Assembly (UPA). This was done by challenging the system with ISS analog waste streams. This paper details the results of the AES WRP CDS performance testing

Terrestrial Testing of the CapiBRIC, a Microgravity Optimized Brine Processor

Utilizing geometry based static phase separation exhibited in the radial vaned capillary drying tray, a system was conceived to recover water from brine. This technology has been named the Capillary BRIC; abbreviated CapiBRIC. The CapiBRIC utilizes a capillary drying tray within a drying chamber. Water is recovered from clean water vapor evaporating from the free surface leaving waste brine solids behind. A novel approach of optimizing the containment geometry to support passive capillary flow and static phase separation provides the opportunity for a low power system that is not as susceptible to fouling as membranes or other technologies employing physical barriers across the free brine surface to achieve phase separation in microgravity. Having been optimized for operation in microgravity, full-scale testing of the CapiBRIC as designed cannot be performed on the ground as the force of gravity would dominate over the capillary forces. However, subscale units relevant to full-scale design were used to characterize fill rates, containment stability, and interaction with a variable volume reservoir in the PSU Dryden Drop Tower (DDT) facility. PSU also using tested units scaled such that capillary forces dominated in a 1-g environment to characterize evaporation from a free-surface in 1-g upward, sideways and downward orientations. In order to augment the subscale testing performed by PSU, a full scale 1-g analogue of the CapiBRIC drying unit was initiated to help validate performance predictions regarding expected water recovery ratio, estimated processing time, and interface definitions for inlets, outlets, and internal processes, including vent gas composition. This paper describes the design, development and test of the terrestrial CapiBRIC prototypes

Advances in Spacecraft Brine Water Recovery: Development of a Radial Vaned Capillary Drying Tray

Technology improvements in the recovery of water from brine are critical to establishing closed-loop water recovery systems, enabling long-duration missions, and achieving a sustained human presence in space. A genre of 'in-place drying' brine water recovery concepts, collectively referred to herein as Brine Residual In-Containment, are under development. These brine water recovery concepts aim to increase the overall robustness and reliability of the brine recovery process by performing drying inside the container used for final disposal of the solid residual waste. Implementation of in-place drying techniques have been demonstrated for applications where gravity is present and phase separation occurs naturally by buoyancy-induced effects. In this work, a microgravity-compatible analogue of the gravity-driven phase separation process is considered by exploiting capillarity in the form of surface wetting, surface tension, and container geometry. The proposed design consists of a series of planar radial vanes aligned about a central slotted core. Preliminary testing of the fundamental geometry in a reduced gravity environment has shown the device to spontaneously fill and saturate rapidly, thereby creating a free surface from which evaporation and phase separation can occur similar to a terrestrial-like 'cylindrical pool' of fluid. Mathematical modeling and analysis of the design suggest predictable rates of filling and stability of fluid containment as a function of relevant system dimensions; e.g., number of vanes, vane length, width, and thickness. A description of the proposed capillary design solution is presented along with preliminary results from testing, modeling, and analysis of the system