Chemical Engineers in the New Space Race

This week I've been joined by a Chemical Engineering colleague and I'm excited for us to jump into the Space Engineering Services & Workforce Solutions arena together.

I was expecting another Mechanical Engineer but it gives us the ideal chance to develop our capabilities quickly and so I thought I'd explore what our Chemical Engineers might be involved with. 

Sitting in the shadows of the physicists and mechanical engineers, are the chemical engineers. With the resurgence of space exploration there is a very clear need for new chemical processes to help provide the means for far more advanced processes.

Contributing in a number of ways

Chemical Engineers (Chem Es) contribute to the space industry in a number of ways:

• Fluid Flow - Chem E’s study and deal with compressible (gas phase) and non-compressible (liquid phase). The "plumbers" of space. Liquid fuel rockets are very complex examples of “plumbing” - the fuel and the oxidizer need to be transferred from the tank to the engine at precise times and in precise amounts at the correct temperatures - think pumps, controls, heat & mass transfer (thermodynamics). Even satellites often have “reaction motors” which can adjust the position / attitude / orbit of the satellite.
• Heat transfer - Space is a vacuum, which is a good insulator. Part of a Chem E’s curriculum is heat transfer and thermodynamics. You study how heat is transferred through various material, how to remove heat, how to add heat.
• Material science - Many fuels & fluids used in rockets, satellites and space stations can be highly corrosive. Chem E’s learn what materials do best against what agents. Also, what materials can withstand extreme temperatures, environments, etc.
• Reaction Kinetics - the burning of rocket fuel is a highly exothermic reaction (i.e. controlled explosion). The rate of “explosion” is partly determined by the fuel & oxidizer used and the controlled mixing of the fuels and oxidizer.
• Control Theory - Everything on a rocket, satellite, or space station needs to be controlled extremely well or else you have a major problem. Space is unforgiving. Chem E’s study control theory for chemical plants, but it is directly applicable to space. For example, controlling the temperature of the crew cabin in a capsule is typically based on the standard PID control loop…

The Complete Journey 

Our state of the art launch rocket propulsion systems (liquid hydrogen & oxygen) for the achievement of earth orbit and thereafter are for now irreplaceable.

As we extend our exploration we must consider the production of necessary fuels to make a two-way trip. More to come later. 

Our current ability to launch and deliver equipment to another planet/satellite dictate that the size and scale must be small. Miniaturizing propellants and life support is the greatest challenge. Welcome our Chem Es, who are now tasked with producing an entire production facility that can be lifted to space and delivered to the destination.

Furthermore, we need to consider the extremities of launch pressures to zero pressure of loss of gravitational forces. Equipment failure in these conditions means an inability to use the planned stay and return the products required.

Lastly, process efficiencies need consideration. Any facility located in space, on the Moon or Mars has limited utilities.

Cryogenics, in situ resource utilization (ISRU), miniaturization, launch-ability and process efficiencies are but a few of the areas that Chem Es provide support and exploration for.

Launch Cryogenics

The industrial processes applied in relation to space are extremely unusual and so too the principals of chemistry. Low-temperature fluids, unique uses of chemical reactions for the production of fluids and oxidizers, high-pressure gases and new materials of construction (3d printing more recently) stretch the skills of our best Chem Es.

Efficient transport and storage of cryogenic liquids on other planets is essential for a successful return mission. Up until recently the cost of launch per pound was up to $14000 for a small rocket, however with the arrival of Elon Musk's "1st principle" approach that's now brought this down to approaching $700 - astonishing!

It's been done through a number of different approaches, not least of which is dramatic weight reductions.

The Return Journey

Fuel in place/propellants can be utilized both as fuel for the return journey and of course as fuel back-up for life support. The In Situ Propellant Production (ISPP) component of the ISRU is the enabler technology to allow us to realize the objective of performing meaningful work while on another planet, such as Mars.

The elements required for ISPP are carbon, oxygen and hydrogen

Since hydrogen is very light this can be brought from earth, whereas Carbon and Oxygen can be found on Mars, albeit in the form of carbon dioxide (95%). Rather than using power to collect this, instead a sorbent bed can be constructed. This will absorb carbon dioxide during the cold Martian nights (-90 Celsius). The warmth of the day that follows would easily release the trapped gas, making it available for processing.

Launch capability

Launching from a low-energy base to break through our atmosphere, to orbit the earth and to travel to a far off planet are extremely difficult and strenuous. The challenges include:

• Launch forces
• Payload balancing and packaging
• Dramatic condition changes (acceleration forces 3-5g, vehicle rolls, pressure and temperature changes and now without the benefit of ground systems)
• Free-flight conditions (the reconsideration of structures and mechanics without gravity for extended periods of time)
• Course adjustments (sudden zero gravity to immense thrust or artificial gravity, sometimes unbalancing the payload)
• Flight termination (with minimal atmosphere, landing requires reverse thrust landing procedures and or a blended float, glide and bounce to a final stop.

New Propulsion thinking

Because of the orbital paths Mars and Earth take around the Sun, the distance between them varies between 54.6 million km and 401 million km.

Missions to Mars are launched when the two planets make a close approach. During one of these approaches, it's expected using conventional chemical rocket fuel to take nine months to get to Mars.

That's a long time for anyone to spend traveling. But engineers, including those at the US space agency (NASA), are working with industrial partners to develop faster methods of getting us there.

So what are some of the most promising technologies?

Solar electric

Given lower power and slower journey times, it makes more sense to use this as a cargo transporter for a payload of life support that could be waiting for the astronauts later arrival. The journey time is expected to be nearer 2 years as against nine months for the astronauts.

Nuclear thermal electric

The idea is the use of chemical rockers for take-off and landing on Mars, while nuclear thermal energy is used for the journey in between.

In a nuclear thermal electric rocket, a small nuclear reactor heats up liquid hydrogen. The gaseous form of the element expands and shoots out of the thruster. This hybrid propulsion approach might be able to cut transit time to 90-days and thus reduce radiation potential exposure (ignoring the risk of exposure from the engine, of course!)

The bottom-line for at least the sake of the astronauts is to go fast. Very fast!

With 200MW slung in the rear of the spacecraft it's estimated it could be done in 39-days.

We'll let the Chemical Engineers and the Physicians figure that one out!

Design, Engineering & Manufacturing Acceleration

Satellites, Propulsion, Thermal, Avionics, Guidance, Navigation & Control, Systems, Aeronautical and of course more - the skills required to accelerate our steps into the future world and space.

Need help?

Let us know who you need for your engineering team.

Andrew Sparrow

I'm a huge believer in constant change.

Standing still is going backwards

It starts with People changing their mindsets & Processes, enabled through Technology.

Innovative Products, Smarter Manufacturing all happens through Agile Revolutions - start small, empower people & scale fast.

Oh, I can "boil the ocean" with the best of them, but let's not live there. Analysis leads to paralysis. Dreaming of & waiting for perfection is the enemy of execution.

Do something, get some quick wins and start building momentum.

I like to bring attention to Innovation, Smart Manufacturing, Global People Integration & Human Sustainability - I Blog, Vlog, Podcast, host a few Live Shows and love being involved in your revolutionary programs.

I love & thrive in working with some of the world's largest companies & most innovative organizations.

I'm a big people-person & have spent my life meeting as many people & cultures as I can. At my last count, I am lucky enough to have visited & done business in over 55 countries

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