Multi-stage Oxygen and Regolith Resource Extractor

Blueshift LLC d/b/a Outward Technologies proposes to continue development of a Multi-stage Oxygen and Regolith Resource Extractor (MORRE) for the production of high purity minerals and metals in addition to oxygen from lunar regolith. The underlying method utilizes novel process and temperature control systems to extend terrestrial vacuum metallurgical extraction processes used since the 1940s to lunar regolith feedstocks not typically associated with vacuum metallurgy. MORRE requires little to no process consumables while yielding multiple high purity products. The process takes advantage of the lunar environment and utilizes demonstrated terrestrial industrial processes to reduce technical risk. Development of the MORRE concept will increase humanitys presence in space by leveraging the readily available ultra-high vacuum on the Moon to unlock the abundant resources found within lunar regolith. The MORRE system not only enables the production of high purity materials on the lunar surface, but can also be implemented for space-based vacuum metallurgical processes that are currently not economically viable in terrestrial industries. The objective of the Phase II project is to raise the technology readiness level of the MORRE system from TRL4 to TRL5. A medium fidelity prototype reactor will be manufactured and tested. Thermodynamic and kinetic models will be developed and validated through MORRE prototype testing in a relevant vacuum environment. Establishing permanent lunar infrastructure requires abundant materials which are prohibitively expensive if launched from Earth. The natural resources found on the Moon must therefore be leveraged wherever possible to reduce these costs. Current SOA lunar materials extraction techniques require terrestrially based consumables. MORRE enables the extraction of multiple purified materials from regolith including silica, alumina, iron, and oxygen without the need for consumables, and high-purity silicon and aluminum through secondary refining while utilizing comparatively lightweight equipment. The MORRE system achieves this using an innovative materials reduction and separation process that utilizes the lunar conditions to facilitate an ultra-high vacuum environment for reducing process temperatures and total mass of hardware by eliminating heavy pumps, valves, and gas handling/separation systems. The MORRE system represents a fundamental shift in regolith resource extraction for establishing a thriving lunar economy. In Phase I, feasibility of MORRE was established through process modeling and demonstration testing to advance the technology from TRL 3 to 4. In Phase II, a medium fidelity system will be built and tested in a relevant vacuum environment to raise the TRL from 4 to 5. This will be accomplished by meeting the following technical objectives: Produce a high-fidelity model of the MORRE process that incorporates non-ideal thermodynamic behavior and process kinetics. Produce a functional medium fidelity prototype reactor to characterize different process parameters including temperature, vacuum level, and reducing environment. Characterize MORRE process and optimize distillation column design to maximize product yield and purity. Demonstrate end-to-end MORRE process functionality targeting the production of 7 g of silica, 0.6 g of iron, and 1 g of alumina from 100 g of lunar highlands regolith simulant. Develop a full-scale system design, CONOPS, and technology advancement roadmap. Proposed deliverables for the project include interim and final reports detailing advancements and results achieved throughout the project in addition to New Technology Reports, Summary Charts, and Certifications required by the contract.
Benefits: The primary application within NASA’s technology roadmap is TX 07.1 In-Situ Resource Utilization. The MORRE system can be incorporated into several future NASA missions to produce purified minerals and metals including silica, magnesium, alumina, and iron, and secondary refining of these minerals to produce high-purity silicon and aluminum for in-space production of robotic components, PV cells, and wiring. The MORRE system will enable low-cost fabrication and construction of infrastructure elements for towers, habitats, cabling, and more. In lunar markets, the production of high purity materials from regolith are of high interest to commercial customers for use in structural materials, thermal/radiation shielding, and refined minerals for further material processing. In terrestrial markets, applications focus on extractive vacuum metallurgy for the recovery of co-products from a mixed ore feedstock.