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6.5 The Sabatier Reactor: Overview and Optimization Considerations 49 simulate launch vibration loads. The details of the test and its results can be found in Junaedi et al. (2011). Finally, due to the lower channel length-to-diameter ratio (l/d) of the Microlith®, one would expect the pressure drop to be lower than that of a conventional monolith. However, since the Microlith®-based reactor has a more tortuous path for the reactants, it will also have a higher friction factor (f). Since the pressure drop is directly related both to f and l/d, the tradeoff between these two factors decides whether or not the Microlith®-based reactor will have a lower pressure drop than a conventional monolith. Presumably, there are some challenges with these Microlith® structures in terms of wash coating the catalyst and costs, as these structures are more sophisticated than conventional monoliths. However, at least in the near future, these challenges are more relevant for terrestrial applications than for space applications. 6.5.3 Sabatier Reactor System Design Considerations, Including Thermal Management Managing heat from the exothermic process in Sabatier reactors is a complex task and to the best of our knowledge, it is not something that has not been demonstrated in the scale of interest for a human-rated ascent vehicle. The mass of the Sabatier system is comprised of the reactor mass and the mass of the ancillary equipment used for separation, storage, and heat management. Thus, in the search for an optimal solution to minimizing the mass of the Sabatier system, one possible design that is worth considering is catalyzed heat exchangers. A catalyzed heat exchanger is made by depositing a catalyst on a heat transfer-friendly substrate. A design concept for catalyzed heat exchangers for steam reforming has been proposed by Farrauto et al. (2007). The idea was to couple steam reforming reactions (endothermic) to a combustion reaction (exothermic). They propose that this can be achieved by having two reaction chambers partitioned by a metal plate, with the steam reforming catalyst coated on one side and the combustion catalyst coated on the other. For our application, we can have a similar design with the Sabatier reaction (exothermic) on one side, coupled with a suitable endothermic reaction on the other. A system design would include active thermal management from CO2 and H2 acquisition (cooler) and heat shedding required by the Sabatier reactor, to intertwine with the condenser for water extraction from the system. Two-phase materials, such as thermal wax, or active and passive cooling with reactor system inlet and outlet lines are one of the best ways to save mass and provide thermal management to a methanation system. The Curiosity Mars Rover also featured an advanced heat rejection system with hot and cold fluid loops for heating and cooling and thermal management. Integrating thermal management into the entire system can save mass and power.PDF Image | ISRU Challenge Production of O2 and Fuel from CO2
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