Integrated Mars In Situ Propellant Production System

Pioneer Astronautics has developed a system that harvests CO2 from a simulated Martian atmosphere and reacts it with H2 into rocket propellant at a rate of 1 kg/day. A prototype system operated autonomously for 5 consecutive days, during which it maintained a 100% conversion rate (to detectable limits) of CO2 and H2 into products, maintaining a constant O2:CH4 ratio in the product stream with only minor adjustments. The integrated Mars in situ propellant production system (IMISPPS) uses a mixed catalyst bed to conduct the Sabatier methanation reaction and the reverse water gas shift in a single reactor. A recycle loop makes performance resistant to operational changes, with product ratios stable regardless of reactor temperature changes of as much as 100°C. An optimized IMISPPS is projected to produce 1 kg/day of O2:CH4 propellant and have a mass of 50 kg with a methane purity of 98+% while consuming 700 W of electrical power. With hydrogen from Earth, the system demonstrates a mass leverage of 18:1 in useful rocket propellant produced on Mars compared with imported feedstock.