1979021033 ,_. NationalAeronautics and _-' Space Administration •_': I I -"_._-?- Houston.Lyndon B.TexaoJohnson77058Space Center • _"' .. ,.i "_L ,. _ 3D Scptember 1978 !i, 5"_ _a3 -! r_'% '_i,. (NAS A-CR-158870) _ITRATERRESTRIAL MATERIALS N79-2920q _:-. PROCESSING AND CONSTRUCTIO_ Final Report _'-4 (Lunar and Planetary Inst°) 476 p ,.,,._ , HC A21/MF 101 CSCL 22A Unclas ./_. G3/12 31645 x' .L .,.- EXTRATERRESTRIALMATERIALS PROCESSINGAND _ CONSTRUCTION / FINAL REPORT -- NSR 09-051-001Mod. No. 24 _- 1979021033-002 ,! £. _. EXTRATERRESTRIALMATERIALS •:.: PROCESSINGAND , CONSTRUCTION -_i FINAL REPORT _ NSR 09-051-001Mod. No. 24 !: LUNAR _ PLANETARY INSTUTUTE 3303 NASA ROAD 1 HOUSTON, TEXAS 77058 _:' 71 3-488-5200 PRINCIPAL INVESTIGATOR Dr. David R. Criswell _ L W : 30 September 1978 l 1979021033-003 OBJEC',IVES AND RECOMMENDATIONS Present day space operations support the service segments of the national and world economies. Astounding advances have been made over the past twenty years in the development of space tools for observation, communication and exploration Major advances are forthcoming which will be characterized in part by . a widening and increasing occurrence of direct connections between terrestrial individuals and space hardware. However, an economy & " capable of directed original growth in potency must be self- t sufficient• It must be supported by the more fundamental materials economy. The creation of materials economies i_ the industrial revolution which has a 400 year history. Keys to the development of a materials economy are the availebility of matter to be worked, energy to do the work and ski_l to use energy to mold matter to new uses and combinations. Developlaent of a s.pace materials economy or true space industrialization is strongly inhibited by the extremely high costs of obtaining matter from earth with which to work in space. Solar energy is clearly avail- able to do work in space. The moon, and possibly certain asteroids, ,w are primary sources of raw materials for large scale use in space. • Space systems have been proposed in detail which can provide large quantites of lunar and eventually asteroidal materials at low unit costs ($/kg) for industrial use in cis-lunar space• In this study we examine the application of available terrestrial skills to the gathering of lunar materials and the processing of raw lunar materials into industrial feed stock. We , find that much terrestrial technology can be transferred to 'i 1979021033-004 k \ the gathering of lunar materials and the processing of raw : lunar materials Into industrial feed stock. We find that much terrestrial technology ca. be transferred to industrial operations i in space. Immediate development of plans and operations to make use of lunar materials in the IgSO's in space Is appropriate and feasible from the standpoint of gathering lunar surface Materials and processing them in space. Planning for and the creating of a materials industrial econom_ in space can be initiated now. Major immediate objectives, which appear achievable, are to decrease the complexity of the physical systems and the capital expenditures needed to establish the first space industries. Space industrialization is technically feasible. Jur challenge is to craftily employ the skills available to us in our university, industrlal/commercial and government organizations to create the initial materials econom_ in cis-lunar space for a minimum investment and in a minimum time. Now is ) i the time to exploit the accomplishments resulting from this ) nation's lO0 billion dollar investment in space, one fourth of ( t f, that in lunar operations to produce a viable materials economy in the cis-lunar space. Q 't 1979021033-005 ,t i " CONTENTS • OBJECTIVES AND RECOMMENDATIONS i CONTENTS iii STUDY PERSONNEL z 4 CHAPTERA. I.INTRODUCEXECUTIVETION OVERVIEW I-I I-l B. THE MOON AS A SOURCE OF INDUSTRIAL I-5 MATERIALS C. SCHEMATIC OVERVIEW OF SPACE I-9 INDUSTRIALIZATION D. SPACE POWER STATIONS AND MATERIALS 1-12 PROCESSING SCALES t E. CHEMICAL PROCESSING 1-21 F. LUNAR STRIP _INING 1-26 G. BENEFICIATION OF LUNAR SOILS 1-27 H. LUNAR GLASS AND CERAMIC PRODUCTS 1-29 I. MATERIAL GOODS AND THEIR INTRINSIC VALUE 1-30 ($/kg), MASS AND ENERGY OF PRODUCTION ; _, • TABLES 1-55 FIGURES 1-65 CHAPTER II. PROCESSING OF LUNAR & ASTEROIDAL II-l MATERIALS INTRODUCTION, BACKGROUND II-I 4_! PART ONE METHODOLOGY II-3 ,: A. GENERAL CONSIDERATIONS II-3 1979021033-006 CONTENTS - continued Potential Availability 11-3 Recovery Potential 11-5 Derivable Products 11-8 Product Mix Options ll-g Bootstrap Operational Capabilities ll-lO B. MATERIALS PROCESS SELECTION ll-ll Introduction ll-ll , Criteria for Process Evaluation II-12 Process Constraints II-15 C. GENERAL CLASSIFICATION OF MATERIALS II-16 PROCESSING SYSTEMS Flow Chart Analysis II-17 c , General Survey or Overview of ll-lg Processing Methods General Observations Concerning II,-20 Chemical Conversions Classification of Previously II-22 Proposed Processes _.ssessment of Prior Methods II-22 Solution Processes for Chemical II-23 Separations Reduction Processes II-24 D. CHEMICAL PLANT DESIGN II-28 General Considerations II-28 Space Environment Factors II-2g Reagent and Equipment Mass II-31 Unit Operations II-33 General Sizing Considerations II-38 PART TWO - SPECIFIC PROCESSES II-40 E. ANHYDROUS PROCESSES II-40 q ' INTRODUCTION II-40 1979021033-007 J CONTENTS - continued l. Carbochlorinatton 11-40 _ 2. Electrolysis of Holten Silicates II-43 F. HYDROCHEMICAL(AQUEOUS) PROCESSES II-43 1. HF Acid Leach Process II-44 2. HCL Acid Leach Process II-47 3. NaOH Basic Leach Process II-51 • G. SYNOPTIC COMPARISONSOF PROPOSED II-53 PROCESSING SYSTEMS • H. SOME PERSPECTIVES IN THE MINING/ II-54 REFINING PHASES OF SPACE INDUSTRIALIZATION BENEFICIATION/MATERIALS PROCESSING/ INTRODUCPARTTIONTHREE - TECHNOLOGYDEVELOPMENT I1-58 II-58 Io TIME, COST & SCALE OF TECHNOLOGY II-60 DEMONSTRATION PROGRAMS J. INFORMATION REQUIREMENTS FOR MANAGEMENT II-62 DECISIONS IN THE IMPLEMENTATION OF SPACE PROCESSING TECHNOLOGY K. PROCESS SELECTION AND QUALIFICATION II-64 ' L. DETAILED RECOMMENDATIONS II-68 " M. TECHNOLOGY INTERACTION STUDIES II-76 REFERENCES II-80 TABLES II-83 • FIGURES II-!O0 APPENDICES II-134 (A) MASS HEAT TRANSFER CONSIDERATIONS II-134 IN LOW PRESSURE DISTILLATIONS (B) ELECTRODEPOSITION OF ACTIVE II-136 METALS AS AMALGAMS v 1979021033-008 r CONTENTS - continued : (C) MINIMIZATION OF POWERPLUS SPACE I1-138 RADIATOR MASS BY HEAT PUMPING (D) COMPARISONOF CONTAINER AND CONTENT II-140 WEIGHTS OF SPHERICAL AND CYLINDRICAL VESSELS (E) ANALYSIS OF OPTIMUM MASS FOR DRYING II-142 PROCEDURES B (F) PROJECTED MASSES FOR SPACE ELECTRIC II-144 AND THERMAL POWER AND RADIATORS (G) ENGINEERING DESIGN PARAMETERS II-146 > (H) CARBOCHLORINATION PROCESS II-148 i ENGINEERING DATA (1) HF ACID LEACH PROCESS ENGINEERING II-157 DATA (J) MATERIALS SPECIFICATIONS II-176 CHAPTER Ill. LUNAR STRIP MINING ANALYSIS III-l SUMMARY III-I A. INTRODUCTION III-l , B. MINING PLAN III-3 _' I. Mining Rate I!I-3 2. Mine Geometry III-4 3. Early Year of Mine III-4 C. NUMBER OF HAULERS AND EXCAVATORS III-5 l General Expression III-5 " 2 Discussion of Factors III-5 3 Complete Expression Ill-16 4 Number of Haulers Required Ill-16 5 Hauler-Excavator Match Ill-19 6 Spare Vehicles and Spare Parts III-20 7 Summary of Mining Equipment III-20 _- v_ 1979021033-009 t ,) "j --j _Y CONTENTS - continued z, D. MASS OF MINING EQUIPMENT III-20 ,. 1. Mass of Haulers III-20 2. Mass of Front-End Loader III-21 ;I 3. Cumulative Mass of Mining Equipment III-22 E. ENERGY REQUIRED FOR MINING SYSTEM III-22 I. Hauler Transport III-22 i 2. Ballistic Transport III-24 I i I F. PERSONNEL III-25 i I. Lunar-Based Personnel III-25 2. Automatic Haulers III-26 3. Remote-Controlled Front-End Loader III-27 G. ADDITIONAL STUDIES III-27 H. REFERENCES III-30 I. TABLES III-31 .J. FIGURES III-4O CHAPTER IV. BENEFICIATION OF LUNAR SOILS IV-I SUMMARY IV-I A. GENERAL IV-l C. A LOOK AT THE EXPECTED LUNAR MINERAL IV-9 I B. PRINCIPLES OF ELECTROSTATIC SEPARATION IV-3 6ENEFICIATION TO BE CARRIED OUT ON THE MOONSURFACE , m D. KEY STUDIES NECESSARY FOR A DEFINITIVE IV-17 EVALUATION OF THE APPLICABILITY OF ELECTROSTATIC SEPARATION TO LUNAR SOILS E. CONCEPTUAL DESIGN FOR AN EXPERIMEt|TAL IV-20 APPARATUS TO STUDY THE ELECTROSTATIC SEPARATION OF _HE LUNAR SOILS _ vii 1979021033-010 : CONTENTS - continued F. CONCEPTUALDESIGN OF A LUNAR FACILITY FOR 1V-22 PRODUCING 1 MEGATONOF BENEFICIATED ORE PER YEAR G. CONCLUSIONS IV-25 H, REFERENCES 1V-28 I. TABLES IV-32 J. FIGURES !V-35 K. APPENDICES IV-50 (A) Patents IV-S0 (B) Tribo and Traveling Fields IV-62 (C) Forces on Charges Particles IV-64 CHAPTER V. LUNAR GLASS AND CERAMIC PRODUCTS V-I A. INTRODUCTION V-l B. LUNAR MATERIALS OF IMPORTANCE AS GLASS AND CERAMIC PRODUCTS V-I I. Lunar Soil as Found V-2 2. Anorthite from Purfied Plagioclase V-3 3. Silica from Silicon Oxidation V-4 4. Alumina and Magnesia V-5 C. PROCESSING OF LUNAR MATERIhLS - V-5 GENERAL CONSIDERATIONS D. SOME SPECIFIC EXAMPLES OF PROCESSING V-8 ° COMMO_ GLASS AND CERAMICS IN SPACE AND ON THE MOON I. Production of Glass Windows in Space V-8 2. Production of Glass Wool in Space V-9 or on the moon 3. Production of Refractories on the Moon V-9 viii 1979021033-011 "_lll E. SPECIAL "GLASSESCONTENTS" BASED- ONcontiHIGHnued V-lO VACUUMAND/OR ZERO GRAVITY F. CONCLUSIONS AND RECOMMENDATIONS V-ll G. RFERENCES V-12 H. TABLES V-'' I. FIGURES + CHAPTER VI. INTRINSIC VALUE ($/KG)) TOTAL MASS I-1 ¢, L . (KG) AND PRODUCTION ENERGY _F _ SELECTED GOODS A. BACKGROUND VI-1 t B. SELECTION CRITERIA VI-5 f . C. METHODOLOGY VI-1] D.