Carbotek, Inc.

Christian W Knudsen

Michael A Gibson

Charles R Stahl

A reactor apparatus for production of Lunar oxygen uses feed stocks comprising a particulate hydrogen-reducible enriched feed in the size range from about 20-200 microns, containing 80-90% Lunar ilmenite (FeTiO.sub.3) and ferrous Lunar agglutinates. The reactor apparatus has three vertically spaced fluidized zones with downcomers from the upper to the central fluidized zone and openings for introducing a hydrogen-containing gas stream through the lower fluidized zone. A solid-to-gas RF-dielectric heater has a ceramic honeycomb with small parallel channels separated by thin, ceramic walls and electrodes surrounding the honeycomb connected to an external RF power source for heating the gas stream to a reducing reaction temperature. A top inlet introduces the enriched feed into the upper fluidized zone for fluidization therein and flow into middle and lower fluidized zones countercurrent to the flow of the gas stream. A solid-state electrolyzer is composed of calcium oxide- or yttrium oxide-stabilized zirconia ceramic fabricated by sintering or slipcasting into a perforated cylindrical shape having platinum electrodes on outer and inner longitudinal surfaces thereof. The electrolyzer cylinder is mounted inside two disk-shaped, impermeable ceramic baffles and centered inside a refractory-lined metal pressure shell. Gaseous effluent containing an equilibrium amount of water from the central fluidized zone passes through the electrolyzer for continuous electrolysis of the water. Apparatus is provided for separating oxygen from the electrolyzer and recycling hydrogen to the gas stream.

Apparatus for manufacture of oxygen from lunar ilmenite

A feed material which is a mixture of chemically reduced lunar ilmenite and lunar agglutinates having a particle size in the range of 20-200 microns produced by hydrogen reduction in a fine particulate state is compacted into a shape and sintered to produce structural, radiation shielding construction blocks or bricks.

Integrated lunar materials manufacturing process

A manufacturing plant and process for production of oxygen on the moon uses lunar minerals as feed and a minimum of earth-imported, process materials. Lunar feed stocks are hydrogen-reducible minerals, ilmenite and lunar agglutinates occurring in numerous, explored locations mixed with other minerals in the pulverized surface layer of lunar soil known as regolith. Ilmenite (FeTiO.sub.3) and agglutinates contain ferrous (Fe.sup.+2) iron reducible by hydrogen to yield H.sub.2 O and metallic Fe at about 700.degree.-1,200.degree. C. The H.sub.2 O is electrolyzed in gas phase to yield H.sub.2 for recycle and O.sub.2 for storage and use. Hydrogen losses to lunar vacuum are minimized, with no net hydrogen (or any other earth-derived reagent) consumption except for small leaks. Feed minerals are surface-mined by front shovels and transported in trucks to the processing area. The machines are manned or robotic. Ilmenite and agglutinates occur mixed with silicate minerals which are not hydrogen-reducible at 700.degree.-1,200.degree. C. and consequently are separated and concentrated before feeding to the oxygen generation process. Solids rejected from the separation step and reduced solids from the oxygen process are returned to the mine area. The plant is powered by nuclear or solar power generators. Vapor-phase water electrolysis, a staged, countercurrent, fluidized bed reduction reactor and a radio-frequency-driven ceramic gas heater are used to improve thermal efficiency.

A manufacturing plant and process for production of hydrogen on the moon uses lunar minerals as feed and a minimum of earth-imported, process materials. Lunar feedstock is the pulverized surface layer of lunar soil known as regolith. The regolith contains up to about 150 ppm (wt.) hydrogen presumably derived from the 'solar wind'. The regolith is screened and fines of less than 200 micron size are recovered. The 200 micron, and smaller, particles are introduced into a fluidized bed reactor and fluidized in a hydrogen gas stream at a temperature of about 600.degree. C. The off-gas is passed through an absorber to separate by-product gases, such as hydrogen sulfide, which may be generated in the process, part of the hydrogen is removed to storage, and the remainder is recycled to fluidize the reactor. The recovered raw product gas is preferably further treated using combinations of selected membrane permeations and cryogenic distillations to purify product hydrogen and recover byproduct .sup.3 He, .sup.4 He, N.sub.2, carbon oxides, hydrogen sulfide and other species desorbed with the hydrogen.

Lunar hydrogen recovery process

An evacuated double wall tubing is shown together with a method for the manufacture of such tubing which includes providing a first pipe of predetermined larger diameter and a second pipe having an O.D. substantially smaller than the I.D. of the first pipe. An evacuation opening is then in the first pipe. The second pipe is inserted inside the first pipe with an annular space therebetween. The pipes are welded together at one end. A stretching tool is secured to the other end of the second pipe after welding. The second pipe is then prestressed mechanically with the stretching tool an amount sufficient to prevent substantial buckling of the second pipe under normal operating conditions of the double wall pipe. The other ends of the first pipe and the prestressed second pipe are welded together, preferably by explosion welding, without the introduction of mechanical spacers between the pipes. The annulus between the pipes is evacuated through the evacuation opening, and the evacuation opening is finally sealed. The first pipe is preferably of steel and the second pipe is preferably of titanium. The pipes may be of a size and wall thickness sufficient for the double wall pipe to be structurally load bearing or may be of a size and wall thickness insufficient for the double wall pipe to be structurally load bearing, and the double wall pipe positioned with a sliding fit inside a third pipe of a load-bearing size.

Double wall vacuum tubing and method of manufacture

A thermally-enhanced oil recovery method and apparatus for exploiting deep well reservoirs utilizes electric downhole steam generators to provide supplemental heat to generate high quality steam from hot pressurized water which is heated at the surface. A downhole electric heater placed within a well bore for local heating of the pressurized liquid water into steam is powered by electricity from the above-ground gas turbine-driven electric generators fueled by any clean fuel such as natural gas, distillate or some crude oils, or may come from the field being stimulated. Heat recovered from the turbine exhaust is used to provide the hot pressurized water. Electrical power may be cogenerated and sold to an electric utility to provide immediate cash flow and improved economics. During the cogeneration period (no electrical power to some or all of the downhole units), the oil field can continue to be stimulated by injecting hot pressurized water, which will flash into lower quality steam at reservoir conditions. The heater includes electrical heating elements supplied with three-phase alternating current or direct current. The injection fluid flows through the heater elements to generate high quality steam to exit at the bottom of the heater assembly into the reservoir. The injection tube is closed at the bottom and has radial orifices for expanding the injection fluid to reservoir pressure.

Growing community of inventors

Houston, TX, United States of America

Christian W Knudsen