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Mars NASA Businesses Earth Space Technology

NanoRacks Plans To Turn Used Rocket Fuel Tanks Into Space Habitats (ieee.org) 130

An anonymous reader writes from a report via IEEE Spectrum: A couple of weeks ago NASA announced it has committed $65 million to six companies over the course of two years for the purpose of developing and testing deep-space habitats that could be used for future missions to Mars. One of the six companies, called NanoRacks, is attempting to take empty fuel tanks from the upper stages of rockets and turn them into space habitats on-orbit. IEEE Spectrum reports: "A rocket like the the Atlas V, which can deliver payloads of nearly 19,000 kg to low Earth orbit, consists of three primary pieces: on the bottom, you've got the first stage booster, which consists of a huge engine and some big tanks holding kerosene fuel and oxidizer. Above that, there's the second stage, which consists of one or two smaller engines, a big tank for storing liquid hydrogen fuel, and a smaller tank for oxidizer. The payload, which is what all of the fuss is about, sits on top. The first stage launches the rocket off of the pad and continues firing for about four minutes. Meanwhile, the second stage fires up its own engine (or engines) to boost the payload the rest of the way into orbit. On the Atlas V, the second stage is called Centaur. Once Centaur gets its payload where it needs to go, it separates, and then suicides down into Earth's atmosphere. Getting a payload into space is so expensive because you have to build up this huge and complicated rocket, with engines and guidance systems and fuel tanks and stuff, and then you basically use it for like 15 minutes and throw it all away. But what about the second stage? You've got a whole bunch of hardware that made it to orbit, and when getting stuff to orbit costs something like $2,500 per kilogram, you then tell it to go it burn itself up in the atmosphere, because otherwise it's just useless space junk." NanoRacks thinks this is wasteful, so they want to turn these tanks into deep space habitats. IEEE notes that the hydrogen fuel tank on a Centaur upper stage has a diameter of over 4 meters, and an interior volume of 54 cubic meters, while the inflatable BEAM module that arrived at the ISS earlier this year has an interior volume of 16 cubic meters. For more details, IEEE Spectrum spoke with Jeff Manber, CEO of NanoRacks, and Mike Johnson, NanoRacks' Chief Designer. You can read their responses here.
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NanoRacks Plans To Turn Used Rocket Fuel Tanks Into Space Habitats

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  • I just want to be sure this isn't an advertorial for yet another Kickstarter.

    • by Anonymous Coward

      In my day, the girls with nano racks were undatable.

  • by telchine ( 719345 ) on Tuesday August 23, 2016 @02:09AM (#52753775)

    I don't understand how this can possibly be cost effective. Can anyone explain?

    • Very easy: just apply the concepts that were behind the new economy boom in 2001 to today's space travel industry. Now sit down and wait for the crash...
    • It's the concept of the wet workshop [wikipedia.org] that goes back to the Apollo days. The thought was that if funding continued, they could either retrofit the tanks of a spent S-II stage after you already spent the energy to get it into orbit into a workshop / living area, and then push it deeper into space to use; or you have the equipment already mounted in there and sealed up, and when you reach orbit you vent the remaining fuel to space and then go in and deploy your gear.

      A 'dry workshop' version of this was actual

  • NanoRacks (Score:5, Funny)

    by Gravis Zero ( 934156 ) on Tuesday August 23, 2016 @02:16AM (#52753789)

    I guess tinytits.com must have already been taken. ;)

  • For some reason, when I was reading the summary, I kept reading it as "Saturn V" and I was like "since when is anyone building those anymore?"

    • by GuB-42 ( 2483988 )

      Well, maybe because NASA considered this with Saturn V for Skylab.
      Finally if was deemed more effective to build to station on the ground entirely rather than to recycle the used fuel tank.

      • by LWATCDR ( 28044 )

        Actually Skylab was built in a fuel tank. The the idea was to launch it using a Saturn Ib but a Saturn V was used because one was available. BTW that s why the the floors of Skylab where an open grid. There was even a plan to put a Skylab in orbit around the Moon.

  • As I recall the inflatable module has a multilayer lining to protect from radiation and micro meteors and other stuff. I don't recall fuel tanks having the same concerns. Also the inflatable module used for comparison is a prototype and full size inflatable modules will be substantially larger.

    All in all I don't see how a second stage tank will compete.

    • by Anonymous Coward

      Or you could make it a habitat first, add all the shielding for radiation and micro meteors even add some live support systems.
      Then just fill the habitat with fuel.

      • by Rei ( 128717 )

        Because all of the hardware that goes in a habitat is just totally compatible with being submerged in liquid oxygen and/or liquid hydrogen?

        • Put the sensitive bits in sandwich bags and cable tie them off.

          I mean, you could use duct tape but where's the fun in that? Not every engineer at NASA is qualified to use it.
  • by wisebabo ( 638845 ) on Tuesday August 23, 2016 @03:05AM (#52753923) Journal

    Too bad it's too late for them to be able to use the Space Shuttle external tanks.

    There were around 135 launches (so I guess the number of tanks that made it almost to orbit would be 134). Of course many (most?) of these missions were not in the correct orbital plane for use as space habitats (I guess they would not be easily reachable by subsequent manned flights). Still when one considers the sheer volume (about 2 million liters!) you'd think they'd be very useful. Also because they didn't have much heavy external hardware (like engines) they'd be easier to move around and keep in orbit.

    What could they have been used for? I'm not sure but a whole bunch of interesting applications come to mind. If they could hold a full atmosphere's worth of pressure they'd make huge living spaces. If only a low pressure environment could be maintained, perhaps plants could survive in a mostly CO2 atmosphere; with a slow rotation about the long axis and a central light column running down the length of it, it could be a huge hydroponic garden for waste recycling and food. If they turned out to be pretty durable then perhaps propellent storage or even reuse as fuel tanks for interplanetary expeditions could be envisioned. Since they are light, perhaps they could be sent, empty, to a passing comet to refill with water and then sent back to earth orbit using some of the collected mass as fuel. If nothing else, they could have been cut up and used as raw materials for use in providing shielding against micrometeorites.

    Anyway, there were well over a hundred of these giant things that, with just a little more delta-V (and admittedly, long term boosting to counteract atmospheric drag) could have been a valuable orbital resource. I guess it wasn't done because some infrastructure wasn't available (cheap orbital "tugs" perhaps using ion drives for low fuel consumption) and the vision and political will wasn't there. Too bad because this could've been like Skylab but hundredfold.

    • by Rei ( 128717 ) on Tuesday August 23, 2016 @04:54AM (#52754151) Homepage

      Shuttle ETs never got up to a stable orbit. It would have been possible to use the OMS to take them up there, but then the Shuttle would have had basically no payload capacity on that mission.

      Of course, that's one of the lesser problems with the concept. Often proposed, often investigated, but never considered worth throwing serious money into.

      • Shuttle ETs never got up to a stable orbit. It would have been possible to use the OMS to take them up there, but then the Shuttle would have had basically no payload capacity on that mission.

        On that issue, the shuttle actually used the OMS engines to steer the ET into a quick re-entry, then dropped it and used the OMS engines to get into the orbit they wanted. They used extra fuel to do this. (This doesn't address the other issues with the concept, of course.)

      • Shuttle ETs never got up to a stable orbit. It would have been possible to use the OMS to take them up there, but then the Shuttle would have had basically no payload capacity on that mission.

        And even then, the tanks would be low enough to require regular reboosts. Without reboosts, any tanks launched before around the turn of the century would already have re-entered.

  • by Anonymous Coward

    The concept of a Wet workshop [wikipedia.org] (reuse an upper stage as a habitat) was first proposed by Wernher von Braun in the early 1960s.

  • Nonsense (Score:5, Interesting)

    by DerekLyons ( 302214 ) <fairwater AT gmail DOT com> on Tuesday August 23, 2016 @04:02AM (#52754049) Homepage

    From the interview: "The reason that Skylab wasn't build like this is kind of a strange story: [NASA] had fewer Saturn IBs than they had Saturn Vs, so von Braun just decided to use a Saturn V and fly up a "dry" lab, with all of the equipment aboard it already."

    Um, not quite. When a 'spare' Saturn V became available (because a lunar mission was cancelled), they swapped from a IB 'wet' lab to a V 'dry' lab because the 'wet' labs were very expensive for their very low capability. The expense came from needing to have considerable amounts of structure and infrastructure designed to survive inside the cryogenic conditions inside the tank, from redesigning the tanks to serve a dual role, and then re-certifying the whole deal for flight. The low capability came from the requirement that everything that couldn't survive a bath in deep cryogens having to be manhandled into place via the very narrow docking hatch. While a dry lab was more expensive than a wet one - the leap in capability was far greater than the leap in cost.

    That's also why NASA built their ISS modules with the large CBM [wikipedia.org] hatches - manhandling large amount of stuff through tiny hatches (like those the Ixion will use) simply isn't very efficient. (And that's without considering the headaches that splitting all your equipment down into tiny chunks brings. Not just handling - but installation and integration too.) All of the ISS cargo craft that NASA is responsible for uses CBM, as does the Japanese HTV.

    "In the commercial sector, it's getting interesting, because people are taking more risks. Not unnecessary risks, but acceptable risks to reduce costs."

    Moving your man hours (outfitting the module) from expensive ones on the ground to hellishly expensive ones on orbit is not a recipe for cutting costs. Especially since you still have to pay for the launch of the module (Centaur) *and* the launch of the stuff to go inside it. (You can't piggyback because no Centaurs are headed anywhere near the ISS.) Even in lower inclination orbits, the mission module, the rendezvous systems, and outfitting the Centaur to survive years on orbit are all going to cost money and cut into it's payload - which will make piggybacking unattractive to Centaur's usual customers.

    "We want to keep hardware costs as low as possible: it's not about building something on the ground that could cost hundreds of millions of dollars. Why do that when you have perfectly good hardware going to space, paid for already?"

    You don't have perfectly good hardware going to space already. You have a vehicle designed for a completely different purpose and completely lacking the "stuff" customers will pay you for going to orbit.

    Or, in short, nothing in the article or interview leaves me with a warm fuzzy that they've solved any of the well known problems with 'wet' systems.

  • by Anonymous Coward

    This must be easy.
    1) Construct the habitat/fuelcontainer here on earth.
    2) Put a big plastic bag inside and fill the plastic bag with rocket fuel.
    3) When in space, attach the habitat to ISS and rip out the plastic bag.
    4) Open all windows for a while to remove any remaining smell of rocket fuel.

    • by Rei ( 128717 )

      What plastic are you thinking of and at what thickness, that is compatible with liquid oxygen, retains flexibility at LOX (or worse, LH) temperatures, and withstands the pressure, all without adding a massive mass penalty? How is the plastic supposed to deform around every little structure in the habitat (aka, not face multiple atmospheres of asymmetric pressure)? What sort of hardware are you thinking of where every last element is just fine with being frozen down to LOX (or worse, LH) temperatures? How

      • If you're doing the (larger) hydrogen tank, how 100% sure are you that you're not making an explosive fuel-air mixture, given that hydrogen burns at just a couple percentage concentration?

        Well, for the actual system they're considering, it's the larger (volumetrically) part of a single tank, the LH2 and LOX being separated by a "fibreglass honeycomb", which I guess is glued in place after welding together the bottom end of the tank and the main length of the tank body, but before welding on the top end. I'm

  • . . I've heard the story, on and off over the years, that Sen. William Proxmire stopped funding for NASA studies on taking the External Tank into orbit, and using it for the basis of a Station.

    But I can't seem to find an actual reference, anybody seen one, or is this an Urban Legend of the Space Program ?

  • Skylab came out of a set of proposals that included exactly this kind of "wet" (because formerly full of fuel) habitat. https://en.wikipedia.org/wiki/... [wikipedia.org]
  • "Tank Farm Dyname" (Score:5, Informative)

    by dpilot ( 134227 ) on Tuesday August 23, 2016 @07:54AM (#52754639) Homepage Journal

    Story by David Brin, using Shuttle external tanks. Whaddya know, the whole story is on the web: http://www.davidbrin.com/tankf... [davidbrin.com]

    • As long as we're sharing related SF, see also Michael F Flynn's novel "Firestar" and its three sequels. It's basically a series about a Space X-like company that wrapped up the year Space X was actually founded, and has the reuse of fuel tanks as habitats as a side note.

      And in response to all the people saying that the cost of either modifying the tanks to server dual purposes or performing additional construction in space makes it infeasible you're probably right. If we were talking about a one time deal
    • by Dareth ( 47614 )

      Thanks for the post. I really enjoyed reading that. I was wondering why all the yeast until they got to the ale/beer part.

    • by sconeu ( 64226 )

      Don't forget Kim Stanley Robinson's Mars series. The Ares was essentially built from Shuttle ETs.

  • Isn't the contents of the tanks kind of nasty? Will opening the tanks to the vacuum of space be enough to evaporate it all out?
    • Isn't the contents of the tanks kind of nasty?

      You're probably thinking of things like hydrazine, or some of the hypergolic mixtures. (A and B are "hypergolic" if mixing A and B results in explosion in milliseconds without needing any initiator, detonator etc. Very good if you want your motor to re-start reliably. The explosion delay is an important characteristic. Milliseconds matter.)

      The main fuel in the Centaur stages under discussion are liquid hydrogen ("LH2") and liquid oxygen ("LOX"), but the reliabl

  • This was a minor plot in some scifi novel from the ~90's. Damned if i can remember the name though but they built a large station out of used space shuttle tanks.
  • Which they are now, orbiting junk, and a hazard as long as they drift along.

    But recycling them offers an opportunity to raft a few together, build a new, viable habitat, and reduce the clutter.

    Oh, and when do we send up the garbage scows to harvest the real junk and delitter the low orbits?

  • Why not use these as server farms? Solar power would be easy. Microwave comm link. No need to waste energy cooling it.

    • A solution chasing a need.
    • It costs energy to move heat. Expending energy generates heat. Moving heat generates heat.

      Condensed version of the Laws of Thermodynamics : you can't win ; you can't break even ; you can't stop playing ; absolutely everything is subject to the Laws of Thermodynamics, including specifically anyone who objects to the tyranny of the Laws of Thermodynamics.

  • Surely they could be used as storage tanks, instead of living spaces. I doubt they'd be rated, after the stresses of launch, for long-term habitation, but there's going to be ample need for the bulk storage of mass. One of the sad things that is done, is the jettison and burning of trash; perfectly good organics and mass that might be someday useful in orbit, when the technology is developed to make use of them. Then the containers themselves could be used as raw material for some hypothetical future proces

    • I doubt they'd be rated, after the stresses of launch, for long-term habitation,

      Is anything at all "rated" for long term habitation in space. You'd never get the physical ailments consequent on a 6-month spaceflight past any industrial safety laws. Seriously, not.

      but there's going to be ample need for the bulk storage of mass.

      You've gone from step 1 to step 100 without showing any of your intermediate working. This blank assertion does not convince me. Would you fill in a few of the steps by which you arriv

  • ... the outer space version of people who want to convert shipping containers and pallets into micro houses.

  • Back in the late '80s there was talk about having the space shuttle hang on to the big external fuel tank until it got into orbit. The idea was the tank could be modified on the ground to have a docking port and basic necessities like basic ventilation ducts and electrical harness already installed. Since the shuttle almost never had anything near its max cargo load the added weight of the tank would not have been an issue for the shuttle to get into orbit. Sadly the idea never went anywhere.
  • What I'd like to see is

    Send up a hub.
    Slot the used Centaurs into the hub as spokes
    Connect the spokes on the outside rim
    Spin 'er up as a rotating wheel space station.

    You've always known you want one of these [wikipedia.org]!

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