The Mars Homestead Project A Project of the

The Mars Homestead Project ™ A Project of the non-profit Mars Foundation. TM Our Mission: To design, fund, build and operate the first permanent settlement on Mars, opening the new frontier! Presented by: Bruce Mackenzie Bruce@Mars. Home. org (781)944 -7027 Partial list of design team: April Andreas – Mars Cookbook James Burk – Webmaster Frank Crossman – Polymers & Glass Robert Dyck – Refining, Space Suits Damon Ellender – Metals, Gas Plant Gary Fisher – Waste Treatment Inka Hublitz – Agriculture William Johns, MD – Psychology Mark Homnick - Mgr K. Manjunatha – IT / IC / Comm Joe Palaia – Electrical, Nuclear Georgi Petrov - Architecture Richard Sylvan, MD. - Medical To Arrive, Survive & Thrive! 1

Outline • We need your help! • Initial Destination Mars • Task Forces • How do we get from vision to reality? • Prototype Projects • R&D & Outreach Center • A vision for Martian settlement • Comparing this world and the next • Future Directions • Conclusion • Resources to build a new home Pat Rawlings, Inevitable Descent 2

Mars settlement will open up the solar system to humanity and life Asteroids can support Trillions of people… … someday But, Start with Mars, reasons: 1. Water for Food 2. Carbon for Food 3. N 2, nutrients for Food 4. 4. a. Carbon – for Polymers 4. b. Water for industrial processing 4. c. Atmosphere, replenish air leaks, cooling 4. d. Dirt, raw materials, Si, Fe, Al, Si. O, O 2, 4. c. 24. 6 hour day 4. d. …. Learn: Interplanetary travel, Life support, Bootstrap Manufacturing, 3

How do we get from Vision to Reality? • Feasibility study • Prototype Projects • Research & Outreach Center • Change Mindset • Mars Mission • Permanent Mars Settlement • Settle Luna, Asteroids 4

Vision - The Hillside Base • Built largely from local materials • ~90% self-sufficiency by mass • Industrial capabilities enable settlement of the frontier Graphic by Georgi Petrov. Copyright © 5

Comparing this World, and the Next… 6

Selected Location: Candor Chasma Valles Marineris 69. 95 W x 6. 36 S x -4. 4 km 7

Possible locations for landing zones that don’t overfly the settlement Settlement Location 8

Settlement Construction Staging Plan Phase 1 • Completely Robotic. No humans on site. • Timeframe : First 2 years. • Objectives : Deploy first nuke, well drilling equipment, gas plant. Establish water well and initial gas reserve. Phase 2 • 4 People on Site • Timeframe : Second 2 years. • Objectives : Deploy and setup mining / refining / manufacturing equipment. • MRM production runs. Produce material needed for settlement construction. Phase 3 • 8 People on Site • Timeframe : Third 2 years. • Objectives : Continued MRM as needed. Settlement shell construction. No settlement electrical loads yet. Construct shell around agriculture, manufacturing & nuke BOPs. Phase 4 • 12 People on Site • Timeframe : Fourth 2 years. • Objectives : Finalized settlement construction. Commissioning. All settlement loads coming online. 9

Temporary Habitats Graphic by Georgi Petrov. Copyright © 10

Graphic by Georgi Petrov. Copyright © 11

Graphic by Georgi Petrov. Copyright © 12

Standardized Modules Graphic by Georgi Petrov. Copyright © 13

Lower Level Graphic by Georgi Petrov. Copyright © 14

Regolith Overburden holds internal air pressure • B-B Cross Section Thru Greenhouse and Kitchen 15

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Lower Level Graphic by Georgi Petrov. Copyright © 17

Upper Level Graphic by Georgi Petrov. Copyright © 18

First Permanent Settlement for 12 People Build Phase 1 100 m Graphic by Georgi Petrov. Copyright © 19

Settlement Expansion to 36 People Build Phase 3 Build Phase 2 100 m Graphic by Georgi Petrov. Copyright © 20

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Resources to build a new home • What do we have to work with? • What you bring from Earth • Local Resources (Atmosphere, Water & Soil) • Humans & robots working synergistically 22

Resources we bring from Earth 250 metric tons of Cargo / Habitat / People • Robots, automation systems • People – Temp. living quarters – Life Support & dry food • Power System – Nuclear Reactors, backup solar – Electrical distribution components • Construction Equipment • Mining, Excavation, Hauling Equipment • Refining Equipment • Manufacturing Equipment – Gases, chemicals, metals, plastics, ceramics, masonry, glass • Other high-tech / low mass / or items to manufacture items • Equipment & material scavenged from Descent Craft – Control systems, wiring, actuators, sensors, metal, parachutes, etc. 23

Technologies / Building Materials 24

Martian Atmosphere 25

Use of Atmospheric Gases Atmospheric Composition 95. 3% carbon dioxide (CO 2) 2. 7% nitrogen (N 2) 1. 6% argon (Ar) 0. 15% oxygen (O 2) 0. 03% water vapor (H 2 O) Output Products of Gas Plant • Oxygen • Habitat buffer gases (N 2/Ar mix) • Methane (CH 4) & H 2 Fuel • Longer Chain Hydrocarbons • Plastics (including epoxy) Pressure: 5 -7 mbar 26

Gas Liquefaction and Storage 27

Martian Water By R. S. Murray 28

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Greenhouse Water Use Graphics by Georgi Petrov. Copyright © 2005 30

WRS - Waste Recycling System, (portion of system) 31

Martian Soil by Robert-Murray 32

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Glass Process • Floated on Tin, Pilkington Process, 2 mx 4 m float tray, made from local brick, covered to protect from dust • Cooled using CO 2 in Lehr, 2 mx 2 m, made from local brick. Rollers imported. • Cut into 1 m x 1 mx 5 mm glass panels for transport and further cutting. • Located Outdoors 34

Drawing the Glass Fiber Next steps: • Pulling fibers from the melt • drawing them down from 1 mm to 10. 0 E-6 m, a reduction ratio of 100 • Organosilane coatings are applied to protect the filament surfaces and also to promote better wetting and bonding between the glass filaments and thermosetting resin during the filament winding process. • taking them up as a single strand on the forming winder or to fiber chopper 35

Filament winding the pressure vessel modules A Filament Winder is like a lathe with a long “cutting arm” that adds material (fiber and resin) instead of removing material The composites filament winding area may have to be ~30 m high to accommodate vertical winding of Homestead modules A large crane is required to support the mass and to maneuver it from vertical to horizontal 36

Chemical Synthesis (example) Aliphatic Organic Synthesis Sequence* * Patent Pending Ag 3 a. CH 2 -CH 2 O oxirane CH 2=CH 2 ethene H 2 O 3 b. HOCH 2 OH ethylene glycol To ethylbenzene 4. To polyethylene 1. To cumene 6. H 2 CO 2 + CO 1. MTO CH 3 OH methanol 2. CH 3 CH=CH 2 propene HOCH 2 CH=CH 2 2 -propenol 4 a. Cl 2 5 a. CH 2 Cl. CH=CH 2 3 -chloropropene H 2 O 2 4 b. HCl HOCH 2 CHOHCH 2 OH HOAc glycerol 4 c. Cl 2, H 2 O Ca. O 5 b. As co-reactant for LDPE H 2 CH 3 CH 2 CH=CH 2 + CH 3 CH=CHCH 3 1 and 2 -butenes 7 a. Cl. CH 2 CHOHCH 2 Cl 6. glycerol dichlorohydrin CH 3 CH 2 CH 3 butane H 2 O, H 2 SO 4 CH 3 CH 2 CHOHCH 3 8 a. 2 -butanol Cu 8 b. As solvent for polyethylene 1. O O=C C=O 7/2 O 2, 400 - 480 o. C CH=CH 0. 3 - 0. 4 Mpa maleic anhydride CH 3 CH 2 COCH 3 2 -butanone, MEK H 2 S 2 O 8 8 c. Ca. O CH 2 -CHCH 2 Cl O epichlorohydrin CH 3 CH 2 CH 3 HOOCOOCOOH CH 3 CH 2 CH 3 MEKPO dimer CH 3 COOH CO 9. Acetic acid CO, O 2 CH 3 OCOOCH 3 Cu. Cl, 130 o. C, 2000 k. Pa Dimethyl Carbonate 37

Chemical Synthesis (example) Polyethylene Part Manufacture • Polyethylene can be synthesized in three steps: (1) methane to (2) ethylene to (3) polyethylene pellets or flake. • As a thermoplastic it can be remelted and re-extruded as sheet, piping, bottles. Extrusion machines and dies are complex and will need to be imported from Earth initially. • PE is limited to use at low temperatures due to creep/viscoelastic deformation. • It is chemically resistant to the point of being difficult to bond to other parts except by welding or by mechanical joining. Extrusion product lines are compact 38

O 2 42. 5% Si 20% Fe 15% Mg 5% Al 5% Ca 4% Na 3% S 2% P 1% Cl 0. 8% K 0. 6% Ti 0. 6% Mn 0. 3% Cr 0. 2% Sand for Mortar 2000 kg per batch* Front End Loader ORE BENEFICIATION To Gravel Storage and Land Fill To Al To Lime Refining Sand washing process shares time with ore washing. Elect (200 KWh each batch, 140 KWel for 16 hr ops) HCl* H 2 Prod/Stor (~33 kg) Cl 2 Na. OH & Na. Cl from KOH Crusher Prod/Stor To Al 3 m 2 footprint Al & Lime Water (~75 kg) Refining and 2 m high. Recycle (Part recovery Class/Dryer of Na & K, Magnetic 8 m 3. Si ~2% of ore) Separation 2000 kg ore (4000 kg dry per (~400 kg) 46 deg. C batch each hour) Pneumatic Crusher & misc Hydraulic Dryer + Ca. XX Separation (6 -30 mm Mass 2000 kg (60 min size) Classification Fines batch time) Pressure Iron (~10 u. M) Fines Lock Condenser (~300 kg Fe) Fines <6 mm + misc Water HWH To Brick & Ceramic Refining Separation 270 KWth 130 KWth Tank Notes: 2000 kg 1. Assume 5% of raw ore mass moisture. Makeup Auto Sand for 2. Excavation area ~7500 m 2. ~0 gallons Strainer To Iron & Mortar *24 sand/ore batches/day @4000 kg each of Water Steel Refining Mixing Backwash required through Classification for Cl for HCl. Raw Ore Graphic by Mark Homnick. Copyright © 39

Requirements • • Steel Processing 400 kg/day 1500 K Aluminum Processing 25 kg/day 1000 K Glass Processing 200 kg/day 1200 K-1400 K Manufactured Products as needed for construction(i. e. Structural, wire, …) • Dual use or Flexible equipment used where possible 40

Tubing Mill-Formers • Rolls strips into a tube and welds. • Tubing out can be rolled or cut in lengths. 41

Overview of Nuclear Reactor Design • Concept developed by MIT Nuclear Engineering Dept. (Presented at Mars Society Convention 2004) • 400 k. We, 2 MWth • 25 year EFPL (Effective Full Power Lifetime) • CO 2 coolant, insensitive to leaks or ingress • Shielded by Martian soil, rocks and water • Hexagonal block type core (slow thermal transients, large thermal inertia) • Epithermal spectrum • Dimensions L=160 cm, D=40 cm • Mass 3800 kg • Fuel 20% enriched UO 2 dispersed in Be. O • 20% efficient Brayton cycle energy conversion, both open and closed cycles possible. 42

MRM Electrical Energy Demand 43

MRM Thermal Energy Demand 44

Energy Distribution Grid 45

Typical Round Trip Mission Plan (NASA Design Reference Mission (DRM) Hab & Crew Ascent+Fuel+Power Earth Return 3 Crews of 6 = 18 people, 1. 5 years on surface, 3 + 3 + 1 spare = 10 craft, + 10 fuel = 20 heavy launches 46

Mars Homestead Plan Do Not sent (most) return craft / Do send refining & manufacturing Hab & Crew Extra Manuf. Equip. Ascent+Fuel+Power Earth Return Result: for the same 250 T of payload, we get a Permanent Base for 12 ( … 24, 36, 48 …) Same launch cost as 3 Round Trips for 3 x 6 = 18 people 47

Prototype Projects Small projects suitable for local groups, students, university classes. Design or select equipment for: • Furniture Manufacture • Kitchen equipment • Inflatable structures • Masonry structure (foam? ) • Table top process demos • Miniature plastics moulding • Miniature machine shop • equipment • Recycle spacecraft hardware Greenhouse Experiments • Clothing from parachutes • Portable power supplies • Felt & paper manufacture • Mars Cookbook • Metal Refining AAA / / / • Surface Vehicles < Explosives > • Robotic assistants / / / VVV • Flexible chemical equipment • Gas separation equipment • Fiberglass winding • Brick laying robots Outfit a Single Module Small Robot Projects 48

Conclusion of Hillside Base description Presented by: Bruce Mackenzie Bruce@Mars. Home. org (781)944 -7027 Graphic by Georgi Petrov. Copyright © 49

The Mars Homestead Project ™ ™ A Project of the non-profit Mars Foundation. TM Info@Mars. Home. org www. Mars. Home. org Bruce Mackenzie April Andreas – Mars Cookbook James Burk – Webmaster Frank Crossman – Polymers & Glass Robert Dyck – Refining, Space Suits Damon Ellender – Metals, Gas Plant Gary Fisher – Waste Treatment Mark Homnick - Mgr Inka Hublitz – Agriculture William Johns, MD - Psychology K. Manjunatha – IT / IC / Comm Joe Palaia – Electrical, Nuclear Georgi Petrov - Architecture Richard Sylvan, MD. - Medical You could live here! Help us make it happen! Graphic by Georgi Petrov. Copyright © 2005 Mars Foundation. 50

Mars Homestead Future Directions Presented by: Bruce Mackenzie Bruce@Mars. Home. org (781)944 -7027 And Frank Crossman Damon Ellender Gary Fisher Georgi Petrov Graphic by Georgi Petrov. Copyright © 51

Next Steps for Mars Foundation Mars Homestead project: • Mars Settlement Reference Plan • Refine Design / Hillside / Any Site As Available: • Safe Haven / Passive Thermal Control • Novel Technologies • Contests • Prototype Projects, ie, Brick / Agriculture / fiberglass • Economize Staging Sequence • Design Mockup “Mars Homestead” • TBD – Major Project • Triple Launch • Demo Site for Contests/Technologies • Economic models, finance Settlement • Fun Designs: • Children, Hands-On / Museum • Outlying “Mars Homesteads” • Truck Stop / Pony Express • City design • Internship, admin help, editor, webmaster, graphic artist 52

Mars Settlement Reference Plan ™ • Chapter format on web, and • Optional book format • Document current work (Hillside Base 1) • Continue to later work 53

Future Directions Refine / Economize Deployment: • Not Site Specific, no hillside required • Start with fewer construction materials to delay transportation costs: perhaps fiberglass, ceramics, sintered regolith (brick) • Add additional construction materials as base develops: Plastics, steel aluminum, pressboard, paper • Use for non-life critical construction, only, at first Greenhouse tanks, trays, Interior partitions, furnishings Trailers, • Construct Habitat pressure shells, later 54

Future Directions Safe Haven / Passive Thermal Control -Greenhouse Outside Modules -Radiation Shielding -Kitchen & Workshops Inner Modules -Side Lit with Mirrors -Emergency Living Quarters -Convective Cooled -Low Power in Emergency -Curtains to Retain Heat 55

Safe Haven / Passive Thermal Control 56

Private Suites More detailed design of the private suites. • Currently the plans and 3 D don't quite match up. They need to be • studied in more detailed to make sure that we have a viable design. • I'm attaching a couple of images that you can use for your slides. • Cheers • Georgi 57

Future Directions Novel Technologies Investigate new technologies, or ones not cost effective on Earth Example: Iron Carbonyl Process: - Use CO to extract Iron, high pressure liquid, ~ 200 ° C -Deposit directly into a mold to leave solid Iron (James B. ) 58

Future Directions Contests - Proposal to refine specific materials with COTS equipment Brick, Fiberglass , Polyethylene, Al, - Breadboard to make specific materials - Demo minimal mass of equipment needed - Demo increasing strength of finished material - Construct a finished object given X kg of equipment, make a pressurized pipe NASA Centenial Challenge, administer (Gary F. ) 59

Prototype Projects Small projects suitable for local groups, students, university classes. Design or select equipment for: • Furniture Manufacture • Kitchen equipment • Inflatable structures • Masonry structure (foam? ) • Table top process demos • Miniature plastics moulding • Miniature machine shop • equipment • Recycle spacecraft hardware Greenhouse Experiments • Clothing from parachutes • Portable power supplies • Felt & paper manufacture • Mars Cookbook • Metal Refining AAA / / / • Surface Vehicles < Explosives > • Robotic assistants / / / VVV • Flexible chemical equipment • Gas separation equipment • Fiberglass winding • Brick laying robots Outfit a Single Module Small Robot Projects 60

Manufacture of Brick Barrel Vaults • -Use of Robotics to manufacture brick barrel vaults • Assumptions • Possible Methods • Basic Design • Kinematic Design • Work Flow Analysis • Recommendation Agricultural Concepts • research for construction methods, • crop selection, crop efficiencies, • facility management systems. • Insulated and Temp Controlled • Solar and Opaque Greenhouses • Complete Mass balance and Energy Balance Calcs • Crop Efficiency versus Ph 1 programming estimates • Modular to allow for concurrent experimentation Dar al Islam school, Abiquiú, New Mexico 61

Funding / In Kind Support Large and small Contact us to help 62

Triple Launch • Send 3 Crews, • To improve chance of success, • Lessen chance of program abandoment (Gary) Case for Mars 2, conference workshop, Drawn by Carter Emmart 63

Outlying Mars Homesteads First Settlement grows to be “Manufacturing Center” New Arrivals land at spaceport (St. Louis) Outfit yourself with Supplies &Rover (Conestoga Wagon) Travel to site of your new home/farm/mine/outpost, Set up home and tools of your trade. Pony Express Routes Establish travel routes on Mars between settlements, Set up ‘truck stops’ (wayside lodges) along the route, Travelers stop for meals, stretching, lodging, provided by Inn keeper and family. Frequent emergency shelters, double as automated farms 64

Future Directions Economics: large-scale commercial settlement Business model of full settlement of the Red Planet. Passenger tickets paid in Earth dollars, spacecraft maintained by Mars, fuel from in-space resources. This provides profit to Earth investors without bringing a physical product back. -a fully reusable Earth-orbit-to-Mars-orbit transport - ship, the size of an ocean passenger ship - permanent Mars shuttle; Mars surface to Mars orbit and back - an Earth shuttle: surface to LEO, the only part paid by Earth money -city on Mars to receive new arrivals, and - provide equipment and provisions for new settlers. -A "company town" built by the same corporation that operates the ship, and populated mostly by it's employees. (Rob D. ) 65

Full-Scale Mars Prototype/Research Center: • A research facility studying future permanent Mars Settlement. • Publicly demonstrates the feasibility and advantages of living beyond the Earth. Goals: 1. Research feasibility of early, low-cost, permanent settlement of space (starting with Mars). 2. Publicity, Education, Public Involvement; especially children. Uses: • A site to integrate research equipment. • Research on processing food with minimal equipment • Research on building techniques, using local Martian materials • Research on (semi-closed) biological life support, • Open to the Public • Contests (rover run-offs, construction, etc. ) • School tours, special programs, children's camp, private events • 'Living History' community (Plymouth, Sturbridge) • Apply lessons learned to Earth ecology. 66

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Future Directions (for FUN ! ) City Design (Bill M. ) 68

Mars Homestead project of the Mars Foundation, Hillside Base pictured Presented by: Bruce Mackenzie Bruce@Mars. Home. org (781)944 -7027 Join Us Graphic by Georgi Petrov. Copyright © 69