Metalysis, manufacturer of solid-state metal and alloy powders, has been awarded European Space Agency (ESA) funding, for its project titled, ‘The Metalysis FFC Process for Extra-Terrestrial Oxygen Production from ISRU,’ which forms part of ESA’s Space Resources Strategy and carried out under the General Support Technology Programme.

The Metalysis process has recently been proven for the industrial-scale production of metals and alloys, leading to the present investigation into the potential application of this process to regolith-like materials in a lunar context. An initial proof of concept study has resulted in a metallic powder where 96% of the total oxygen is successfully extracted, in conjunction with giving a mixed metal alloy product that can be used for in-situ manufacturing.

The project will provide an assessment to prepare and de-risk technology developments, focussed towards oxygen production for propellants and life support consumables. The ability to extract oxygen on the moon is vital for future exploration and habitation, being essential for sustainable long duration activities in space. In-Situ Resource Utilisation (ISRU) will significantly reduce the payload mass that would be needed to be launched from earth.

A previous NASA-funded study, undertaken in 2004, investigated the applicability of the FFCCambridge process for the electrolysis of lunar ilmenite, termed the Ilmenox process. At the time of this previous work, the development of the FFC-Cambridge process was still in its early stages and had only been proven at a laboratory scale.

Since this time, Metalysis has successfully scaled-up its technology, with a further three generations designed, commissioned, and in operation. As of 2018, titanium and tantalum metal production has been developed at an industrial scale, and the production of many other metals and alloys has also been proven. More recently, the production of intermetallics of aluminium and scandium has been increased to industrial scale.

Ian Mellor, managing director at Metalysis, said: “We are really pleased Metalysis is involved in this exciting programme; taking an established earth-based technology and applying it to a lunar setting. The fact that the process is capable of simultaneously producing both oxygen and metal powders is unique, offering potential solutions to two key areas of the ESA Space Resources Strategy.”

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