Sunday, September 28, 2025

Starships to Mars!

Starships to Mars

Elon Musk founded SpaceX to "make Earth Life multi-planetary" and "to insure that humanity doesn't die out from something like the giant asteroid impact that killed the dinosaurs". His passion is Mars, and that passion fueled his creation of Space Exploration Technologies (SpaceX); he was shocked to learn that NASA did not have a program for Mars colonization, or even a crewed Mars mission, at all. 

His BFR concept predated the Falcon 9 (per "Elon Musk" by Ashlee Vance, 2015), but the success of the Falcon 9, and it's demonstration of booster landing and reuse (successfully landing Falcon 9 boosters over 500 times since that first success on 22-DEC-2015) are unprecedented. Like Elon also said, "Rockets should land like they do in science fiction": gracefully and without parachutes. The BFR (now lovingly called the "Starship Superheavy") will soon be landing both the booster and the spaceship, essentially ready to refuel and fly again. And that ability makes his Mars colony plans much more feasible.

Note that Elon Musk has long talked about sending thousands of Starships to Mars, most containing just equipment and supplies, and some carrying people: colonists to build a new world. He has shown pretty images of cities on Mars, and hopes to have a million people there by 2050! 

However, SpaceX expects to be the transport, not the total solution. They hope and expect that others will solve the problems of surviving (and thriving) on Mars, including technologies for mining, drilling for water, capturing CO2, Nitrogen, and Argon from Mars' atmosphere, converting some of those into methane and oxygen to fuel ships returning to Earth, and the rest into farms, and buildings, and everything else needed to support a growing industrial civilization on Mars.

That will take a LOT of effort, by a great many people and businesses and governments on Earth as well as on Mars.

First SpaceX Mars Landing Mission

The first mission will be a test mission, perhaps 4 or 5 Starships, unmanned, to prove the ability to land. There may be a crew of Tesla Optimus robots (will we call them "robonauts"?), probably some Cybertrucks for exploration and support, and possibly some heavy equipment for excavation and regolith moving, and importantly, access to water (drills? pipes? holding tanks?). Elon has stated that he wants to start producing LOX and liquified Methane to fuel return Starships, and that is a likely target for his robonaut crew! Of course, they'll need to deploy an array of solar panels, but at least the robonauts won't need to worry about radiation, or the near-vacuum conditions, although I'll wager the cold will be a consideration, especially for their internal batteries. If I was Elon, I'd send a bunch of extra robonauts with cameras to video everything - they would serve as spares, and the publicity would be incredible.

Since that first mission will be to prove a point, and to do some initial up-front work, and possibly to establish a fuel depot, the configurations of the Starships won't be appropriate for colonists. No need for farms, or housing, or any of the other things that are needed for human habitation.

That will come on the ... 

Second SpaceX Mars Mission: First Colonists

The first priority will be surviving! Mars has a shortage of liquid water, breathable air (oxygen and nitrogen on Earth), radiation protection, meteorite shielding, and, of course, food! We'll need to build safe shelters, and grow our own food (recycling CO2, water, and nutrients into food and oxygen) almost from day one. That first resupply mission won't arrive for 30 months (from this mission's Earth launch, so we have to plan on a 900 day, plus some, for emergency everything)! So we'll probably want emergency stores of food for at least that long, and have triply redundant equipment to manufacture oxygen and recycle water, at the very least, not to mention solar panels and batteries to keep the lights on and the pipes thawed!

That first mission has a vital purpose: (a) to survive and communicate back to Earth, and (b) to find the resources needed to make the colony viable (#1: water, lots of water; #2: location to live, #3: location of vital long-term resources such as regolith, building materials, metal ores, hopefully nutrients such as the P and K of NPK so those don't have to be transported from Earth. The "N" is in the air, comprising 2.7% or so, by volume.) 

That "survive" task has multiple components, including deploying solar panels and batteries to produce a power supply to light the lights, warm the air, operate the pumps, illuminate the plants we need for food, oxygen, etc.). 

While the colonists can live in the Starships that brought them to Mars, at least for a while, they need to unload supplies and set up camp. Build the habitats, the farms, the factories, the whatever.

It also includes radiation protection: we probably need to get underground ASAP. The easiest way to do that is probably by building the colony on the surface, and using bulldozers to push a bunch of Mars regolith on top to block radiation and meteorites. A couple of meters should do the trick. We don't want to depend too much on Mars dust, as it tends to blow away, but even coarse sand should stay in place, if we can find it!

Considerations for Colonists

There are two main considerations concerning the colonists on the first manned mission to Mars.

First, how many? Elon has stated several times that the first crewed mission would involve about 4-5 Starships carrying about a dozen people and many tons of supplies. He has also stated that the next mission might send about 20 colonists, and the next about 100, and the next about 500.

Second, what will the crew look like? Everyone agrees that all crew members will be trained in multiple areas to provide, if nothing else, some level of backup / redundancy.

My own models send 8 people per Starship, probably on two Starships, with more Starships carrying supplies. Note that the skills of each Starship crew should be well distributed, to prevent a vital loss of function if one fails to land successfully. That goes for the cargo, as well: no one ship should carry the only one of some vital component (such as solar panels or battery packs).

The journey to Mars takes about four months (assuming arriving using aerobraking to slow down to land), and lots of things can go wrong and it is smart to have a broad set of skills represented on-board so you can fix things. Or people. Here is a set of skills, needed on board and on Mars:

  1. Medical
  2. Food (preparation, planning)
  3. Agriculture (mandatory on Mars, useful on board as we can recycle CO2 by growing 25% of our calories as veggies, plus have a running start when we finally arrive on Mars)
  4. Electrical (someone to keep the lights on, the fans blowing, the water running)
  5. Electronic (maintain and operate the computers & communication equipment)
  6. Air (not needed on Earth but in Space and on Mars someone needs to monitor and maintain proper air pressure, temperature, and contents, keeping O2 up and CO2 down). Think HVAC technician with a PhD!
  7. Water (someone needs to monitor and maintain the water supply, even finding it on Mars!) Is this a plumber with a PhD?
  8. Recycling (waste collection & recycling, cleaning & laundry, ?police and fire services?)
  9. Housing & Construction (on Mars, we even have to build the farms!)
  10. Exploration & Mining
  11. Manufacturing (metals, plastics, cellulose, & products made from them (including toilet paper))!
  12. Planning & Government & Administration

The percentages of each we'll need will be different in the initial, early, and later years of the Colony. Agriculture, food prep, waste, & recycling will dominate early, as will housing & construction as long as the Colony is growing rapidly. Mining is likewise more resource-intensive in the early years, as are medical services (1/3 doctors, 2/3 nurses). In the long term, occupations will tend toward parity with the US Census which reported 12% manufacturing, 10% agriculture (including food prep, waste & recycling), 6% services (food, laundry, cleaning, financial, etc.), and 5% medical. If those numbers seem low, consider that in a large (but still growing) economy, 8.6% of the population are infants, 23.6% are students, and 17.2% are retired: essentially half of the population is working, half not!

There is another, third, important consideration: we are sending colonists, not scientists & explorers. A "colony" differs from an "outpost" by a simple distinction: families. If you aren't having children, you are in an outpost, and probably don't intend to spend your life there. Families are different. You have children and want a long term future for them. Toward that end, I believe that ALL "colonists" should initially consist of (fairly) young married couples, not sterile, and intending to have children. The "married" part of that statement is intended to reduce stress, as there will always be a lot of that on Mars! I don't object to gay and lesbian couples, as long as the women plan to have their fair share of the children (and the men can contribute their own share of child care and of DNA for genetic diversity). Note that genetic diversity is vital, in the long term. But healthy DNA is also important, so we may want to exclude some potential colonists on the basis of their genetics. Having said that, there may be some conditions where life on Mars is easier for those with certain mutations: bad backs, for example!

Considerations for Starships

Starships need to safely transport crew and supplies to the surface of Mars. 

For the journey to Mars, the spacecraft must provide comfortable living conditions, breathable air, drinkable water, edible food, and deal with the waste products of humans! Communications and entertainment and exercise may just be icing on the cake. Somewhat debatable is gravity: if the Starship does not provide gravity (such as by having two Starships tethered and spinning end-over-end), then there will be a necessity for significant exercise, and toilets, food prep, and bathing facilities that can operate in zero G. Accidents (crumbs, water spills, etc.) do not self-organize on the floor, but rather head for wherever they can be the most troublesome (such as electronics).

Personally, I think that artificial gravity (possibly at Mars' 38% G) is important, if for no other reason than the same toilets, showers, and food prep/eating tools will work on the Starship in space and on the ground at Mars. And people won't get space sickness! And won't suffer permanent damage to their eyes! And so many other things we see in astronauts returning to Earth after a long stay on the ISS.

Once landed on Mars, more challenges remain: 

  1. Colonists will need a way to get themselves and their supplies down to the surface. Elon has described a crane/elevator to provide transportation from the Starship payload bay down to the surface and back, but we have few details.
  2. Colonists will need a place to live, temporarily, while they build new homes on Mars. This implies that the layout of the Starship should be designed for living, not only for the months of the journey, but for the first months on Mars.
  3. The Starship must maintain a substantial air pressure, but Mars is essentially a vacuum. Therefore, we'll need an airlock, or two, to keep the Starship livable while it is being unloaded. We'll also need spacesuits (or at least Mars suits) for every colonist. This may also mean that the individual modules may need to be pressure-tight (or vacuum safe) during the transition from on-board to on-planet. Alternatively, the transport container that carries the modules itself might provide pressure, oxygen, and thermal support through the airlock, down to the ground via the crane, and then towed into place in the growing city.
  4. Speaking of "modules", I propose that the Starship be configured with multiple modules that serve as living quarters, etc., for the transit that can be disconnected and moved - essentially intact - to their new Mars home, where they can be connected and used rather quickly. This means that the crane & airlock must be able to handle whole modules!

Modules? What are "modules"?


Modules are sort-of intermodal containers, but for Starships and Life on Mars. Outwardly identical, self-contained, and stackable. Think of them as rooms, used for living, or eating, or storage, or whatever. But they are all the same size (probably), and sized so we can stack a lot of them into the payload bay of a Starship.

If a module is a cube 2.75m wide (9 feet), you can fit five of them on one level of the Starship Payload Bay (plus four more diagonal half-cubes, which gives you seven cube-equivalents per layer). There is enough room for 4 layers full width, assuming my guesses about the V3 Starship & Superheavy are accurate. Four layers holds 20 full modules plus another 16 half-modules (great for storage, or even a bathroom). Note that leaves plenty of room above for odds-and-ends, such as a Cybertruck, or a MegaPack, or a large roll of pond liner which can be used to hold the air into a stack of modules in a pyramid or dome structure on the surface, or a large collection of solar panels. Or an excavator, or a bulldozer, or a module-friendly trailer (to be towed behind said Cybertruck) making it easier to move things around. Note than many homes have rooms (bedrooms, kitchens, bathrooms, living rooms, whatever) which are the size of these modules. And just like Intermodal Containers, you can build houses (or condos) which are an assemblage of modules, perhaps with some walls opened up for a door or completely to make a larger room. In a pinch (such as that first couple of years on Mars) a couple could live in one, including their private storage space, as long as they had other public places to eat, drink, entertain, and use the bathroom or shower facilities!

Slightly larger modules (3m / 10 ft wide cubes) also work, but only four fit on a layer, so you can only get 16 in four layers of payload bay.

Slightly smaller ones, work, too, as seven 2.4m / 7ft 11in modules also fit in a layer, yielding 28 per Starship, but by the time you account for ceiling/floor depth, and wall thickness, this begins to feel seriously cramped, and might only work for that first manned mission. Your colonists, after all, must have something to look forward to!

Something very important about standardized modules: they can be pre-configured on Earth for deployment on Mars. Bedrooms can include beds, and closets, and night stands. Lights, power, and standardized connections for air, water, power, and communications as needed. Bathrooms, kitchens, bunkrooms for lots of kids, whatever makes sense. Community showers and bathroom facilities. Community kitchens and dining areas. Rooms containing pumps and blowers to handle the rest of the rooms. Water tanks, waste tanks, agricultural tanks (just like vertical farms or container farms on Earth). I would even suggest that we use some of these on every manned Starship to recycle CO2 and H2O while producing a little bit of fresh food for the tables. This could be done along the outside walls of containers otherwise used to travel between layers and room, serving a dual function of overhead (transportation) and recycling. As a bonus, they can be ported into permanent Mars habitats while already producing enough oxygen for the colonists to breathe and veggies for the colonists to eat, allowing the "farmers" to focus on growing food crops with higher calorie and protein and fat content.

How Many Starships Are Needed?


Elon thinks that the initial mission (unmanned) will have 4 or 5 Starships. He has also said that the first crewed mission will carry 8 astronauts, on 4 Starships. And then he'll multiply the people and Starships by five for each subsequent mission. These numbers are needed to hit his goal of a million people by 2050, which most everyone believes is not realistic. But if he can simply double the number of Starships in each Mars transfer window, he can reach his target only a few years late, sending over 100,000 new colonists in the 2050 window. But that would take a 100,000 Starships, and I don't see SpaceX funding that level of effort, let alone being able to build that many in only two years.

Seeing the first million people on Mars is still viable, it will just take a bit longer, or a lot more support from the rest of the world. If the USA sends a thousand Starships, and China sends a thousand, and Europe sends a thousand, and India sends a thousand, and Japan sends a thousand, and Indonesia sends a thousand, .... (well, you get the picture)!

Thursday, July 24, 2025

Colonies in Space are Hard; Colonies on Mars are Harder!

I've long been a believer in Orbital Colonies, huge habitats (initially) in Earth Orbit with tens of thousands of inhabitants, in very Earth-like settlements spinning for 1.0 gravity.

But Science Fiction (whether written or watched) has overwhelmingly assumed that we will find Earth-like worlds around many (perhaps most) Sol-like suns. Astronomers have not helped to clarify that vision, describing "habitable zones" that allow liquid water somewhere on the surface of a planet, somewhere allowing stable orbits, and somehow allowing Earth-like atmospheric pressures and potentially oxygen/nitrogen atmospheres. Personally I would prefer temperatures closer to freezing than to boiling. I also prefer gravity near Earth's 1.0G (not half, certainly not double). I also prefer a fairly wet planet, like the Earth (70% ocean), and not a water world or a dry desert pole-to-pole. Hey, beaches are nice, but water is a necessity! And seasons are nice, and a day length of anywhere near 24 hours would be great. Not tidally locked to its sun (infinite day length), and not spinning like a top, but actually we could live with that.

Note that first of the two planets in our Solar System closest to the Earth is Venus (97% gravity, a day that is 117 Earth-days long, with 92 times the air pressure at 867 °F, not exactly a pleasant spring day on Earth. Did I mention that the atmosphere is composed of 96.5% CO2?). 

And the other planet is, of course, Mars, which has 38% of Earth gravity, only 1% of the Earth's air pressure, also almost entirely consisting of CO2. In Mars' favor, however, is its day length of 26 hours, and its surface temperature which ranges from −243 to 68 °F. Shirt sleeve weather on a good day! It's 1.4au from the Sun, which means that we'll need twice the area of solar panels to generate the same electrical power as on Earth. There is so little atmosphere that radiation and meteorite impacts are serious problems, and we can't venture "outdoors" without serious pressure and oxygen support, suggesting that we live underground instead of in the pretty surface cities depicted in so much literature.

The Mars of Edgar Rice Burroughs was always a fantasy.

But Mars has long fascinated space hopefuls: it's visible, it's reachable, and it has climate and weather (the icy poles switch from north to south and back by the seasons, and there are planet-wide dust storms that are visible in telescopes on Earth). One of those fascinated by Mars is Elon Musk, and he brings thousands of fellow Mars colony enthusiasts, not to mention a Starship big enough to move a serious mass of people and supplies from here to there and back, at a small fraction of the price charged by "Big Space".

A lot of people DO believe in moving humanity to additional planets, and Mars is the easiest planet to reach from Earth. So Mars is first! Elon Musk founded SpaceX largely with people who believe in Mars as a potential habitat for Humanity. 

Here are a few thoughts about placing a colony on Mars. I'll be expounding of several of these in future posts.

The current version of the SpaceX Starship / Superheavy consists of a 1st stage (booster) that is 9 meters (30 feet) in diameter and stands 71 m (233 ft) tall. It is powered by 33 Raptor 2 engines that burn CH4 and LOX. The 2nd stage (Starship) is also 9m (30 ft) in diameter, 52 m (171 ft) tall, and powered by 6 Raptor 2 engines. Note that the Starship is designed to be refueled in orbit, so it can be launched with a full 100 or 150 (or eventually 200) Mg (Megagrams, or Metric Tons) of payload, and refueling in orbit (via a tanker version of Starship) allows it to carry a full payload all the way to Mars. The payload bay is the inside of the 9 m stainless steel tube, which tapers down to nothing at the top. The full-width portion of the payload bay is about 11 m tall. All-in-all, there is over 1100 cubic meters of payload space, which is comparable to the entire ISS (International Space Station). And the next (Block 3) version of both Starship and Superheavy are a bit larger.

For my purposes, the key points are:

  1. Mars transfer launches occur in ~month-long windows that occur every ~26 months. The average transit time is about 3.5 months (assuming aerobraking at Mars), less with more fuel (or less payload), longer with more payload (or less fuel).
  2. You must carry enough supplies to get to Mars, and live there until you can grow your own food, etc., OR receive resupply. Since you might NOT successfully grow your food, the smart thing is to take at least 30 months of supplies! Note that “supplies” include everything not available on Mars, including computers, LEDs, PDAs, lubricants, electrical components, solar panels, batteries, TOILET PAPER (and every other kind of paper), plus all of the nutrients needed to grow the next generation of crops (like nitrogen, phosphorus, potassium, calcium, magnesium, & sulfur, plus a smattering of micronutrients). Look around you: How much of your environment consists of plant products (wood and paper), or petroleum products (mostly plastics of many types)? Don’t forget fabrics!
  3. SpaceX is planning to send a few Starships to Mars (carrying supplies but no colonists) during the next window (late 2026) proving that Starship can make it that far and successfully land. Hopefully with all of the ships landing within walking distance of each other.
  4. Another goal is to produce CH4 and LOX on Mars, to have return fuel ready for use.
  5. Starships carrying colonists would depart during the following window, very early 2029, in a fleet of multiple Starships, most of which would carry only equipment and supplies.
  6. The first colonists would likely live on the Starships for several months as they build a place to live, and the farms to sustain them.
  7. I think the ideal solution is to fill each Starship with standardized modules, and live in some of them while others are unloaded. Eventually, all would be unloaded.
  8. Each module would be a cube 2.75 meters (9 feet) on a side. They might be configured as tanks (water?), supply rooms, plant grow rooms, or simply rooms for living and working. Note they can be pre-configured, possibly (for example), as greenhouses already recycling CO2 and H2O into food and oxygen, things we’ll need both during the journey and on Mars. But note that we only need 25% of the greenhouse space to recycle CO2 into O2 as we would need to produce food to eat (it makes sense to have a fraction of the greenhouse space during the transit and early Mars habitation).
  9. Recycling: per NASA, each day the average colonist consumes 0.835 kg of O2, 0.617 kg dry food, and 3.909 kg of H2O, while producing 0.998 kg of CO2, 0.109 kg of dry waste, and 4.254 kg of waste water. The water clearly needs to be recycled, and the CO2/O2 as well. Dry waste contains vital nutrients that are needed to grow more food! There are also many minor chemicals that must be dealt with, such as ammonia, methane, and other gases produced by sweating and breathing and farting. Note that, on average, we eat about 25% of the plants that we grow. For example, we eat corn, but not the husks, cobs, stems, leaves, or roots. We eat tomatoes, but all those leaves and stems are poisonous to us. This means that the CO2 we exhale is only sufficient to grow about 25% of the next crop! We need to turn ALL of that crop waste into CO2, water, and minerals, perhaps by digging it up and burning it. Or we could dig it up and feed it to fish, chickens, rabbits, and goats. Maybe some fungi, or some worms. There are many forms of burning, only one is really fast. Composting is really slow. Did I mention that the total dry food above does NOT include crop, food prep, or plate waste? So we really need 10%-40% more than the dry totals above (0.617 kg/colonist/day), plus even more if we save part of our crops for a rainy day...
  10. SpaceX plans to have a crane on each Starship (heading to Mars) that will be used to ferry colonists and supplies (I think whole modules) to the surface. Plans include a huge cargo door, but I’ve never seen plans for Starship that include air locks (which I’m sure will be a requirement).
  11. Unlike the pretty SpaceX depictions of cities on Mars, the lack of atmosphere and magnetosphere mean that meteorites and radiation are serious long-term problems: we will need to live (and work, and conduct agriculture) underground. So, imagine laying out the modules, stacking as appropriate, then covering them with two or three meters of dirt!

My questions:

  1. What is the optimal number of colonists per Starship? 8? 16? SpaceX says that a Starship can carry 100+ passengers, but that is for Earth-to-Earth missions like a commercial aircraft.
  2. What fraction of the needed supplies (including O2, H2O, & food) should we recycle during the journey to Mars, and during our early months ON Mars. Note it will take a while to build infrastructure (such as solar panels to gather energy), and then it will take about 4 months to grow a crop (which we can repeat every 4 months). At least while growing the crop we’ll have all the O2 we can handle (actually, more, about 3 times more!). Do we take the water we need, or just (thoughts and prayers) hope we can quickly find and access underground water? How long does that take?? At least CO2 is plentiful on Mars.
  3. Until we have a complete ecosystem on Mars, we'll need more CO2 & fertilizers & water than we'll produce (from consuming foods), and we'll produce more O2 and wastes than we can use. We'll need a LOT of water to grow crops, even with perfect recycling, because every kg of plant matter stores about 3kg of water, so by the time you've grown enough crops to feed a colonist for 4 months, you have stored over a metric ton of water in the plants (NASA estimates minimum biomass at 1.5 Mg/colonist).
  4. Initially, we'll likely grow our foods in hydroponic / aeroponic systems similar to the vertical farming units now growing fresh vegetables near you (aka "container farms"). These work great for veggies (lettuce, spinach, etc..) but less well for fruiting crops (tomatoes, peppers, squashes, beans) or underground crops (onions, potatoes, carrots, garlic). But they do work. They don't work all that well for cereals (wheat, rice, corn, cane) and our normal diets depend on them for the majority of our calories! Research is needed: I can't imagine life without breads, pasta, rice, and corn products even excluding HFCS! Of course, I can't imagine life without milk, cheese, bacon, beef, and more. NASA funded several studies on the minimum crops needed for full nutrition, most of which returned a list of 15-20 crops, and when I did my own list the minimum was more like 50 crops, and I could easily justify 100+ once you include variants like bell peppers, poblano peppers, jalapeno peppers, cayenne peppers, etc.. Just the spices alone are scary.
  5. We need a great deal of redundancy in our Mars farms! At least triply redundant (let's grow crops in at least three widely separated areas, not connected via water or direct air supplies so that pests or molds or viruses don't kill everything at once), plus we'll need different growing conditions in any case, as some crops like it hot, others like it cold, some like it dry, some like it wet, and of course some like it "just right". There are a lot of other variations such as length of day, or necessary changes in nutrients to induce blooming, stuff like that. Plus, we don't want all of the crops harvesting at once, we'd like to spread it out to simplify the labor and processing involved, and minimize storage. Note that "greens" can often be grown very quickly, even planting-to-harvest in as little as a month, using optimal conditions including 24-hour lighting. Yes, we'll be using LEDs to light our crops. (see https://ramblingsonthefutureofhumanity.blogspot.com/2009/11/lighting-our-space-habitats.html).
  6. What should our infrastructure (modules, shelves, tanks, etc.) be made out of? Starships are made from stainless steel, but that is heavy. I would suggest using UHMWPE (Ultra-High Molecular Weight Poly-Ethylene) since it is stronger than most steel, and is lighter than water. Steel has a density of 7.8 Mg/M^3, while UHMWPE has a density of 0.97. The strength of steel varies from 300 MPa (Mega Pascals) to 2000 MPa, while UHMWPE has a strength of perhaps 3,000 MPa. It’s thus 10 times stronger and 8 times lighter, meaning 1 kg of UHMWPE is as strong as 80 kg of common steel! Plus, it is used as armor on Earth, as the strongest mooring lines for container ships, and is an excellent radiation shield! The only downsides are that it softens at boiling water temperatures, is flammable, and is really hard to glue, cut (machine), or paint.
  7. What is the fraction of people Starships or supplies only Starships? Elon only says that more Starships will be carrying equipment and supplies than colonists.
  8. The Sun only produces about half the energy at Mars compared to at Earth. So you need twice as many solar panels, and you can’t use wind or hydro or fossil fuels for energy. Also, the sun doesn’t shine at night or during dust storms! So we need batteries, a lot of them. Should we take modular nuclear generators? After all, those rare planet-wide dust storms can last for months!
  9. We will need pollinators on Mars from the get-go. Honeybees require large colonies (25,000 to 100,000 bees), and about 1 sf of wildflower per bee (and you do get honey!). Bumblebees are happy in colonies of 50-100 individuals, so they can pollinate much smaller greenhouses. But they don’t make honey. 
  10.  How soon should we introduce fish / fowl / mammal meats? What about shrimp? Are goats adequate for meat and milk and cheese?? It might be easier to start vegetarian, but it takes about 30% more planting area for a vegetarian diet (since we have to find a way - other than eating - to recycle all of the uneaten portions of the crops).
  11. Should we allow pregnancies? After all, with only 38% of Earth's gravity, we don't know if human children can thrive, and we suspect children raised in such low gravity will never have the strength of muscles and bones to be able to visit the Earth.
  12. How soon can we allow pregnancies? Note you have an “outpost”, not a “colony”, if there are no children. Should we only allow colonist who are young, fertile, and married?? Define “young”, and define “married”. We WILL need a growing population to become a self-sufficient industrial civilization before the Earth stops being able to ship supplies to Mars.
  13. Can we live without gravity for the journey? Note it takes a lot of exercise (2+ hours per day) to mitigate the worst of the zero-gravity side effects. NASA targets 2,800 kcal/person/day with the needed exercise, versus 2,000 for a normal person. We can get gravity by tethering two ships nose-to-nose and spinning them end-over-end. Complicates course changes and telecom, and raises the question of can we do entirely without zero-G toilets and showers? Note, too, that gravity greatly improves the ability to keep the air clean and messes controlled. The ISS demonstrates many of the problems with trying to live in a zero gravity environment (try Googling ISS clothing, bathing, personal hygiene including zero gravity toilets, etc., and don't forget the odors).

Wednesday, July 23, 2025

An Apology...

 It's been 14 years since my last post in this blog!

The first half of that was thanks to the company I helped found, Deep Space Industries, who argued that my ideas belonged to the company and should not be published except in forms that benefitted DSI.

I certainly continued to be active in Space Settlement stuff, and in Asteroid Mining, and attended (and gave talks) to many space conferences, some hobbyist, some academic. I was DSI's "Director of Research and Development", won multiple NASA contracts (team efforts), and opened the DSI Lab in Orlando, Florida, to be close to our partners at the University of Central Florida and, of course, to NASA at Kennedy Space Center. We closed our Florida lab when the last of our active NASA contracts completed on 30-JUN-2018.

The next 7 years I've spent traveling with - and entertaining - my wife, Doris, who has needed my full-time attention as her condition deteriorates (the doctors prefer "progresses"). We are now back in Dayton, Ohio, her home town which is where I met her and spent 17+ years before moving to Dublin, Ohio for 7 years then to St. Augustine, FL for 10+ years, then to Orlando for four more. When I retired from DSI, we bought a 40' Diesel RV and travelled the USA visiting friends and relatives, without a permanent home. Yes, I grew a beard to look properly "homeless".

I've settled down enough to start writing blog posts again. I've got a lot I've been working on, and I plan to share it all on this blog.

I'm back!

Respect Science, Respect Nature, Respect Each Other.
Stephen D Covey
www.StephenDCovey.com (writer)
www.galleries.com (rockhound)
www.RamblingsOnTheFutureOfHumanity.com (space geek)
www.DeepSpaceIndustries.com (now retired, formerly co-founder and Director of Research & Development for this asteroid mining company)

Thursday, July 7, 2011

Technologies for Asteroid Capture into Earth Orbit

The following is my presentation “Technologies for Asteroid Capture into Earth Orbit” given at the International Space Development Conference in Huntsville, Alabama, on May 19, 2011.

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The focus of this presentation is on a specific technical approach which enables us to capture an asteroid using essentially current technologies; the missions, tools, and complications of that approach; and then some asteroid selection criteria and a few specific asteroid capture opportunities.

Using the asteroid 99942 Apophis, I outline a possible capture mission, its requirements, and a timeline.

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So why capture an asteroid? The main reason is to gain convenient access to its resources. Even a relatively resource-poor low-iron, low-metal LL chondrite contains 20% iron, significant quantities of water and other volatiles in the form of minerals such as clays, and oxygen to burn.

The asteroid Apophis (likely one of those LL chondrites) contains enough materials to construct about 150 five-gigawatt solar power satellites at 25,000 tons of steel and silicon each, plus Kalpana One style habitats for 100,000 people, all shielded by the slag remaining after iron is smelted out of asteroid ore. The oxygen freed from iron compounds during smelting amounts to well over a million tons more than is needed for the habitats, valuable fuel mass for ion thrusters to move the habitats and solar power satellites into their chosen orbits and to spin them up.

Of course, a space habitat providing food, water, oxygen, fuel, construction supplies, gravity, radiation shielding, and skilled human workers situated above much of the Earth’s gravity well is an ideal platform from which to continue the exploration and exploitation of space.

And we should not forget that placing an asteroid into a stable Earth orbit prevents it from colliding with the Earth.

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So, how do we capture an asteroid? Even a tiny one masses millions of tons, and we don’t yet have the technologies to manhandle them and put them wherever we want. Luckily, we don’t have to. When a spaceship or asteroid passes close to a planet or large moon, its orbit is changed, sometimes dramatically.

In principle, the Earth can impart a delta-V of up to 60km/s to an asteroid in orbit around the Sun, although in practice the limits are a small fraction of this. More importantly, small changes in the position or timing of an existing close approach are enormously magnified.

We aren’t limited to the Earth, in that close encounters to other planets might be used to alter an asteroid such that it passes close to the Earth at a later time where its orbit can be further tuned by the Earth’ gravitational field.

If we can adjust the asteroid’s orbit such that it makes a subsequent close approach to the Moon with a relatively low velocity, the resulting slingshot can drop that asteroid into an Earth orbit. The Moon can (in principle) remove up to 2 km/s of velocity relative to the Earth, although less is easier.

A point I’d like to emphasize: In my opinion, gravitational slingshots are as much art as engineering, especially when considering the variations involved in multiple slingshots around one or more bodies. The people who dreamed up the Cassini and Messenger missions are both geniuses and artists, and I have every confidence that they can find suitable mission plans to capture any potentially hazardous asteroid into Earth orbit, although the missions may be very long and complex thanks to a shortage of appropriate close encounters and/or the need for significant changes to the asteroid’s orbital parameters.

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When selecting an asteroid for a potential capture, the most important consideration is simply the proximity of an asteroid’s orbit to a useful keyhole through which the orbital engineers can design a capture mission in a reasonable timeframe.

The second consideration is the size of the asteroid. Bigger is not better when a 1 kilometer asteroid masses fifty times as much as Apophis, and thus requires a fifty-fold increase in the product of mission time and fuel mass. On the other end, a small 120m LL asteroid massing 2 million tons (and relatively poor in useful metals and volatiles) still has sufficient materials to build a single small Kalpana One style habitat for 8,000 colonists plus a dozen 5 gigawatt SPSs. Thus I view 120 meters as the smallest asteroid worthy of (first) capture, since it is barely large enough to build a permanent habitat rotating at 3rpm for Earth-normal gravity and with adequate radiation and meteoroid shielding.

Another consideration is the V-infinity of the asteroid, because slower asteroids are easier to move a distance large enough to make a significant difference in the slingshot.

The potential magnitude of a gravity assist is also constrained by how close to the center of the Earth the asteroid passes – and I think it’s important to keep it out of the lithosphere. Also, for a rubble pile we don’t want to pass closer than the Roche limit or the asteroid may be torn apart by tidal effects, much as Jupiter’s tide tore the comet Shoemaker-Levy into 20 fragments. The actual Roche limit depends upon density, but is likely to be of the order of 20,000 kilometers for a rubble pile asteroid passing near the Earth, and perhaps 5,000 kilometers for the Moon.

One might think that the composition of an asteroid would be the number 1 criteria, but in reality most asteroids should be quite valuable (see Mining the Sky by John S. Lewis). A common carbonaceous chondrite might contain 25% nickel-iron mostly in the form of metal grains, 10% water, and several percent carbon plus everything else needed for life in space. But even a lowly LL chondrite will work.

The last consideration here is the opportunity for intercept missions. We need to modify an asteroid’s orbit when it is easy, some months or years before the targeted close approach. This is difficult for a high-inclination or long-period asteroid because it might only approach closely enough to the Earth for low-delta-V intercept missions once every ten or a hundred years. But an asteroid with a two-year period might present suitable launch windows every two years. Also, for asteroids with periods close to a year and with low inclinations, there may be two launch windows per year as the asteroid passes inside and then outside the Earth’s orbit.

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This table presents some possible asteroid capture candidates as of 25-APR-2011, all brighter than 24th magnitude and expected to pass within 120 Earth radii in the next 50 years. Some of these may be eliminated by further refinement of their orbital parameters, while others can likely be added as new asteroids are discovered, or as orbits are corrected for known ones.

The entries on this table were gleaned from the Near Earth Object Close Approach database. The various tables, databases, and lists at the NASA web site are inconsistent, sometimes even on the same page. For example, the orbit visualization tool often has significantly different closest approaches than the “close approach” data on the same page.

A side note: Many asteroids have only been observed over a few days, resulting in large uncertainties in their orbital parameters. The shapes, diameters, and masses of most asteroids are estimated, not known. Diameters are estimated from an asteroid’s brightness and distance. But we can’t measure the actual albedo, and observations at multiple wavelengths are used to judge the asteroid class, and from that a typical reflectivity, and from that a formula results in an estimate of the diameter, and assuming an average density, we calculate the mass. This process has extremely large error bars. In April of 2010, radar imaging resolved the asteroid YU55. Previous estimates were that its diameter was 140 meters and its mass 4Mt. The actual measurement revealed a diameter of 400 meters and an estimated mass of 87Mt, a 22 fold mass increase.

Let’s consider these asteroids.

Apophis is fairly well characterized, although it may not be an LL chondrite, and may therefore have a different albedo, diameter, and mass. As a candidate for Earth-orbit capture, it has the advantages of passing quite close, and relatively slowly, plus launch windows occur in Aprils and Octobers near close approaches, suitable for a 1, 1.5, 2, or 2.5 year mission. It masses 27 million tons, roughly twelve times larger than the minimum useful capture size.

2001 WN5 is a bit on the large side, but it may pass about halfway between the Earth and Moon in 2028 which offers an opportunity to adjust its subsequent Earth approaches in 2037 and 2046. But being more than 20 times as large as Apophis means a lot of fuel is required, so 2001 WN5 will have to wait for a later, poorer opportunity, probably with a robotic mission.

2005 YU55 is three times as massive as Apophis, and approaches Earth, Venus, and Mars, giving multiple possibilities for gravity assists. Next year it will pass about 20% closer than the Moon’s orbit, but it won’t be that close again for quite a while. It makes frequent approaches, about every 11 years, with relatively close approaches in April of 2021, 2032, 2043 (etc), and in November of 2022, 2033, 2044 (etc). We can likely tune one close approach to allow a closer approach 11 years later that can lead to a capture 11 years after that.

1999 AN10 is a large (50x Apophis), fast, and dangerous asteroid which will pass about as close as the Moon in 2027. It is large enough to build 7,500 5-Gigawatt Solar Power Satellites, or to house 2 million people in a 2 mile diameter habitat. Actually, we can solve Earth’s energy problem for the next thousand years AND build a habitat for one million people, with materials to spare. While it is difficult to capture, it should be worth the effort.

2009 WM1 is only half the size of Apophis, and should be easy to capture some fifty years from now at its next close approach.

Lastly, 1999 RQ36 is 7 times the size of Apophis and passes 1.2 Lunar distances from the Earth in 2060. It, too, won’t be easy to capture, but is also worth the effort.

I’d like to point out that every one of these asteroids were placed into their current orbits by a slingshot around the Earth, a fact clear at a glance at the orbital simulation on the NASA web site. One of the principles of orbital mechanics is that an orbiting body (in a 2-body system) will always return to the altitude and velocity vector of its last orbit change. Ignoring hyperbolic orbits, one near Earth pass means more, until the body collides with the Earth or is deflected away by another planet.

Note, too, that capturing Apophis in 2029 would provide ample fuel to capture those big asteroids a few decades later.

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But it seems that nothing is ever simple. Part of the problem is that we don’t really know much about asteroids. Many of them appear to be rubble piles, and in some cases these spin so rapidly that their shape is constrained by their spin, yielding flying-saucer shapes. Others are contact binaries which might be exceptionally awkward to manipulate. We have more options with solid bodies, but we can’t plan on that.

So how do we apply thrust? Two ways come to mind: dock and push, or use a gravity tractor to pull. Gravity tractors can only apply tiny amounts of thrust, but that might work, especially on longer missions. It would also help to dangle heavier components such as nuclear reactors and fuel as close as possible to the asteroid, with the thrusters some distance away so they can aim off to the side without much loss of thrust efficiency. But a 1,700 ton mass dangling 170 meters from the center of Apophis would be needed to apply the necessary delta-V over a 10 month period. Gravity tractors generally require very long missions.

We can dock with an asteroid and push against it in a traditional way, but there are complications due to microgravity and asteroid rotation. It is possible that a number of cables could be looped around the asteroid to hold the tugship securely in place. Even then, a spinning asteroid means that thrust can only be applied during a fraction of each rotation, wasting thrust and fuel to the extent that the applied thrust isn’t directed in the correct vector.

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Let’s consider a specific example. The asteroid Apophis will approach Earth to within 30,000 kilometers on April 13, 2029, significantly inside the orbits of our geostationary satellites. If we do nothing, the Earth’s gravity will slingshot Apophis into a new orbit as it deflects it by about 28 degrees and boosts its velocity by 3.04 km/s. The result of this is that Apophis changes from a 0.89 year period Aten class asteroid orbiting mostly inside the Earth’s orbit to an Apollo class asteroid with a 1.167 year period and an orbit mostly outside of the Earth’s. I should point out that we don’t yet know with any degree of certainty exactly what the resulting orbit will be, because tiny changes in the position of closest approach have a huge impact on the resulting orbit. The period I’m quoting here corresponds to the keyhole that targets an Earth impact in 2036.

My main point is that delaying Apophis’ arrival at the Earth’s orbit by changing its velocity by only 10 cm/s results in a 1.5 km/s reduction in delta-V - a velocity gain of a factor of 15,000. I chose that particular slingshot because it results in a semi-major axis of exactly 1 au, with a period of 1 year. I used a program named GravitySimulator by Tony Dunn to model several Apophis orbit variations, and simultaneously to gain a true appreciation of the art and genius needed to find useful orbits.

The Tisserand criterion indicates that it’s possible to change Apophis’ eccentricity to zero at the same time, although that would result in an inclination of about 10.5 degrees, and requires a much larger delta-V. In any case, what we really want is not a near-Earth orbit, but rather a subsequent low-speed slingshot around the Moon to remove excess velocity and drop the asteroid into Earth orbit. That may require some finesse and multiple slingshots, but I’m confident it can be done. Look at the success of Cassini, Messenger, and other missions that have relied on gravity assist slingshots to achieve what once was considered impossible for our current technology.

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We still need to give Apophis that 10 cm/s nudge. I don’t suggest abrupt changes from nuclear bombs or high-velocity impacts, partly because we need finesse to fine-tune the orbit, and that’s best done by the equivalent of titration. We need a tugship, a long-mission, highly fuel-efficient spacecraft to gradually move the asteroid into a new orbit.

Magnetoplasmadynamic or VASIMR thrusters are likely the best choice to apply delta-V, as their high exhaust velocities reduce the total fuel mass needed, they can generate significant levels of thrust, and they should be able to achieve sufficiently high reliability.

Of course, we need to push or pull the asteroid, which isn’t simple, partly because they are rotating, undoubtedly along an inconvenient axis. And they have enormous angular momentum which we can’t simply cancel. This means we’ll either have to dock – not land – at an appropriate location and thrust a fraction of the time, or use a gravity or magnetic tractor approach which might limit us to lower thrusts and longer missions.

Note that ion thrusters take copious amounts of energy. 25 megawatts can be generated by a 300 by 300 meter solar array, or by a single compact nuclear module available commercially. We do have a lot of experience with high-power nuclear modules in submarines and aircraft carriers, so that’s an option I personally lean toward, but politics may dictate a less proven approach. Also, working fluids and cooling grids need to be addressed for nuclear or for solar dynamic electric generation.

Given an appropriate power supply, we still need enough time and fuel to move an asteroid. So how much do we need?

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From our mission-time derived flight plan, we compute the needed delta-V, and conservation of momentum allows us to compute the needed momentum change and the product of fuel mass times exhaust velocity. The asteroid’s mass is a given, but we can choose to some extent our mission time, and thus the needed delta-V. Double the mission time, halve the delta-V.

Note that doubling the exhaust velocity quadruples the needed energy (100 times the energy is needed for 10x velocity for a given amount of fuel). But doubling Vex also halves the fuel mass required, so the net effect is doubling the required power for a given thrust duration. At a specific impulse of 5000, consuming 55 tons of fuel over a 10 month period requires 5 megawatts of continuous power.

With a lot of energy, we don’t need much fuel at all. These numbers are all well within our technological capabilities. Of course, additional fuel will be needed to deliver the tugship and its load of fuel to the asteroid, but again, the numbers are within our capabilities. We can do this.

However, remember that Apophis is rotating and we may only be able to apply thrust half of the time. This doubles the thrust and power required.

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I’m proposing a mission with two main phases and a three-year (or so) timeframe.

The first phase is to launch the necessary components and assemble them in orbit, some time in 2027.

The actual deep-space phase begins with a lunar slingshot for intercept injection in October of 2027, and docking with Apophis some 5 months later. This requires 3 km/s of delta-V, and about 15 tons of fuel.

We would grapple Apophis, and apply 400 Newtons of thrust (enough to deliver 1.0 cm/s/month of acceleration) for half of every 30-hour day. Ten months of thrust consumes 55 tons of fuel. Then there is a three-month coast until the slingshot.

The major slingshot must occur on April 13, 2029. The goal is to change Apophis’ orbit to achieve a lunar slingshot 1 year later to capture the asteroid into Earth orbit. Note that the initial thrust moves Apophis further from the Earth, and the subsequent lunar slingshot is necessarily even further out.

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I want to talk briefly about that tugship.

It must support an extended deep-space mission, providing everything the crew needs to thrive. My supplies estimate assumes ammonia provides hydrogen for carbon dioxide recycling, and food to be dehydrated.

My mission plan requires 55 tons of fuel to change the asteroid’s orbit, plus 15 tons for the intercept and docking, plus contingencies. I’d suggest at least 100 tons total, perhaps more. Note that if properly oriented, the fuel can provide significant radiation shielding during the trip to Apophis, and then the asteroid itself provides even more, especially if the crew quarters can be partially buried.

We need to apply 200 newtons of thrust continuously for 10 months, or double that for half of the time. We’d need to double the power as well, 10 megawatts total. A 200 meter square array of 25% efficient solar cells generates 12 megawatts, the extra needed since ion thrusters aren’t 100% efficient.

Lastly, we need some way to grab hold of the rotating asteroid. I suggest using 6 harpoons with 1-km lines launched around Apophis, the ends retrieved and securely tied to the tugship. This would function as an effective net and friction applies sufficient traction to apply thrust even at high angles of attack. We could break several of the lines and still hold on. Note that this is a good example of where people can easily accomplish a task which might be nearly impossible for an automated system.

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This project plan assumes a separate launch of a construction shack housing six or more workers for several months.

Their job is to assemble all of the components, as I’d expect at least 5 launches of 50+ tons each are required.

-Two launches for the solar panels and supporting structures – total 100 tons

-Two launches for the fuel and thruster assemblies – another 100 tons

-One launch for the tugship (crew quarters) itself

-The construction shack is a sixth launch, and the assembly crews, mission crew, and supplies are likely two more man-rated launches. Note I’m assuming the assembly crew is launched early, and the mission crew at the last minute, because the deep-space mission already requires a very long time. The number of people in each is an estimate, of course. While 6 workers may suffice to assemble the tugship during a two month project, double the people would simplify training, ease workloads, and provide significant redundancy.

-Likewise with the deep-space mission crew. Two people may be able to handle the workload, but that is cutting it close. I’d suggest four at a minimum, and six is better.

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Continued research tops the list of the several logical next steps we should take. NASA is ideally suited for several of these, and the continuing search for potentially hazardous asteroids identifies the same candidate asteroids as a search for potentially capturable ones.

We do need to address several legal issues, which pose a serious problem for Western civilization private enterprise. Key among this is the right to own and exploit objects in space. If a person or company does not have the right to exploit space-based resources, they can have no incentive to acquire them, and the future of humanity in space is effectively dead.

We must also address the liability of moving asteroids. Certainly this should be done with the utmost care and intense oversight tempered with some sense of practicality. For example, the adjustment to Apophis orbit that I propose appears to pass through the 2036 impact keyhole. Does that mean we must move the orbit out and around that keyhole, or simply that we use reliable, even redundant systems, and closely monitor to track the potential need for additional intervention? I’m afraid that science and logic may have little to do with the outcome of that discussion.

We need to design and build a tugship using thruster and power technologies available in an appropriate timeframe. Of course, that research is an excellent task for NASA’s Marshall Space Flight Center. I think the biggest challenge here might be in supporting deep-space, long-term missions with the human crews I believe are necessary to get the job done.

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The bottom line is that we CAN capture asteroids into Earth orbit, thanks to the amplification of delta-V due to gravitational slingshots.

There are several candidate asteroids today, and there will be more tomorrow. Also, I did not look for opportunities where the asteroid close approach was to Venus, or Mars, or Mercury, and there is every chance that good candidates exist although longer missions (and an extra slingshot or two) would be required.

The most important consideration to me is that capturing an asteroid such as Apophis places millions of tons of raw materials into Earth orbit where we need them to build solar power satellites, permanent orbiting habitats, and to advance humanity’s exploration and further exploitation of the vast resources of space.

Lastly, we should never forget that capturing a potentially hazardous asteroid converts a dangerous threat into a resource of immense value.

President Obama needs a grand goal for NASA and the nation in the next decades, one comparable to Kennedy’s “We choose to go to the moon in this decade.” I believe that capturing Apophis into Earth orbit is such a grand goal, with benefits to global energy and warming (via those solar power satellites), and to space exploration, and to permanent, self-sustaining habitats in space. And it removes a threat to the Earth.

If you agree that we need a space-faring humanity and that exploiting asteroids is key, if you agree that sending cheap solar energy to Earth simultaneously helps humanity and reduces global warming, if you agree that we should act to prevent asteroid impacts on the Earth, then please share the word. Follow this link (Project Apophis) and tell President Obama that he holds the key to the future of humanity in space, that capturing Apophis is feasible, affordable, solves many problems in a single step, and is a Grand Goal worthy of his – and this nation’s – focus. Thank you.

Tuesday, February 22, 2011

A Project Plan for Space Based Solar Power

OVERVIEW OF A SPACE BASED SOLAR POWER PROJECT

In my post, Space Based Solar Power, I present an overview of SBSP and its value to humanity. I also propose the use of asteroids for raw materials to reduce the cost to profitable levels. Still, the construction of the first Solar Power Satellite (SPS) is special, as we must incur all of the up-front (bootstrap) costs in addition to building the SPS itself.  I will demonstrate that it still can be a profitable venture. However, this project plan targets the initial construction of a dozen SPS’s, because the slag by-product of that much steel is the correct mass of shielding needed for a Kalpana-One style habitat for the workers (see my post, designing a space habitat).

The approach I recommend is to capture an asteroid (see  Asteroid Capture into Earth Orbit) and use its resources to produce the steel and other materials needed to construct and operate a constellation of SPS’s.

This approach has a relatively high up-front investment and results in a relatively low per-SPS cost. The project has many phases:

  1. Research & Development
  2. Capture a suitable asteroid into Earth orbit
  3. Launch Mining & Manufacturing Tools
  4. Launch Construction Shacks & Workers
  5. Construct & Deploy the SPS(s)
  6. Construct the Kalpana-One style Habitat(s)
  7. Repeat 5-6 as long as asteroid resources remain

For the purposes of this post, I make several assumptions:

  • we have chosen the asteroid 99942 Apophis, which also locks us into a 2029 timeline (project start in 2027, launch capture mission in early 2028).
  • use of SpaceX’s Falcon 9 Heavy launch vehicle (announced with pricing, but not yet built, yet alone flown).
  • pricing in 2011 dollars which must be adjusted for inflation.
  • Worker launch costs initially average $24M/person, but in a 2031 timeframe human-rated transports will be built for the Falcon 9 Heavy (or eventually Falcon X Heavy) that can transport 30 to 100 people per launch into LEO at a price of $1,000,000 per ton (also per person).
  • I ignore in-space worker salaries (small compared to launch costs)
  • For income, I only consider Solar Power Satellites, ignoring tourism, the sales/rentals of housing and retail space, sales of propellants to outside parties, product placement, tie-ins, naming rights, or any other potential revenue sources.

RESEARCH & DEVELOPMENT

It may be an unreal oversimplification, but I will ignore the R&D costs for this project although they are large and unknown. I believe that NASA, the various governments, and the network of universities should bear this cost as part of their normal operations (supported by tuitions, taxes, and donations), although the more directed research will be borne by the corporations that will profit from the sales of related equipment and supplies. Known areas of research & development include:

  • Heavy lift launch vehicles
  • Space taxies / trucks (using ion thrusters to cheaply change orbits and to capture the asteroid)
  • Long-term life support (recycling & farming in space)
  • Zero Gravity Mining, Smelting, Refining, and Manufacturing (note need to recycle reagents and to capture and utilize bi-products such as CO2).
  • Manufacturing Solar Photovoltaic Panels from asteroid materials
  • High-efficiency Muilti-Gigawatt Microwave Transmitters / Receivers
  • Large-scale in-space construction techniques (of SPS and habitats) with limited resources

CAPTURE A SUITABLE ASTEROID

How to capture an asteroid is largely covered by my previous post, Asteroid Capture into Earth Orbit, and a future post will detail the components of the capture project, including a proposed project breakdown of the needed components, launches, delta-v budgets, and a project timeline.

The Asteroid Capture Project begins in 2027 with construction (in orbit) of a space tug. The tugship launch from LEO to intercept Apophis occurs in April of 2028, and the final Lunar slingshot of Apophis effecting capture into Earth orbit occurs 18 months later, in October of 2029. These dates are driven by orbital dynamics.

A simplified overview of the Apophis Capture Project (using current or near-term launch vehicles) is:

  1. Launch tugship, fuel, solar panels to LEO: total 150 tons, needs 5 Falcon 9 Heavy launches ($500M); cost of tugship, etc. another $1.5B. This cost is lower than many space-based projects because of the extensive use of modular components assembled by humans in space(reducing the need for first-time perfection).
  2. Launch in-orbit assembly crew: 1 @ $100M, probably another $1B for training, tools, supplies, support staff.
  3. Launch mission crew & supplies: 1 @ $100M
  4. Intercept mission uses ion thrusters and a lunar slingshot to enter Apophis intercept trajectory in April 2028.
  5. 2 months to intercept; 3 months of thrust to change Apophis orbit; 1 month of contingency; 6 months of coasting. After the slingshot around the Earth in April of 2029 there is another 6 months of coasting (with likely trajectory tweaking) before the final drop into Earth orbit via a Lunar slingshot in October, 2029. Capture Mission duration is a little over 18 months; with recycling of water & oxygen, 600 days of food & water & hydrogen (to recycle CO2) for a crew of 4 masses four tons; a similar mass is needed for the associated equipment (triply redundant).

Total capture cost: $3.2B (ignoring R&D and ground support costs).

LAUNCH MINING & MANUFACTURING TOOLS

This is a big unknown, in that we don’t yet know how to best do mining, smelting, refining, and manufacturing in space (microgravity, necessity to recycle & save everything) from asteroid resources. We can make good guesses, however. Also, the facilities should grow over time, but the initial launches should suffice for starting manufacturing, especially since we are largely launching tools to make tools. After the initial launches, most of the needed additional equipment will be manufactured in space. These launches would begin in 2029; I expect the tugship will be used to transport these components from LEO to the asteroid now in Highly Eccentric Earth Orbit.

  • Solar Power generator: 1 launch, $200M
  • Mining facility (ore movers, grinders, separators): 2 launches, $400M
  • Solar smelter, gas collection & refining, metal purification: 5 launches, $1B
  • Steel production: 5 launches, $1B
  • Rolling mill (girders, rods, sheet metal): 3 launches, $600M
  • Finished metal product plant (nuts, bolts, rivets, connectors, pipes, tanks, etc.): 2 launches, $400M
  • Silicon refinery, solar panel manufacturing (3 launches, $600M)
  • Slag processing, shaping, rock wool production, & slag handling (1 launch, $200M)

Total estimate is $4.4B for equipment and 22 launches, and this phase begins in 2029, ends in early 2030.

LAUNCH INITIAL WORKERS & THEIR CONSTRUCTION SHACKS

The initial workforce for all of the mining & manufacturing  equipment, even assuming significant automation, is considerable. I estimate 36 workers, needing 6 launches using Falcon 9’s and Dragon X capsules (total $600M) just to get started. Each crew member will likely require a ton or more of life support equipment and supplies.

The Construction Shacks are the living quarters, recycling equipment, supplies, and solar panels for the initial mining and manufacturing workforce, intended to be buried beneath asteroid regolith for radiation and meteorite shielding (alternately regolith may be bagged and packed around the shacks). This will need to be repeated as the workforce grows (until a permanent habitat is at least partially completed).

The Falcon 9 payload faring may be equipped to house up to 12, with room for supplies and equipment. Three of these would provide adequate housing and first-year supplies for the initial 36 workers, at a cost of $600M bringing the total cost to $1.2B ($33M/person).

Subsequent workers initially have similar high launch and support costs, ramping down to $15M per-person as capacity grows to produce living quarters, water, and oxygen in space. When the interim habitat is ready and larger capacity people launchers (32 workers/launch) become available, per-worker launch costs should plummet to roughly $3M per person (in 2031), and as low as $1M per worker in subsequent years (with use of dedicated people-carrying spacecraft ferrying 100 workers into space per launch). Note that a 1 ton per worker mass allowance includes some essentials that cannot be easily fabricated in space, such as high-efficiency LEDs for the farms,  some fertilizers, and medical supplies.

The workforce & construction shack launches could begin in late 2029.

This initial 36 worker contingent will be sufficient to prove the feasibility of mining, refining, and manufacturing in space, but will be inadequate to achieve sufficient volumes of production for a timely project completion.

A ramp up to 500 workers during 2030 should result in a steel production rate of roughly 100 tons per day, which in turn allows construction of the habitat pressure shell plus containers for the volatiles (oxygen, CO2, and H2O) in one year. At this point (an interim habitat consisting only of a spinning pressurized shell with partial radiation shielding), many of the workers can work without pressure suits, gravity prevents long-term health problems of zero-G living, and in-space production of food can begin. 

Doubling the population and production annually allows the first SPS to be completed by the end of 2031 (when steel production is 200 tons per day, comparable to a small mill on Earth). 2032 should see 2 more SPS’s completed, and 2033 results in 4 more and completion of the habitat structure (with room for 8,000). By the end of 2033 the habitat capacity is reached, and the associated manufacturing facilities should be capable of building 8 SPS’s per year. Remember, it takes all of the slag associated with building the first 12 SPS’s to fully shield the habitat, which occurs during 2034. By the end of 2034, the first permanent habitat (8,000 person capacity) is complete, along with 15 Solar Power Satellites.

The total worker cost through completion of the first SPS and the habitat shell would be $15B (by the end of 2031, a total of 1,500 workers). Adding 2,000 more workers in 2032 and 4,000 more workers in 2033 would cost only another $6B.

This analysis has ignored the cost of salaries for space workers (and the cost of ground support). One reason to ignore the salaries is that they are insignificant compared to launch and equipment cost in the early years.

Another reason to ignore them is that portions of each “salary” may be offset: workers may be charged for rent (or purchase of a condo), for food, water, recycling, even oxygen. The cost of living is very high in space, and salaries should reflect that, but the net cost of a worker is difficult to estimate. Many of the readers of this blog would likely volunteer to work for little more than the right to permanently live in space and be a part of humanity’s spacefaring future – I know I would. Very few of the workers would view these orbiting factories and habitats as temporary jobs and expect to return to Earth in a few years, especially if they were afforded the opportunity to buy a home and raise a family in the habitat.

CONSTRUCT & DEPLOY THE SPS

The construction of a Solar Power satellite requires multiple components, most of which will need to be built in orbit. For more details, see Solar Power Satellite Design Considerations. The components are:

  • Solar Panels (from high-grade silicon, in thin sheets such as commonly manufactured today)
  • Steel structures to frame and aim the panels.
  • Steel structures and motors to maintain alignment of the panels with the sun, and the antenna with the target Earth station.
  • Microwave transmitting antenna
  • Microwave transmitter
  • Shield mass to protect the electronics from meteorite damage.
  • Fuel to insert the SPS into the target geosynchronous orbit

I expect that the motors and electronics (including the microwave transmitter) will be launched from Earth, for which I’ve budgeted $200M per SPS.

A considerable amount of fuel is needed to move each newly constructed SPS from the near-Lunar location of its birth and insert it into an appropriate geostationary orbit. The total delta-V needed is roughly 2 km/s, the total mass is 25,000 tons, and even using 5,000 ISP VASIMR ion thrusters, 1,000 tons of fuel is needed. Luckily, that is a tiny fraction of the 15,000 tons of oxygen produced as a by-product of the smelting of iron ore into steel for each SPS. Also luckily, we’ll have a lot of power available, so the time required for this orbit change is limited largely by the number of ion thrusters (and thus the fuel flow rate) we wish to dedicate to this task. We’ll have plenty of oxygen to spare, so our ion thrusters should be optimized for this most available rocket fuel.

Each SPS will require a matching ground receiving station consisting of a large (10+ kilometer) rectenna plus power conversion and distribution. These costs are only a guess, but I’d estimate that $1B each is more than enough. I have not included this portion of the per-SPS cost in my summary, as this cost would be born by the receiving local electric utility.

CONSTRUCT THE HABITAT

Another post details the Design of a minimum Kalpana-One style Habitat: a 100-meter radius cylinder, 130 meters wide, spinning at 3rpm for 1G along the outer rim, lined with 3 meters of slag which provides excellent shielding against radiation and meteorites.

The outer pressure shell is built using average strength (easily welded) steel plates nearly 1 inch thick, and masses approximately 28,000 tons. Completed first, once spun up it provides a shirt-sleeve environment with gravity, boosting the productivity and health of the workers.

Over time, blocks of slag are brought inside to line the exterior walls, and interior structures are built as housing, workspaces, and farmland. Most of the volume is left open to eventually become a 12 acre cylindrical park. The core will be available as a low-gravity industrial and research space. Agriculture space (primarily for crops) is more than 5.5 million square feet; residential space is over 2.5 million square feet, there is 1.5 million square feet of offices / light industrial and a million square feet of storage and overhead space. The total internal structures including the outer 15 meters along the endcaps and perhaps 6 stories of rooms lining the cylinder rim, plus a 40 meter diameter core structure, masses 126,000 tons (a generous allowance). This is less tonnage than an Oasis Class Cruise Ship (225,000 tons carrying 8,000  passengers and crew) yet much more spacious.

Power (6 kw/inhabitant or 50 megawatts total) is provided by solar panels lining the exterior surface of one endcap, plus a ring extending 100+ meters beyond the cylinder (effectively a 425-meter diameter solar panel array).  Additional power needed for exterior factories (such as the smelter) is included in their structures and allowances. The spin axis of the habitat points to the sun, requiring a massive gyroscope at the center of the habitat to slowly precess the spin axis at one revolution per year.

Speaking of spin, it takes a lot of fuel and energy to spin up the habitat to 3rpm: about 1150 tons of fuel (oxygen) at an ISP of 5,000. Using 25 megawatts (half of the habitat’s available power), the spin up takes nearly 2 years. However, the empty shell (no shield mass) spins up very quickly; the majority of the energy is needed to maintain the spin as roughly a million tons of shield mass is gradually added to the habitat’s periphery. 

Once complete, this habitat houses 8,000 workers / colonists, and provides all life-support needs. All of the steel (154,000 tons) and shield mass (1,600,000 tons of slag) are from the asteroid, along with the oxygen, water, and carbon needed for the life support system. The known components to be launched from Earth include the LED’s and other light sources for the farms and interior (see Lighting our Space Habitats), various electronics, seeds, and perhaps 50 kilograms of nitrogen (per inhabitant) needed as fertilizer.

There are no additional launch or equipment costs not included elsewhere (possibly excluding the ion thrusters needed for spin-up).

REPEAT

This project is an eight-year plan (5 years to the first SPS) culminating in the deployment of a permanent, self-sustaining habitat with a population of 8,000 and fifteen 5-gigawatt Solar Power Satellites in geostationary Earth orbit. By completion, the project will have consumed approximately 10% of Apophis, leaving  90% available to build additional habitats and Solar Power Satellites.

The capacity will be in place to build additional Solar Power Satellites at the rate of 8 per year, but note that demand is much higher: current global electric demand would need 400 five-gigawatt SPS’s to fill, and total projected energy demand might require more than 4,000 by 2050 (most energy is used for heating, generally by burning fossil fuels). Apophis alone has sufficient resources to build up to 150 Solar Power Satellites (while building 10 habitats accommodating 8,000 people each), but in the long run additional asteroids will be needed.

We should build additional habitats, including larger ones, as part of an ongoing project. We’ll likely need a “mining town” for each asteroid we capture, and an SPS construction / maintenance habitat just outside of geostationary orbit, and even a large habitat in low Earth orbit (as low as possible without serious atmospheric drag) as an Earth to LEO launch target and tourist destination. Good arguments can be made for additional habitats in various Lagrange points such as L5, and for transition orbits such as LEO to Geostationary, or to the Lagrange points. There may even be a 3:1 Lunar synchronous stable Earth orbit that visits L3, L4, and L5 in succession, 9.1 days apart – an ideal platform from which to host interplanetary missions, including to Mars.

SUMMARY

It all sounds time consuming and expensive: $22.8 Billion before that first SPS is operational. But remember, in 2032 that first SPS will generate $1.3B in cash flow (at a wholesale price of $0.03/kwh), in 2033 the 3 deployed SPS’s generate another $3.9B, in 2034 the 7 deployed SPS’s generate $9.1B, and subsequently the 15 SPS’s generate nearly $20B/year. The steel production rate is 800 tons per day, allowing 8 or more additional SPS’s to be built each year. The peak cash outlay is $25B with all investment repaid in 2035 – and huge net profits after that.

Even considering only that first SPS, the total cost is comparable to the $5 billion per gigawatt that my local power company may spend on a nuclear power plant, without any need for radioactive waste disposal or refueling, and without quite as much local objection to the installation.

Yes, I’ve been accused of being an optimist. Yes, it is likely to take longer than this project plan, due to unforeseen setbacks. Yes, I’ve ignored the cost of money in this analysis. I’ve even ignored the cost of bringing all these workers back to Earth (assuming they’d want to return). But even if it takes another year or two before breakeven, even if the costs might run 20% (or 100%) higher, even if you factor in the up-front R&D costs, even if you add a generous salary for every in-space worker plus free room & board, it is still a wildly profitable venture.

And did I mention that Apophis has enough raw materials to repeat this project another nine times, at a fraction of the cost each (and completely funded by free cash flow)?

Is there an entrepreneur listening that likes the sound of $200 Billion per year of free cash flow for a measly $30 billion investment? And with the bonus of earning a permanent place in the history books as the party responsible for bootstrapping humanity’s move into the Solar System?!