Integrated Process Modelling and Design of a Self-Sustaining Modular Hydrogen Production System under Lunar Conditions

Abstract

The establishment of long-term human presence on the Moon requires resource-efficient and environmentally resilient energy infrastructures. Although hydrogen is widely recognized as a key energy carrier for extraterrestrial systems, existing studies largely focus on water electrolysis and solar-driven routes, while the potential of biomass-assisted and circular hydrogen production under lunar conditions remains insufficiently explored. In this study, a novel modular hydrogen production system specifically tailored for the lunar environment is proposed and systematically modeled within an in-situ resource utilization (ISRU) strategy. Wheat straw is selected as a representative lignocellulosic feedstock due to its compatibility with controlled space agriculture and closed-loop life support systems. To capture lunar-specific constraints, conventional process simulations performed in Uni-SIM Design R460 (R) are coupled with custom MATLAB (R) models via the CAPE-OPEN interface, enabling the incorporation of reduced gravity effects, cryogenic thermal boundaries, and non-terrestrial phase separation behavior. The proposed compact module integrates gasification, electrostatic particulate removal, passive condensation, and a gravity-independent helical two-phase separation unit. Simulation results indicate that a single module operating at a biomass feed rate of 27.78 g/s can achieve an annual hydrogen production of 34.96 tons, while generating CO2, N2, O2, and biochar streams that are fully recoverable within the lunar ISRU ecosystem. A process-integrated thermal management further reduces external energy demand. This study provides one of the first process-level assessments of biomass-based hydrogen production under lunar conditions, offering a scalable and resource-efficient pathway for sustainable lunar energy infrastructures in large-scale settlements with established agricultural systems.