Development of a Testbed for the Beneficiation of Lunar Regolith - Concentrating an Ilmenite-Rich Feedstock for In-Situ Oxygen Production on the Moon

The utilization of extraterrestrial resources may one day enable mankind’s further exploration and sustainable colonization of the Solar System. An easily accessible and very versatile resource found on Earth’s celestial neighbor, the Moon, is lunar regolith. This unconsolidated mixture of soil and rocks contains large quantities of oxygen, which in return can be used to produce consumables for propulsion and life support systems. However, the oxygen is chemically bound to minerals and must, thus, be extracted. The preparation of a feedstock that is chemically and physically suited for the extraction is termed beneficiation and depicts a vital stage in the context of in-situ oxygen production. Developing a test stand that demonstrates the technical feasibility of lunar mineral beneficiation in a laboratory setting is the purpose of this master’s thesis. The testbed’s main function is to concentrate the target mineral ilmenite (a titanium-iron oxide), to reject unwanted gangue minerals (like silicates), and to remove unfavored size fractions (e.g., dedusting and oversize grain removal). To ensure that the end product fulfills this function in a satisfactory manner, a systematic engineering design process consisting of seven work packages is applied. This involves a review of existing studies and an investigation of available processes, the definition of requirements and specification, as well as various conceptualization activities (process and setup selection plus sketching). Moreover, results of design calculations and data of methodically selected components are integrated into a 3D model, to be created using computer-aided design software. Production planning activities like the preparation of procurement-related documentation completes the development. The outcome of this thesis is a well-engineered and methodically mature beneficiation system that encompasses three dry separation stages: Particle size separation, magnetic separation, and electrostatic separation. This multi-stage approach guarantees the reliable and efficient enrichment of ilmenite from lunar regolith simulant. Hence, it is ready to be brought into being through assembly, integration, and test and can eventually be used for beneficiation-related experiments