NASA’s newly developed cryogenic cooling technology is paving the way for crewed missions to Mars. This innovation will enable the long-term storage of liquid propellants for both outbound and return journeys.
Another Hurdle Cleared for Human Missions to Mars
One of the biggest obstacles to crewed Mars missions—the challenge of fuel storage—is about to be overcome, thanks to a new two-stage cryogenic cooling system developed by NASA. Recent tests at the Marshall Space Flight Center in Alabama have proven this super-cooler can store volatile fuels like liquid hydrogen and oxygen for years with virtually no loss.
In traditional space missions, liquid propellants (liquid oxygen, hydrogen, or methane) slowly evaporate passively in tanks despite the cold environment of space. Liquid hydrogen, in particular, must be kept at an extremely low temperature of -252.9 °C. While passive insulation can limit evaporation, losses over Mars missions exceeding two years can jeopardize mission success. For example, a tank carrying 38 tons of liquid hydrogen could lose 16 tons annually, meaning astronauts arriving at Mars might be stranded without return fuel.
NASA’s new solution lies in a system called “tube-on-tank,” which consists of two cooling loops. In the first loop, pipes carrying liquid helium cooled to -253 °C are wrapped directly around the fuel tank, cooling its contents. In the second loop, slightly warmer helium (183°C) blocks heat behind the insulation layers, protecting the tank from external influences. This two-stage structure prevents all heat ingress, keeping the liquid fuel stable.
As long as a power source is provided, this system can preserve fuels indefinitely. This eliminates the need to carry excess fuel and allows for extended mission durations. Kathy Henkel from NASA stated, “For long-duration missions to deep space, such as the Moon and Mars, it is essential to implement technologies that reduce propellant loss. Two-stage cooling prevents propellant loss and allows for long-term storage of propellants during transit or on planetary surfaces.”
What other technological advancements do you think are crucial for the success of long-duration deep space missions?
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