Sylvie Willis
The cost of rocket fuel is an important consideration for space exploration. NASA's planned trajectory for the first EM mission has raised questions about the expenses involved in space travel and the potential returns for investors. NASA's SLS program, for example, is estimated to cost a total of $35 billion, a significant investment that highlights the high costs associated with space exploration. The price of rocket propellant, such as the liquid oxygen (LOX) and liquid hydrogen (LH) used by NASA, plays a crucial role in these overall costs. While the specific prices paid by NASA for rocket fuel may not be readily available, the choice of propellant is influenced by factors such as efficiency and payload capacity.
| Characteristics | Values |
|---|---|
| Cost of liquid oxygen (LOX) and liquid hydrogen (LH2) per gallon | $1.65 |
| Cost of Aerojet Rocketdyne's RS-25 engine | $40 million |
| Cost of four RS-25 engines for SLS core stage | $160 million |
| Annual spending on SLS program | $3 billion |
| Estimated total program cost | $35 billion |
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What You'll Learn
Liquid oxygen and liquid hydrogen cost NASA $1.65 per gallon
NASA's first trip to Mars will employ the RS-25 rocket engine, which will be laid on its side and tested at full blast. This engine burned through 150,000 gallons of liquid oxygen and 60,000 gallons of liquid hydrogen during a 535-second test, costing NASA $247,500 in propellant. The engine surpassed its maximum certified sea-level thrust, achieving 109% of its rated capacity, or 512,000 pounds of vacuum thrust.
The choice of rocket fuel is critical in space exploration due to the high costs involved. Liquid propellants, which consist of fuel and an oxidizer, are commonly used in the industry. Engineers work to optimize propellant ratios to maximize payloads, as more efficient propellants result in higher costs. Cryogenic propellants, for example, are used in some of the world's highest-mass launch vehicles due to their exceptional specific impulse, which refers to how quickly mass can be expelled from the engine.
NASA's planned Ground Systems Development and Operations Range for the future will likely involve significant fuel costs, as the agency is already spending about $3 billion annually on the SLS program, with an estimated total program cost of $35 billion. Aerojet Rocketdyne and Orbital ATK are expected to be the most profitable companies from this space program.
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NASA paid $40 million per Aerojet Rocketdyne RS-25 engine
The cost of rocket fuel is a significant expense for space agencies like NASA. In 2015, NASA reportedly spent $350,000 on fuel for a test of the Aerojet Rocketdyne RS-25 engine, burning through 150,000 gallons of liquid oxygen and 60,000 gallons of liquid hydrogen during the 535-second test.
Aerojet Rocketdyne's RS-25 engine has been a popular choice for NASA, powering the Space Shuttle into orbit and now selected for the new Boeing-built Space Launch System (SLS). The RS-25 engines are not cheap, and back when they were actively used in the Space Shuttle program, each engine cost NASA about $40 million. With four of these engines required in the SLS core stage, that's a cost of $160 million per launch just for the engines.
The high cost of the RS-25 engines has been a topic of discussion, with some questioning the value despite Aerojet Rocketdyne's defence of the price tag. In 2023, NASA awarded Aerojet Rocketdyne a contract worth $1.79 billion to produce 18 RS-25 engines for future SLS flights. This implies a cost of almost $100 million per engine, and when including previous contracts, NASA is spending nearly $3.5 billion for 24 engines, or about $145 million each.
It's important to note that the cost of an engine isn't just the sum of its parts. Jim Maser, a senior vice president at Aerojet Rocketdyne, emphasised that the contract price includes various other factors such as special test equipment, overhead, and the labour involved in human spaceflight projects. Additionally, the company is working on cost reduction methods, such as design changes and additive manufacturing, which could potentially reduce production time and expenses.
While the exact cost breakdown of the RS-25 engines may not be publicly available, it's clear that NASA's investment in these engines is substantial, reflecting the complex nature of space exploration and the ongoing pursuit of technological advancements.
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The SLS program is estimated to cost $35 billion in total
The Space Launch System (SLS) is a NASA program that began in 2011. The SLS is a rocket that will be used to launch payloads and crew into space, replacing the Space Shuttle. The development of the SLS has been ongoing since its inception, with the first launch occurring in 2022.
The SLS program has been scrutinized for its high costs, with concerns raised as early as 2014. The total cost of the program is estimated to be $35 billion, with NASA spending about $3 billion per year. This estimate includes the cost of the rocket, spacecraft, upgrades to the launch pad, and other facilities. The cost per launch of the SLS is estimated to be $4 billion, and the total cost to the taxpayer is estimated at "over $2 billion" per launch.
The high costs of the SLS program have been attributed to various factors, including "poorly defined requirements, poor contractor performance, and increased material cost". Additionally, the cost of assembling, integrating, preparing, and launching the SLS and its payloads is funded separately and is currently anticipated to be about $600 million per launch.
Despite the high costs, the SLS program has strong political support and is seen as a way to promote human space exploration and scientific discovery. However, the Trump administration's fiscal year 2026 budget proposal called for terminating the SLS and Orion spacecraft programs after Artemis III, describing the SLS as "grossly expensive".
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Liquid propellants are the most frequently used
The cost of rocket fuel is an important consideration in space exploration. Liquid propellants, consisting of a fuel and an oxidizer, are the most frequently used in the industry. They are favoured for their efficiency, which rocket scientists refer to as specific impulse—essentially, how quickly mass can be expelled from the engine. A high specific impulse means that less propellant needs to be packed, which is advantageous given the high cost of rocket fuel.
Liquid propellants are used in some of the world's highest-mass launch vehicles. They are versatile, with the ability to throttle their flow or turn it on and off, making them suitable for complex missions and reusable rockets. This versatility, combined with their high specific impulse, makes liquid propellants a popular choice for rocket fuel.
The most common liquid propellant combination is liquid oxygen (LOX) as the oxidizer and liquid hydrogen (LH2) as the fuel. This combination has the highest specific impulse of all propellants. However, LH2 requires extremely low temperatures of -253 degrees Celsius to remain in its liquid state, necessitating large insulating tanks that add weight to the rocket.
NASA, for example, has used the LOX/LH2 combination in its RS-25 rocket engines, which are planned for use in the Space Launch System (SLS). During a 535-second test, an RS-25 engine burned through 150,000 gallons of LOX and 60,000 gallons of LH2, costing the agency about $1.65 per gallon. While liquid propellants offer high efficiency, solid boosters can be added to liquid-fueled rockets to increase payload capacity without adding excessive dead weight. This combination has been used in various rockets, including NASA's Space Shuttle and Space Launch System.
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Cryogenic propellants are used in high-mass launch vehicles
Cryogenic propellants are also advantageous because they do not require an oxidizer, which reduces the complexity and cost of the propulsion system. Additionally, cryogenic propellants have a low storage temperature, which further increases the mass of the launcher. However, this requires thermal insulation, which can offset some of the weight savings achieved by using cryogenic propellants.
The use of cryogenic propellants in high-mass launch vehicles also presents some challenges. Cryogenic liquids are highly susceptible to phase changes due to minute changes in pressure and temperature. This can make it difficult to quantify their flow rate and maintain their stability during storage and transport.
To address these challenges, advancements have been made in cryogenic fluid management technologies, enabling long-term cryogenic fluid management for sustainable presence on the Moon and crewed missions to Mars. These technologies include propellant depots in orbit, which can host fuels for several years and enhance the range of exploration spacecraft.
Overall, the use of cryogenic propellants in high-mass launch vehicles offers several benefits, including increased payload capacity, reduced mission costs, and simplified propulsion systems. However, it also comes with challenges related to fluid management and storage stability, which are being addressed through ongoing research and development in the field of space exploration.
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Frequently asked questions
NASA pays around $1.65 per gallon for liquid oxygen (LOX) and liquid hydrogen (LH) propellant.
NASA spent $350,000 on fuel for its first trip to Mars.
NASA estimates the SLS program will cost a total of $35 billion.
