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SPM

In support of the first Energiya mission in 1987, the Salyut Design Bureau constructed a 100-ton class spacecraft called Polyus. Although the vehicle never reached orbit due to an attitude control problem, its designers have expanded upon the original concept to propose the heavy Space Processing Module (SPM), also known as the Engineering Production Module (TMP) (References 812-814). With a 102 metric ton launch mass, the SPM possesses an on-station (350-400 km, 51.6 degree inclination) mass of a mere 88 metric tons. In typical Russian style, the Salyut Design Bureau engineers adapted well-known hardware to create the SPM. The heart of the facility (the Laboratory Compartment), where the materials processing equipment is installed, is based on the main core cylinder of the Proton launch vehicle's first stage. Above it is a heavy Kosmos module (the Instrument-Cargo Compartment) of the Kvant 2, Kristall, or Biotechnologiya class.

In orbit the SPM is approximately 35 m long with a main diameter of just over 4 m. In addition to the two sizable solar arrays extending from the Instrument-Cargo Compartment, the SPM has two very large arrays attached to the Laboratory Compartment - total span = 60.4 m. Together, they can produce more than 60 kW for a mission exceeding five years. Total payload mass of up to 25 metric tons is possible with microgravity conditions of 10⁵-10⁶ g.

Expanding upon the idea of multiple return capsules proposed for the Biotechnologiya Space Vehicle, the SPM designers have included a similar capability using 361 kg ballistic capsules with a payload mass of 141 kg anda payload volume of 92.5 liters. Robotics are used to remove a ballistic capsule from storage, load it, and then transfer it to a small air-lock for ejection. This operation cycle would occur every 1-3 months. Nine types of processing units have been proposed for the SPM for a total of 45 individual installations for an annual production capacity of more than one metric ton per year.

A novel element of the SPM program is the option for man-tended operations. Docking ports at both the aft and forward end of the SPM would be compatible with a Soyuz TM spacecraft or the proposed MAKS spaceplane. The latter could be launched either by the Energiya M launch vehicle or from an air-based platform-like the An-225. A maintenance or resupply crew could spend up to 10 days on the SPM unloading supply ships and repairing equipment. Unmanned resupply missions using Progress M or heavy Kosmos spacecraft are also envisioned. The advent of MAKS would also increase the opportunities (and therefore mass) for returning processed materials to Earth. Complete design of the SPM will require two years, followed by four years of building and testing the flight module before launch. However, with the demise of the Energiya and Energiya-M programs and Russia's participation in the International Space Station, the SPM concept is unlikely to be developed further.