Hydrogen peroxide is under investigation with regard to its potential to replace the presently used highly toxic rocket propellants NTO and MON-3. Catalytically decomposed hydrogen peroxide results in a steam–oxygen mixture at elevated temperature and can be used either as a monopropellant or as an oxidizer in a bipropellant system. To guide the monolith catalyst design, a lumped parameter model of the decomposition implemented into a numerical thermal model has been developed. The one dimensional flow model includes decomposition and is coupled to a finite element structural domain of the decomposition chamber and catalyst to investigate the impact of the catalyst and the chamber structure on the decomposition behavior. Special focus is laid on the transitional behavior of hydrogen peroxide conversion to facilitate immediate start-up of the thruster system after valve opening command. The numerical results have been validated with experimental data. Major findings of the model such as the existence of a radial temperature gradient across the catalyst have been experimentally validated. The presented theoretical method predicted a strong impact of structural mass capacities of catalyst and decomposition chamber on the transient decomposition performance. This prediction has shown to be in good correlation with the experimental results.

Structural impact of honeycomb catalysts on hydrogen peroxide decomposition for micro propulsion

Hydrogen peroxide is under investigation with regard to its potential to replace the presently used highly toxic oxidizers such as NTO or MON-3. Catalytically decomposed hydrogen peroxide results in a steam-oxygen mixture at elevated temperature and can be used either as a monopropellant or as an oxidizer in a bipropellant system. In order to achieve high decomposition efficiencies it is essential to understand and to be able to control the decomposition processes in detail. In particular, the choice of catalyst is one of the most essential issue in designing a propulsion system based on hydrogen peroxide. However a catalyst is defined by a multidimensional parameter matrix including the catalyst nature, diameter, length, inner and outer shape, heat capacity and conductivity of the carrier material, and, manufacturing method and many others. Reliable experimental investigation of a catalyst is a time consuming effort. To guide the experimental assessment, Fotec (formerly Austrian Institute of Technology – AIT) has developed an analytical model of the decomposition implemented into a numerical thermal model. The one dimensional decomposition model coupled to a finite element structural domain of the decomposition chamber is used to investigate the impact of the catalyst and, in addition, of the chamber structure on the decomposition behavior. Special focus is laid on the transitional behavior of hydrogen peroxide conversion to facilitate immediate start-up of the thruster system. The numerical results have been validated with experimental values. The comparison shows high accuracy of the predictions not only in the general decomposition behavior but also in intrinsic details such as the transitional behavior. Major findings of the model such as the existence of a radial temperature gradient across the catalyst have been experimentally validated. These findings point to an overestimation of experimentally determined decomposition performances, in the case of temperature measurements just downstream of the catalysts cental line. Another major finding is the identification of an mass flow overload threshold by the simulation, yielding a sudden decrease in decomposition performance after surpassing the threshold. This sudden decrease in decomposition performance has been experimentally verified.

Hydrogen Peroxide Decomposition for Micro Propulsion: Simulation and Experimental Verification

Catalytic decomposition of energetic compounds is used for different purposes like propulsion application (launcher, satellites and missiles) and gas generator (e.g. rescue systems). The energetic liquids (H 2O2, N 2H4, ionic liquids, N 2O, …) are decomposed on catalytic beds which must present very good thermal and mechanical properties to resist frequent thermal shocks and high flow rates. Compared to conventional alumina-based supports developed specifically for this application about 30 years ago (extrudates, pellets, spheres), honeycomb monolith catalysts show many advantages: (i) lower pressure drop, (ii) better thermal shock and attrition resistance, (iii) uniform flow distribution and mass/heat transfer conditions, (iv) shorter diffusion length, and (v) large heritage from cleaning of car exhaust gases. Therefore, monolithic reactors represent very attractive alternatives to traditional systems with the future ability to develop chemical micro-propulsion systems. These new monolith applications demand a careful control of the substrate chemical nature, the surface impregnation by the thin porous wash-coat layer and the impregnation of this layer by the active phase precursor. An overview is given and two applications to the decomposition of hydrogen peroxide and ionic liquid solutions are presented and discussed.

Catalytic decomposition of energetic compounds - Influence of catalyst shape and ceramic substrate

Catalytic decomposition of energetic compounds -Influence of catalyst shape and ceramic substrate 42h AIAA/ASME/SAE/ASEE Joint Propulsion, July 2006(USA).

Ceramic Catalysts for the decomposition of H2O2. Influence of the wash-coat procedure and the active phase. 8th Intern. Hydrogen Peroxide Propulsion Conf., Purdue, IN, Sept. 2005.

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Ceramic Catalysts for the decomposition of H2O2. Influence of the wash-coat procedure and the active phase. 8th Intern. Hydrogen Peroxide Propulsion Conf., Purdue, IN, Sept. 2005.