AIAA-01-3250 Advancements in High Concentration Hydrogen Peroxide - PowerPoint PPT Presentation

AIAA-01-3250 AIAA-01-3250 Advancements in High Concentration Hydrogen Peroxide Catalyst Beds M. C. Ventura, E . J. Wernimont General Kinetics LLC, Lake Forest, CA July, 2001 GE NE RAL KINE TICS LLC

AIAA-01-3250 Summary • Compare 90% and 98% H2O2 • H2O2 Catalyst Bed Requirements • 98% H2O2 Catalyst Bed Issues • 98% H2O2 Catalyst Bed Options • 98% H2O2 Catalyst Beds • 98% H2O2 Test Set-Up • 98% H2O2 Test Data & Summary • Conclusions GE NE RAL KINE TICS LLC

AIAA-01-3250 Comparison of 90% and 98% H2O2 MIL-P-16005E MIL-P-16005E FMC Type 90 FMC Type 98 (mg/l) (mg/kg) (mg/kg) (mg/kg) H2O2 Assay % by wt. 90.0 to 91.0 90.0 to 91.0 90.0 to 92.0 98.0 to 99.0 Aluminum 0.5 max 0.35 max 0.2 max 0.25 max Chloride 1.0 max 0.7 max 0.3 max 0.35 max Ammonium 3.0 max 2.2 max 2.2 max 2.1 max Nitrate 5.0 max 3.5 max 3.5 max 3.5 max 3.0 min 2.2 min 2.2 min 2.1 min Phosphate 0.2 max 0.15 max 0.15 max 0.14 max Sulfate 3.0 max 2.2 max 0.3 max 0.35 max Tin 4.0 max 2.9 max 2.9 max 2.7 max 1.0 min 0.7 min 1.0 min 0.7 min Carbon 200 max 145 max 30 max 30 max Evaporative residue 20 max 15 max 15 max 14 max Stability 2% max 98% min 98% min 98% min Particulate 1.0 max 0.7 max 0.7 max 0.6 max Chromium 0.02 max 0.02 max Lead 0.02 max 0.02 max Manganese 0.02 max 0.02 max Iron 0.03 max 0.035 max Copper 0.02 max 0.02 max Nickel 0.02 max 0.02 max Weight % of H2O2 Weight % of H2O2 Property 90 98 Property 90 98 Density (lbm/gal.) 11.57 11.95 Mole fraction of H2O 0.7076 0.6748 Boiling point, 1 atm (deg. F) 286.2 299.2 Mole fraction of O2 0.2924 0.3252 Freezing point, 1atm (deg. F) 11.3 27.5 Ave. Molecular Weight 22.1 22.57 Vapor pressure, 77 deg. F mm Hg 3.8 2.2 Gamma 1.266 1.251 Viscosity, 77 deg. F centipoise 1.153 1.155 Temperature (deg. F) 1364 1735 Surface tension, 68 deg. F dynes/cm 79.3 80.2 Heat of Vaporization, 77 deg. F Btu/lb 700.3 662.0 GE NE RAL KINE TICS LLC

AIAA-01-3250 H2O2 Catalyst Bed Requirements • Overview – Life: 1-2 hrs., > 5000 cycles – Mass flux: 0.1 to > 0.4 lbm/sec-sq. in – Fluid temperature: 40 to > 150 degrees F – Operating pressure: 100 to > 1000 psia – Environment: Vibration & shock – Pressure drop: < 100 to 300 psid – Cost, reliability, mass, transients, etc… Adiabatic Decomposition Temperature of H2O2 • Silver based screen packs are a good fit for 90% H2O2 and these requirements 2000 1900 1800 1700 • 98% H2O2 catalyst should be comparable to 1600 Temperature (deg. F) 1500 silver based catalysts with respect to generally 1400 1300 1200 meeting requirements 1100 1000 900 • Primary challenge is higher operating 800 700 temperature 600 500 400 300 200 70 75 80 85 90 95 100 Weight % of H2O2 GE NE RAL KINE TICS LLC

AIAA-01-3250 98% H2O2 Catalyst Bed Issues Effect of Feed Temperature and Pressure on Adiabatic Decomposition Temperature, 90% H2O2 • 98% H2O2 has ~ 350 degree hotter 1700 decomposition temperature 1650 Temperature (deg. F) 1600 • Decomposition temperature of 90% 1550 H2O2 is ~ 360 degrees colder than Linear (100 psia) 1500 Linear (1000 psia) Linear (2000 psia) melting point of silver 1450 • 98% decomposition temperature 1400 virtually same as melting point of silver 1350 1300 • Decomposition temperature is a function 50 100 150 200 250 Feed temperature (deg. F) of propellant feed temperature (1.6 Adiabatic Decomposition Temperature, 90% to 100% degrees F/deg. F) H2O2 • Decomposition temperature is a function 2000 of operating pressure 1900 Temperature (deg. F) • Actual operating temperature dependent 1800 on concentration, prop. temperature and 1700 Poly. (90%) Poly. (98%) 1600 Poly. (92%) operating pressure. Poly. (99%) Poly. (100%) 1500 • Worst case applications are high 1400 pressure staged combustion 98% 1300 combustion devices using H2O2 regen. 1200 0 500 1000 1500 2000 2500 3000 Chamber Pressure (psia) GE NE RAL KINE TICS LLC

AIAA-01-3250 98% H2O2 Catalyst Options • Various options tested in the past – High melting point silver alloys (i.e. silver-palladium) – High temperature metallic catalysts (including alloys) • Platinum • Palladium • Iridium • Ruthenium • Cobalt – Non-metallics • Manganese dioxide • Barium oxides • No obvious solutions that provide comparable performance as silver with 90% H2O2 • Relaxation of requirements permits some concepts – Stennis Space Center manganese dioxide facility catalyst bed, operated with 98% H2O2 GE NE RAL KINE TICS LLC

AIAA-01-3250 98% H2O2 Catalyst Beds • GK has built several functioning 98% catalyst beds in past 12 months • Most of this work is proprietary and not currently available to the public • An example of a flight like catalyst bed has been built and tested to reasonable operating conditions. • Low cost manganese dioxide catalyst beds are also available • Flight-Like Catalyst Bed – GK proprietary catalyst – Tested with X-L Space Sys 98% H2O2, 10/00 – Demonstrated typical performance – Test terminated due to test stand contamination GE NE RAL KINE TICS LLC

AIAA-01-3250 98% H2O2 Test Set-Up Legend Pressurization Panel Pneumatic Supply Interface 2-way sol. vlv P position sensor Ambient Environment GN2 supply interface press. gauge Interface thermocouple T venturi Pressurization Panel Pneumatic Supply turbine flow meter 3-way sol. vlv Temp. #1 P Inlet #1 T T ball vlv P Temp. #2 T T press. P transducer Cat Bed burst P P Feed Panel disc P Inlet #2 Pneumatic Supply P Exit #1 Interface 2-way P P manual vlv P Exit #2 P filter hose Note: Some instrumentation not manual reg. shown for clarity. GN2 Gas Supply Interface check vlv dome loaded Feed Panel Pneumatic Supply reg. 98% Catalyst Bed Test Set-Up P/N GK-MD018-504-001, Rev. B bottle Originator: M. Ventura 7/2/01 orifice GE NE RAL KINE TICS LLC

AIAA-01-3250 98% H2O2 Test Data 98% Catalyst Bed Pressures 98% Catalyst Bed Temperatures Test 101300_020 Test 101300_020 1100 2000 1000 1800 Temperature (degrees F) 900 1600 800 Pressure (psia) 1400 700 1200 600 P Exit Temp. #1 1000 P Inlet 500 Temp. #2 800 400 300 600 200 400 100 200 0 0 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Time (seconds) Time (seconds) • Pressures – Decomposition roughness low (Data is 1 kHz with 250 Hz low pass filter) – Behavior comparable in features to 90% catalyst bed – Pressure is high, but expected with flux and higher gas temperatures • Temperatures – Behavior comparable in features to 90% catalyst bed – Lower than expected temperature due to propellant concentration being ~ 96% to 97% GE NE RAL KINE TICS LLC

AIAA-01-3250 98% H2O2 Test Data Summary Parameter Value Number of tests 37 Total test time 1112 seconds Max. mass flux 0.5 lbm-sec/sq.-in Pressure drop 430 psid @ G=0.5 Roughness 1% to 2% Min. start temperature 250 degrees F H2O2 concentration 96% to 97% C-Star Efficiency Approx. 100% GE NE RAL KINE TICS LLC

AIAA-01-3250 Conclusions • 98% H2O2 catalyst beds have been built and tested under typical operating conditions • Performance of these catalyst beds is comparable in general characteristics to 90% H2O2 catalyst beds - risk of 98% catalyst beds is low • A 98% H2O2 catalyst bed has demonstrated typical performance with life > 1000 seconds • 98% catalyst beds can be developed for emerging systems at diminished risk. GE NE RAL KINE TICS LLC