1. Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Institute of Aviation
Al. Krakowska 110/114
Warsaw, POLAND
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

2. Space propulsion - new concepts
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Space propulsion - new concepts
REACH* in Europe - hydrazine and its derivatives
Storable propellants – hazard, cost, availability
New „Players” – SME’s, R&D’s
GREEN high performance propellants
* Registration, Evaluation an Authorization of Chemicals
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

3. Green mono-propellants
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Green mono-propellants
ADN-based – LMP-103S
HAN-based – AF-M315E
HTP – High Test Peroxide (RGHP)
Green mono- and bi-propellants
HTP
Performance increases with concentration
MIL-PRF-16005F: Type 98 (98%+, 98-99%), High Purity
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

4. Pure silver (wire mesh screens)
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Catalyst
SUPPORT ACTIVE PHASE
Pure silver (wire mesh screens)
- up to 90% HTP, high purity
- sensitive to poisoning
98% HTP – silver melts
Metal–ceramic wire mesh
- good mechanic properties
- low surface area
- poor cold-start characteristics
Platinum
Iridium
Other transition metals
Manganese oxides
- less sensitive for poisoning than transition metals
Ceramics (pellet):
α-Al2O3, γ-Al2O3
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

5. Basic research on catalytic decomposition of 98%+ HTP
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Scope of the project
Composite catalyst bed – zonal, axial distribution of various catalysts:
ceramic pellet + MnxOy,
steel-ceramic wire mesh + platinum
Basic research on catalytic decomposition of 98%+ HTP
50 – 60 various samples (10 types of support, various active phase content)
catalyst chamber, under pressure
thruster configuration
Steel-ceramic-platinum wire mesh (Catator)
3 mm spheres,
high surface area (IoA)
3,2 mm pellets
high surface area (IoA)
1 – 2,5 mm pieces, (IoA)
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

6. Test conditions and parameters
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Scope of the project
Propellant
98%+ HTP, ultra-pure
prepared in-house (IoA)
98%+ HTP samples (IoA)
Catalyst bed
modular
50 and 100 mm casing
measurement ports for pressure and temperature:
100 mm casing: 20, 50, 80 mm from the injector plate
50 mm casing: 14, 35 mm from the injector plate
100 mm catalyst bed (IoA)
Test conditions and parameters
chamber pressure: 10 bar
flow rate: 15 cm3/s
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

7. Investigation of dynamics:
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Test plan
Investigation of dynamics:
Rate of pressure and temperature build-up,
Maximum temperature - aft end of the catalyst bed.
Realized by:
Numerous short pulses – test sequence the same for all experiments,
Heating and cooling cycles – structural changes, cracking, disintegration,
Comparative analysis – selection of best results, rejection of structural failures.
Expected result
1st phase: 100mm casing - selection of catalysts, length of the catalyst bed,
2nd phase: resultant length of the casing – final selection of catalysts,
3rd phase: composite bed testing.
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

8. Test campaign Test sequence Σ Valve control Measurement
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Test campaign
Test sequence
chalanges: over 50 experiments, need for numerous pulses, propellant consumption,
propellant limit for every test: 320 cm3,
Sub-sequence
Start
Flow
Pause Σ I
Cold 5 3 2 10 II
200°C 6
III
400°C 1
IV, V, …
Hot
Valve control
stainless steel, solenoid,
opening and closing: 20÷30 ms,
PC, measurement card, power supply, solid state relays.
Measurement
pressure: test tank, inlet, chamber (2÷3 PS)
temperature: test tank, chamber (2÷3TC)
thrust: axial
continuous monitoring
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

9. Visual evaluation – cold start
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Test campaign
Visual evaluation – cold start t0
t0 + 0,6 s
t0 + 0,2 s
t0 + 1,0 s
t0 + 0,4 s
t0 + 1,4 s
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

10. Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Results – 1st phase
CATALYST : α-Al2O3, 4,8 mm spheres, low surface area, active phase: 11,5%
1 sub-seq100 mm chamber, cold start
II sub-seq100 mm chamber, 200°C start
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

11. Results – 1st and 2nd phase
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Results – 1st and 2nd phase
CATALYST : bimodal γ-Al2O3, 3,2 mm pellets, high surface area, active phase: 5,57%
1 sub-seq,100 mm chamber, cold start
I sub-seq, 50 mm chamber, cold start
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

12. Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Results - 2nd phase
CATALYST : bimodal γ-Al2O3, 3,2 mm pellets, high surface area, active phase: 5,57%
1I sub-seq, 50 mm chamber, 200°C start
1V sub-seq50 mm chamber, hot start
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

13. Application Maturity level Further development Application TRL3
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Application
Maturity level
TRL3
Further development
Catalyst lifetime
Environmental:
Vacuum chamber
Ambient temperature
Application
Thrusters – mono- and bi-propellant
Engines – liquid and hybrid
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium

14. Catalyst activity and performance
Developing and Testing a New Composite Catalytic Bed for Decomposition of 98% HTP
Conclusions
Al2O3/MnxOy for 98%+ HTP
good performance,
low-cost
good cold-start characteristics
Catalyst activity and performance
strongly depends on the type of support (e.g. alumina doped with silica exhibited the best resistance towards the heat shock)
The research has been done under the ESA Project “Research of the composite catalyst bed for decomposition of highly concentrated hydrogen peroxide to be applied in monopropellant thruster”, contract number No /13/NL/KML
The 65th International Astronautical Congress
Session C4.3 Space Propulsion Symposium