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

GE NE RAL KINE TICS LLC 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

Weight % of H2O2 Property 90 98 Density (lbm/gal.) 11.57 11.95 Boiling point, 1 atm (deg. F) 286.2 299.2 Freezing point, 1atm (deg. F) 11.3 27.5 Vapor pressure, 77 deg. F mm Hg 3.8 2.2 Viscosity, 77 deg. F centipoise 1.153 1.155 Surface tension, 68 deg. F dynes/cm 79.3 80.2 Heat of Vaporization, 77 deg. F Btu/lb 700.3 662.0 Weight % of H2O2 Property 90 98 Mole fraction of H2O 0.7076 0.6748 Mole fraction of O2 0.2924 0.3252

• Ave. Molecular Weight

22.1 22.57 Gamma 1.266 1.251 Temperature (deg. F) 1364 1735

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

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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…

• Silver based screen packs are a good fit for

90% H2O2 and these requirements

• 98% H2O2 catalyst should be comparable to

silver based catalysts with respect to generally meeting requirements

• Primary challenge is higher operating

temperature

Adiabatic Decomposition Temperature of H2O2

200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

70 75 80 85 90 95 100

Weight % of H2O2 Temperature (deg. F)

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98% H2O2 Catalyst Bed Issues

• 98% H2O2 has ~ 350 degree hotter

decomposition temperature

• Decomposition temperature of 90%

H2O2 is ~ 360 degrees colder than melting point of silver

• 98% decomposition temperature

virtually same as melting point of silver

• Decomposition temperature is a function
• f propellant feed temperature (1.6

degrees F/deg. F)

• Decomposition temperature is a function
• f operating pressure
• Actual operating temperature dependent
• n concentration, prop. temperature and
• perating pressure.
• Worst case applications are high

pressure staged combustion 98% combustion devices using H2O2 regen.

Effect of Feed Temperature and Pressure on Adiabatic Decomposition Temperature, 90% H2O2

1300 1350 1400 1450 1500 1550 1600 1650 1700 50 100 150 200 250

Feed temperature (deg. F) Temperature (deg. F)

Linear (100 psia) Linear (1000 psia) Linear (2000 psia)

Adiabatic Decomposition Temperature, 90% to 100% H2O2

1200 1300 1400 1500 1600 1700 1800 1900 2000 500 1000 1500 2000 2500 3000

Chamber Pressure (psia) Temperature (deg. F)

• Poly. (90%)
• Poly. (98%)
• Poly. (92%)
• Poly. (99%)
• Poly. (100%)

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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

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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

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98% H2O2 Test Set-Up

GN2 supply interface

98% Catalyst Bed Test Set-Up P/N GK-MD018-504-001, Rev. B Originator: M. Ventura 7/2/01

P T

2-way sol. vlv position sensor

• press. gauge

thermocouple venturi turbine flow meter 3-way

• sol. vlv

ball vlv press. transducer burst disc 2-way manual vlv filter hose manual reg. check vlv bottle dome loaded reg.

Legend

Pressurization Panel Pneumatic Supply Interface

Ambient Environment Interface

P

GN2 Gas Supply Interface

• rifice

Pressurization Panel Pneumatic Supply Feed Panel Pneumatic Supply Interface

P P

Feed Panel Pneumatic Supply

P P T T

• Temp. #1
• Temp. #2

P Exit #1 P Exit #2

P P T T

Note: Some instrumentation not shown for clarity.

Cat Bed P Inlet #2 P Inlet #1

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98% H2O2 Test Data

98% Catalyst Bed Pressures Test 101300_020

100 200 300 400 500 600 700 800 900 1000 1100 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Time (seconds) Pressure (psia)

P Exit P Inlet

98% Catalyst Bed Temperatures Test 101300_020

200 400 600 800 1000 1200 1400 1600 1800 2000 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Time (seconds) Temperature (degrees F)

• Temp. #1
• Temp. #2
• 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%

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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%

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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.