AIAA 2002-3852 CATALYST BE D TE STING FOR DE VE LOPME NT OF A - - PowerPoint PPT Presentation

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AIAA 2002-3852 CATALYST BE D TE STING FOR DE VE LOPME NT OF A - - PowerPoint PPT Presentation

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1 AIAA 2002-3852 CATALYST BE D TE STING FOR DE VE LOPME NT OF A 98% HYDROGE N PE ROXIDE PROCURE ME NT SPE CIFICATION E . Wernimont & M.C. Ventura General Kinetics, LLC Lake Forest, CA Date: July 9, 2002 M9982-jpc02-6 2

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AIAA 2002-3852 CATALYST BE D TE STING FOR DE VE LOPME NT OF A 98% HYDROGE N PE ROXIDE PROCURE ME NT SPE CIFICATION

E . Wernimont & M.C. Ventura General Kinetics, LLC Lake Forest, CA

Date: July 9, 2002

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Overview

  • Project Objectives & Motivation
  • Baseline and Poisoned Tests Approach
  • Baseline Test Results
  • Poisoned Tests Results

– C-Star – Pc Roughness – Pressure Drop – SEM Analysis

  • Recommended Specification: 98% H2O2
  • Cyclic Thermal Load Test
  • Acknowledgements
  • Conclusions
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Project Objectives & Motivation

  • No 98% H2O2 Procurement Specification Presently Exists
  • Reduce Technology Risk (98% H2O2 & Catalyst)

– Push State of Art Operational Duration of catalysts to 5000 sec – Determine Bounds of 98% H2O2 Impurity/Stabilizer limits without Performance Reduction

  • Test three impurities (SS, Al, Carbon)
  • Test three excess stabilizers (Tin, Phosphate, Nitrates)

– Use Test Results to Formulate Future 98% H2O2 Procurement Specification – Perform cyclic combined thermal/load tests to determine material fatigue effects

  • Test two catalysts systems to the cyclic duty cycle representative of shuttle RCS

thrusters

  • Catalyst Vendors: GK, RD
  • Single Fluid Supplier (selected competitively): FMC
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Baseline and Poisoned Tests Approach

  • Baseline Run with Nominal Propellant

– Total Run Duration 5000 sec – G ~ 0.27 lbm/(in^2-s) – Pc ~ 550 psia – 0.5” Diam Catalyst Bed – GK 2” Long, RD 4” Long Catalyst Bed

  • ‘Poison’ Test

– Dope Nominal Propellant – Total Run Duration 3000 sec – Use a new catalyst bed for each poison test – Clean test equipment between each test sequence – Nominal 500 sec steady state runs

  • Perform SEM analysis post test
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Baseline Test Results

  • Baseline (Nominal 98% H2O2, 5000 sec) Test Results

– GK & RD Both Performed Well and Lasted Duration – C* Greater Than 95%, (Correct RD Data for Nozzle Erosion) – 3-Sig Pc Roughness

  • GK < 5%
  • RD < 5% to 4000 sec, < 20% to 5000 sec (Maybe a Leak)

– Pressure Drop: GK 30 - 50 psid, RD 100 - 325 psid

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Poison Tests Results

  • Poison Test Results - Deviations From

Baseline

– NO3, TOC, SS

  • Nominal (GK & RD)

– Sn

  • Roughness Increase to ~20% at 3000

sec (GK & RD)

  • Pressure Drop to ~Zero at 3000 sec

(GK)

– PO4 on GK

  • Flooded at 10 -15 sec of Total Time

(GK)

  • Mild Increase Roughness ~10-15% ,

Reduction C-Star ~95% (RD)

– Al

  • Possible Memory Effect, Performance

Recovery to nominal at 1500 sec (GK)

  • Nominal (RD)
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C-Star Comparison Catalyst Tests NRA8-30

0.88 0.9 0.92 0.94 0.96 0.98 1 1.02 1000 2000 3000 4000 5000 6000

Cumulative Time (sec) C -Star Eff (% )

GK Baseline GK High NO3 GK High Sn GK High PO4 GK High Al GK High TOC GK High SS

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C-Star Comparison Catalyst Tests NRA8-30

0.88 0.9 0.92 0.94 0.96 0.98 1 1000 2000 3000 4000 5000 6000

Cumulative Time (sec) C -Star Eff (% )

BR Baseline BR High NO3 BR High Sn BR High PO4 BR High Al BR High TOC BR High SS

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Pc Roughness Comparison Catalyst Tests NRA8-30

5 10 15 20 25 30 1000 2000 3000 4000 5000 6000

Cumulative Time (sec) Pc R oughness +/-3 Sigm a of M ean (% )

GK Baseline GK High NO3 GK High Sn GK High PO4 GK High Al GK High TOC GK High SS

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Pc Roughness Comparison Catalyst Tests NRA8-30

5 10 15 20 25 30 1000 2000 3000 4000 5000 6000

Cumulative Time (sec) Pc R oughness +/-3 Sigm a of M ean (% )

BR Baseline BR High NO3 BR High Sn BR High PO4 BR High Al BR High TOC BR High SS

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Pressure Drop Comparison Catalyst Tests NRA8-30

10 20 30 40 50 60 70 1000 2000 3000 4000 5000 6000

Cumulative Time (sec) C atalyst B ed PR essure D rop (psid)

GK Baseline GK High NO3 GK High Sn GK High PO4 GK High Al GK High TOC GK High SS

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Pressure Drop Comparison Catalyst Tests NRA8-30

50 100 150 200 250 300 350 400 1000 2000 3000 4000 5000 6000

Cumulative Time (sec) C atalyst B ed PR essure D rop (psid)

BR Baseline BR High NO3 BR High Sn BR High PO4 BR High Al BR High TOC BR High SS

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Poison Tests Results

  • SEM Results

– Sn, Sn, Sn Everywhere, Every Form (All poisons & Pulse Test GK, RD) – RD Additional Elements

  • P for PO4 Test
  • Al for Al Test
  • Traces Mg, Na, S, Fe, Ni, Cr Otherwise

– GK Additional Elements

  • Al for Al Test
  • Traces Mg, Fe, Ni, Cr, Cu, Na, P Otherwise
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Recommended Specification: 98% H2O2

  • Requires concurrence of NASA, USAF, and Suppliers

Expected Spec Ref Parameter Level MIL-P-16005E Assay Wt % 98-99% 98-99% Al 0.35 mg/l max 0.5 mg/l max Chloride (Cl-) 0.5 mg/l max 1.0 mg/l max Ammonium (NH4+) 3.0 mg/l max 3.0 mg/l max Nitrate (NO3-) 3 - 5 mg/l 3 - 5 mg/l Phosphate (PO4-) 0.2 mg/l max 0.2 mg/l max Sulfate (SO4-) 0.5 mg/l max 3.0 mg/l max Tin (Sn) 1 - 4 mg/l 1 - 4 mg/l TOC 40 mg/l max 200 mg/l (C) max Evaporative Resid 20 mg/l max 20 mg/l max Stability 2.0% max AO 2.0% max of AO Ni .03 mg/l max N/A Cr .03 mg/l max N/A Fe .05 mg/l max N/A Cu .03 mg/l max N/A Mn .03 mg/l max N/A Notes

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Cyclic Thermal Load Test

Each Cycle Number of cycles Total burn time Cum Burn time Cum cycles On Pulse Off-pulse Seconds Sequence A .080 sec 1.52 sec 1000 80 80 1000 Sequence B 1 sec 19 sec 100 100 180 1100 Sequence C 10 sec 190 sec 10 100 280 1110 Sequence D .080 sec 0.42 3000 240 520 4110 Sequence E 1 sec 5.5 sec 270 270 790 4380 Sequence F 10 sec 55 sec 30 300 1090 4410 Sequence G .080 sec 0.24 5600 448 1538 10010 Sequence H 1 sec 3 sec 450 450 1988 10460 Sequence I 10 sec 30 45 450 2438 10505

  • Replaced run valve in test stand to achieve higher computer

driven valve response

  • Performed test sequence A through I
  • Pulse Test Results

– Nominal (GK) – Slightly Different Pressure Drop Increase Behavior (RD)

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C-Star Comparison Catalyst Tests NRA8-30

0.88 0.9 0.92 0.94 0.96 0.98 1 1.02 1000 2000 3000 4000 5000 6000

Cumulative Time (sec) C -Star Eff (% )

GK Baseline GK Pulse BR Baseline (Not Corrected) BR Pulse

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Pc Roughness Comparison Catalyst Tests NRA8-30

2 4 6 8 10 12 14 16 18 20 1000 2000 3000 4000 5000 6000

Cumulative Time (sec) Pc R oughness +/-3 Sigm a of M ean (% )

GK Baseline GK Pulse BR Baseline BR Pulse

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Pressure Drop Comparison Catalyst Tests NRA8-30

50 100 150 200 250 300 350 400 1000 2000 3000 4000 5000 6000

Cumulative Time (sec) C atalyst B ed PR essure D rop (psid)

GK Baseline GK Pulse BR Baseline BR Pulse

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Acknowledgements

  • MSFC NRA8-30 (Space Launch Initiative)

– Mr. Curtis McNeal & Mr. Deon Smith

  • FMC

– Mr. Steven Yuan

  • Boeing Rocketdyne

– Mr. Terry Lorrie & Kevin Lohner

  • H2O2 Community
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Conclusions

  • Completed Risk Reduction Study of 98% H2O2

– Over 48000 Sec of Hot Fire Time on GK and RD Catalyst – Pulse Tested Over 10500 cycles (.08 to 1 sec pulse widths) GK & RD – Tested 6 Elevated stabilizers/impurities (Sn, NO3, PO4, Al, TOC, SS) – Both GK & RD catalyst Ran 5000 sec with Nom Propellant

  • C-star Efficiency > 95%
  • 3 Sigma Pc Roughness < 5%
  • Cat Press Drop 30-50 psid GK, 100-325 psid RD

– Elevated Material Levels to Avoid Sn, PO4

  • Greatly Increased Knowledge of Catalyst/H2O2 Behavior
  • Procurement Specification Data Generated With No Known Gaps