Is it safer to use bleach as rocket fuel?New 3D-printed catalyst bed helps develop hydrazine fuel alternative

22 February 2022 Simon Reed, PhD in Engineering from the University of Canterbury, Christchurch, New Zealand is currently working on a3D printingofceramicsA catalyst-based device that efficiently converts concentrated hydrogen peroxide, a type of bleach, into non-toxic rocket fuel and is expected to be used in low-to-medium-thrust launch vehicles.

It is understood that he is now working with local launch company Dawn
aviation
aerospace
The company (Dawn Aerospace) collaborated on testing.

△3D printingCeramic-based catalyst beds are capable of converting hydrogen peroxide into a gas that can be used as rocket propellant. Image via University of Canterbury.

The search for safer propellants

Hydrazine was first developed in the late 19th century and is still a commonly used rocket propellant in aerospace today. However, while the substance remains an efficient means of fueling the rockets needed to put satellites into orbit, it is also unstable when dry, and it is so toxic to humans that it is now suspected of being a carcinogen.

According to Reid, special care is required when handling hydrazine, including the necessary safety gear and protocols during use, which also makes it more expensive to use, thus requiring a safer, lower-cost propulsion fuel to substitute. Interestingly, the engineer’s chosen alternative was hydrogen peroxide, a product often used to bleach hair or clean wounds and cause only mild irritation upon contact.

Applying the household bleach to a propellant requires a catalyst, usually made of precious metals, that can break it down into a gas, Reid said. In a follow-up study, he 3D printed a ceramic device coated with a catalyst that effectively induces chemical changes when hydrogen peroxide passes through it. Antarctic Bear speculates that the choice to use ceramic as the catalyst bed may be due to its much lower cost than silver or platinum.

“As liquid hydrogen peroxide passes through the catalyst bed, it accelerates the decomposition reaction,” explains Reid. “This reaction dissociates the molecule, turning it into water and oxygen. It’s the breakdown of that molecule that generates a lot of energy and heat. The heat vaporizes the water and creates a hot gas, which passes through a nozzle to provide the thrust. “

△University of Canterbury PhD student Simon Reed with his 3D printed catalyst bed. Image via University of Canterbury.

Using bleach as rocket fuel

Now, in three-and-a-half years of Ph.D. study, Reed is seeking to perfect the design of his 3D-printed bleach-conversion catalyst bed. Specifically, the engineer’s goal was to maximize the thrust produced by hydrogen peroxide while limiting catalyst loss from the bed, and to make all parts of his equipment as lightweight and commercially competitive as possible.

To achieve this, Reid has begun working with New Zealand’s state-backed Callaghan Innovation Facility to 3D print the device into geometries with other catalytic materials with improved properties, resulting in better thruster performance.

One approach that the PhD student found particularly promising for optimizing catalytic conversions was 3D printing his catalytic bed in the shape of a top, which was not possible with conventional production methods. In doing so, Reid believes his latest design will be an upgrade over its predecessor, as it will minimize catalyst losses, avoid huge pressure drops, and better balance thrust with fuel concentration.

Going forward, the graduate student now intends to test the efficacy of his improved catalytic bed and compare the results to previous designs. Rather, he also intends to work further with project collaborator Dawn Aerospace, which uses hydrogen peroxide as fuel for its reusable space shuttles, and to try to find a catalyst that can be recycled more efficiently.

Reid concludes: “In fact, as early as the 1960s, some airlines tried to use hydrogen peroxide as a propellant, but it was not possible due to the rudimentary catalyst device at that time. Today, only a few companies are seriously considering the use of hydrogen peroxide. As rocket fuel, I hope we can design a more efficient catalyst that can replace hydrazine with hydrogen peroxide and help improve the safety factor of the aerospace industry.”

△Dawn Aerospace’s Mk II Aurora hydrogen peroxide-fueled space shuttle. Image via Dawn Aerospace.

The potential of 3D printed rocket propellants

With its powerful creative capabilities, additive manufacturing serves the needs of rocket manufacturers around the world, not only in the production of advanced propulsion systems, but also in the fuels used to power those systems. One of the most high-profile examples of this is Rocket Lab, which last year sold a $4.1 billion SPAC toM&AThe case went public, and it is said to power its rocket’s Rutherford engine by printing propellant.

Back in late 2020, Firehawk Aerospace also raised $2 million for research and development work on its unique additively manufactured propulsion system. The company’s 3D-printed solid fuel rods, powered by a fuel designed to provide a safer, more reliable and lower-cost propellant for the engines of satellite launchers, were said to offer a new level of performance at the time.

Likewise, in a similar project, scientists at James Cook University in Australia have previously proposed 3D printing fuel particles capable of powering a hybrid rocket engine. In response to the rapid growth in commercial space launches, the commercial polymer-integrated rocket fuel developed by the team has shown strong potential in testing as a convenient means of launching devices into low Earth orbit (LEO).

(responsible editor: admin)

Is it safer to use bleach as rocket fuel?New 3D-printed catalyst bed helps develop hydrazine fuel alternative

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