Novel Structured Catalysts for Hydrogen Peroxide Decomposition in Monopropellant and Hybrid Rockets

This paper describes the development of a novel catalytic system capable of decomposing hydrogen peroxide. The system is based on ceramic honeycombs in yttria-stabilized zirconia, with manganese oxides as the active phase. The effectiveness of different catalyst preparation procedures, entirely developed in house, has been evaluated using a plug-flow reactor operating with diluted hydrogen peroxide vapors. A monopropellant test bench has been then assembled to verify the performance of a selected number of catalytic samples in a test environment closer to the actual operating conditions of a space propulsion system: the catalysts have demonstrated decomposition efficiencies exceeding 90%. The concept has been finally scaled up to a hybrid configuration based on the utilization of hydrogen peroxide as the oxidizer and high-density polyethylene as the fuel: the possibility to ignite and reignite the fuel grain has been demonstrated and propulsive efficiencies close to 90% have been measured.