Design and Analysis of a High-Performance Hydrogen Peroxide Thrust Chamber Assembly

Abstract

Hydrogen Peroxide (H2O2) bipropellant rocket engines have been in use since the 1950’s in launch vehicles, sounding rockets, and as RATO (Rocket Assisted TakeOff) units for aircraft. Often, these engines function at a low chamber pressure using pressure-fed propellants, open-cycle turbo-pumps, or low-pressure closed-cycle turbo-pumps. As a result, hydrogen peroxide bipropellant rocket engines have generally had limited performance relative to other engine architectures. Modern advances in high-pressure catalyst bed design at Purdue’s Zucrow Research Laboratories as well as select use of transpiration cooling have made it possible to improve upon prior art by operating with a high-performance closedcycle pump arrangement at high chamber pressure (3200 psia). This leads to higher specific impulse, lower weight, and smaller engine components. The following report describes a design study for the injector, combustion chamber, and nozzle assembly associated with a small, 5,000 lbf thrust engine using this high-pressure cycle concept with 90% hydrogen peroxide and RP-1 propellants. Engine cycle design, chamber sizing, cooling selection and analysis, performance analysis, and structural design and analysis are all discussed. While many elements of the engine design require additional development prior to manufacturing, this study shows that very high-pressure closed-cycle hydrogen peroxide bipropellant engines should be feasible.