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Design, Fabrication, Testing and Cost Optimization of Monopropellant

Thruster

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 Global Journal of Researches in Engineering: D
Aerospace Science
Volume 17 Issue 1 Version 1.0 Year 2017
Type: Double Blind Peer Reviewed International Research Journal
Publisher: Global Journals Inc. (USA)
Online ISSN:2249-4596 Print ISSN:0975-5861

Design, Fabrication, Testing and Cost Optimization of

Monopropellant Thruster
By Salahudden, Udyan panday, Pranjal Nag, Harshvardhan J
& Dr. Ramesh Kandadai
University Chennai
Abstract- The objective of this experiment is to developed 287N thrust approximately with
potassium permanganate as a catalyst to reduce the cost of monopropellant thruster because
potassium permanganate is very much cheap as compare to silver in same quantity. The major
issues concerning the development of the monopropellant thrusters is the non-environment
friendly exhaust that the fuels like Hydrazene [NH2-NH2]. Use of Hydrogen Peroxide [H2O2]
makes things easier & simpler, as the exhaust comprises of gases, namely Oxygen [O2] and
Water vapors (Steam) [H2O]. The most difficult problem for Peroxide test, which is used in
monopropellant thruster for outer space propulsion, is the catalyst bed design. According to the
literature survey, silver has the best catalytic performance for this test, but its low melting point
usually sinters the silver catalyst bed during decomposition processes..
Keywords: thruster, catalyst, electronic & pressurization system.
GJRE-D Classification: FOR Code: 090102

DesignFabricationTestingandCostOptimizationofMonopropellantThruster

Strictly as per the compliance and regulations of:

© 2017. Salahudden, Udyan panday, Pranjal Nag, Harshvardhan J & Dr.Ramesh Kandadai. This is a research/review paper,
distributed under the terms of the Creative Commons Attribution-Noncommercial 3.0 Unported License
http://creativecommons.org-/licenses/by-nc/3.0/), permitting all non commercial use, distribution, and reproduction inany
medium, provided the original work is properly cited.
 Design, Fabrication, Testing and Cost
Optimization of Monopropellant Thruster
Salahudden α, Udyan panday σ, Pranjal Nag ρ, Harshvardhan J Ѡ & Dr. Ramesh Kandadai ¥

Abstract- The objective of this experiment is to developed
287N thrust approximately with potassium permanganate as a
catalyst to reduce the cost of monopropellant thruster because
potassium permanganate is very much cheap as compare to
silver in same quantity. The major issues concerning the
sustaining the large number of thermal cycles imposed
by typical mission profiles and not requiring (if possible)
pre-heating for efficient operation. Nowadays the most
frequently used catalyst materials for H2O2 are metallic
silver, permanganates of alkali metals (Musker6),

2017
development of the monopropellant thrusters is the non-
environment friendly exhaust that the fuels like Hydrazene manganese oxides like manganese dioxide (MnO2) and

Year
[NH2-NH2]. Use of Hydrogen Peroxide [H2O2] makes things Di-manganese trioxide (Mn2O3).
easier & simpler, as the exhaust comprises of gases, namely
Oxygen [O2] and Water vapors (Steam) [H2O]. The most II. Thruster Design
31
difficult problem for Peroxide test, which is used in
To obtain the design parameters, various
monopropellant thruster for outer space propulsion, is the

Global Journal of Researches in Engineering ( D ) Volume XVII Issue I Version I

catalyst bed design. According to the literature survey, silver
has the best catalytic performance for this test, but its low
melting point usually sinters the silver catalyst bed during
decomposition processes. A superior catalyst bed design has
to deal with the balance of the highest specific impulse
produced and life-span of the active catalyst bed
performance.
Indexterms: thruster, catalyst, electronic & pressurization
system.
I. Introduction
assumptions, such as one dimension flow, frictionless
flow , ideal gases, isentropic flow, fully decomposition of
H2O2 propellant, and chemical equilibrium, are made.
The designed thrust at sea level and chamber pressure
are 200 N and 4 bar, respectively. 50% hydrogen
peroxide by concentration is chosen. Equations [1] ~
[16] are used to obtain ideal values of the thruster
parameter. Table I lists the parameters value of the
thruster.
γ−1

T
2γRu TC Pe
� + VC 2 �
γ
Ve = ��� � �1 − � � (1)
he physical properties of hydrogen peroxide are Mw (γ−1) Pc
close to those of water, with two notable
γ+1
differences: H2O2 has a significantly higher RTc γ+1 2(γ−1)
density and a much lower vapor pressure. It remains in C∗ = � � � (2)
γ 2
the liquid state at ambient pressure in a wide range of
temperatures and is relatively easy to handle with
respect to other common liquid rocket propellant γ+1 γ−1

oxidizers like Di-nitrogen tetra-oxide, nitric acid and 2 (γ−1) 2 Pe γ

CF = γ��� � � � �1 − � � ��
liquid oxygen (Ventura and Muellens3). The propulsive γ+1 (γ − 1) Pc
performance of hydrogen peroxide monopropellant (𝑃𝑒 −𝑃𝑎 ) 𝐴𝑒
rockets is about 20% lower than hydrazine, but the + � � (3)
𝑃𝑐 𝐴𝑡
volume specific impulse achievable with 90%H2O2 is
higher than most other propellants due to its high (Ue)est =(C*)est×(CF)est (4)
density. This is particularly useful for systems with m.=
T
(5)
significant aerodynamic drag losses and/or stringent Ue

volume constraints. With respect to bi-propellant and C∗

At= m ̇× (6)
hybrid rocket engines, hydrogen peroxide yields a PC
specific impulse comparable to other liquid oxidizers like T
Isp = (7)
dinitrogen tetroxide, nitric acid and even liquid oxygen. ̇
wp
The most significant technology challenge for
1
the realization of hydrogen peroxide monopropellant SPC = (8)
Isp
thrusters is the development of effective, reliable, long-
lived catalytic beds, giving fast and repeatable 1 1
2 𝑃 𝛾
performance, insensitivity to poisoning by the stabilizers A=�� �
𝛾−1
� 𝐶� �
𝛾+1 𝑃𝑒
and impurities contained in the propellant, capable of
Author α σ ρ Ѡ ¥: Department of aerospace engineering SRM University
Chennai. e-mail: qazisalahudden@gmail.com
© 2017 Global Journals Inc. (US)
 Design, Fabrication, Testing and Cost Optimization of Monopropellant Thruster

𝛾−1
Fig. 1: Design layout
𝛾+1 𝑃𝐶 𝛾
𝐵 = ��� � �1 − � � ��
𝛾−1 𝑃𝑒

A
=ϵ (9)
B

4×ṁ
Dinj = � � (10)
Cd ×π×�2×(∆p)ρ
Nozzle Injector Plate
̇ )
(m×t
Vpt = �1.1 � (11)
ρ

Pt ×∅t
t tank = � � (12)
2017

S
Year

𝑃𝐶 ×∅𝑐
𝑡𝑤 = � � (13)
𝑆
32 Cartridge shell Injector cup
𝛄+𝟏
𝐀 𝟐+𝛄−𝟏�𝐌𝟐 � 𝟐(𝛄−𝟏) 𝟏
=� � � � (14)
Global Journal of Researches in Engineering ( D ) Volume XVII Issue I Version I

𝐀𝐭 𝛄+𝟏 𝐌

𝛄+𝟏
𝐦̇ 𝛄 𝟐 (𝛄−𝟏)
(𝐏 𝐀 )
�𝐓𝐜 = ��𝐑 �𝛄+𝟏� � (15)
𝐜 𝐭

1+cos α°
σ= (16)
2

Table no: 1

Thruster Design Parameters

Design Parameters
Hydrogen peroxide
H2O2 propellant 50 %
Ve Exit velocity 599.94 m/s
C* Characteristic velocity 581.092m/s
CF Thrust coefficient 1.03247
(Ue)est Estimated exit velocity 512.965m/s
ṁ Mass flow rate 0.560k g/s
Isp Specific impulse 52.37 s
SPC Specific propellant consumption 0.01909/s
Ae / At Exit to throat area ratio 1.2343
Dinj Injector diameter 13mm
Vpt Volume of the propellant tank 19liters
t tank Thickness of the tank 3.159mm
T Ideal Thrust 287.75N
Pc Chamber pressure 4bar
Pa Ambient pressure 1bar
Α Divergent angle 5 Degree
Β Convergent angle 30.67 Degree
Γ Specific heat ratio 1.357
∅i Inlet diameter 74mm
∅e Exit diameter 39mm
At Throat diameter 34.7 mm
Me Design Mach number 1.605
2
G Gravity constant 9.81 m/s
Lc Convergent length 11.25mm

© 2017 Global Journals Inc. (US)

 Design, Fabrication, Testing and Cost Optimization of Monopropellant Thruster

Ld Divergent length 22.6 mm

Σ Divergence loss-co-eff 0.998
Pe Exit pressure 1bar
R Specific gas constant 8.324 J/Kkg
Tc Chamber temperature 423K

residence time of 1.10 ms for catalyst mesh.The length

of the catalyst pack is given by,
𝐑 ∆𝐭 𝐓𝟎
𝐋𝐜𝐩 = �� � . �𝐦̇ � . � �� (𝒎𝟐 )
𝛍 𝐀𝐜𝐩 𝐏𝐜

Where,

2017
J
R = 8.314 � �mol. K�

Year
kg
µ = 0.0227 � �mol�
33
kg

Global Journal of Researches in Engineering ( D ) Volume XVII Issue I Version I

ṁ = Maximummass�lowrate ( )
Fig. 2: Isometric view of assembly s

III. Mesh Design and Catalyst ∆t = residencetime[1.10(ms)]

Selection
The catalyst chosen for this project is a
potassium permanganate. The catalyst bed is prepared
by putting potassium permanganate pellets on a
stainless steel mesh.
The spacing between the wires in the mesh also
known as the sieve size or mesh spacing is taken in the
range 0f 1-2mm.this corresponds to mesh number 10
and 18,respectively, as per available standard sizes.
The bed–loading of the catalyst is taken in the
recommended range of 117-280 �𝑘𝑔�𝑚2 . 𝑠 � . since the
value of bed-loading decides the cross-sectional area of
the mesh and hence the mesh diameter, a value is
chosen such that the mesh diameter is close to the
diameter of the combustion chamber.
The cross-sectional area of the catalyst is given by-
ṁ
Acp = � � (m2 )
L ∅=meshwirediameter(m)
Where,
Acp = cross-sectional area of catalyst (m2 )
kg
ṁ = Maximum mass flow rate ( )
s
L = bed loading ( 𝑘𝑔�𝑚2 . 𝑠 ).
The value of L is taken as 207.875 ( 𝑘𝑔�𝑚2 . 𝑠 )
and the maximum mass flow rate is 0.8 kg/s. hence, for
a value of 𝐴𝑐𝑝 = 0.0038(𝑚2 ), the diameter of the
catalyst mesh is 7cm.
To calculate the length of the catalyst pack
which decides the number of mesh screens to used, we
need to assume a value for the residence time of the
propellant in the catalyst mesh. The residence time
ranges from 0.7-1.50 ms. We assume an average
Acp = cross − sectional area of the mesh (m2 )
T0 = combustion chamber temperature (K)
Pc = combustionchamberpressure(pa)
∴ 𝐋𝐜𝐩 = 𝟖. 𝟖𝟓𝟐𝐜𝐦
Therefore, we take the length of the catalyst
pack as approximately 9 cm. To maximize the surface
area of the catalyst, the stainless steel mesh will have to
be electroplated silver at a very high current to result in a
rough finish. Also, a figure of the merit of such a catalyst
the total surface area – to- volume ratio of the mesh.
The volume taken up by the mesh is given
∅2 3
Vn = �π. � . ��n − � . R + ��R2 − {(n − 1). s}2 ��
4 2
Where,
1
n=numberofwirein mesh(excludingcross-hatching)
4
S=wire spacing (opening size) (m)
R=radius of mesh screen (m)
And the total surface area of the mesh is given by
𝑇𝑆𝐴𝑚𝑒𝑠ℎ =
3
(8. 𝜋. ∅) ��n − � . R + ��R2 − {(n − 1). s}2 ��
2
Taking the ratio of the Total surface Area of the
mesh to the volume taken by the same, we get
TSA 4 −1
= (m )
Vn ∅

© 2017 Global Journals Inc. (US)

 Design, Fabrication, Testing and Cost Optimization of Monopropellant Thruster

Where,
∅=Mesh wire diameter (m)
Therefore,
The smallest wire diameter available for a given
wire spacing must be used.
Two sets of mesh screens are used to make the
catalyst .one set will have wire spacing 1mm and a wire
diameter of 0.27mm which corresponds to mesh#18, as
per industry standard .the other set will have a wire
spacing of 2mm and wire diameter of 0.27mm which
corresponds to #10, as per industry standards100 Fig. 4: Temperature sensor connection with aurduino
screens of mesh #18 and 50 screens of mesh #10
there will be distribution plates placed in between to IV. Pressurization and Electronic
ensure that channeling of peroxide flow does not take System
2017

place.the mesh screens interspersed with the To pressurize the system the nitrogen cylinder
Year

distribution plates will be 9 cm long which will fit into was adopted with following specifications –
catalyst cartridge.
34 The last of the lot was KMnO4. Potassium Table No.2: Nitrogen cylinder specifications
permanganate has been considered to be a good
Type Two stage -
Global Journal of Researches in Engineering ( D ) Volume XVII Issue I Version I

catalyst for the decomposition reaction of peroxide to

occur. These two react vigorously, but the same was Max. outlet
expected for silver and peroxide. So the reaction of pressure 8 Bar
permanganate & peroxide was tested in the laboratory Max flow 1000 L/min
using KMnO4 in the powdered form The reaction was
studied, and to the naked eye was the most suitable one Modal SN-5 -
for carrying out in future tests for peroxide. The steam Application Pressuring , -
came out within fractions of a second. purging &
Potassium Permanganate is easily available refrigeration
and can be used as pellets in the catalyst pack, much calibrated beam type load and two PT-100
easier to use than the Silver or the Fe, which needed temperature sensor is chosen to measure the thrust,
either the electroplating of metal over the Wire gauze, or chamber temperature and exit temperature along with
filling of the metal into the pack, by welding gauzes at proper connection of arduino uno and amplifier with
certain distances. code of-
/*
A4 -> DT
A5 -> SCK
*/
#include "HX711.h"
#define calibration_factor 110100.0 //This value is obtained
using the SparkFun_HX711_Calibration sketch
#define DOUT A4
#define CLK A5
HX711 scale(DOUT, CLK);
void setup() {
Serial.begin(115200);
Fig. 3: Load cell connection with amplifier and arduino Serial.println("HX711 scale");
scale.set_scale(calibration_factor); //This value is obtained
by using the SparkFun_HX711_Calibration sketch
scale.tare(); //Assuming there is no weight on the scale at
start up, reset the scale to 0
Serial.println("Readings:"); pinMode(A0, INPUT);
pinMode(A2, INPUT);
}
float temp1, temp2; void loop()
{

© 2017 Global Journals Inc. (US)

 Design, Fabrication, Testing and Cost Optimization of Monopropellant Thruster
temp1 = (analogRead(A0) * 5.0) / 1024.0; temp2 =
(analogRead(A2) * 5.0) / 1024.0; temp1 = (temp1 - 0.5) *
100;
temp2 = (temp2 - 0.5) * 100;
temp1 = ((temp1 - 32) / 9) * 5 - 12; temp2 = ((temp2 - 32) /
9) * 5 - 12;
Serial.print((9.81*scale.get_units()), 2); //scale.get_units()
returns a float
Serial.print(" Newtons \t"); //You can change this to kg but
you'll need to refactor the calibration_factor
Serial.print("Nozzle wall exit deg C: "); Serial.print(temp1);
Serial.print("\tChamber wall deg C: "); Serial.print(temp2);
Serial.println();
delay(100);
} dissociation taking place inside the tank, Flush with
Fig. no. 5: Load Cell – Thermocouples mounting
V. Testing Proceedure
a) Pneumatic pressure testing procedure
Examine all connections prior to test to ensure
proper tightness and perfect sealing., Determine
pressure rating for all connected fittings and devices to
ensure they are rated for the maximum testing
pressure., After the required 10 minutes, reduce the
pressure to 4 bar or a predetermined pressure,
Discharge pressure slowly and gradually to avoid
escaping air stream, debris and high decibel noise level
and Record the appropriate pressure & temperature
readings in long sheets with date and time of the test.
b) Sequence of Operation
Prior to filling, ensure all pipelines and valves
are free of debris, dust and any foreign particles., If
possible, flush the system with water prior to filling and
wait for the system to dry, Ensure the person in-charge
of filling are wearing latex gloves and face-masks,
Ensure that MBV-1 is closed (unenergised). [Note: This
valve only opens on giving power supply, Ensure the
DBV is closed, Ensure that NV and MBV-2 are both
closed, Connect the hose/line to the inlet of the DBV,
Open the DBV and begin flow of Hydrogen Peroxide into
the tank, slowly. Allow air in the tank to escape
periodically, by pausing in between filling., After filling
prescribed quantity of HP(leaving some space & ullage
volume), shut off the FBV, Wipe off any residual HP from
the mouth of the FBV using a wet cloth only. Dry cloth
might catch fire, as organic matter catches fire when it
comes in contact with HP, Ensure that there is no
leakage from the drain line, Check the HP tank pressure
gauge and note down the reading in the test document.
It must be nearly atmospheric pressure, Let the HP stay
2017
in the tank for about 5 minutes to ensure that there is no
Year
water after usage by using a hose pipe connected to the
filling line, Run water for some time to clear away any
foreign material, The switches of the MBV will need to be 35
ready for toggling
Global Journal of Researches in Engineering ( D ) Volume XVII Issue I Version I
Fig. no.7: 2 Seconds into firing
Fig. no.6: Test setup after the testing
VI. Result and Discussion
Figure shows the variation of thrust with time the
total operating time was approximately 25 seconds in
which from 1 to approximately 9 seconds the thrust
variation is almost constant this time interval take to
build the chamber pressure, temperature and
dissociation process when pressure reaches to design
pressure (4bar) and temperature reaches to design
value of (423K) the exit velocity increases monotonically
by equation 1 this increase in velocity lead to increase
© 2017 Global Journals Inc. (US)
 Design, Fabrication, Testing and Cost Optimization of Monopropellant Thruster

the thrust time interval of approximately 16 to 19

Chamber temperature vs time

Chamber temperature ( degree

seconds the thrust variation is constant because in this
time interval the exit velocity and mass flow rate is 100
constant from time interval 19 to 25 seconds the thrust
drop drastically in this time interval the catalyst bed is no 80
longer able to produce superheated steam and cartage

celcius )
60
pack completely got damage due to this the liquid form
of hydrogen peroxide was coming out from the nozzle 40
exit in this interval the velocity drastically reduces due to
this the sudden drop in thrust take place. 20

0
Thrust vs time 0 10 20 30
2017

200 Time ( sec )

180
Year

160 Fig. no 8: Chamber temperature vs Time

Thrust ( Newton )

36 140
120
Figure shows the theoretical variation of
chamber pressure along with time while doing the
100
Global Journal of Researches in Engineering ( D ) Volume XVII Issue I Version I

experiment we had force sensor and temperature

80
60
40
20
0 corresponding to various temperature value initially
0 10
Time ( sec )
Fig shows the variation of chamber temperature
along with time initially before starting the setup the
inside temperature was approximately 39 degree
Celsius when hydrogen peroxide come into contact with
potassium permanganate the dissociation process take
place and superheated steam will form this will lead to
increase the chamber temperature and approximately
sensor but we were unable to put pressure sensor
inside the chamber because of fully packed structure of
catalyst pack, by using equation of state with proper
assumption we found the various pressure value
20 30 pressure increases due to increases in temperature
after reaching the peak value of 4 bar approximately the
pressure reduce due to decrease in temperature as
stated above in fig but not in a similar manner because
of difference in theoretical aspects and reality.
Chamber pressure vs time
4.5
4
Chamber pressure ( bar )

at 19 second it reaches the peak value approximately 83 3.5

degree Celsius after that temperature decreases and 3
reach to approximately 46 degree Celsius at 25 second 2.5
the reason of showing this temperature is that 2
conduction takes time that is why the maximum thrust 1.5
time and maximum chamber temperature time is not
1
matching exactly.
0.5
0
0 10 20 30
Time ( sec )

Fig. no 9: Chamber pressure vs Time

Fig shows the variation of chamber nozzle exit
wall temperature along with time initially before starting
the setup the temperature was approximately 35.5
degree (Atmospheric temperature) Celsius when
hydrogen peroxide come into contact with potassium
permanganate the dissociation process take place and
superheated steam will form this will lead to increase the
nozzle exit wall temperature and approximately at 17

© 2017 Global Journals Inc. (US)

 Design, Fabrication, Testing and Cost Optimization of Monopropellant Thruster
second it reaches the peak value approximately 38.5
degree Celsius after that temperature decreases and
reach to approximately 37 degree Celsius at 25 second
the reason of showing this temperature is that
conduction takes time that is why the maximum thrust
time and maximum nozzle exit temperature time is not
matching exactly
FIg. no 10: nozzle exit wall temperature vs time
Table No.3: Compression between theoretical value
experimental value
parameter Experimental Theoretical % July 8-11, 2007
value value error
Max. 1792.92 287.20 37.35
Thrust
Mach 1.3013 1.6051 18.92
Number
VII. Conclusion
The objective of the project was to optimize the
cost of the monopropellant thruster because silver is
very much costly compare to potassium permanganate,
to get the optimum thrust and to commission a
technology demonstrator for future use in the upcoming
Propulsion Laboratory in SRM University Chennai. The
project initiated with the vision of using the convention
catalyst – Silver, but due to lack of availability of
Peroxide (50% Concentration), we tested different
catalysts for the same. Finally, after testing 6 potential
catalysts we selected Potassium Permanganate as the
suitable catalyst. The setup is ready to be taken for use
by the students as it has given positive test results. The
results were 63% coherent to the theoretical design.
Different types of nozzles can also be studied with this
setup as the thrust chamber is detachable. Currently the
setup is placed in Propulsion Laboratory in Aerospace
Hangar in SRM University.
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References Références Referencias
1. Pirault-Roy, L., Kappenstein, C., Guèrin, M., Eloirdi,
R., and Pillet, N., “Hydrogen Peroxide
Decomposition on Various Supported Catalysts
Effect of Stabilizers,” Journal of Propulsion and
Power, Vol. 18, No. 6, 2002, pp. 1235–1241
2. Blank, R., Pourpoint, T., Meyer, S., “Experimental
Study of Flow Processes and Performance of a High
Pressure Hydrogen Peroxide Catalyst Bed”, AIAA-
2007-5469, 43rd AIAA/ASME/SAE/ASEE Joint
Propulsion Conference and Exhibit, Cincinnati, OH,
July 8-11, 2007
3. Beutien, T., Heister, S., Rusek, J., Meyer, S., ”
2017
Cordierite-Based Catalytic Beds for 98% Hydrogen
Year
Peroxide”, AIAA-2002-3853, 38th
AIAA/ASME/SAE/ASEE Joint Propulsion Conference
and Exhibit, Indianapolis, Indiana, July 7-10, 2002 37
4. Pasini, A., Torre, L., Romeo, L., Cervone, A.,
d'Agostino, L., Musker, A. J., Saccoccia, G.,
Global Journal of Researches in Engineering ( D ) Volume XVII Issue I Version I
“Experimental Characterization of a 5 N Hydrogen
Peroxide Monopropellant Thruster Prototype”, AIAA-
2007-5465, 43rd AIAA/ASME/SAE/ASEE Joint
Propulsion Conference and Exhibit, Cincinnati, OH,
5. Pasini, A., Torre, L., Romeo, Luca, Cervone, A.,
d'Agostino, L., “Testing and Characterization of a
Hydrogen Peroxide Monopropellant Thruster ”,
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vol.24 no.3 (507-515) doi: 10.2514/1.33121
6. Yung-An Chan, Hung-Wei Hsu, Gung-Bang Chen,
and Yei-Chin Chao, December, 2010, Study of Silver
Catalyst Packing for a low-thrust Hydrogen Peroxide
Monopropellant Thruster, Asia Pacific Conference
on Combustion, Hyderabad, India, Dec, 2010
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9. Aircraft engine design by Jack D mattingly.
10. Encyclopedia of (A.E) AIAA-by Richard Blockdy.
11. Rocket propulsion elements by George P Sutton.
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