AIAA 2009-4966 45th AIAA/ASME/SAE/ASEE Joint Propulsion Conference & Exhibit 2 - 5 August 2009, Denver, Colorado Mixtures of Nitrous Oxide and Oxygen (Nytrox) as Oxidizers for Rocket Propulsion Applications Arif Karabeyoglu* Space Propulsion Group Inc. Sunnyvale, CA Abstract Most of the oxidizers available to be used in chemical propulsion applications are highly hazardous materials that are either toxic or explosive in nature. Among the short list of oxidizing agents, liquid oxygen (O2) and nitrous oxide (N2O) stand out as the most practical propellants due to their wide availability, broad base of use, cost effectiveness and relatively benign nature. A new class of oxidizers (Nytrox) which are composed of equilibrium or non-equilibrium mixtures of nitrous oxide and oxygen are formulated in order to maximize the benefits of the pure components while retaining their practical advantages. Note that in the mixture O2 serves as the pressurizing agent, whereas N2O is the densifiying component. The primary advantages of this new system over the pure oxidizers can be listed as 1) self pressurization capability, 2) high density and density impulse, 3) non-cryogenic operational temperatures, 4) higher Isp performance compared to N2O, 4) improved safety 5) efficient gas phase combustion and 6) easier development of stable and efficient motors compared to liquid oxygen due to the exothermic decomposition of the N2O molecule. Unlike the pure oxidizers, the mixture allows for two independent control variables (temperature and pressure) which can be fine tuned to optimize the system for a particular application. I) Nomenclature A: a: B: b: f: k ij : Coefficient for cubic equation of state Attraction parameter Coefficient for cubic equation of state van der Waals covolume Fugacity Interaction coefficient for ith and jth components m: P: Pc : R: T: Tc : Peng Robinson coefficient Pressure Critical pressure Gas constant Temperature Critical temperature Tr : x: Z: Zc : Reduced temperature Mole fraction Compressibility Critical compressibility α: Function of Tr and acentric factor * President & CTO, Space Propulsion Group Inc., Consulting Professor in the Department of Aeronautics and Astronautics Stanford University. Member AIAA. 1 American Institute of Aeronautics and Astronautics Copyright © 2009 by Arif Karabeyoglu. Published by the American Institute of Aeronautics and Astronautics, Inc., with permission. v: Specific volume Acentric factor ω: II) Introduction Unlike the wide range of fuels that are currently available to be used in chemical propulsion systems, the list of potential oxidizers is quite limited. Figure 1 classifies the materials that can be used as oxidizing agents in propulsion applications based on the chemical group that they belong to. Note that pure chemicals and mixtures are listed separately. The general classes considered are halogens, oxygen based materials, hydrogen oxides, solid oxidizers, oxidizes of nitrogen, nitric acid and other oxidizers which include the mixed compounds of the elements oxygen, nitrogen, chlorine, fluorine and hydrogen. In order to accesses the practicality of each oxidizer, red fonts are used for the highly hazardous (toxic or explosive) oxidizers, whereas blue fonts are used for materials with poor performance. It can be shown that each oxidizer on this short list can be associated with some significant shortcoming which adversely influences its use as a practical propellant. For example, the high density storable oxidizer H2O2 has major safety issues due to its tendency to self-decompose (and potentially detonate). The commonly used N2O4 is highly toxic. Solid phase oxidizers used in solid rocket applications generally suffer from low Isp performance, and widely used perchlorate based solid oxidizers raise significant environmental concerns. Figure 1: Classification of oxidizers. Based on these arguments, it is clear that development of new improved oxidizing agents would constitute a critical technological enhancement in the field of chemical propulsion. The search for better oxidizers requires a clear description of the desirable attributes for the oxidizing component of the propellant system which can be listed as: • • • • • • • • • • • • High Isp performance with common fuels High density Good combustion stability and efficiency characteristics Chemical stability – for safety and long term storage Low toxicity Storability under normal conditions Adequate self pressurizing for pressure fed systems (or low vapor pressure for pump fed systems) Low freezing point Hypergolic behavior with common fuels Ease of handling Low cost Compatibility with tank and feed system materials 2 American Institute of Aeronautics and Astronautics III) Properties of O2 and N2O as Oxidizers Note that two oxidizers, liquid oxygen (LOX) and nitrous oxide (N2O), that are listed in Figure 1 can be isolated from the rest of the group as being the most practical materials due to their relatively low hazard level, environmental friendliness, wide availability, broad base of use in other applications, low costs and better than modest performance. These virtues resulted in the wide use of these oxidizers over a range of propulsion applications. Liquid oxygen is a high performance oxidizer which is commonly used in liquid and hybrid rockets with substantial total impulse requirements due to its advantages that can be listed as • • • • • High Isp performance. High chemical stability of the diatomic oxygen. Wide experience base. Low cost. Low optimum oxidizer to fuel ratio reducing the fraction of liquids in the case of a hybrid system. Despite its wide use LOX has some serious disadvantages. • • • • • LOX is a deep cryogenic material with a boiling temperature of approximately 90 K. This introduces significant operational difficulties and inconveniencies. The low operational temperature has an adverse effect on the mass fraction of the propulsion system due to 1) requirement for a tank insulation layer to minimize the boil off and 2) limit on the range of materials that can be used as the tank material (for example LOX capable composite tank technology is still not available). Motor stability and efficiency is hard to obtain. In the case of hybrid systems, stable and efficient operation is typically achieved by adding a heating source at or around the injection point of the LOX. This undesirable fix complicates the design and increases the cost and weight of the overall propulsion system. For liquid rocket systems, it is well known that LOX engines running with hydrocarbons such as RP1 tend to produce rough combustion. These systems typically require a significant amount of development effort until the desired stability margin is attained. LOX is almost never used as a self pressurizing oxidizer since the density is quite low at higher pressures. For example at 50 atm the density of liquid oxygen is only 550 kg/m3. LOX presents a strong dependency between density and pressure along its saturation line. Oxygen cleaning of the feed system components is critical. LOX fires are common. N2O has generally been the choice for relatively small rocket systems due to its self pressurizing capability arising from its high vapor pressure at room temperature. Self-pressurization can be useful because it eliminates the additional weight, complexity and cost of the pressurization system or the turbopump system needed to feed a liquid oxidizer into the combustion chamber at high pressures. The other advantages of N2O can be listed as • • • • Stable and efficient combustion is easier to attain due to the exothermic decomposition reaction of the oxidizer molecule. Extensive experience base exists in the hybrid propulsion field. Easily accessible chemical commonly used in several other industries. Modest cost. The following disadvantages limits the use of N2O to small systems • • • Low Isp performance. Low density (when self pressurization is needed). At low temperatures the density can be improved but the pressure drops significantly. Low density impulse. 3 American Institute of Aeronautics and Astronautics • • • High dependence of density and pressure on the temperature. Temperature conditioning is required for most practical applications. Nitrous oxide molecule has a positive heat of formation. Self decomposition in the tank, feed lines and the combustion chamber is possible and might result in catastrophic failure. System optimizes at high oxidizer to fuel ratios requiring a high mass fraction of liquids. IV) Opportunity: Mixtures of N2O and O2 As shown in Figure 1, equilibrium mixtures of pure compounds have been widely used as oxidizers in chemical propulsion. As long as the materials are miscible, mixtures within the same family (intrafamily) and mixtures of substances from different families (interfamily) are both feasible. The interfamily oxidizers are particularly interesting and are typically formulated for a specific reason. For example the primary function of oxygen in the FLOX system is to limit the mole fraction of the heavy combustion product CF4 to maximize the Isp performance with hydrocarbon fuels. A new possibility of an interfamily oxidizer, which has never been considered in the context of propulsion applications, is the mixture of oxygen and nitrous oxide (Nytrox)1. Since these two materials that have already been identified as the most appealing oxidizers from a practical sense, their mixture is also expected to retain the practicality advantage. It is interesting to note that the mixtures of O2 and N2O have been studied extensively, since the mixture is commonly used as anesthetic in medical/dental applications. As discussed in Refs. 2 and 3, the two substances are highly miscible in the liquid phase which opens up the possibility of using the mixture as an oxidizer for chemical propulsion systems which would potentially maximize the benefits and eliminate the shortcomings of the individual components. Specifically, the goal is to formulate a high density, self pressurizing oxidizer that does not have to operate at deep cryogenic temperatures. Note that in the mixture, the oxygen is the volatile component which serves as the pressurizing agent whereas the N2O is the less volatile one with the primary function of densifying the mixture. A simplistic explanation of the Nytrox concept is given in Figure 2 which shows the oxygen, nitrous oxide and the mixture of the two as a function of temperature in the oxidizer tank. At deep cryogenic temperatures, oxidizer is liquid oxygen in its pure form. As the temperature is increased mixtures of the two substances become feasible and the Nytrox oxidizers are formulated. As the temperature increases, oxygen content of Nytrox decreases and finally at temperatures close to the room temperature pure nitrous oxide becomes the practical oxidizer. Figure 2: Nytrox concept. The advantages of Nytrox oxidizers compared to its pure components can be summarized as 4 American Institute of Aeronautics and Astronautics • • • • • • • Partial self pressurization possible at high densities (eliminates or minimizes the use of expensive helium as pressurant). Improved Isp performance compared to N2O. Not a deep cryogen as liquid oxygen. Oxidizer at -80 C (or at warmer temperatures) is much easier to manage. Composite tanks can be used. Lower freezing point compared to pure N2O is expected. This is a useful virtue for space applications. Optimization based on mission requirements is possible. The critical control variables are the temperature and pressure which determine the oxidizer mass fraction in the liquid and vapor phases of the mixture. Thermodynamic non-equilibrium mixtures can be used in order to increase the system performance significantly. The Nytrox systems are much safer than blow down nitrous oxide systems since the vapor phase of the Nytrox system has a large O2 concentration, in the rage of 50-90 % by mass. A typical Nytrox system with 70% oxygen in the vapor phase requires 4-5 orders of magnitude larger ignition energy compared to pure nitrous oxide. In summary, Nytrox vapor is virtually impossible to ignite with any conceivable ignition source. A comparison of the LOX, N2O and Nytrox as oxidizers is summarized in Table 1. The table shows the clear advantage of Nytrox over the pure substances in many key areas which would allow the designer to formulate an oxidizer ideal for the particular application of interest. Table 1: Comparison of pure O2, N2O and Nytrox as oxidizers. Feature O2 N 2O Isp Performance Density Impulse Density Chemical stability Toxicity Storability Self Pressurization Capability Gas Phase Combustion Hypergolicity Ease of handling Material Cost Chemical compatibility Performance tuning capability Motor Stability/Efficiency Overall Safety 5: Best performance, 1: Worst performance * He pressurization 5 4 4 5 5 1 1 1* 1 3 5 5 1 2 3 Nytrox 3 2 1 4 4 5 5 3 1 5 4 5 2 5 2 4 4 3 4 4 3 3 5 1 4 4 5 5 4 5 V) Properties of the O2/N2O Mixtures The goal of this section is to outline the methods that can be used to predict the important thermodynamic properties of the Nytrox oxidizers such as specific heats, densities and mole fractions in the liquid and vapor phases at a selected state specified by a combination of pressure and temperature. For equilibrium mixtures, for which this paper will be limited to, this task can be achieved by using the methods of classical thermodynamics, specifically by the implementation of an Equation of State (EOS) with a mixing rule. The details of the calculation process are outlined in the Appendix. Even though due to its relatively simple form and reasonable accuracy, the Peng-Robinson EOS4 has been selected for the calculations discussed in this paper, the use of a more accurate EOS is recommended for detailed design purposes. Some of the important results from equilibrium thermodynamic calculations are discussed in the following paragraphs. 5 American Institute of Aeronautics and Astronautics The equilibrium phase data for the oxygen-nitrous oxide mixtures has been reported in Ref. 2 and 3 over a limited range of temperatures. Zeinenger2 lists vapor and liquid mixture data for temperatures in the -60 C to 20 C range, whereas Bracken et al.3 reports results for temperatures between -30 C and 30 C. Both data sets have been used in this study to determine the variation of the mixture interaction parameter, k12, as a function of temperature. As an example, for the O2/N2O system at -30 C, the mole fractions of oxygen in the liquid and vapor phases have been calculated using the Peng-Robinson EOS and plotted in Figure 3. The phase equilibrium data from Bracken et al. has also been included in the figure. The fit for the liquid branch is excellent, whereas the predicted oxygen mole fractions in the vapor phase are lower than the measured data. However, it is clear that even in the vapor phase, the error bounds are small and are expected to be close to the accuracy level of the experimental data. The Peng-Robinson interaction parameter that gives the best fit at this particular temperature is determined to be 0.0819. The deviation from an ideal mixture (which requires an interaction parameter of zero) is small but finite. Figure 3: Oxygen mole fraction as a function of pressure at -30 C. Data is from Ref. 3. The process described in the previous paragraphs has been repeated for all of the data at varying temperatures as they are reported by Zeinenger and Bracken et al. The interaction parameter, k12, values obtained as a best fit to the experimental data has been plotted as a function of temperature in Figure 4. Using standard analysis and curve fit techniques, it has been determined that the data given by Bracken et al. is more reliable than the Zeinenger data and the k12 fit used in the calculations have been based on the Bracken et al. data in the temperatures ranging from -30 C to 30 C. For temperatures between -30 C and 60 C the values obtained from the Zeinenger data has been used. Note that other than the 20 C case, the k12 values obtained from two data sets are in reasonably good agreement. The exact form of the k12 curve is governed by the change of intermolecular interactions with temperature and the observed convex shape is consistent with the results reported for other mixtures such as methane/decane5. 6 American Institute of Aeronautics and Astronautics Figure 4: Peng-Robinson parameter estimated from data reported in Refs. 1 and 2. In the following section the important performance parameters for Nytrox oxidizers, which are predicted using the methods developed in this section and the Appendix, will be presented. VI) Performance of Nytrox Oxidizers Figure 5 shows the liquid densities estimated for the O2/N2O mixtures as a function of pressure at different temperatures. As a reference the liquid densities for pure substances (N2O and O2) are also included in the figure. Note that for pure O2 and N2O, each point on the liquid density pressure curve is associated with a different temperature, since for a two phase, single component system Gibb’s phase rule dictates that a single intensive variable uniquely establishes the state of the substance. On the contrary since Nytrox is a two component and two phase system, two intensive properties are needed to uniquely determine the state. This expands the one dimensional operational space (saturation line) that exists for a pure substance to a wide area (two dimensional) in the P-T diagram for the case of Nytrox. Note that all of the states enveloped by Nytrox at its freezing temperature (-90 C or lower) and the N2O saturation line are feasible. The most important observation from Figure 5 is that at a selected self-pressurization level, the densities of the O2/N2O mixtures are significantly higher than the densities of the pure substances. The other important observation is that for the O2/N2O mixture at a given temperature, the liquid density is not sensitive to the system pressure as long as the pressure is not close to the critical value at that temperature. This feature of the O2/N2O mixture gives the designer the flexibility of selecting the system pressure without affecting the liquid oxidizer density significantly. 7 American Institute of Aeronautics and Astronautics Figure 5: Liquid density as a function of pressure at various temperatures for the O2/N2O mixtures. Figure 6 shows the mass fraction of oxygen in the mixture as a function of pressure for various temperatures. The general trend is that the oxygen mass fraction in the liquid increases with increasing pressure and decreasing temperature. As shown in the figure, at 60 atm and -60 C, oxygen constitutes approximately 15% of the liquid mass. Figure 6: Oxidizer mass fraction in the liquid as a function of pressure at various temperatures for the O2/N2O mixtures. The specific impulse and c* performance of the O2/N2O mixtures at different oxygen concentrations have been calculated using a thermochemical equilibrium calculation program. All calculations were conducted 8 American Institute of Aeronautics and Astronautics using paraffin as the fuel. The chamber pressure is 34 atm (500 psi), the nozzle area ratio is 70 and the ambient pressure is zero. The results are shown in Figure 7 and 8 for specific impulse and c*, respectively. The data for pure oxidizers, liquid oxygen, N2O4 and N2O, are also included for reference. It is important to note that the 35% O2/N2O mixture matches the Isp performance of N2O4. The other interesting observation is that even at low oxidizer concentrations (such as 10%) the performance benefit and the shift in the optimal O/F is significant. Figure 7: The specific impulse performance for the mixtures of O2/N2O. Figure 8: The c* performance for the mixtures of O2/N2O. The data is shown in uniform 10% increments of the O2 mass fraction in the mixture. 9 American Institute of Aeronautics and Astronautics Figures 9 show the maximum Isp as a function of the oxygen mass fraction. Note that the O2/N2O mixture with oxygen mass fraction that matches the inherent oxygen mass ratio of the N2O4 molecule outperforms N2O4 due to the negative heat of formation of the dinitrogen tetroxide molecule. Also note that the optimum O/F (for maximum Isp) decreases as the oxygen concentration in Nytrox increases. Figure 9: The maximum Isp as a function of the mass fraction of oxygen for the mixtures of O2/N2O. The performance of the equilibrium mixtures of O2/N2O is best summarized by Figures 10 and 11, which show the plots of specific impulse and density impulse as a function of pressure at various temperatures. Note that the specific impulse plot follows the oxidizer mass fraction trend given in Figure 6 as expected. The density impulse which is a product of density and specific impulse follows the general trend of density, since the variation of the density dominates the moderate changes in Isp for the range plotted in Figure 10. Figure 10: Specific impulse as a function of pressure at various temperatures for the O2/N2O mixtures. 10 American Institute of Aeronautics and Astronautics Figure 11: Density impulse as a function of pressure at various temperatures for the O2/N2O mixtures. The most critical observation from Figure 11 is that the density impulse of the cryogenic LOX system (at 14.7 psi of vapor pressure and 90 K of temperature) is almost matched by the O2/N2O mixture at -80 C and 60 atm of vapor pressure. The elimination or minimization of the external pressurization system and the higher temperature operational capability would favor the O2/N2O mixture for a wide range of applications where good performance, low cost and operational simplicity are critical. Figure 12: Specific impulse as a function of oxidizer temperature for O2/N2O mixtures operating at a pressure of 60 atm. Nozzle area ratio 70, shifting equilibrium, chamber pressure is 34 atm. Finally as an example case, the performance of an O2/N2O system operating at 60 atm has been calculated for various temperatures. The results are shown in Figures 12 and 13. As indicated in Figure 12, a system 11 American Institute of Aeronautics and Astronautics operating at -60 C has approximately 10 seconds of Isp advantage over the pure N2O system. More remarkably the system has almost 70% improvement in the density impulse over the pure N2O oxidizer (see Figure 13). Figure 13: Impulse density as a function of oxidizer temperature for O2/N2O mixtures operating at a pressure of 60 atm. Figure 14: Regression rate as a function of the mass fraction of oxygen in the mixture. The regression rate estimated using the classical theory arguments and normalized with respect to the regression rate of pure N2O. Classical hybrid rocket combustion theory as developed by Marxman et al.6 has been applied to predict the effect of the oxygen mass fraction on the regression rate for a generic solid hydrocarbon fuel. The results are plotted in Figure 14. Note that an increase of 29% in the regression rate is predicted by the classical 12 American Institute of Aeronautics and Astronautics theory as the mass fraction of O2 is increased from 0% to 100%. Note that this is a very crude prediction and the regression rate law needed for the detailed design process should be developed from subscale motor testing. VII) Safety Advantages of Nytrox Oxidizers Similar to hydrogen peroxide (H2O2) or hydrazine (N2H4), nitrous oxide can be regarded as a monopropellant since its decomposition reaction is exothermic in nature7. The ignition of nitrous oxide (in the vapor phase) can take place homogenously when the material is uniformly heated to a temperature larger than its autoignition temperature (approximately 880 K) or locally when enough energy (or free radicals) is locally introduced to the vapor at lower temperatures such that a self sustaining deflagration wave (flame) can start to propagate in the medium8. Local thermal ignition is the most common failure mode observed in rocket propulsion applications, since it is rather difficult to heat large quantities of nitrous oxide to the auto-ignition temperature within the short periods that the rocket operation takes place. Nitrous decomposition events have commonly been observed in the testing of rocket motors. A particularly dangerous mode of failure is the decomposition of the N2O vapor in the oxidizer tank. Due to the large quantities of N2O in the tank ullage, a decomposition process in the tank could potentially produce large explosions resulting in injury to personnel and/or major hardware loss. Unfortunately at larger scales the situation gets worse since the surface to volume ratio reduces as the tank size grows. This is especially a problem for propulsion systems with closely coupled oxidizer tank and combustion chamber. For such systems, at the end of the liquid burn, the hot injector could potentially heat the nitrous vapor in its vicinity and start a deflagration wave that could propagate in the tank. Note that for pure nitrous oxide in a closed vessel at 300 K, complete decomposition could result in a 24 fold increase in the tank pressure (a number much larger than the safety factor of all flight tanks and most run tanks used for ground testing). This indicates that even a partial decomposition could lead to a structural tank failure and loss of mission. The safety advantage of Nytrox over N2O comes from the dilution effect of O2. Note that the vapor phase of the Nytrox system has a large O2 concentration, in the range of 50-90 % by mass (i.e. see Figure 3). The minimum energy to start a self sustaining deflagration wave in nitrous oxide with varying initial concentration of oxygen is shown in Figure 15 for three initial pressure levels 40, 50 and 60 atm. Note that the calculations are conducted assuming a spherical ignition kernel for a N2O/O2 gas mixture. As indicated in the figure, a Nytrox system, even at a relatively low oxygen concentration of 35% by mass in the vapor phase, requires more than 4,000 times more ignition energy compared to pure nitrous oxide. In summary, Nytrox vapor is practically impossible to ignite with any ignition source that might exist in the tank. The figure also shows that the effect of pressure is small (at the high pressure levels relevant to rocket applications) compared to the effect of dilution. Nytrox also presents some significant safety advantages compared to liquid oxygen due its reduced cryogenic and fire hazards. The safety advantages of Nytrox oxidizers are expected to reduce the development, recurring and operational costs associated with the propulsion system. 13 American Institute of Aeronautics and Astronautics Figure 15: Minimum ignition energy for N2O/O2 mixtures at three pressure levels. VIII) Systems Advantages of Nytrox Oxidizers In this section we summarize the results of a systems study that has been conducted to quantify the performance advantages of Nytrox over the traditional oxidizers liquid oxygen and nitrous oxide. The performance of several hybrid rocket concepts using different oxidizers have been calculated by matching their total impulses to a baseline solid rocket. In order to directly compare the performance capability of the hybrids to a modern operational solid, ATK’s GEM40 motor has been selected as the reference system with the following properties. Property Gross Mass, kg GEM40 13,080 Structural Mass Fraction 0.10 Vacuum Isp, sec Length, m (in.) Diameter, m (in) Nozzle Area Ratio 274.0 13.0 (511.8) 1.02 (40.0) 10.65 In the design process the following parameters are matched to their values for the GEM40 system: Total Impulse: 3,162,107 N-sec Outside Diameter: 1.02 m (40 inches) Burn Time: 63.3 sec The gross mass and the overall length of the hybrid systems are left free to change to meet the desired performance requirements. Several hybrid options have been considered in the study for comparison purposes: 1) N2O/paraffin with 20% aluminum powder by mass: This relatively low performance, yet commonly used oxidizer has been included in the trade space as a reference point. Even though N2O can be stored for extended durations at room temperature, it still requires thermal management since the vapor pressure and the density are highly sensitive to temperature variations. The aluminum concentration in the fuel is limited to 20% in order to keep the recurring costs low and to minimize two phase losses in the nozzle. 2) Nyrox60/ paraffin with 20% aluminum powder by mass: The temperature of this particular grade of Nytrox is -60 C. 14 American Institute of Aeronautics and Astronautics 3) Nyrox80/ paraffin with 20% aluminum powder by mass: The temperature of this grade of Nytrox is -80 C. 4) LOX/paraffin: Even though this is a high performance system, the cryogenic nature of the oxidizer requires the use of metal tanks which compromises most of the performance gains associated with its high Isp. The operations with this cryogenic material are expected to be much more complicated and expensive compared to the other oxidizers. Fuel is straight paraffin, since aluminum addition does not increase the specific impulse performance for high energy oxidizers such as oxygen. Note that only nontoxic, environmentally green, low cost, chemically stable and readily available oxidizers have been considered in this investigation. For all systems other than the N2O motor which operates in the blow down mode, the oxidizer mass flow rate is assumed constant. All of the hybrids included in this study are pressure fed systems and the design details of the pressurization system on the system performance are critical. The N2O is a self-pressurizing oxidizer at room temperature and does not require any external pressurization hardware. This description is smowhat misleading since at the end of the liquid burn, the vapor in the tank constitutes 10-15% of the total oxidizer mass. In most system studies conducted with N2O a vapor phase combustion process is included in the estimation of the total impulse. However sustaining stable and efficient combustion during the vapor phase of the operation is problematic due to the sudden shift in the mass flow rate and consequently oxidizer to fuel ratio during transition process from the liquid phase operation to the vapor phase operation. SPG’s past motor testing experience with blow-down N2O motors indicates that the vapor phase combustion is either not sustainable (sudden extinction of the flame at the moment of transition to vapor) or it is highly unstable and inefficient. For this reason in the present system study, the vapor phase combustion is not allowed and the contribution of the remaining mass at the end of the liquid burn to the total impulse is assumed to be due to the expulsion of the cold N2O vapor. This feature makes the N2O systems quite inefficient, since, in effect, the pressurization is achieved by a heavy noncombustible gas (N2O vapor itself). The weight savings associated with the lack of extra pressurization hardware is also partially eliminated since the oxidizer tank size has grown significantly (tank contains the liquid oxidizer and also the incombustible pressurant generated from the liquid through evaporation). The LOX-based system is the other extreme for which all of the pressurization is supplied by a foreign gas. In this case helium is used to minimize the weight of the pressurant gas. As shown in Table 2 helium constitutes a very small fraction of the overall system mass (0.82%). Its contribution on the total impulse, which is also quite small, is produced in the cold gas thruster mode. The pressurization situation with Nytrox oxidizers is interesting. As mentioned before, Nytrox systems are partially self-pressurized. They start at high pressures but in the blow down mode they lose pressure at a fast rate, since oxygen is expected to come out of solution rather slowly. Thus they require a supplementary pressurization system. This can be achieved either by helium or gaseous oxygen. The advantage of helium is its lightness. However helium is a limited natural resource and it has become quite expensive and inaccessible in recent years. This trend is expected to get worse in the upcoming years. The other alternative is to use gaseous oxygen as the supplementary pressurant for the Nytrox systems. For such a system, at the end of the liquid burn most of the vapor is composed of oxygen (typically more than 90%). Note that the optimal oxidizer to fuel ratio (in terms of c*) for the oxygen paraffin system is around 2.2 as opposed to 7.5 in the case of N2O. As discussed above, the sudden reduction of oxidizer flow rate in transition to the vapor phase, which results in a significant drop in the oxidizer to fuel ratio, is ideal for an oxygen/paraffin hybrid. It is expected that the combustion process in this GOX hybrid operating close to its optimum O/F can be sustained much more readily than the combustion with the N2O vapor (also note that oxygen is a much more energetic oxidizer). Past experience with GOX/paraffin hybrids indicates that the gas phase operation would be stable and efficient. Based on these arguments, in the calculations with Nytrox systems, we have assumed that the gas phase combustion contributes significantly (more that 4% as sown in Table 2) to the total impulse. 15 American Institute of Aeronautics and Astronautics Table 2: Summary of the performance parameters for the hybrid systems considered in the study. System N2O/20% AlNytrox60/20% Nytrox80/20% LOX/Paraffin Paraffin Al-Paraffin Al-Paraffin Gas Phase Impulse, 2.50 4.54 4.33 0.38 %* Gas Phase Mass, 12.69 5.32 5.12 0.82 %** Oxidizer Temperature, 22 -60 -80 -183 C Oxidizer Tank Al. lined Al. lined Al. lined Al. 2219 Material Graphite-epoxy Graphite-epoxy Graphite-epoxy Oxidizer Specific 0.750 1.130 1.180 1.140 Density Pressurization O2-pressurized O2-pressurized Self-pressurized He-pressurized Scheme partial partial Oxidizer to Fuel Ratio 6.0 5.0 5.0 2.7 Chamber Pressure, atm 40.8 40.8 40.8 (psi) (600) (600) (600) Liquid Isp, 271.3 278.4 279.8 sec Effective Isp, 237.5 274.3 275.8 sec Structural Mass 0.133 0.102 0.100 Fraction Propulsion System 15,650 13,086 12,987 Mass***, kg Increase in Mass, 19.7 0.0 -0.7 % * Percent of total impulse, ** Percent of gross mass, ***GEM40 gross mass is 13,080 kg 40.8 (600) 306.8 304.8 0.200 13,233 1.2 The systems calculations have been conducted using SPG’s hybrid vehicle design code. Since the complicated mission requirements have been replaced by the simple total impulse requirement on the propulsion system, the flight modules have been disabled. The structural mass fraction is estimated within the code using the preliminary design equations for the major components such as the oxidizer tank, combustion chamber, pressurization system and nozzle. Available mass data have been used for small components such as valves, regulators and ignition system. A mass margin of 15% has been added to the calculated structural mass. The code outputs all the relevant performance, weight and geometrical parameters which are summarized in Tables 2-4 for all systems considered in this study. The oxidizer tank material for the LOX-based system is selected to be aluminum 2219. For all other systems (which are not cryogenic), the tanks are made out of aluminum lined graphite-epoxy composite material. The combustion chambers are also made out of graphite-epoxy composite with polymeric liners. For the cryogenic LOX system an insulation thickness of 1.27 cm (0.5 inches) has been used. For both Nytrox systems the thickness is assumed to be 0.64 cm (0.25 inches). Note that for all systems the outside diameter of the insulation is matched to the GEM40 diameter of 1.02 m (40 inches). In order to simplify the fabrication process and minimize the fuel sliver fraction, all motors are designed to use a single circular port fuel grain. The initial to final diameter ratio for the fuel port is taken to be 2.0 to limit the port Mach numbers and the hoop stresses on the port surface due to internal pressure loading. The thickness of the motor insulation liner is 0.64 cm (0.25 inches) for all systems. A fuel sliver thickness of 0.25 cm (0.1 inches) has been assumed at the end of the burn (liquid and gas when possible). This corresponds to fuel utilization of approximately 97% which has been successfully demonstrated in paraffinbased hybrid motor testing. The nozzles are made out of ablative silica phenolic inner shell and a structural outer shell made out of glass phenolic. The nozzle erosion rates are extrapolated from actual motor test 16 American Institute of Aeronautics and Astronautics data. An erosion rate of 0.1524 mm/sec (0.006 in/sec) has been assumed at the reference chamber pressure of 34.0 atm (500 psi). A linear variation for the erosion rate is assumed with the chamber pressure. Moderate variations in the erosion rate are not expected to affect the system performance significantly. For all systems the c* and nozzle efficiencies are assumed to be 0.96 and 0.98. Even though the chamber pressure for the GEM40 system is 55.6 atm (817 psi), the hybrid systems have optimized at a lower average pressure of 40.8 (600 psi). Note that this is due to the pressure independent regression rate behavior, which is a key advantage of hybrids compared to solids. Since chamber pressure can be selected independent of the internal ballistic considerations, more effective optimization is possible (essentially one of the constraints is lifted). Despite their reduced chamber pressures, all systems with the exception of the N2O motor deliver a better Isp than the GEM40 system (listed vacuum Isp for GEM 40 is 274.0 sec). The structural mass fraction of LOX system is quite high at 20% due to the use of aluminum tank material. The structural mass fraction for the Nytrox systems is similar to the value for the GEM40 system (10%). This is mainly due to the fact that the hybrids are optimized at a significantly reduced pressure. The structural mass fraction for the N2O system is higher than the values for the Nytrox motors primarily due to the low density of this oxidizer. The propulsion system weights for all systems are listed in Table 2. All systems other than N2O are close to the weight of the GEM40 motor. In fact the Nytrox 80 system is 0.7% lighter. Note that the N2O system is almost 20% heavier. The weight distribution for the major components is shown in Table 3. The important observation is the high tank weight for the LOX system. Also note that the weight increase in the tank weight for the N2O system compared to the Nytrox systems is much larger than the weight of the pressurization system for the Nytrox motors. Table 3: Summary of the component masses for the hybrid systems considered in the study. System N2O/20% AlNytrox60/20% Nytrox80/20% LOX/Paraffin Paraffin Al-Paraffin Al-Paraffin Propulsion System 15,650 13,086 12,987 13,233 Mass, kg Structural Mass, 2,077 1,335 1,298 2,657 kg Tank Mass, kg 951 429 410 1,366 Chamber Mass, kg Pressurization System Mass*, kg Nozzle Mass, kg *Excluding gas mass 282 283 282 426 0 79 76 98 160 164 164 170 The overall lengths of the hybrid systems along with other important geometrical data are listed in Table 4. Note that all systems are longer than the GEM40 solid due to the low effective density of the hybrid propellants. The N2O based booster is almost twice as long as GEM40 which makes it an unpractical system. The shortest of all the systems considered in this study is the Nytrox80 based booster, around 40% longer than GEM40. Nytrox60 and LOX based systems also have manageable length increases (less than 52%) over the baseline GEM40 booster. Note that for all systems, the motor outside diameter is matched closely to the tank diameter, a virtue which can only be achieved with fast burning fuels for single port hybrids. Hybrid configurations considered in this study are shown in Figure 16. 17 American Institute of Aeronautics and Astronautics Table 4: Summary of the dimensions for the hybrid systems considered in the study. System N2O/20% AlNytrox60/20% Nytrox80/20% LOX/Paraffin Paraffin Al-Paraffin Al-Paraffin Initial Nozzle Area 11.8 11.8 11.8 11.8 Ratio Effective Nozzle 10.2 10.8 10.8 10.8 Area Ratio Tank Diameter, m 1.02 1.00 1.00 0.99 (in) (40.0) (39.5) (39.5) (39.0) Motor Diameter, m 0.96 0.99 0.99 1.00 (in) (37.8) (39.1) (39.0) (39.5) Overall Length, m 25.78 18.84 18.24 19.69 (in) (1015.0) (741.6) (718.2) (775.0) Length Increase*, 98.3 44.9 40.3 51.4 % * Length of the GEM40 system is 13.0 m (511.8 inches). Figure 16: Hybrid configurations for GEM40 replacement. Even though the Nytrox-based hybrids are expected to be larger in size compared to the solids, their throttling, safety and potential cost advantages make them superior to the solid rocket systems for a wide range of applications. This fact has been demonstrated with the GEM 40 replacement study discussed in this section. There are also critical advantages of using Nytrox over LOX which do not directly influence the systems performance but affect the cost and reliability of the system. Some of these can be listed as • The replacement of a cryogenic propellant with a cold liquid reduces the system and life cycle cost and increases the reliability. Note that a respectable number of the system failure modes are associated with the use of cryogenic propellants. For example cryogenic valve failures have been commonly observed in rocket systems. Also note that cryogenic feed system components are significantly more expensive. 18 American Institute of Aeronautics and Astronautics • • • The cryogenic propellants constantly boil in the tank and they must be topped off (or actively refrigerated) until the moment of launch. This is an expensive operation for ground launch applications. For air launch systems cryogenic propellant management is even more difficult and hazardous. Due to the exothermic nature of the N2O decomposition process and warmer temperature of the Nytrox oxidizer, the development of stable and efficient combustion systems is expected to be less difficult with the Nytrox oxidizers compared to the cryogenic oxidizers. The injector design would also be simpler for the same reasons. There is a wide range of state properties (liquid density and oxygen mass fraction) that can be realized by selecting the temperature and pressure of the Nytrox system. This feature allows the designer to optimize the oxidizer for a given application. For example, higher oxygen concentrations and densities might be desirable for certain applications where the lower temperature operation would be acceptable. The systems advantages of Nytrox over N2O are primarily due to its higher specific impulse and density. Secondary effects such as safety and enhanced possibility of efficiently burning the gas phase would also add value to Nytrox. Even though this study is limited to a GEM 40 replacement hybrid, it is expected that there are many other systems that would benefit from the use of Nytrox. Moreover even for the system considered in this study, a full optimization on the Nytrox temperature and pressure has not been conducted. A much more detailed system study that would quantify the advantages of Nytrox over a wider range of applications including a more through optimization process would be beneficial for a better comparison of systems. Nytrox oxidizers are perfectly applicable to liquid systems and they are expected to result in benefits similar to the ones demonstrated for hybrids. In order to demonstrate this fact, a comparison of LOX/RP1 and Nytrox80/RP1 systems is shown in Table 5. Note that the Nytrox system is more than 10% denser than the LOX based system. The density benefit along with the reduction in the tank weight (use of composite materials), tank insulation weight and pressurization system weight would make the Nytrox stage lighter and smaller compared to a LOX stage. Thus an all Nytrox vehicle would be significantly lighter and smaller for a selected payload and target orbit compared to the baseline LOX system. Table 5: Density Comparison - Liquid Systems. Oxidizer to Fuel Ratio Oxidizer Density, kg/m3 Fuel Density, kg/m3 Propellant Density, kg/m3 LOX/RP1 2.7 1,140 810 1,027 Nytox80/RP1 7.0 1,200 810 1,132 IX) Variations of Nytrox Oxidizers As discussed in detail in the previous sections, the most basic version of the Nytrox technology uses the equilibrium liquid mixtures of N2O and O2 as the oxidizing component of the propellant. This system is composed of a liquid mixture and vapor mixture in phase equilibrium. The phase equilibrium determines the oxidizer tank pressure and oxidizer density for a selected combination of temperature and oxidizer concentration in the mixture. Note that the temperature and pressure can be adjusted to obtain the best oxidizer mass fraction, liquid density, specific impulse combination for the specific mission. In the following paragraphs we discuss some of the important variations of the baseline version of Nytrox oxidizers that could have some merit in certain applications. The first variation is to employ the use of equilibrium gas mixtures of N2O and O2 as oxidizing component. This is a single phase oxidizer which would be readily available from gas companies. The gas phase mixtures of N2O and O2 are expected to have better density than pure O2 gas and better Isp performance compared to pure N2O. 19 American Institute of Aeronautics and Astronautics The other possible variation is the non-equilibrium liquid mixtures of N2O/O2. These mixtures would potentially have better performance than the equilibrium mixtures since more oxygen can be loaded into the system at a given temperature. Non-equilibrium systems should be meta-stable for the short durations of operation typical in most rocket propulsion applications. The safe storage period is expected to depend on the extent of non-equilibrium and storage conditions. Potential shortcomings of the non-equilibrium systems are the limitation on the storage duration and the potentially more complicated oxidizer fill procedures. Another variation of Nytrox is the equilibrium and non-equilibrium mixtures of oxygen and other oxides of nitrogen such as N2O4 or MON (mixtures of nitrogen oxides). These mixtures exhibit similar density and pressure characteristics as the baseline Nytrox system (mixture of N2O and O2) at higher temperatures. The important shortcoming is their toxicity. Note that some of the mixtures with practical significance are N2O4/O2, N2O/O2/NO, N2O/O2/O3 or N2O/O2/NO/O3. The addition of NO into the baseline Nytrox would add some extra pressurization capability, enhance the Isp performance and improve the reactivity of the oxidizer. Addition of small quantities of ozone, O3 into baseline Nytrox would also be beneficial in terms of enhancing the decomposition rate of nitrous oxide and the Isp performance, possibly improving motor stability and efficiency. In the simplest form of Nytrox, the pure N2O, N2O4 or MON oxidizer is pressurized by gaseous oxygen (in the ullage). Note that in time some of the oxygen would be absorbed into the liquid oxidizer and eventually the equilibrium composition at the corresponding temperature and pressure would be obtained. In this mode of operation, the motor can be ignited well before the system equilibrates. The prime advantage of the oxygen pressurization as opposed to the pure blow down system (pure N2O operating at room temperature) or pressurization using an inert gas (i.e. He or N2) is that full combustion during the vapor flow stage of the system operation (following the depletion of all the liquid in the oxidizer tank) is possible and the pressurant gas contributes significantly to the total impulse increasing the efficiency of the overall propulsion system. Addition of other minor ingredients to control the chemical reactivity of the Nytrox formulations could also be beneficial. As an example He could be added to reduce the sensitivity of Nytrox to chemical decomposition or small amounts of organic or inorganic fuel component(s) can be incorporated to enhance the reactivity of the baseline Nytrox. Addition of higher concentrations of fuels would result in a highly sensitive but also a high performance monopropellant that could be beneficial for certain propulsion applications. Note that the fuel component should be selected such that it would be highly miscible with Nytrox but would have a low vapor pressure at Nytrox temperatures (to minimize the possibility of the vapor phase explosion). The other types of additives that could prove to be beneficial are gelling agents. X) Conclusions The following is a summary of the important aspects of the Nytrox technology as it relates to rocket propulsion applications. • • • • • • Nytrox oxidizers are equilibrium or non-equilibrium mixtures of oxygen and nitrous oxide. It has been shown in the medical literature that oxygen and nitrous oxide are perfectly miscible. Significant quantities of oxygen can be dissolved in liquid nitrous oxide at low temperatures and high pressures. The equilibrium mixtures are easy to prepare. Nytrox oxidizers retain the practical advantages of its components. Nytrox oxidizers have significant advantages over the pure components making them prime candidates for hybrid and liquid propulsion systems. The systems studies conducted for a GEM 40 replacement indicated that Nytrox systems have significant weight and length advantages over systems using liquid oxygen or nitrous oxide making hybrids a viable option for the existing solid rocket systems over a wide range of applications. No technical show-stoppers are anticipated in the development of Nytrox oxidizers. Preliminary laboratory experiments and motor testing results are very promising. 20 American Institute of Aeronautics and Astronautics XI) Acknowledgements I would like to thank my colleagues at SPG, Stanford University and NASA Ames for all of the stimulating discussions that greatly helped mature the Nytrox technology. This work was supported by SPG’s IR&D funds. XII) References 1 Karabeyoglu A.,”Mixtures of Nitrous Oxide and Oxygen (Nytrox) as Oxidizers for Propulsion and Power Generation Applications”, Patent Pending, Nov 2006. 2 Zeinenger H., “Flussikeits/Dampf-Gleichgewichte der Binaren Systeme N2O/N2, N2O/O2 und N2OCH4 bei Tiefen Temperaturen und Hohen Drucken”, Chem. Ing. Techn., Vol. 44, p 607, 1972. 3 Bracken A. B., Broughton G. B. and Hill W., “Equilibria for Mixtues of Oxygen and Nitrous Oxide and Carbon Dioxide and Their Relevance to the Storage of N2O/O2 Cylinders for Use in Analgesia”, J. Phys. D: Appl. Phys. 3, p. 1747-1758, 1970. 4 Peng Ding-Yu and Robinson Donald B., “A New Two Constant Equation of State”, Ind. Eng. Chem. Fundam., Vol. 15 No. 1, 1976, p. 59-64. 5 Zudkevitch D. and Joffe J., A.I.Ch.E.J. 16, 112, 1970. 6 Marxman G. A., Wooldridge C. E. and Muzzy R.J., “Fundamentals of Hybrid Boundary Layer Combustion”, Progress in Astronautics and Aeronautics, Vol.15, 1964 p 485. 7 Rhodes G. W., Investigation of Decomposition of Characteristics of Gaseous and Liquid Nitrous Oxide”, Air Force Weapons Lab. Report no. AD-784802, Kirkland AFB, NM, 1974. 8 Karabeyoglu M. A., J. Dyer, J. Stevens and B. Cantwell, “Modeling of N2O Decomposition Events”, AIAA-2008-4933, 44th AIAA/ASME/SAE/ASEE Joint Propulsion Conference and Exhibit, Hartford, CT, July 21-23, 2008. Appendix: Equilibrium Mixtures of Oxygen and Nitrous Oxide It is critical to determine the properties of the equilibrium mixtures of oxygen and nitrous oxide in order to quantify the performance benefits outlined in this paper. This requires the development of a state equation for the mixture. The Peng-Robinson equation of state (EOS) which is given by Eq. 1 is widely used for pure systems and mixtures due to its simplicity and higher accuracy (especially at high pressures) compared to the other cubic EOS such as Soave-Redlich-Kwong equation. P= RT a(T ) − v − b v (v + b ) + b (v − b ) (1) Here P, T, v are pressure, temperature and molar volume, respectively and R is the gas constant. Note that the attraction parameter, a, is a function of temperature and the van der Waals covolume, b, is constant. For most applications it is convenient to express Eq. 1 in the following cubic form. Z 3 − (1 − B) Z 2 + ( A − 3B 2 − 2 B) Z − ( AB − B 2 − B 3 ) = 0 (2) Here the coefficients A and B and the compressibility Z are defined as A= aP 2 2 R T , B= bP Pv and Z = . RT RT 21 American Institute of Aeronautics and Astronautics (3) Note that in the two phase region, the largest root of Eq. 2 corresponds to the compressibility of the vapor phase whereas the smallest root is the compressibility of the liquid phase. At the critical point the attraction parameter, van der Waals covolume and the compressibility become a (Tc ) = 0.45724 R 2Tc2 RT , b(Tc ) = 0.07780 c and Z c = 0.307 . Pc Pc (4) For all other temperatures the two coefficients can be written as a (T ) = a(Tc ) α (Tr , ω ) and b(T ) = b(Tc ) . (5) Note that α is a function of the reduced temperature, Tr, and the acentric factor, ω, for the particular molecule of interest. α 1 / 2 = 1 + m(1 − Tr1 / 2 ) and m = 0.37464 + 1.54226ω − 0.26992ω 2 (6) The reduced temperature is defined as Tr = T . Tc (7) The following parameters can be used for nitrous oxide and oxygen: ω N 2O = 0.162 (Tc ) N 2O = 309.6 K ( Pc ) N 2O = 71.6atm ωO 2 = 0.02 (Tc ) O 2 = 154.7 K ( Pc ) O 2 = 49.8atm The fugacity, f, of a single component can be expressed as A f Z + 2.414 B ln = Z − 1 − ln( Z − B) − ln P 2 2 B Z − 0.414 B (8) Note that at phase equilibrium, the fugacities of the liquid and the vapor should be matched. fl = fv (9) Predicting the properties of equilibrium mixtures: It has been determined that a single parameter (k12) binary mixing rule used in conjunction with the PengRobinson equation of state results in predictions that are in reasonably good agreement with the experimental findings. The following “mixture rule” which is recommended by Zudkevitch and Joffe5 is commonly used for predicting the properties of non-ideal solutions of fluids as applied to the above EOS. N a= N ∑∑ xi x j aij i =1 j =1 22 American Institute of Aeronautics and Astronautics (10a) N b= ∑ xi bi (10b) i =1 aij = (1 − k ij )(ai a j )1 / 2 (10c) Here xi refers to the mole fraction of the ith component. The interaction coefficient, kij, accounts for the interaction between the molecules and it is typically experimentally determined. For an ideal solution, kij is zero and deviation from zero indicates strong molecular interaction. In general, the interaction parameter is a function of temperature and it typically takes a minimum value at an intermediate temperature value. This fact has been demonstrated in Figure 4 for the N2O/O2 mixture but also has been observed for many other mixtures such as methane/butane or methane/decane. The reason for the minimum is believed to be due to the strong interaction in the liquid phase at low temperatures and strong interaction in the vapor phase at high temperatures. The fugacity of the kth component in the mixture can be expressed as N 2 x a i ik f k bk bk Z + 2.414 B A i =1 ln = ln ( Z − 1) − ln( Z − B ) − − . a b Z − 0.414 B 2 2B Px k b ∑ (11) Note that the equilibrium composition of the mixture can be obtained from the following condition for equilibrium. f kl = f kv (12) For binary mixture of oxygen and nitrous oxide the “mixing rule” reduces to a = a O 2 xO2 2 + 2a12 x O 2 (1 − xO 2 ) + a N 2O (1 − xO 2 ) 2 (13a) b = bO 2 xO 2 + b N 2O (1 − xO 2 ) (13b) a12 = (1 − k12 ) (a O 2 a N 2O )1 / 2 (13c) Example Case: It is instructive to use an example to illustrate the method of determining the critical performance parameters (such as Isp and impulse density) for the mixtures of oxygen/nitrous oxide as oxidizers. For the purposes of this example, we arbitrarily select an initial tank temperature and pressure of -40 C and 60 atm, respectively. Note that the density and oxygen concentration in the liquid phase are the two critical state variables that are needed to estimate the propulsion system parameters. In order to obtain these state variables, one can use a proven mixture rule and equation of state combination as discussed in the previous paragraphs. Assuming a desired pressure of 60 atm and a temperature of -40°C, Figure 5 can be used to read a liquid density value of 1,070 kg/m3. Similarly, from Figure 6, the oxygen mass fraction in the liquid phase can be determined to be 0.12. For this particular mixture, by using a standard thermochemical calculator (such as NASA Glenn’s CEA program), one can calculate the maximum specific impulse for a selected fuel, nozzle area ratio and combustion chamber pressure. Specifically for a paraffin-based fuel, a nozzle area ratio of 70, and a chamber pressure of 50 atm, a maximum specific impulse value of 327 s has been estimated. 23 American Institute of Aeronautics and Astronautics
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