Catalyst – solid sorbent – or support therefor: product or process – Catalyst or precursor therefor – Metal – metal oxide or metal hydroxide
Statutory Invention Registration
1998-03-20
2001-03-06
Jordan, Charles T. (Department: 3641)
Catalyst, solid sorbent, or support therefor: product or process
Catalyst or precursor therefor
Metal, metal oxide or metal hydroxide
C502S241000, C502S243000, C502S317000, C502S324000, C502S300000, C502S347000, C502S325000, C502S353000, C502S320000, C502S305000, C423S579000
Statutory Invention Registration
active
H0001948
ABSTRACT:
MICROFICHE APPENDIX
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to high-activity hydrogen peroxide decomposition. More particularly, the present invention uses an activated catalyst for high-activity hydrogen peroxide decomposition. Most particularly, the high-activity hydrogen peroxide decomposition is sufficiently rapid enough to provide thrust within rocket and/or other power systems.
2. Brief Description of the Related Art
Catalysts are used in the decomposition of hydrogen peroxide (H
2
O
2
) for monopropellant thrusters, liquid rocket engines, hybrid rocket systems and the like. Hydrogen peroxide decomposes into water vapor and oxygen. The oxygen product can react with conventional rocket fuel or grains to provide thrust. Within propulsion systems, hydrogen peroxide has been successfully used as an oxidizer for U.S. Navy torpedo systems, U.S.A.F. attitude control thruster“s on the X-15, and for reaction control thrusters on the NASA Scout launch vehicles and Mercury spacecraft.
Catalyst are formed into packs by using layers of nitric acid or samarium salt activated silver plated screens. Within this system, hydrogen peroxide decomposition activity is relatively low. However, increasing the number of screens also increases the activity, but also increases the pressure drop. Contaminants within the hydrogen peroxide may also plate out onto the silver screens. This reduces the active surface area, which in turn reduces the effective decomposition of the hydrogen peroxide. Additionally, the cost of the materials and fabrication are high.
Catalyst pack screens have been disclosed in U.S. Pat. Nos. 5,077,257 (Baldi), 4,927,798 (Baldi), and 4,292,208 (Baldi et al.). However, these patents do not address a low cost hydrogen peroxide catalyst applicable for use as an efficient propulsion system, providing low pressure drop and low weight.
SUMMARY OF THE INVENTION
The present invention provides a high-activity hydrogen peroxide decomposition catalyst comprising an impregnated and calcined substrate with a catalyst mixture, the catalyst mixture comprising a hydrogen peroxide catalytically active compound containing a transition metal cation mixed with an alkaline promoter, wherein the substrate further comprises a porous support material selected from the group consisting of alumina, silica, aluminosilicate, polar ceramics and combinations thereof.
The invention further provides a process for forming a high-activity hydrogen peroxide decomposition catalyst comprising the steps of providing a polar substrate comprising a porous support material selected from the group consisting of alumina, silica, aluminosilicate, polar ceramics and combinations thereof; mixing, in an aqueous solvent, a soluble salt containing a hydrogen peroxide catalytically active compound containing a transition metal cation with an alkaline promoter; applying the mixture over the substrate, wherein the mixture soaks the substrate surface area, thereby impregnating the substrate; drying the applied soaked mixture sufficiently causing the removal of the solvent; and calcining the dried mixture sufficiently to form an activated catalyst.
Additionally, the invention provides a product of high-activity hydrogen peroxide decomposition made by the process of providing a polar substrate comprising a porous support material selected from the group consisting of alumina, silica, aluminosilicate, polar ceramics and combinations thereof; mixing, in a solvent, a soluble salt containing a hydrogen peroxide catalytically active compound containing a transition metal cation with an alkaline promoter; applying the mixture over the substrate, wherein the mixture soaks the substrate surface area, thereby impregnating the substrate; drying the applied soaked mixture sufficiently causing the removal of the solvent; calcining the dried mixture, wherein an activated catalyst is formed; housing the formed activated catalyst into a hydrogen peroxide reaction chamber having a hydrogen peroxide inlet port; and, flowing a compound of hydrogen peroxide through the inlet port wherein the hydrogen peroxide comes in contact with the calcined, impregnated substrate with mixture, wherein the hydrogen peroxide decomposes in a high-activity reaction thereby releasing water, oxygen and energy.
REFERENCES:
patent: 3019197 (1962-01-01), Saunders
patent: 3333419 (1967-08-01), Baumgartner et al.
patent: 3710573 (1973-01-01), Hubbuch et al.
patent: 4292208 (1981-09-01), Baldi et al.
patent: 4601884 (1986-07-01), Coeckelberghs et al.
patent: 4629718 (1986-12-01), Jones et al.
patent: 4656153 (1987-04-01), Wennerberg
patent: 4927798 (1990-05-01), Baldi
patent: 5077257 (1991-12-01), Baldi
patent: 5080882 (1992-01-01), Yoshimoto et al.
patent: 5212139 (1993-05-01), Ovalles et al.
patent: 5212140 (1993-05-01), Yoshimoto et al.
patent: 5597539 (1997-01-01), Fakley et al.
patent: 5711146 (1998-01-01), Armstrong et al.
Anderson Nicole
Rusek John J.
Bokar Gregory M.
Jordan Charles T.
Kalmbaugh David S.
Sanchez Glenda L.
The United States of America as represented by the Secretary of
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