Safety issues of high-concentrated hydrogen peroxide production used as rocket propellant

Safety issues of high-concentrated hydrogen peroxide production used as rocket propellant

Acta Astronautica ] (]]]]) ]]]–]]] Contents lists available at ScienceDirect Acta Astronautica journal homepage: www.elsevier.com/locate/actaastro ...

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Acta Astronautica ] (]]]]) ]]]–]]]

Contents lists available at ScienceDirect

Acta Astronautica journal homepage: www.elsevier.com/locate/actaastro

Safety issues of high-concentrated hydrogen peroxide production used as rocket propellant O.V. Romantsova a,n, V.B. Ulybin b a b

Saint Petersburg State Polytechnical University, Russia Saint Petersburg State Technological Institute, Technical University, Russia

a r t i c l e i n f o

abstract

Article history: Received 10 October 2014 Accepted 14 October 2014

The article dwells on the possibility of production of high-concentrated hydrogen peroxide with the Russian technology of isopropyl alcohol autoxidation. Analysis of fire/ explosion hazards and reasons of insufficient quality is conducted for the technology. Modified technology is shown. Non-standard fire/explosion characteristics required for integrated fire/explosion hazards rating for modified hydrogen peroxide production based on the autoxidation of isopropyl alcohol are defined. & 2014 IAA. Published by Elsevier Ltd. All rights reserved.

Keywords: Fire/explosion characteristics Risk assessment Hydrogen peroxide Isopropyl alcohol autoxidation Propellant

1. Introduction Spaceflight safety has recently become a topic of heated discussion. Safety in spaceflight includes various aspects. One of them is proper choice of fuel. Many researches are devoted to different types of rocket propellants analysis and their characteristics comparison [1–5]. Over hundreds of different liquid propellants were lab tested. The primary factors which are needed to choose a propellant include ease of operation, cost, hazards/environment and performance. One of the promising agents for the propellants is hydrogen peroxide. It is considered to be used as both an oxidizer and a monopropellant. Propellant based on hydrogen peroxide has a number of advantages such as high density, non-toxic, high specific impulse and others. In order to use the hydrogen peroxide as a propellant it must be of high quality and above 90% concentration to reduce the decomposition on the surfaces of contact [6–8]. High-concentrated hydrogen peroxide is very insensitive to detonation by shock or impact. Obtaining hydrogen peroxide of required quality is a particular problem. n

Corresponding author. Tel.: þ7 812 552 97 14. E-mail addresses: [email protected], [email protected] (O.V. Romantsova).

Nowadays three major industrial methods of hydrogen peroxide production exists (electrochemical, anthraquinone autoxidation, and isopropyl alcohol autoxidation). The first technology provides the highest quality product but with a very high power consumption. It is used only to obtain a highly concentrated product. It can be used in a special technique because of its high quality despite of its cost. Comparison of other two methods shows that product quality is practically the same, as well as its cost. However, in Russia method of isopropyl alcohol autoxidation has spread. This technology is more environment friendly but more explosive compared to anthraquinone autoxidation, which is spread in the rest of the world [9]. Ensuring safety in the hydrogen peroxide production based on the isopropyl alcohol autoxidation is a complex scientific and technical task. 2. Features of the hydrogen peroxide production technology based on the isopropyl alcohol autoxidation Hydrogen peroxide production consists of three main steps: isopropyl alcohol autoxidation, hydrogen peroxide extraction, and acetone extraction. Hydrogen peroxide is obtained as a result of reaction of isopropyl alcohol with

http://dx.doi.org/10.1016/j.actaastro.2014.10.022 0094-5765/& 2014 IAA. Published by Elsevier Ltd. All rights reserved.

Please cite this article as: O.V. Romantsova, V.B. Ulybin, Safety issues of high-concentrated hydrogen peroxide production used as rocket propellant, Acta Astronautica (2014), http://dx.doi.org/10.1016/j.actaastro.2014.10.022i

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air (1). This process is carried out at 105–134 1С and 1.1–1.2 MPa (10–12 atm) in a liquid-phase. There are also concurrent reactions (2)–(5). Exothermic reaction heat of some of them is bigger than heat of the main one (1), so uncontrolled concurrent reaction can cause the thermal explosion. СН3СНОНСН3 þО2-Н2О2 þСН3СОСН3 þ117.21 kJ/mol (1)

СН3СНОНСН3 þН2О2-СН3СОСН3 þ2Н2Оþ313.27 kJ/mol

(2)

СН3СОСН3 þ2Н2О2-СН3СООН þСО2 þ3Н2Оþ 1114.28 kJ/mol

(3)

3СН3СОСН3 þ 3Н2О2-С9Н18О6 þ3Н2О 359.44 kJ/mol (4)

Н2О2-Н2Оþ0.5О2 þ98.03 kJ/mol

(5)

Besides in the process a dangerous by-product acetone peroxide С9Н18О6 occurs (4), which is primarily a high explosive. It is susceptible to heat, friction and shock. Another feature of the technology is simultaneous presence in the working mixtures of flammable liquids (isopropyl alcohol and acetone) and oxidizers (oxygen and hydrogen peroxide). In this connection there is a risk of forming an explosive mixtures inside the equipments. Also characteristics of working mixtures are different from the characteristics of the components which it consists of. For example, autoignition temperature of working mixture decreases with increasing concentration of hydrogen peroxide in it (Fig. 1) [10]. These factors increase the dangers of the process, risks of explosive on every step of the production.

3. Modification of the hydrogen peroxide production technology based on the isopropyl alcohol autoxidation Nowadays hydrogen peroxide after isopropyl oxidation can be concentrated up to 55% [11]. Current technology does not provide enough quality of the product. Increasing the concentration is not possible because of the organic impurities containing in the product. So that sort of hydrogen peroxide cannot be used as rocket propellant. However, the production can be modified to improve the quality of the product. The main idea is to change the order of the working mixtures separation [12]. Under the current technology after the step of isopropyl alcohol autoxidation working mixture of hydrogen peroxide, isopropyl alcohol, acetone and other by-product enter in a vacuum distillation column where aqueous solutions of hydrogen peroxide are separated from the mixture of acetone, isopropyl alcohol and other low-boiling impurities with the further refining and concentration. The next step is the separation of mixture of acetone, isopropyl alcohol in another vacuum distillation column (Fig. 2). According to the modified technology acetone should be separated first in a distillation column at atmospheric pressure. And after that use a vacuum distillation column to extract aqueous solutions of hydrogen peroxide from its mixture with isopropyl alcohol (Fig. 3). This method can significantly reduce energy costs, improve the quality of hydrogen peroxide and eliminate the possibility of the acetone peroxides formation, one of the most hazardous by-products [12]. However, this process is still explosive. 4. Non-standard fire/explosion characteristics To control potential risks of the modified technology of hydrogen peroxide production standard and non-standard fire/explosion characteristics should be evaluated. The list of the standard fire/explosion characteristics are given in Federal law of Russian Federation no. 123-FZ [13]. Their values

Fig. 1. Autoignition temperature of working mixture.

Please cite this article as: O.V. Romantsova, V.B. Ulybin, Safety issues of high-concentrated hydrogen peroxide production used as rocket propellant, Acta Astronautica (2014), http://dx.doi.org/10.1016/j.actaastro.2014.10.022i

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Fig. 2. Scheme of current technology of working mixture separating: 1. vacuum distillation column for hydrogen peroxide separation; 2. vacuum distillation column for acetone separation; 3. container; 4. dephlegmator; 5. boilers; 6. refrigerators; and 7. heaters.

were obtained in accordance with standard procedures and are listed in Refs. [14–19]. Non-standard fire/explosion characteristics have been developed according to the features and hazards of the process. There are four types of accidents which require nonstandard researches to constructing their models:

 thermal explosion in the liquid-phase;  inflammation of the gas phase inside the equipment;  inflammation of the working mixture followed by equipment depressurization;

 explosion of primary high explosive by-products crystallized on the walls of the equipment (acetone peroxides).

Each of these accidents characterized by a number of indicators allowing to determine the conditions of development of hazardous situation. Some of these standard fire/ explosive characteristics, such as the autoignition temperature, the ability to exothermic decomposition, etc., should be calculated from the standard values adjusted to high pressure and temperature. So a list of non-standard characteristics required for the technology risk assessment can be formed: 1. induction period of thermal explosion; 2. critical temperature and critical diameter of thermal explosion; 3. autoignition temperature of the gas phase of the working mixture inside the equipment with required adjustment; 4. critical dimensions of the gas phase (critical diameter); 5. flammability limit in the gas phase of working mixture adjusted to elevated pressure and temperature; 6. ignition temperature of the working mixture at depressurization equipment;

Fig. 3. Scheme of modified technology of working mixture separating: 1. hydrogenation of acetone; 2. distillation column for acetone separation; and 3. vacuum distillation column for hydrogen peroxide separation.

7. places of accumulation hazardous by-products (acetone peroxides); 8. quantity of hazardous by-products (acetone peroxides). These non-standard characteristics should be evaluated to determine safe operating modes of the modified technology. 5. Conclusions High-concentrated hydrogen peroxide is a unique agent and can be used as a propellant. Modified technology of the production based on isopropyl alcohol autoxidation in Russia should enable to produce high-concentrated hydrogen peroxide with sufficient quality for this goal. The main hazards of the process are determined. It includes potential risk of explosions, autoignition of the working mixture,

Please cite this article as: O.V. Romantsova, V.B. Ulybin, Safety issues of high-concentrated hydrogen peroxide production used as rocket propellant, Acta Astronautica (2014), http://dx.doi.org/10.1016/j.actaastro.2014.10.022i

O.V. Romantsova, V.B. Ulybin / Acta Astronautica ] (]]]]) ]]]–]]]

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forming dangerous agents. Non-standard fire/explosion characteristics required for integrated fire/explosion hazards rating for the production are defined. [11]

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Please cite this article as: O.V. Romantsova, V.B. Ulybin, Safety issues of high-concentrated hydrogen peroxide production used as rocket propellant, Acta Astronautica (2014), http://dx.doi.org/10.1016/j.actaastro.2014.10.022i