Advanced cooling techniques for high-pressure hydrocarbon-fueled engines

The regenerative cooling limits (maximum chamber pressure) for 02/hydrocarbon gas generator and staged combustion cycle rocket engines over a thrust range of 89,000 N (20,000lbf) to 2,669,000 N (600,000 lbf) for a reusable life of 250 missions were defined. Maximum chamber pressure limits were first determined for the three propellant combinations (O2/CH4, O2/C3H8, and O2/RP-1 without a carbon layer (unenhanced designs). Chamber pressure cooling enhancement limits were then established for seven thermal barriers. The thermal barriers evaluated for these designs were: carbon layer, ceramic coating, graphite liner, film cooling, transpiration cooling, zoned combustion, and a combination of two of the above. All fluid barriers were assessed a 3 percent performance loss. Sensitivity studies were then conducted to determine the influence of cycle life and RP-1 decomposition temperature on chamber pressure limits. Chamber and nozzle design parameters are presented for the unenahanced and enhanced designs. The maximum regenerative cooled chamber pressure limits were attained with the O2/CH4 propellant combination. The O2/RP-1 designs relied on a carbon layer and liquid gas injection chamber contours, short chamber, to be competitive with the other two propellant combinations. This was attributed to the low decomposition temperature of RP-1.