Performance Degradation and Regeneration of Palladium Catalysts for Hybrid Rockets

The renewed interest in hydrogen peroxide-based space propulsion systems has highlighted the persistent issue of catalyst degradation during long-term operation. Although several studies have investigated the underlying causes of this phenomenon, effective regeneration techniques capable of restoring catalytic activity have not yet been clearly demonstrated. This study investigates the mechanisms responsible for performance degradation and proposes a viable regeneration strategy for palladium-based catalysts. Experimental analyses were conducted on a batch of commercial Al2O3/Pd pellets subjected to multiple firing cycles in a 10 N-class hybrid mini-thruster. Monitoring of the propulsive performance revealed a progressive decline in catalytic activity, ultimately preventing ignition of the hybrid rocket engine. To characterize the degradation mechanisms, the pellets were examined through visual inspection, static hydrogen peroxide decomposition tests, and Temperature Programmed Reduction (TPR) analysis. The results indicated significant surface oxidation of palladium, leading to reduced decomposition efficiency. A chemical regeneration procedure based on sodium borohydride (NaBH4) treatment was subsequently developed to restore catalytic performance. The regenerated pellets were tested under the same experimental conditions that had previously led to ignition failure. Their propulsive performance was then compared with both the degraded pellets and a new batch of equivalent catalysts. The results demonstrate that the regeneration process successfully restored the catalytic activity to levels comparable with the original state, enabling stable and efficient hybrid combustion. These findings confirm the role of surface oxidation in catalyst degradation and demonstrate that targeted chemical treatment can significantly extend catalyst lifetime. The proposed regeneration strategy offers a practical method to reduce costs of ground-based experimental campaigns and support the future deployment of hydrogen peroxide-based propulsion systems in space applications by providing insights into the mechanisms that can degrade the performance of palladium catalysts.