Rocket fuel mixture and method of manufacturing

Abstract

Rocket fuel mixtures and methods for manufacturing are described. The rocket fuel mixtures include coal nanoparticles, aluminum and / or aluminum oxide nanoparticles, and propellant particles. The rocket fuel mixtures are provided in the form of one of a powder, a gel, or an aqueous slurry and are configured for catalytic combustion during use.

Description

ANTONIJO LICITAR ET AL. FEBRUARY 3, 2026P5891 PC00ROCKET FUEL MIXTURE AND METHOD OF MANUFACTURING

[0001] The present application claims the benefit of US provisional patent application 63 / 753,662 filed on February 4th, 2025.BACKGROUND

[0002] Solid propellants have been used since the 13thcentury invention of gunpowder. Solid propellants were continually developed and were commonly used as a rocket fuel including in aerospace applications. Solid rocket fuels provide the benefits of a high propellant density and allow for easy storage and handling. Additionally, solid rocket fuels also require a simpler engine design as compared to liquid rocket fuels. However, solid rocket fuels also present problems in propellant efficiency and in controlled use. The solid fuels produce high levels of pollutants, have a low specific impulse, and are not able to be throttled once in use. As a result, liquid rocket fuels were developed to address the deficiencies in solid rocket fuels.

[0003] Liquid rocket fuels have a higher specific impulse than solid rocket fuels allowing for more efficient fuel use. Furthermore, the flow of the liquid fuel is controllable allowing for the throttling, shutting down, and restarting of the rocket engine. Liquid rocket fuels must be stored at a low temperature which allows for the use of the fuels as a coolant for the rocket engines. These advantages led to the widespread use of liquid rocket propellants, including liquid hydrogen and liquid methane, in main rocket engines. However, liquid rocket fuels are more reactive than solid rocket fuels. Liquid rocket fuels have a lower density than solid rocket fuels and require more storage space while increasing the mass of the rocket. Liquid fuels additionally may leak and require a more complex storage system and rocket engine to prevent this potential issue.

[0004] There exists a need for an improvement in rocket fuel technology to address the deficiencies in both solid rocket fuels and liquid rocket fuels.SUMMARY

[0005] In some aspects, the techniques described herein relate to a rocket fuel mixture including: coal nanoparticles having an average size of about 150 nm to about 900 nm; and aluminum-containing nanoparticles having an average size of about 150 nm to about 900 nm and including one or more of aluminum nanoparticles and aluminum oxide nanoparticles.

[0006] In some aspects, the techniques described herein relate to a rocket fuel mixture, wherein the rocket fuel mixture is one of an aqueous slurry or a gel.

[0007] In some aspects, the techniques described herein relate to a rocket fuel mixture, wherein the rocket fuel mixture has a pH level of about 8.0 to about 11.0.

[0008] In some aspects, the techniques described herein relate to a rocket fuel mixture, wherein the rocket fuel mixture includes at least one propellant oxidizer.

[0009] In some aspects, the techniques described herein relate to a rocket fuel mixture, wherein the propellant oxidizer includes silica.

[0010] In some aspects, the techniques described herein relate to a rocket fuel mixture, wherein the propellant oxidizer includes silica nanoparticles with an average size of about 150 nm to about 900 nm.

[0011] In some aspects, the techniques described herein relate to a rocket fuel mixture, wherein the propellant oxidizer is present from about 10 wt. % to about 50 wt. % of the mass of the rocket fuel mixture.

[0012] In some aspects, the techniques described herein relate to a rocket fuel mixture, wherein the propellant oxidizer and the aluminum-containing nanoparticles are present in the rocket fuel mixture a mass ratio of about 1:1.

[0013] In some aspects, the techniques described herein relate to a rocket fuel mixture, wherein the rocket fuel mixture includes aluminum flakes.

[0014] In some aspects, the techniques described herein relate to a rocket fuel mixture, wherein the coal nanoparticles and the aluminum-containing nanoparticles are present in a mass ratio of about 5:1 to about 1:5.

[0015] In some aspects, the techniques described herein relate to a method of manufacturing a rocket fuel mixture, the method including: providing an aqueous coal nanoparticle slurry including coal nanoparticles, wherein the coal nanoparticles have an average size of about 150 nm to about 900 nm; providing an aqueous aluminum nanoparticle slurry including aluminum-containing nanoparticles, wherein the aluminum-containing nanoparticles include one or more of aluminum nanoparticles and aluminum oxide nanoparticles, and have an average size of about 150 nm to about 900 nm; and mixing the aqueous coal nanoparticle slurry and the aqueous aluminum nanoparticle slurry to form a fuel mixture.

[0016] In some aspects, the techniques described herein relate to a method, wherein the fuel mixture is one of a gel or an aqueous slurry.

[0017] In some aspects, the techniques described herein relate to a method, wherein the fuel mixture has a pH level of about 8.0 to about 11.0.

[0018] In some aspects, the techniques described herein relate to a method further including providing a propellant oxidizer and mixing the propellant oxidizer into the fuel mixture.

[0019] In some aspects, the techniques described herein relate to a method, wherein the propellant oxidizer includes silica.

[0020] In some aspects, the techniques described herein relate to a method, wherein the propellant oxidizer includes silica nanoparticles with an average size of about 150 nm to about 900 nm.

[0021] In some aspects, the techniques described herein relate to a method, wherein the propellant oxidizer is present in the fuel mixture from about 10 wt. % to about 50 wt. % of the mass of the rocket fuel mixture.

[0022] In some aspects, the techniques described herein relate to a method, wherein the propellant oxidizer and the aluminum-containing nanoparticles are present in the fuel mixture in a mass ratio of about 1:1.

[0023] In some aspects, the techniques described herein relate to a method, further including providing aluminum flakes and mixing the aluminum flakes into the fuel mixture.

[0024] In some aspects, the techniques described herein relate to a method, wherein the coal nanoparticles and the aluminum-containing nanoparticles are present in the fuel mixture in a mass ratio of about 5:1 to about 1:5.BRIEF DESCRIPTION OF FIGURES

[0025] Figure 1 schematically illustrates an example of a method for manufacturing a rocket fuel.DETAILED DESCRIPTION

[0026] Embodiments are directed towards a rocket fuel mixture including coal nanoparticles and aluminum-containing nanoparticles. The use of the coal nanoparticles and aluminum-containing nanoparticles rocket fuel mixture provides catalytic combustion to reduce particle emissions as compared to traditional rocket fuels. In some embodiments, the rocket fuel mixture can be a gel, a powder, or an aqueous slurry. In some embodiments, the rocket fuel is a powder, and the rocket fuel is configured to be combined with water during combustion. The use of a gel rocket fuel mixture allows for the controlled ignition and shut down of combustion resulting in a more controlled use of the fuel. In some embodiments, the rocket fuel mixture may include at least one propellant oxidizer configured to enhance burning of the rocket fuel mixture and provide a source for oxygen. In some embodiments, the propellant oxidizer may include silica nanoparticles. In some embodiments, the rocket fuel mixture may include aluminum flakes. The use of coal nanoparticles and aluminum-containingnanoparticles provides a catalytic reaction to reduce the emissions of the rocket fuel. The catalytic reaction can be further controlled though the size distribution and shape of the nanoparticles. The increase in surface area provided by the use of coal, aluminum-containing, and silica nanoparticles increases both the oxidation the reaction speed during ignition increasing the propulsion of a rocket. Furthermore, the mixture of the coal nanoparticles and aluminum-containing nanoparticles in water allows for the control of the specific impulse and the rate of burning of the rocket fuel.

[0027] In some embodiments, the coal nanoparticles may have any average particle size effective for combustion as a rocket fuel. In some embodiments, the coal nanoparticles have an average particle size of about 1 nm, about 2 nm, about 3 nm, about 4 nm, about 5 nm, about 6 nm, about 7 nm, about 8 nm, about 9 nm, about 10 nm, about 15 nm, about 20 nm, about 25 nm, about 30 nm, about 35 nm, about 40 nm, about 45 nm, about 50 nm, about 100 nm, about 150 nm, about 200 nm, about 250 nm, about 300 nm, about 350 nm, about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, about 650 nm, about 700 nm, about 750 nm, about 800 nm, about 850 nm, about 900 nm, about 950 nm, about 1000 nm, or any value between any two of these values. In some embodiments, the coal nanoparticles have an average particle size of about 20 nm to about 900 nm, about 50 nm to about 600 nm, or about 100 nm to about 500 nm.

[0028] The coal nanoparticles may include any coal type. In some embodiments, the coal nanoparticles include one or more of anthracite coal, bituminous coal, subbituminous coal, or lignite. The coal nanoparticles may have any calorific value effective for combustion as a rocket fuel. In some embodiments, the calorific value of the coal nanoparticles is about 10.0 MJ / kg, about 10.5 MJ / kg, about 11.0 MJ / kg, about 11.5 MJ / kg, about 12.0 MJ / kg, about 12.5 MJ / kg, about 13.0 MJ / kg, about 13.5 MJ / kg, about 14.0 MJ / kg, about 14.5 MJ / kg, about 15.0 MJ / kg, about 15.5 MJ / kg, about 16.0 MJ / kg, about 16.5 MJ / kg, about 17.0 MJ / kg, about 17.5 MJ / kg, about 18.0 MJ / kg, about 18.5 MJ / kg, about 19.0 MJ / kg, about 19.5 MJ / kg, about 20.0 MJ / kg, about 20.5 MJ / kg, about 21.0 MJ / kg, about 21.5 MJ / kg, about 22.0 MJ / kg, about 22.5 MJ / kg, about 23.0 MJ / kg, about 23.5 MJ / kg, about 24.0 MJ / kg, about 24.5 MJ / kg, about 25.0 MJ / kg, about 25.5 MJ / kg, about 26.0 MJ / kg, about 26.5 MJ / kg, about 27.0 MJ / kg, about 27.5 MJ / kg, about 28.0 MJ / kg, about 28.5 MJ / kg, about 29.0 MJ / kg, about 29.5 MJ / kg, about 30.0 MJ / kg, about 30.5 MJ / kg, about 31.0 MJ / kg, about 31.5 MJ / kg, about 32.0 MJ / kg, about 32.5 MJ / kg, about 33.0 MJ / kg, about 33.5 MJ / kg, about 34.0 MJ / kg, about 34.5 MJ / kg, about 35.0 MJ / kg, or any value between any two of these values.

[0029] In some embodiments, the coal nanoparticles may comprise coal nanoparticles that have been activated by soaking in a flammable substance. In some embodiments, theflammable substance may comprise one or more of a liquid hydrocarbon-based fuel or an alcohol.

[0030] The aluminum nanoparticles may include any aluminum-containing material effective as a propellant for combustion. In some embodiments, the aluminum-containing nanoparticles include one or more of aluminum nanoparticles and aluminum oxide nanoparticles. The aluminum-containing nanoparticles may have any average particle size effective for a propellant for combustion. In some embodiments, the aluminum-containing nanoparticles have an average particle size of about 1 nm, about 2 nm, about 3 nm, about 4 nm, about 5 nm, about 6 nm, about 7 nm, about 8 nm, about 9 nm, about 10 nm, about 15 nm, about 20 nm, about 25 nm, about 30 nm, about 35 nm, about 40 nm, about 45 nm, about 50 nm, about 100 nm, about 150 nm, about 200 nm, about 250 nm, about 300 nm, about 350 nm, about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, about 650 nm, about 700 nm, about 750 nm, about 800 nm, about 850 nm, about 900 nm, about 950 nm, about 1000 nm, or any value between any two of these values. In some embodiments, the aluminum-containing nanoparticles have an average particle size of about 20 nm to about 900 nm, about 50 nm to about 600 nm, or about 100 nm to about 500 nm.

[0031] The rocket fuel mixture may have any mass ratio of coal nanoparticles and aluminum-containing nanoparticles effective for catalytic combustion. In some embodiments, the rocket fuel mixture has a mass ratio of coal nanoparticles to aluminum-containing nanoparticles of about 10:1, about 9: 1 , about 8: 1 , about 7:1, about 6: 1 , about 5: 1 , about 4:1 , about 3: 1 , about 2:1, about 1:1, about 1:2, about 1:3, about 1:3, about 1:5, about 1:6, about 1:7, about 1:8, about 1:9, about 1:10, or any value between any two of these values. In some embodiments, the rocket fuel mixture has a mass ratio of coal nanoparticles to aluminum-containing nanoparticles of about 5: 1 to about 1 :5 or about 3: 1 to about 1 :3.

[0032] In some embodiments, the rocket fuel mixture is one of a gel, a powder, or an aqueous slurry. In some embodiments, the rocket fuel mixture does not include a binder. In some embodiments, the rocket fuel mixture further includes water. In some embodiments, the water is alkaline. The rocket fuel mixture may include any amount of water effective for catalytic combustion. In some embodiments, the water is present in the rocket fuel mixture at about 5 wt. %, about 10 wt. %, about 15 wt. %, about 20 wt. %, about 25 wt. %, about 30 wt. %, about 35 wt. %, about 40 wt. %, about 45 wt. %, about 50 wt. %, about 55 wt. %, about 60 wt. %, about 65 wt. %, about 70 wt. %, about 75 wt. %, about 80 wt. %, about 85 wt. %, about 90 wt. %, about 95 wt. %, or any value between any two of these values.

[0033] The rocket fuel mixture may have any pH level effective for catalytic combustion. In some embodiments, the rocket fuel mixture is alkaline. In some embodiments, the rocket fuel mixture has a pH level of about 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3,8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, or any value between any two of these values. In some embodiments, the rocket fuel mixture has a pH level of about 8.0 to about 11.0 or about 9.0 to about 10.0.

[0034] In some embodiments, the rocket fuel mixture can include at least one propellant oxidizer configured to enhance burning of the rocket fuel mixture and provide a source for oxygen. The propellant oxidizer may be any material effective as an oxidizer known to one of skill in the art. In some embodiments, the propellant oxidizer can include one or more of silica, ammonium nitrate, liquid oxygen, N2O, KNO3, NH4CIO4, H2O2, MgO, CaO, and ammonium perchlorate. In some embodiments, the propellant oxidizer includes silica nanoparticles. The propellant oxidizer may be present in the rocket fuel mixture at any weight percent of the rocket fuel mixture. In some embodiments, the propellant oxidizer is present in the rocket fuel mixture at about 5 wt. %, about 10 wt. %, about 15 wt. %, about 20 wt. %, about 25 wt. %, about 30 wt. %, about 35 wt. %, about 40 wt. %, about 45 wt. %, about 50 wt. %, about 55 wt. %, about 60 wt. %, about 65 wt. %, about 70 wt. %, about 75 wt. %, about 80 wt. %, or any value between any two of these values. In some embodiments, the propellant oxidizer is present in the rocket fuel mixture at about 10 wt. % to about 50 wt. %.

[0035] The rocket fuel mixture may have any mass ratio of the propellant oxidizer and aluminum-containing nanoparticles effective for catalytic combustion. In some embodiments, the rocket fuel mixture can have a mass ratio of propellant oxidizer to aluminum-containing nanoparticles of about 10:1, about 9:1, about 8:1, about 7:1, about 6:1, about 5:1, about 4:1, about 3:1, about 2:1, about 1:1, about 1:2, about 1:3, about 1:3, about 1:5, about 1:6, about 1:7, about 1:8, about 1:9, about 1:10, or any value between any two of these values. In some embodiments, the rocket fuel mixture has a mass ratio of propellant oxidizer to aluminum-containing nanoparticles of about 5: 1 to about 1 :5 or about 3: 1 to about 1 :3.

[0036] The rocket fuel mixture may have any mass ratio of the propellant oxidizer and coal nanoparticles effective for catalytic combustion. In some embodiments, the rocket fuel mixture can have a mass ratio of propellant oxidizer to coal nanoparticles of about 10:1, about 9:1, about 8:1, about 7:1, about 6:1, about 5:1, about 4:1, about 3:1, about 2:1, about 1:1, about 1:2, about 1:3, about 1:3, about 1:5, about 1:6, about 1:7, about 1:8, about 1:9, about 1:10, or any value between any two of these values. In some embodiments, the rocket fuel mixture can have a mass ratio of propellant oxidizer to coal nanoparticles of about 5:1 to about 1 :5 or about 3:1 to about 1:3.

[0037] In some embodiments, the propellant oxidizer includes silica nanoparticles. The silica nanoparticles may have any average particle size effective for an oxidizer for combustion. In some embodiments, the silica nanoparticles have an average particle size of about 1 nm,about 2 nm, about 3 nm, about 4 nm, about 5 nm, about 6 nm, about 7 nm, about 8 nm, about 9 nm, about 10 nm, about 15 nm, about 20 nm, about25 nm, about 30 nm, about 35 nm, about 40 nm, about 45 nm, about 50 nm, about 100 nm, about 150 nm, about 200 nm, about 250 nm, about 300 nm, about 350 nm, about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, about 650 nm, about 700 nm, about 750 nm, about 800 nm, about 850 nm, about 900 nm, about 950 nm, about 1000 nm, or any value between any two of these values. In some embodiments, the silica nanoparticles have an average particle size of about 20 nm to about 900 nm, about 50 nm to about 600 nm, or about 100 nm to about 500 nm. In some embodiments, the average size of the silica nanoparticles is smaller than the average size of the coal nanoparticles. In some embodiments, the average size of the silica nanoparticles is smaller than the average size of the aluminum-containing nanoparticles.

[0038] In some embodiments, the rocket fuel mixture further includes aluminum flakes. The aluminum flakes may have any average particle size effective for a propellant for combustion. In some embodiments, the aluminum flakes have an average particle size of about 1 nm, about 2 nm, about 3 nm, about 4 nm, about 5 nm, about 6 nm, about 7 nm, about 8 nm, about 9 nm, about 10 nm, about 15 nm, about 20 nm, about25 nm, about 30 nm, about 35 nm, about 40 nm, about 45 nm, about 50 nm, about 100 nm, about 150 nm, about 200 nm, about 250 nm, about 300 nm, about 350 nm, about 400 nm, about 450 nm, about 500 nm, about 550 nm, about 600 nm, about 650 nm, about 700 nm, about 750 nm, about 800 nm, about 850 nm, about 900 nm, about 950 nm, about 1000 nm, about 1,100 nm, about 1,200 nm, about 1,300 nm, about 1,400 nm, about 1,500 nm, about 1,600 nm, about 1,700 nm, about 1,800 nm, about, 1 ,900 nm, about 2,000 nm, about 3.0 pm, about 3.5 pm, about 4.0 pm, about pm, about 4.5 pm, about 5.0 pm, about 5.5 pm, about 6.0 pm, about 6.5 pm, about 7.0 pm, about 7.5 pm, about 8.0 pm, about 8.5 pm, about 9.0 pm, about 9.5 pm, about 10.0 pm, about 15 pm, about 20 pm, about 25 pm, about 30 pm, about 35 pm, about 40 pm, about 45 pm, about 50 pm, about 55 pm, about 60 pm, about 65 pm, about 70 pm, about 75 pm, about 80 pm, about 85 pm, about 90 pm, about 95 pm, about 100 pm, about 150 pm, about 200 pm, about 250 pm, about 300 pm, about 350 pm, about 400 pm, about 450 pm, about 500 pm, or any value between any two of these values.

[0039] The aluminum flakes may be present in the rocket fuel mixture at any weight percent of the rocket fuel mixture. In some embodiments, the aluminum flakes are present in the rocket fuel mixture at about 5 wt. %, about 10 wt. %, about 15 wt. %, about 20 wt. %, about 25 wt. %, about 30 wt. %, about 35 wt. %, about 40 wt. %, about 45 wt. %, about 50 wt. %, or any value between any two of these values. In some embodiments, the aluminum flakes are present in the rocket fuel mixture at about 10 wt. % to about 25 wt. %.

[0040] The rocket fuel mixture may have any mass ratio of the aluminum flakes and aluminum-containing nanoparticles effective for catalytic combustion. In some embodiments, the rocket fuel mixture has a mass ratio of aluminum flakes to aluminum-containing nanoparticles of about 10:1, about 9: 1 , about 8:1 , about 7:1, about 6: 1 , about 5: 1 , about 4: 1 , about 3:1, about 2:1, about 1:1, about 1:2, about 1:3, about 1:3, about 1:5, about 1:6, about 1:7, about 1:8, about 1:9, about 1:10, or any value between any two of these values. In some embodiments, the rocket fuel mixture has a mass ratio of aluminum flakes to aluminum-containing nanoparticles of about 5: 1 to about 1 :5 or about 3: 1 to about 1 :3.

[0041] The rocket fuel mixture may have any mass ratio of the aluminum flakes and coal nanoparticles effective for catalytic combustion. In some embodiments, the rocket fuel mixture has a mass ratio of aluminum flakes to coal nanoparticles of about 10:1, about 9:1, about 8:1, about 7:1, about 6:1, about 5:1, about 4:1, about 3:1, about 2:1, about 1:1, about 1:2, about 1:3, about 1:3, about 1:5, about 1:6, about 1:7, about 1:8, about 1:9, about 1:10, or any value between any two of these values. In some embodiments, the rocket fuel mixture has a mass ratio of aluminum flakes to coal nanoparticles of about 5:1 to about 1:5 or about 3:1 to about 1:3.

[0042] Embodiments are directed towards a method of manufacturing a rocket fuel mixture including coal nanoparticles and aluminum containing nanoparticles. An example is illustrated in figure 1.

[0043] A method of manufacturing a rocket fuel includes, at block 100, providing an aqueous coal nanoparticle slurry including coal nanoparticles and providing., at block 120, an aqueous aluminum nanoparticle slurry including aluminum-containing nanoparticles. The method further includes, at block 130, mixing the aqueous coal nanoparticle slurry and the aqueous aluminum nanoparticle slurry to form a fuel mixture. The coal nanoparticles and the aluminum-containing nanoparticles contain similar properties as the components described above.

[0044] The aqueous coal nanoparticle slurry may include any weight percent of coal nanoparticles effective for combustion. In some embodiments, the coal nanoparticles are present in the aqueous coal nanoparticle slurry at about 5 wt. %, about 10 wt. %, about 15 wt. %, about 20 wt. %, about 25 wt. %, about 30 wt. %, about 35 wt. %, about 40 wt. %, about 45 wt. %, about 50 wt. %, about 55 wt. %, about 60 wt. %, about 65 wt. %, about 70 wt. %, about 75 wt. %, about 80 wt. %, about 85 wt. %, about 90 wt. %, about 95 wt. %, or any value between any two of these values.

[0045] The aqueous coal nanoparticle slurry may have any pH level effective for catalytic combustion. In some embodiments, the aqueous coal nanoparticle slurry is alkaline. In some embodiments, the aqueous coal nanoparticle slurry has a pH level of about 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4,9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, or any value between any two of these values. In some embodiments, the aqueous coal nanoparticle slurry has a pH level of about 8.0 to about 11.0 or about 9.0 to about 10.0.

[0046] The aqueous aluminum nanoparticle slurry may include any weight percent of aluminum-containing nanoparticles effective for combustion. In some embodiments, the aluminum-containing nanoparticles are present in the aqueous aluminum nanoparticle slurry at about 5 wt. %, about 10 wt. %, about 15 wt. %, about 20 wt. %, about 25 wt. %, about 30 wt. %, about 35 wt. %, about 40 wt. %, about 45 wt. %, about 50 wt. %, about 55 wt. %, about 60 wt. %, about 65 wt. %, about 70 wt. %, about 75 wt. %, about 80 wt. %, about 85 wt. %, about 90 wt. %, about 95 wt. %, or any value between any two of these values.

[0047] The method further includes mixing the aqueous coal nanoparticle slurry and the aqueous aluminum nanoparticle slurry to form a fuel mixture. The aqueous coal nanoparticle slurry and the aqueous aluminum nanoparticle slurry may be mixed with any mass ratio effective for a rocket fuel. In some embodiments, the aqueous coal nanoparticle slurry and the aqueous aluminum nanoparticle slurry are mixed with a ratio of coal nanoparticles to aluminum containing nanoparticles of about 10: 1 , about 9: 1 , about 8: 1 , about 7:1, about 6: 1 , about 5: 1 , about 4:1, about 3:1, about 2:1, about 1:1, about 1:2, about 1:3, about 1:3, about 1:5, about 1:6, about 1:7, about 1:8, about 1:9, about 1:10, or any value between any two of these values. In some embodiments, the aqueous coal nanoparticle slurry and the aqueous aluminum nanoparticle slurry are mixed with a ratio of coal nanoparticles to aluminum containing nanoparticles of about 5: 1 to about 1 :5 or about 3: 1 to about 1 :3.

[0048] In some embodiments, the method further includes providing a propellant oxidizer and mixing the propellant oxidizer into the fuel mixture. In some embodiments, the method further includes providing an aqueous propellant oxidizer slurry and mixing the aqueous propellant oxidizer slurry into the fuel mixture. The propellant oxidizer contains similar properties as the propellant oxidizers described above.

[0049] The propellant oxidizer may be mixed into the fuel mixture at any weight percent of the fuel mixture. In some embodiments, the propellant oxidizer is mixed into the fuel mixture at about 5 wt. %, about 10 wt. %, about 15 wt. %, about 20 wt. %, about 25 wt. %, about 30 wt. %, about 35 wt. %, about 40 wt. %, about 45 wt. %, about 50 wt. %, about 55 wt. %, about 60 wt. %, about 65 wt. %, about 70 wt. %, about 75 wt. %, about 80 wt. %, or any value between any two of these values. In some embodiments, the propellant oxidizer mixed into the fuel mixture at about 10 wt. % to about 50 wt. %.

[0050] In some embodiments, the propellant oxidizer is mixed into the fuel mixture as an aqueous propellant oxidizer slurry. The propellant oxidizer slurry may have any pH leveleffective for catalytic combustion. In some embodiments, the aqueous propellant oxidizer slurry is alkaline. In some embodiments, the aqueous propellant oxidizer slurry has a pH level of about 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, or any value between any two of these values. In some embodiments, the aqueous propellant oxidizer slurry has a pH level of about 8.0 to about 11.0 or about 9.0 to about 10.0.

[0051] In some embodiments, the method further includes providing aluminum flakes and mixing the aluminum flakes into the fuel mixture. In some embodiments, the method further includes providing an aqueous aluminum flake slurry and mixing the aqueous aluminum flake slurry into the fuel mixture. The aluminum flakes contain similar properties as the aluminum flakes described above.

[0052] The aluminum flakes may be mixed into the fuel mixture at any weight percent of the rocket fuel mixture. In some embodiments, the aluminum flakes are mixed into the fuel mixture at about 5 wt. %, about 10 wt. %, about 15 wt. %, about 20 wt. %, about 25 wt. %, about 30 wt. %, about 35 wt. %, about 40 wt. %, about 45 wt. %, about 50 wt. %, or any value between any two of these values. In some embodiments, the aluminum flakes are mixed into the fuel mixture at about 10 wt. % to about 25 wt. %.

[0053] In some embodiments, the method further includes purifying the coal nanoparticles prior to mixing 102 the coal nanoparticle slurry and the aluminum-containing slurry. In some embodiments, purifying the coal nanoparticles includes removing impurities from the coal. In some embodiments, purifying the coal includes chemically washing the coal. In some embodiments, purifying the coal comprises one or more of deep eutectic solvent leaching, ultrasonic-assisted cleaning, microbial desulfurization, hydrogen plasma treating.

[0054] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds, compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0055] It is to be understood that this invention is not limited to the particular processes, compositions, or methodologies described, as these may vary. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope of the present invention, which will be limited only by the appended claims. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred methods, devices, and materials are now described. All publications mentioned herein are incorporated by reference in their entirety. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention.

[0056] It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a sandwich composite panel” is a reference to “one or more sandwich composite panels” and equivalents thereof known to those skilled in the art, and so forth.

[0057] As used herein, the term “about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50% means in the range of 45%-55%.

[0058] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity.

[0059] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (for example, bodies of the appended claims) are generally intended as “open” terms (for example, the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” et cetera). While various compositions, methods, and devices are described in terms of “comprising” various components or steps (interpreted as meaning “including, but not limited to”), the compositions, methods, and devices can also “consist essentially of” or “consist of” the various components and steps, and such terminology should be interpreted as defining essentially closed-member groups. It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present.

[0060] For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (for example, “a” and / or “an” should be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations.

[0061] In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (for example, the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, et cetera” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, et cetera). In those instances where a convention analogous to “at least one of A, B, or C, et cetera” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, et cetera). It will be further understood by those within the art that virtually any disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

[0062] In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0063] As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, et cetera. As a non-limiting example, eachrange discussed herein can be readily broken down into a lower third, middle third and upper third, et cetera. As will also be understood by one skilled in the art all language such as “up to,” “at least,” and the like include the number recited and refer to ranges that can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a group having 1-3 cells refers to groups having 1, 2, or 3 cells. Similarly, a group having 1-5 cells refers to groups having 1, 2, 3, 4, or 5 cells, and so forth.

[0064] Various of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.

Claims

CLAIMS1. A rocket fuel mixture comprising:coal nanoparticles having an average size of about 20 nm to about 900 nm; and aluminum-containing nanoparticles having an average size of about 20 nm to about 900 nm and comprising one or more of aluminum nanoparticles and aluminum oxide nanoparticles.

2. The rocket fuel mixture of claim 1 , wherein the rocket fuel mixture is one of an aqueous slurry or a gel.

3. The rocket fuel mixture of claim 1 or 2, wherein the rocket fuel mixture has a pH level of about 8.0 to about 11.0.

4. The rocket fuel mixture of any of claims 1 - 3, wherein the rocket fuel mixture comprises at least one propellant oxidizer.

5. The rocket fuel mixture of claim 4, wherein the propellant oxidizer comprises silica.

6. The rocket fuel mixture of claim 5, wherein the propellant oxidizer comprises silica nanoparticles with an average size of about 20 nm to about 900 nm.

7. The rocket fuel mixture of any of claims 4 - 6, wherein the propellant oxidizer is present from about 10 wt. % to about 50 wt. % of the mass of the rocket fuel mixture.

8. The rocket fuel mixture of any of claims 4 - 7, wherein the propellant oxidizer and the aluminum-containing nanoparticles are present in the rocket fuel mixture a mass ratio of about 1:1.

9. The rocket fuel mixture of any of claims 1 - 8, wherein the rocket fuel mixture comprises aluminum flakes.

10. The rocket fuel mixture of any of claims 1 - 9, wherein the coal nanoparticles and the aluminum-containing nanoparticles are present in a mass ratio of about 5:1 to about 1:5.

11. A method of manufacturing a rocket fuel mixture, the method comprising:providing an aqueous coal nanoparticle slurry comprising coal nanoparticles, wherein the coal nanoparticles have an average size of about 20 nm to about 900 nm;providing an aqueous aluminum nanoparticle slurry comprising aluminum-containing nanoparticles, wherein the aluminum-containing nanoparticles comprise one or more of aluminum nanoparticles and aluminum oxide nanoparticles, and have an average size of about 20 nm to about 900 nm; andmixing the aqueous coal nanoparticle slurry and the aqueous aluminum nanoparticle slurry to form a fuel mixture.

12. The method of claim 11 , wherein the fuel mixture is one of a gel or an aqueous slurry.

13. The method of claim 11 or 12, wherein the fuel mixture has a pH level of about 8.0 to about 11.0.

14. The method of any of claims 11 - 13 further comprising providing a propellant oxidizer and mixing the propellant oxidizer into the fuel mixture.

15. The method of claim 14, wherein the propellant oxidizer comprises silica.

16. The method of claim 15, wherein the propellant oxidizer comprises silica nanoparticles with an average size of about 20 nm to about 900 nm.

17. The method of any of claims 14 - 16, wherein the propellant oxidizer is present in the fuel mixture from about 10 wt. % to about 50 wt. % of the mass of the rocket fuel mixture.

18. The method of any of claims 14 - 17, wherein the propellant oxidizer and the aluminum-containing nanoparticles are present in the fuel mixture in a mass ratio of about 1:1.

19. The method of any of claims 11 - 18, further comprising providing aluminum flakes and mixing the aluminum flakes into the fuel mixture.

20. The method of any of claims 11 - 19, wherein the coal nanoparticles and the aluminum-containing nanoparticles are present in the fuel mixture in a mass ratio of about 5:1 to about 1:5.

Images