Adrian Berry  
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Burning Rubber

Cheap and Safe Rocket Fuel

It is interesting how phrases change their meanings over time. We now, for example, regard human history and world history (setting aside the geological connotations of the latter) as meaning the same thing.

But one day the two expressions will be interpreted in totally different ways. The story of man on Earth will one day be the merest footnote to the history of man spread across the galaxy. The space entrepreneur Burt Rutan has seen to that.

If a manned spaceship can fly, at least sub-orbitally, at a cost of only $20 million compared with $500 million for a shuttle mission, then space will soon be open to people of even moderate purse.


The most remarkable, and little-noticed, aspect of the first 2004 flight of SpaceShipOne, was the fuel. It was not liquid hydrogen, as in the space shuttles, but rubber. To be exact, it was polybutadiene, a component of the synthetic rubber from which squash balls are made. It can neither explode nor pollute and is wholly safe to handle.

A palm-sized slab of polybutadiene––as light as three ounces––has enough energy if burned in a combustion chamber to light a 100-watt light bulb for twelve hours.

Rubber-based fuel burned by liquid oxygen produces a hybrid engine which cannot cause a catastrophe like the explosion that blew up the space shuttle Challenger when halfway to orbit. Neither does it pollute the air as it rises. A typical space shuttle launch releases more than 230 tons of hydrogen chloride into the atmosphere. The hybrid motor produces none.

Its only truly regrettable drawback is that it cannot be obtained from the old motor tires that litter the countryside. For these, when burned, give off the unpleasant pollutant sulphur dioxide.

A hybrid rocket works quite differently from the solid or a liquid-fuelled variety that NASA uses. In the latter, the fuel and the oxidiser that makes it burn are mixed together and form a solid propellant ``grain'' inside the combustion chamber. This has led to frequent disasters when electrostatic discharges have caused explosions.

A liquid rocket stores its oxidiser and fuel––both as liquids––in separate tanks. If they come into contact before a controlled ignition they can explode.

But a hybrid motor, combining solid polybutadiene with liquid oxidiser, has no such drawbacks. It can be carried by lorry through city streets without risk, and non-essential workers do not need to be evacuated when it is being readied for launch.

A box of twelve squash balls typically costs about £15. A tankful of liquid hydrogen by contrast, together with the price of storing it and safely transporting it, must cost tens of millions. It would be difficult to imagine a rocket fuel so cheap and so versatile as rubber-based polybutadiene.

Whether future astronauts are likely to soar into orbit on columns of fire from burning rubber or from a lift made of buckyballs is still a matter of some debate.

But in either case, farewell to the platitude that space travel is so expensive that only governments can afford it. Before long, history will not be of one world but of many.

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