Ensuring High-Test Peroxide Propulsion Success: An Interview with Benchmark’s Chemistry Experts

Chemists Sammy Graham and Olivia Vaughn handling propellants in Benchmark's Lab

At Benchmark Space Systems, handling high-test peroxide (HTP) is critical to the development of safe and efficient propulsion systems. With the increasing demand for alternative propellants and sustainable space technologies, our team has gone above and beyond to address the challenges that come with hydrogen peroxide. In this interview, we speak with Benchmark’s chemistry experts—Samantha "Sammy" Graham, Head of Chemistry, and Olivia Vaughn, Propellant Chemist — who discuss their innovative approach to handling HTP and ensuring its storability, safety, and effectiveness in our systems.

Sammy, you have an extensive background in propulsion chemistry. What drew you to Benchmark, and how did you become interested in hydrogen peroxide (HTP)?

Sammy: I started my career as a propellant chemist and propulsion engineer in the UK working on research and development of various rocket propellants - toxic hypergolics and green propellants, including hydrogen peroxide. After many years working with hydrazine and nitrogen tetroxide (NTO), I wanted to focus on something that was both safer and that posed new and interesting chemistry challenges. Green propellants, like hydrogen peroxide, seemed to be the perfect fit. While the chemistry of hydrazine is well-understood, green propellant chemistry still poses a real intellectual challenge. When I found out about Benchmark, I was drawn to their focus on moving away from toxic propellants and the opportunity to work on something truly innovative and difficult! Since joining the team, I became a U.S. permanent resident which enabled me to work on ASCENT, a US-government developed Advanced Spacecraft Energetic Non-Toxic monopropellant. ASCENT comes with its own set of chemistry challenges, even more novel than hydrogen peroxide. I’m thrilled to be part of that process.

Olivia, your journey into propellant chemistry took a different route. Can you tell us about your experience?

Olivia: I worked in a lab specializing in organic synthesis in college and was incredibly interested in drug development. However, after some time in the pharmaceutical industry, I realized though I loved the hands-on side of my work, I also wanted to be more involved in the critical problem-solving side too. I became a Lab Instructor in the Chemistry Department at the University of Vermont, teaching labs in both general and organic chemistry. I loved drawing everything out and working through reactions in the lab with students in the same ways that my professors had with me, which helped me develop a deeper love and understanding of chemistry. I found a unique opportunity in propellant chemistry and took a leap into the field. At Benchmark, I've been able to apply my background in organic chemistry and interest in green chemistry to a completely different set of challenges, working with highly reactive chemicals like hydrogen peroxide or ASCENT. It's been a fascinating and fulfilling shift, especially in the context of developing safe, efficient, and green chemical propulsion systems.

Hydrogen peroxide is thought of as having limited storability. How does Benchmark address this challenge and ensure the storability of HTP?

Sammy: One of the biggest challenges with hydrogen peroxide is its decomposition. It decomposes slowly over time, and if it’s not kept under strict conditions, it can degrade much faster. The key to ensuring it stays stable is keeping it free from contamination. At Benchmark, we’ve developed processes to ensure that HTP remains clean and stored under controlled conditions. We’ve created Standard Operating Procedures (SOPs) that ensure we maintain scrupulous cleanliness at every step, from storage to production to test. This is critical because even a small amount of contamination can accelerate decomposition, causing major problems for space missions.

How does Benchmark ensure that everyone on the team maintains these high standards when handling HTP?

Olivia: It’s all about setting the right culture and practices. From day one, we ensure that new employees understand the importance of cleanliness and safety when handling HTP and other chemicals. As Sammy mentioned, it’s about being meticulous. Whether it’s wearing the right personal protective equipment (PPE) or following strict protocols for cleaning equipment, we lead by example. We reinforce these behaviors through training and ongoing education, but the real strength comes from having a strong team culture. It’s not just about documentation; it’s about everyone internalizing these practices and applying them every day.

You mentioned the importance of clean systems. How does Benchmark differentiate itself from other companies in this regard?

Sammy: Green propellant infrastructure does not have the same inherent controls that come naturally with toxic hypergols.  While the toxicity of HTP is less than that of hydrazine and NTO, it’s still dangerous and very sensitive to contamination. The processes required to keep it clean and stable are non-negotiable. At Benchmark, we’ve built cleanliness and contamination controls into every step of our production process. From our laboratory setup to our clean room systems, everything is designed to ensure that HTP remains pure and stable. It’s a level of discipline that other companies might not have built in yet, but it’s essential for the long-term success of green propellants. The flow of our building also makes it easy for our team to follow these procedures. We make it intuitive for everyone to stay disciplined.

How has Benchmark’s emphasis on cleanliness impacted the development of its propulsion systems?

Sammy: It’s had a huge impact. Not only have we been able to ensure that our peroxide remains stable, but we’ve also generated a substantial amount of data to support our processes. Over the past year, we’ve implemented rigorous testing procedures for peroxide acceptance. This has helped build trust in the quality of our propellant. We can now confidently say that our peroxide and systems are reliable and ready for use in space missions. This data has been critical in ensuring that other teams within the company trust the peroxide we’re using, and it gives our clients the confidence that they’re working with a product that’s been thoroughly tested. Our mission partners and customers trust us because we verify everything that comes into our building, including HTP, ensuring that it meets and maintains the highest standards before it’s used in production.

Olivia, can you tell us about some of the advanced testing methods Benchmark has access to due to your connection with the University of Vermont?

Olivia: The Agilent Laboratory for Chemical Analysis housed in the University of Vermont’s Chemistry Department has world-class testing equipment and experts in a variety of related fields conducting ongoing research. We collaborate on a variety of methods and unique challenges with these experts, while also getting to use incredibly precise instruments to conduct some of our testing. Some of the analysis performed includes evaluating the concentration of metallic ions in the propellant through inductively coupled plasma optical emission spectroscopy (ICP-OES). This helps us ensure that the peroxide is free of contamination that could affect stability. We also test for contamination that might arise in our thrusters. Our partnership allows us to conduct in-depth analysis quickly and efficiently, which is a huge advantage when troubleshooting or verifying the quality of our propellants.

How do you ensure that Benchmark's culture of safety and discipline is ingrained in new team members?

Sammy: It’s all about leading by example. I make sure that every time I step into the lab, I’m following the highest standards of safety, and I encourage others to do the same. We also have a robust onboarding process that emphasizes the importance of cleanliness and safety. I’m proud of how the entire team has embraced this mindset. It’s no longer just tribal knowledge—safety practices and cleanliness are ingrained in the entire company culture, and it’s exciting to see how new employees are quickly adopting these practices.

At Benchmark, our approach to handling hydrogen peroxide is just one example of how we push the boundaries of propulsion technology while ensuring the highest standards of safety and reliability. Through rigorous testing, meticulous procedures, and a culture of discipline, we are setting a new standard for green propulsion systems in the space industry.

Additional Resources:
-"There's No Need To Be So Toxic!"  Interview by The Downlink, A Defense & Aerospace Report Podcast featuring Sammy Graham  
-The Space Economy Will Thrive On Informed Choices At The Propellant Pump SatMagazine Feature
- Press Release: Benchmark Awarded $4.9M Air Force Research Lab Contract to Scale ASCENT-Fueled Thrusters For Government Missions