Abstract: Waste energetic compositions such as solid rocket propellant are treated to reclaim aluminum particles in a form in which they can be reused for the same purpose and to convert the hydrocarbon values of the binder to a useful oil product, by leaching out oxidizer, and heating the aluminum-filled binder in a non-oxidizing atmosphere. The resulting pyrolysis causes the evolution of the oil components as a vapor which is removed, condensed and collected for use as an oil having properties similar to those of diesel oil, leaving as a residue the aluminum particles in the same form in which they were used in the original preparation of the composition now being treated as waste.

Abstract: Waste solid energetic compositions such as waste solid rocket propellant are desensitized for purposes of disposal and burning by being combined with a diluent and a filler which lower the sensitivity, energy output and flame temperature of the compositions and improve their ability to burn in a controlled manner by increasing the burn time. The diluent is an oil with a viscosity of at least about 600 centipoise, and the filler is any of a variety of solid organic material, preferably agricultural waste or wood flour.

Abstract: A castable, thermoplastic composite rocket propellant comprising about 3 to 10 wt % of a thermoplastic elastomer, about 3 to 20 wt % of a plasticizer, balance energetic particulates is provided.Also provided is a process for producing a thermoplastic composite rocket propellant which comprises melt blending a thermoplastic elastomer and about 100 to 300 phr (parts by weight per 100 parts by weight of rubber (elastomer)) plasticizer, adding energetic particulates to the melt, with mixing, and casting the mixture in a suitable mold.