Abstract: The present invention is directed to a process for continuous production of copper (I) nitrotetrazolate (DBX-1) by reacting aqueous copper salt with aqueous 5-nitrotetrazolate salt in the presence of a reducing agent. All the reactants are introduced into a continuous flow reactor system, which is composed of a temperature controlled tubular reactor and a mixer that allows for radial mixing. An optional stirred tank reactor may also be incorporated into the process to complete the reaction and allow for crystal growth.

Abstract: The present invention is directed to a method for preparing 5-nitrotetrazolate using a strongly acidic ionic cation exchange resin that has improve yields over prior art methods. The methods disclosed herein can be used either in a batch process or continuous flow reactor. In one exemplary process, starting material sodium 5-aminotetrazolate in solution is added into a reaction vessel containing a strongly acidic ionic cation exchange resin to facilitate production of 5-nitrotetrazolate. Multiple reactors containing resins may be connected in series to improve 5-nitrotetrazolate yields and purity levels.

Abstract: An improved system and method for using polyethylene glycol (PEG) as a processing fluid additive for safely and effectively treating water-wet hogout propellant as well as any other water-wet propellants, explosives and hazardous wastes (solids and liquids) to make them compatible with the MSO process. The method includes the step of applying liquid PEG to the hazardous waste to create a slurry or feedstock that when fed directly into the MSO reactor vessel prevents the occurrence of smelt-water explosions due to the accumulation of dangerous levels of sodium chloride, and/or sodium sulfide in the molten salt bath. The PEG possesses special qualities that make it ideal for this purpose. It is a low cost, low viscosity, commercially available, non-hazardous (per OSHA standards), water soluble, low toxicity chemical that burns cleanly leaving little or no residue.

Abstract: An improved system and method for using polyethylene glycol (PEG) as a processing fluid additive for safely and effectively treating water-wet hogout propellant as well as any other water-wet propellants, explosives and hazardous wastes (solids and liquids) to make them compatible with the MSO process. The method includes the step of applying liquid PEG to the hazardous waste to create a slurry or feedstock that when fed directly into the MSO reactor vessel prevents the occurrence of smelt-water explosions due to the accumulation of dangerous levels of sodium chloride, and/or sodium sulfide in the molten salt bath. The PEG possesses special qualities that make it ideal for this purpose. It is a low cost, low viscosity, commercially available, non-hazardous (per OSHA standards), water soluble, low toxicity chemical that burns cleanly leaving little or no residue.

Abstract: An apparatus and method for selectively draining melt material, such as molten salt, utilizes an unobstructed drain conduit detachably connected, as by screw threads, to a vessel containing the material. Two heaters are utilized for the conduit, a drain heater at the vessel and a plugging heater spaced from the vessel. The conduit is placed at the plugging heater and partially filled with a predetermined quantity of plugging material in flowable form. The plugging material is, typically, the same salt in particulate form and is retained in the conduit by any suitable closure. The plugging heater is energized to melt the plugging material and is then de-energized so that a solid plug of this material forms in the conduit. The conduit, including the plug, is removed from the closure and the plugging heater and is connected to the vessel when the drain heater is de-energized and when the vessel does not contain molten melt material, as when the vessel is empty or this material is solidified.