Abstract: Slurry and spray dried azide-based gas generant intermediates are made having a hydrazoic acid content of less than about 3.times.10 EXP(-3) M/L, a pH of greater than 8.0 up to about 12.5, and impurity metal ions Ca, Mg, Pb, Fe, Mn and Cu, each below about 25 ppm. These intermediates are made by slurrying powdered ingredients of the azide and oxidizer/reactant in water, wet grinding the slurry and spray drying to form a particulate material which is molded into pellets or tablets which are useful as the gas generant in vehicle crash bags or inflators. The basicity of the water is adjusted to a pH of greater than 8.0 up to about 12.5, preferably about 10, by the addition of a base, such as NaOH, followed by the addition of such solid ingredients as S, MoS.sub.2 and NaN.sub.3, and preferably the NaN.sub.3 is added last, whereby hydrazoic acid production is minimized. The contaminant Ca and Mg ions are minimized by softening the water supplied.

Abstract: Multiple processes and apparatuses for improving the prior system of making gas generant pellets or tablets made of sodium azide, molybdenum disulfide and sulfur wherein powdered ingredients thereof are slurried in water, subjected to wet grinding, spray dried to a powdered material which is molded into pellets or tablets which find use in vehicle crash bags or inflators.The first improvement to the old process and apparatus involves adjusting the basicity of the water to a pH of greater than 8.0 up to about 12.5 via the addition of sodium hydroxide, followed by the addition of sulfur and molybdenum disulfide and finally the sodium azide whereby azide addition is made to a basic mixture of the other ingredients thereby keeping hydrazoic acid concentration levels below about 3.times.10EXP(-3) moles per liter.

Abstract: Multiple processes and apparatuses for improving the prior system of making gas generant pellets or tablets made of sodium azide, molybdenum disulfide and sulfur wherein powdered ingredients thereof are slurried in water, subjected to wet grinding, spray dried to a powdered material which is molded into pellets or tablets which find use in vehicle crash bags or inflators.The first improvement to the old process and apparatus involves adjusting the basicity of the water to a pH of greater than 8.0 up to about 12.5 via the addition of sodium hydroxide, followed by the addition of sulfur and molybdenum disulfide and finally the sodium azide whereby azide addition is made to a basic mixture of the other ingredients thereby keeping hydrazoic acid concentration levels below about 3.times.10EXP(-3) moles per liter.