new explosive ingredients and compositions for the im m795 … · 2017. 5. 19. · explosive...
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Explosive Ingredients and Compositions for the IM M795 Artillery Ammunition
Joint U S Army & U S Marine Corps
Andrew WilsonBAE Systems Ordnance Systems Inc.Holston Army Ammunition PlantKingsport, TN
NDIA IMEMTSMiami, FL
15-18 October 2007
Common Low-cost IM Explosive Program to Replace TNT
slide 2ITAR Approved
Briefing Outline
Background and Introduction to IMX-101, -102 and -103Manufacturing Overview
Non-traditional Ingredients• Large Scale Manufacture
– DNAN, NTO• Lab Scale Manufacture
– Nitrate Salt EutecticCompositions
• Large Scale Manufacture -
IMX-101, IMX-102• Lab Scale –
IMX-103Strategic Supply Capability
Current CapacityPricing and Availability
slide 3ITAR Approved
Background and Introduction
PM-CAS Common Low-cost IM Explosives ProgramSeeking IM Explosives that are:
EffectiveLess sensitiveAffordableProducibleLife-cycle compliant
Phased Evaluation ProgramLed to 3 Primary Candidates
IMX-101, -102 and -103Undergoing Qualification Testing (Phase 3)Formulations & Ingredients:
slide 4ITAR Approved
FormulationsLargely composed of “non-traditional” ingredients:
Formulation AKA Non-traditional Ingredient(s)
IMX-101 OSX-CAN DNAN, NTO
IMX-102 MCX-8 NTO
IMX-103 DEMN-III J Nitrate Salt Eutectic
Eutectic
slide 5ITAR Approved
Pass / Fail
UtilityLife-cycle CostsRisk Analysis
Filter 1 -- Safety & Performance
Filter 2 -- Insensitive Munitions
Business Case Analysis (BCA)
Filter 1 CriteriaCheetah CalculationsStandard Safety TestsElectrostaticFriction Impact SensitivityVacuum Thermal StabilityDifferential scanningCritical Diameter
Filter 2 CriteriaTier 1 IM Tests (BI, FI, SCO)Tier 2 IM Tests (SD)Tier 3 IM Tests (FCO, SCJI)
BCA CriteriaIM Tests, Lethality,Logistics, Safety, PlatformPerformance of the alternatives against weighted factorsRisk analysisComparable cost analysisSensitivity Analysis
IM Explosive Fillfor 120mm
and/or 155mm Arena Test & QualificationArena Test & Qualification
Must Show Improvement
Review of Business Case of Down-selected Candidates
“Funnel” framework to progressively screen candidatesMunitions Fill Types
Focus on Ingredient and Composition Producibility
slide 6ITAR Approved
Manufacturing Producibility Non-Traditional Ingredients
Cost of ingredients:• DNAN• NTO• Nitrate salts
Strategic Synthesis Capability• Current, active manufacturing capacity at HSAAP (as of 2007)• Ingredients synthesized in the HSAAP Agile Plant
– Combined DNAN/NTO capacity is ≈2-3m LB / year» Using existing facilities and infrastructure
slide 7ITAR Approved
Agile Plant Manufacture Overview
Reported at Prior IM EM ConferencesEstablished in CY2001
2,000 Gallon Reactor at Heart of FacilityInstalled in a facility designed to be flexible in operation
• Rapidly reconfigurable• Multi-purpose chemistry capability• Extensive infrastructure support• Expandable
Presently used for the LARGE SCALE manufacture of:DNANNTODMDNBSpecial grades of PETN, RDXTATBR8002 (short-term future production)
slide 8ITAR Approved
Pfaudler 2,000 Gallon Reactor
Product Collection: Nutsche De-watering
Process Control – SIEMENS PCS-7
slide 9ITAR Approved
Batch-ManufactureA Good Melt-phase Insensitive Substitute for TNT
A critical component of IMX-101Two Synthetic Routes Demonstrated on Production ScaleMultiple raw-material sources (U.S., international)Qualified in U.S. Weapon Systems
PAX-21 (60mm Mortar)PAX-41 (SPIDER)
2,4-Dinitro anisole (DNAN)
slide 10ITAR Approved
40
18
96.25 5.8 4.7 4.4 4.1
0
5
10
15
20
25
30
35
40
$ / LB
0-4k 5k-20k
21k-40k
41k-185k
186k-370k
371k-1m
1-1.5m
>1.5m
Quantity (LB)
HSAAP DNAN –
INDICATIVE PRICING
Single-shift Batch Operation
24/5 to 24/7 Continuous Operation
Single-shift Multi-batch Operation
Note: Prices subject to formal RFQ review.
slide 11ITAR Approved
Nitrotriazolone (NTO)
Batch ManufactureSynthesis based upon published routeModified to improve safety and productivityMultiple raw-ingredient sources
Used as an insensitive RDX ReplacementCritical for achievement of adequate product functioning
• Performance and sensitivityAvailable in various particle sizes
• Key to achieving desired processability
slide 12ITAR Approved
80
68
49
37
22 19 17 15 13.5 12
0
10
20
30
40
50
60
70
80
$ / LB
0-50 50-100
100-500
500-1k
1-50k 50-100k
100-500k
500-1M
>1M >1.5M
Quantity (LB)
HSAAP NTO –
INDICATIVE PRICING
Note: NTO pricing is influenced by a key raw-ingredient index, linked to oil prices. Prices subject to formal RFQ review.
Single-shift Batch Operation
24/5 to 24/7 Continuous Operation
Single-shift Multi-batch Operation
slide 13ITAR Approved
Nitrate Salt Eutectic
Manufactured on Lab-Scale only to DateElegant Salt Manufacturing Method
Water-based synthesisAcid-base neutralization
Robust Salt EutecticInsensitive to composition variation (+/-2% tested)
slide 14ITAR Approved
Melt-Pour Explosive Manufacture
Traditional Melt-Pour TechnologyMelt-phase ingredient (TNT, DNAN, Wax etc.)Fillers (RDX, NTO, etc.)Low-shear incorporationFlaking Quality control / assurance, final packaging
Industrial CapacityCurrent active capacity: 6m LB / year
• Surge capacity >25m LB / year
Life-cycle ManagementIMX-101, -102 and -103 are melt-pour explosivesExisting Demil technology base applies to IMX products
Test Quantities of IMX-101 and IMX-102 Manufactured on FULL PRODUCTION SCALE at HSAAP in support of PM- CAS Common Explosive Program (1,500 LB nominal batch size)
slide 15ITAR Approved
Concluding Remarks
IMX-101, -102 and -103 Candidates for 155mm Artillery Projectile
Contain “non-traditional” ingredients• NTO, and/or DNAN, or nitrate-salt eutectic
NTO and DNAN produced on full production scaleNitrate-salt eutectic producible on same scale (not yet demonstrated)Raw ingredients available CONUS and OCONUSIMX-101 and -102 Manufactured on full production scale
Demonstrated IM ComplianceResults far exceeded expectations
Safe, Suitable & Sustainable
slide 16ITAR Approved
AcknowledgementsARL
ARDEC
BAE Systems
PM-CAS
DZI (Kansas)
NTS
slide 17ITAR Approved
Briefing Session Summary
Common Low-cost IM Explosive Program – Jim Rutkowski, PM CAS
The Characterization of IM Explosive Candidates for TNT Replacement
Manufacture of Explosive Ingredients and Compositions for the IMM795 Artillery Ammunition – Andrew Wilson, BAE Holston OSI
The Application of New IM Explosive Candidates in the M795 Projectile – Sanjeev Singh, US Army ARDEC
IM HE Loading of 155 mm Projectiles – Erik Boykin, US Army ARDEC
Less Sensitive and Meets Less Sensitive and Meets Performance RequirementsPerformance Requirements
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