estcp 07 e - wp3 - 021 robert g. shortridge, sara k ...€¦ · clean-up at perchlorate...

Elimination of Perchlorate Oxidizers from Pyrotechnic Flare Compositions ESTCP 07 E - WP3 - 021

Robert G. Shortridge, Sara K. Poehlein and Christina M. Yamamoto, NSWC Crane

Problem• Widespread ground water contamination by perchlorates

• Potentially serious health problems (fetuses/newborns)

• DOD Perchlorate Policy mandates site clean-up at Perchlorate Concentration Action Level (Federal or State, whichever is more stringent)

• Proposed EPA/DOD Action Limit = 24.5 ppb

• Most stringent (Massachusetts) State Action Level = 2 ppb

• Other states likely to set intermediate Action Level (CA = 6 ppb, NJ = 5 ppb)

Started with a formulation, “New Red”

New Red scaled to “concept scale” (≤ 1000 gram batch size)

Several adjustments were made to the composition until New Red passed MPERC (Materials Processes and Equipment Review Committee).

Awaiting MPERC approval for prototype scale-up (≤ 5000 gram batch size).

At prototype scale New Red will undergo numerous tests and evaluations which it must pass to replace the Mk 124 standard in the field.

NSWC Crane has produced an environmentally safe and Warfighter friendly flare with improved luminous intensity and optimized burn time.

Technical Approach Design ProcessPrototype plan

Prototype FabricationMix/Press/Assemble unitsDesign Verification Test Plan

Prototype Test and EvalTecheval package

Final Configuration Build and TestEnvironment/Handling/Durability

Hazard Classification Test

Insensitive Munitions Test

Final WSESRB and DocumentationTest & Demil Plans/Final reports

Advantages of New Red Perchlorate-free FlareMSIS Product Improvement

• No perchlorate contamination• Longer burn time with great potential for burn time tailorability• Superior luminous intensity• Earlier laboratory scale studies under SERDP funding have shown similar success for perchlorate-free green and yellow signal flares as well as spectrally balanced decoy flares• Comparable cost to current item

Potential Commercial Applications for Perchlorate-freeRed Flare Compositions

• Distress flares for highway motorists - 20 - 40 million flares sold annually

• Red flares for commercial fireworks displays - 221 million pounds of fireworks consumed annually in U.S.

• Pyrotechnic scare and signal cartridges for outdoorsmen - Pen flares

�is is a Win/Win Situation with benefits for both the Warfighter and the Environment!

Harnessing the Power of Technology for the Warfighter

Sensitivity Level

Impact height (cm)

50% fire energy (Joule)

Friction (Foot-

pound)

Electrostatic (Joule)

Dangerous <10 <1.96 <30 <0.01

High <32 <6.272 <100 <1.0

Moderate <100 <19.6 <500 <10.0

Low <159 <31.164 <1000 <25.0

Very Low >1000 >25.0<50% fires at 159 cm/31.164 Joule

The following table represents the energy levels required to classify a material with respect to its sensitivity to various forms of external energy

input.

CLASSIFICATION CRITERIA

Sensitivity Testing

A:Distribution Statement Approved for Public Release; Distribution is Unlimited

New Red withHigh Binder

New Red will look like this in full-up configuration

Loose Composition Burn Test at NSWC Crane

Preparing Test Vessel Setting �e Ignition Pellet And Fuse ForIgnition Of New Red Loose Composition

Pouring New Red Loose CompositionOnto Ignition Pellet And Fuse

High Speed Photographs Taken During �e New Red Loose Composition Burn Test Of One Sample of 50 Grams

DivisionCraneNaval Surface Warfare Center

Performance Data(323 Candles Tested)

Electrostatic SensitivityMaximum No Fire

Height (cm) Energy (J) Average Lowest Energy (Joules)

RDX Class 5 - Standard 59.80 11.72 1146.77 890.20 No Response 0.125RSF-4, Lo Binder 172.98 33.90 402.21 33.24 80% Fired 0.151

RDX Class 5 - Standard 42.21 8.27 1239.71 95.70 10% Fired 0.125RSF-4, Med Binder 167.35 32.80 242.96 55.87 90% Fired 0.151

RDX Class 5 - Standard 57.98 11.37 1137.09 890.20 10% Fired 0.200RSF-4, Hi Binder 167.00 32.73 1049.68 179.63 40% Fired 0.180

RDX Class 5 - Standard 35.83 7.02 1150.78 997.11 No Response 0.125RSF-4, Hi Binder 172.98 33.90 1274.94 181.05 10% Fired 0.200RSF-4, Hi Binder 172.98 33.90 780.27 74.49 40% Fired 0.180

Red Standard 112.03 21.96 1277.66 29.67 20% Fired 0.180

Results of April 9, 2008

Results of October 25, 2007

Results of August 13, 2007

SampleImpact Sensitivity Friction Sensitivity

50% fire Energy (ft-lb)Response

• NSWC Crane to collaborate with Army Armament Research Development and Engineering Center (ARDEC) Perchlorate Replacement Team to provide a fast-burning variant of perchlorate-free New Red composition for use in Army Ground Illumination Signal

• Subsequent NSWC Crane/ARDEC collaboration to provide perchlorate-free New Green flare composition for use in Army Ground Illumination Signal

• Risk Reduction Approach using off the shelf ingredients

Future Navy/ArmyCollaborations

Description Candles CP Burn Time Dominant WL Color Purity What's Changed(#) (Candela) (s) (nm) (%)48 4913 17.45 617 94

STDEV ± 744.64 ± 0.637

10 5894.97 21.59 624 95STDEV ± 410.76 ± 0.566

12 5902.87 18.05 643 96STDEV ± 535.04 ± 0.397

10 7008.47 20.37 627 95

STDEV ± 1742.79 ± 0.803

11 8111.79 18.95 640 96

STDEV ± 1023.95 ± 0.633

11 7367.15 18.79 623 95STDEV ± 1403.70 ± 0.703

11 7030.79 20.95 624 95STDEV ± 1805.22 ± 1.078

10 6862.96 20.62 627 95STDEV ± 2401.83 ± 1.003

11 5569.65 22.54 624 96STDEV ± 851.33 ± 0.842

10 5412.65 22.55 613 96STDEV ± 226.55 ± 0.400

21 6410.37 22.13 614 96

STDEV ± 1748.96 ± 1.010

21 8063.62 20.07 614 95STDEV ± 2933.18 ± 1.270

8 8607.64 18.55 616 96STDEV ± 2838.81 ± 0.478

10 7918.6 18.44 616 96STDEV ± 2460.41 ± 0.774

9 9208.93 17.54 615 95STDEV ± 3536.33 ± 0.814

10 9289.17 17.42 618 96STDEV ± 3591.77 ± 0.753

8 7221.67 19.35 617 96STDEV ± 2306.01 ± 1.094

12 6040.06 19.83 621 96STDEV ± 653.90 ± 0.652

38 9991.34 17.38 617 95

STDEV ± 853.89 ± 0.498

21 11664.29 14.89 607 92

STDEV ± 517.57 ± 0.351

21 11206.77 16.07 608 92STDEV ± 501.64 ± 0.465

3rd

2nd

1st

1st High Friction Sensitivity, Performance Surpassed Spec

High Friction Sensitivity, Performance Surpassed Spec

Adjusted Dwell Time For Pressing

Chose 2 Dwell Times/Changed Process New Red Created

3rd

3rd

3rd

5th

4th

4th

3rd

3rd

5th

5th

5th

5th

Med Fuel/Oxidizer Med Binder/Hi PSI

6th

5th

5th

New Red With 24 Hour Pot Life

6th

All Red Standard

No Process Changes Were Made/1 Dwell Time

Red Standard We Based All Data On

Trials/ Attempts

Tried 1 Dwell Time/Changed Process 1st Lo Fuel/Oxidizer

Changed Process/Went Back to Two Dwell Times Checked Reproduciblity

Performance Data of Standard and New Red Replacement

New RedNo Process Changes Were

Made/1 Dwell Time


Hi Fuel/Oxidizer Med Binder/Avg PSI

Hi Fuel/Oxidizer Med Binder/Hi PSI



Hi Fuel/Oxidizer, Ultra Lo Binder/Avg PSI

Hi Fuel/Ox, Lo Binder/ Avg PSI

Hi Fuel/Ox, Lo Binder/ A Range of PSI

Med Fuel/Oxidizer Med Binder/Avg PSI


Ultra Hi Fuel/Oxidizer Med Binder/Avg PSI

Hi Fuel/Oxidizer Med Binder/Avg PSI

Ultra Hi Fuel/Oxidizer Med Binder/Hi PSI



Lo Fuel/Oxidizer Med Binder/Hi PSI

Lo Fuel/Oxidizer Med Binder/Avg PSI

Lo Fuel/Oxidizer Med Binder/Hi PSI


Hi Fuel/Oxidizer Med Binder/Hi PSI

Chose 2 Dwell Times/Changed Process New Red Created

Chose 2 Dwell Times/Changed ProcessCreated Ultra Hi

Chose 2 Dwell Times/Changed ProcessCreated Ultra Hi

Chose 2 Dwell Times/Changed ProcessCreated Hi

Chose 2 Dwell Times/Changed ProcessCreated Hi

Tried 1 Dwell Time/Changed Process Checked Reproduciblity




Control the SPECTRUM Control the FIGHT

estcp 07 e - wp3 - 021 robert g. shortridge, sara k ...€¦ · clean-up at perchlorate...

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