RDECOM ALR Program Lead-Free, DBX-1 Projects Neha Mehta Oct 2016 - PowerPoint PPT Presentation

Unclassified RDECOM ALR Program Lead-Free, DBX-1 Projects Neha Mehta Oct 2016 Distribution A: Approved for Public Release. Distribution is Unlimited. 1

Unclassified Airborne Lead Reduction IPR Qualification of Green Primary Explosive, DBX-1 (ALR 14-01) 08/30/2016 Neha Mehta Technical Lead, Chemical Engineer Explosives Development Branch 973-724-2912 neha.mehta.civ@mail.mil Distribution A: Approved for Public Release. Distribution is Unlimited.

Unclassified-Distribution A Qualification of Green Primary Explosive, DBX-1 (ALR 14-01) Project Description  ARDEC will qualify Copper (I) 5- Nitrotetrazolate (DBX-1) at 500-gram scale to Army performance requirements  Replace lead azide and lead styphnate in detonators, some primers, blasting caps, etc. (studies already completed at lab scale)  Produce and qualify green NOL-130 (stab mix) for detonators 25mm Round M115 Primer  Transition to field through SWO-10 Requirement/Impact Progress Report  Key dates  Addresses AERTA PP-12-09-02 by qualifying  Endorsement signed by PEO-AMMO: 3Q-FY13 a lead-free primary explosive for Army use  TTA signed by PM-CCS: 4Q-FY16  Until DBX-1 is qualified, there are no Army  End/transition point: 3Q-FY16  Recent accomplishments/issues qualified primary explosive alternatives to lead  12 month aging completed based compounds in detonators, primers, etc.  All results compare to PSEMC batch  NAS study on lead exposure on firing ranges  Working on final qualification report finds current occupational exposure level in not protective of soldiers/workers on ranges. Distribution A: Approved for Public Release. Distribution is Unlimited 3

Unclassified-Distribution A Project Description (ALR-14-01)  What is the intended end product?  Qualify DBX-1 as an Army primary explosive as a replacement of lead azide, lead styphnate and DXN-1  Established process to make more environmentally sustainable stab mix qualified for use in the Army  Transition upon approval by Army Energetic Material Qualification (EMQ) Board, incorporate DBX-1 into SWO-10  What is the technical approach?  Perform testing according to Army EMQ matrix with 12 months aging  PSEMC produce 5-100 grams batches of DBX-1 blended to one lot  Load M55 Detonators with DBX-1 as transfer charge and green stab mix at DZI  Complete First Article Testing  DBX-1 not currently qualified to Army requirements  PHC completed Toxicology Assessment of DBX-1 (leverage ESTCP)  What specific weapon system applications will the product transition to?  Stab detonators (M55, M98, M61)  Primers (#41, M42, M115)  Blasting Caps (M6, M7, M11)  APOBS  Hand Grenade Fuze Detonator Distribution A: Approved for Public Release. Distribution is Unlimited 4

Unclassified-Distribution A Requirement/Impact (ALR-14-01)  What performance, regulatory and other drivers is the project addressing?  Addresses AERTA PP-12-09-02 by qualifying a lead-free primary explosive for Army use  Revision to lead NAAQS for airborne lead  NAS study on lead exposure on firing ranges finds current occupational exposure level is not protective of soldiers/workers on ranges  What are the impacts and benefits of the project?  ESOH: Reduce lead from the environment and lead exposure for soldiers/workers in potentially 1000s of items  Economic: Title III Defense Production Act (OSD) office is investing in producing DBX-1 at larger scale, work will start FY16 onwards. Once qualification is complete, material produced through the Title III effort will be used to test in items. Anticipate production costs same as lead azide ($700/lb); reduction in cost of more than 50%.  Scientific: Industry has approved use of DBX-1 but not yet approved to Army requirements. Lead-free primers in industry do not meet Army performance requirements.  Other: Potential range restrictions if firing ranges are not compliant with occupational exposure levels or if occupational exposure level are reduced. Distribution A: Approved for Public Release. Distribution is Unlimited 5

Unclassified Airborne Lead Reduction IPR Continuous Process to Produce NaNT/DBX-1 (ALR 13-02) 08/30/2016 Neha Mehta Andrew Pearsall/Jerry Salan Technical Lead, Chemical Engineer Nalas Engineering Explosives Development Branch 973-724-2912 neha.mehta.civ@mail.mil Distribution A: Approved for Public Release. Distribution is Unlimited.

Unclassified-Distribution A Continuous Process to Produce NaNT/DBX-1 (ALR 13-02) Project Description NaNT Manufacture  ARDEC/Nalas Engineering will develop one- pot, high yielding, safe process to produce NaNT (for production of DBX-1)  Develop kinetic model for the synthesis of NaNT (Nalas Engineering) to understand the reaction kinetics to determine process variables that avoid hazardous conditions and impurities  From one-pot process directly convert the crude NaNT solution to make DBX-1 Lean Process to Produce NaNT/DBX-1  Transition process specification to manufacturer Requirement/Impact Progress Report  Key dates  Addresses AERTA PP-12-09-02 by  Endorsement signed by PEO-AMMO: 3Q-FY13 developing a large-scale production process  TTA signed by PM-CCS: 4Q-FY16 for a lead-free primary explosive: DBX-1  End/transition point: 1Q-FY17  Recent accomplishments/issues  Current production processes can not meet  Nalas Engineering received and installed the 5- Army production requirements. Continuous L reactor with the sampling system – Dec 2014 process will increase throughput and reduce  Produced 3 batches of NaNT successfully worker exposure to sensitive materials.  DBX-1 produced successfully from NaNT  DBX-1 could be used in 1000s of systems  Design and Testing of 20-L reactor completed  2 out of 3 batch produced and were successful Distribution A: Approved for Public Release. Distribution is Unlimited 7

Unclassified-Distribution A Project Description (ALR-13-02)  What is the intended end product?  Develop a one-pot, high yield and safe process to make NaNT and integrate the process to produce DBX-1  Process specification will be transitioned to proposed manufacturer  What is the technical approach?  The current synthetic process for NaNT can not be scaled further since there are issues with unsafe micro-detonations during the process and also requires further purification through a controlled laboratory titration  Design a remote, scalable process that produces high quality NaNT  Fabricate a 20L reactor suitable for “one - pot” NaNT process  Demonstrate that NaNT produced is suitable for DBX-1 process  What specific weapon system applications will the product transition to?  1000s of items use lead based primary explosives  Stab detonators (M55, M98, M61)  Primers (#41, M42, M115)  Blasting Caps (M6, M7, M11) Distribution A: Approved for Public Release. Distribution is Unlimited 8

Unclassified-Distribution A Requirement/Impact (ALR 13-02)  What performance, regulatory and other drivers is the project addressing?  Addresses AERTA PP-12-09-02 by developing a large-scale production process for a lead-free primary explosive: DBX-1  Need a scalable, safe process to make NaNT, as it is the precursor for DBX-1  NAS study on lead exposure on firing ranges finds current occupational exposure level is not protective of soldiers/workers on ranges  What are the impacts and benefits of the project?  ESOH: Reduce lead from the environment and lead exposure for soldiers/workers. Using DBX-1 as LA replacement, DoD will save cost and simultaneously be in compliance with executive orders requiring the replacement of toxic materials. It will also enable DoD to reduce lead exposure on firing ranges and shoot houses.  Economic: Eliminated ~30% labor (e.g. titration, isolating NaNT solids) and ~25% material costs (e.g. titration, waste). Eliminated NaNT solution storage costs (e.g. just in time manufacturing).  Title III OSD office is investing in producing DBX-1 at larger scale, work will start FY17 onwards. This would benefit to have a one-pot process and not delay in the production. This will bring cost of DBX-1 to same or lower than lead azide, $700/lb.  Scientific: This process consists of fewer steps and is a continuous and one pot process instead of tedious unsafe process initially developed.  Other: The current process has challenges with unsafe micro-detonations during the process and requires further purification to afford DBX-1. Need a high yield one pot process to make NaNT. This will reduce worker exposure to material as the current process requires manual separation. Distribution A: Approved for Public Release. Distribution is Unlimited 9

Unclassified Airborne Lead Reduction IPR DBX-1 Particle Size Characterization (ALR 15-01) 08/30/2016 Jerry Salan David Ford Neha Mehta Daving Piercey Technical Lead, Chemical Engineer Nalas Engineering Explosives Development Branch 973-724-2912 neha.mehta.civ@mail.mil Distribution A: Approved for Public Release. Distribution is Unlimited.