Closed Loop Energetics with VOC Emission Reduction (CLEVER)
WP-199704
Objectives of the Demonstration
The batch processing method currently used to produce nitramine propelling charges for Low Vulnerability Ammunition (LOVA) at the Indian Head Division of the Naval Surface Warfare Center utilizes Volatile Organic Compounds (VOC), which are released untreated into the atmosphere as hazardous emissions. This conventional method typically releases one pound of solvent per three pounds of propellant produced. The objective of this project was to demonstrate the ability of the Closed Loop Energetics with VOC Emission Reduction (CLEVER) process configuration to cost-effectively produce acceptable propellant while significantly reducing VOC hazardous waste emissions.
Technology Description
There are two sequential steps in the closed-loop CLEVER process. The first step, developed by the Nobel Chemicals branch of Bofors in Sweden, is a closed-loop process involving dissolution of energetic ingredients and plasticizers into ethyl acetate solvent, steam precipitation of the propellant powder, and evaporation of solvents for recovery and recycle. In the second step, the dried propellant powder is re-processed in a twin-screw extruder for final extrusion and cutting.
Demonstration Results
Two small lots of EX-99 propellant grains were produced for testing in the new Extended Range Guided Munitions (EGRM) round for the Navy 5-inch gun. The CLEVER process reduced VOC emissions by 47 percent and hazardous scrap solid waste propellant by 50 percent, while reducing labor and material costs by 41 percent. Propellant paste and grains passed all required tests for chemical composition, physical and mechanical stability, and safety. Both lots of propellant produced during the demonstration were also successfully gun-fired. Ballistic performance as measured by muzzle energy, chamber pressure, and velocity variation were outstanding, as good or better than any other test propellant produced to date.
Implementation Issues
The capital cost for a 250,000 pounds per year plant at Indian Head was estimated to be $11 million with a discounted payback period of 5.15 years. An additional benefit would be a reduced load on the Thermal Catalytic Incineration System (TCIS), which was mandated by regulators from the state of Maryland to destroy emissions from the existing process. The Navy has awarded contracts to implement the CLEVER process at Indian Head Division. The plant should be operational by fiscal year 2004.
Project Documents
Points of Contact
Principal Investigator
Ms. Valerie Plummer
Naval Surface Warfare Center
Phone: 301-744-1926
Fax: 301-744-4522
Project Documents
Document Types
- Fact Sheet - Brief project summary with links to related documents and points of contact.
- Final Report - Comprehensive report for every completed SERDP and ESTCP project that contains all technical results.
- Cost & Performance Report - Overview of ESTCP demonstration activities, results, and conclusions, standardized to facilitate implementation decisions.
- Technical Report - Additional interim reports, laboratory reports, demonstration reports, and technology survey reports.
- Guidance - Instructional information on technical topics such as protocols and user’s guides.
- Workshop Report - Summary of workshop discussion and findings.
- Multimedia - On demand videos, animations, and webcasts highlighting featured initiatives or technologies.
- Model/Software - Computer programs and applications available for download.
- Database - Digitally organized collection of data available to search and access.