Abstract
ICI Explosives has recently developed a number of novel manufacturing processes for energetic materials. These processes were highly successful in improving manufacturing efficiency, mixing efficiency, product quality and control, safety and environmental friendliness. The propellants and pyrotechnics produced by these processes have enhanced reaction rates and improved completeness of reaction as a result of the highly efficient mixing in the micron and submicron levels. The MicrosafTM Process is ICI's second generation sodium azide propellant technology. The active ingredients are either completely dissolved or mixed in water which allows the use of extremely fine insoluble ingredients. A free flowing powder with excellent product quality is produced by a spray drying process. All reject materials are entirely recyclable. The Freeze-Dry technology uses a fast freezing and vacuum freeze dry process to produce a flowable powder consisting of extremely fine crystals for the dissolved ingredients. The EnerfoilTM Process uses physical vapour deposition technology to coat magnesium on PTFE film. The EnerfoilTM film thus produced possesses unique properties of fast and controlled reaction, enhanced handling safety and ease of conversion to desirable shape for use in many applications such as ignition enhancer and hybrid inflator heating system for airbag inflators.
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