(467g) Process Optimization of Energetic Material Crystallization Using PAT and Modeling Tools

It is crucial to ensure the crystal quality, size, and morphology of energetic materials are well-controlled during the production process to enhance their initiation sensitivity. However, achieving consistent crystal properties at production scale can be challenging due to variations in process conditions, resulting in large particle size distributions that require milling to obtain different particle sizes. To address this challenge, the use of Process Analytical Technology (PAT) to monitor and control the batch and continuous crystallization process in real-time is essential. PAT involves the use of analytical tools such as IR, FBRM, and Easy viewer to provide continuous feedback on process parameters, allowing for timely adjustments to optimize crystal properties. In this effort, a modeling tool (CrySiv) was used to predict kinetic parameters and run a set of Design of Experiments (DoE) experiments. Statistical software such as JMP was used to analyze the results and correlate process parameters with particle size. Overall, the integration of PAT, modeling tools, and statistical analysis can lead to more efficient and effective control of the crystallization process, resulting in consistent crystal properties and improved product quality.