Application of Twin Screw Extrusion for Continuous Processing of Energetic Materials

Continuous processing of energetic materials using a twin screw extruder is gaining importance as it is a safe and cost-effective alternative to conventional batch processing. The continuous process based on a twin screw extruder combines the capabilities of intensive mixing and high pressure extrusion. It is used for processing a variety of energetic materials, such as gun and rocket propellants, plastic bonded explosives, pyrotechnics, thermo-baric explosives, etc. The twin screw extruder process demands various safety features for the processing of energetic materials. Therefore, exhaustive characterisation of the energetic materials in terms of safety and rheology, coupled with characterisation of the mechanical components of the extruder, are essential for designing a safe continuous process. In this article, a technological overview of continuous processing for energetic materials is presented, along with its various features, process design methodology and safety issues.