This program will develop and demonstrate a novel modular, continuous synthesis platform that can be rapidly reconfigured to produce multiple classes of energetic materials. Continuous synthesis of energetic materials has clear safety advantages, but current approaches are slow to realize due to long process development timelines. The proposed program will develop a system integration and control approach that will enable rapid reconfiguration of modular unit operations with minimal software and control development. Using system control strategies initially developed by Purdue University for continuous pharmaceutical manufacturing, Synthio Chemicals will modify existing unit operations developed for continuous synthesis and purification of various energetic materials to demonstrate the proposed concept. In phase I, the project will establish basic system module interface specifications and the hierarchical software control structure. In the phase I option, a single existing unit operation will be modified to accommodate the integration approach. In phase II, more unit operations will be upgraded, and the modules will be reconfigured to demonstration production of four different energetic materials. Phase III will transition this technology into intermediate scale applications.
