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Ammonal


Ammonal is a high composed of as the primary oxidizer and finely powdered aluminum as the , typically blended in a mass ratio of around 95:5 to achieve velocities exceeding 4,000 m/s.
This non-ideal , characterized by its sensitivity to confinement and flow divergence during , produces enhanced and heat output from the aluminum's , making it suitable for applications requiring powerful fragmentation and cratering effects.
Originally formulated in the early 1900s for commercial blasting in mining and quarrying—where its lower cost relative to offered economic advantages—Ammonal gained military prominence during , when the employed it in massive underground charges to undermine German positions.
Notable deployments included the 18.5-ton Ammonal charge at during the on July 1, 1916, which formed a crater over 30 meters deep but inadvertently alerted defenders due to premature visible venting; and larger mines at the Battle of Messines in 1917, where charges up to 45 tons contributed to seismic shocks registering on instruments in .
Postwar, its use declined with the rise of safer, more stable alternatives like , though variants persist in specialized and research contexts owing to their tunable energy release.

Composition

Basic Formulation

Ammonal's basic formulation consists of (NH₄NO₃) as the primary oxidizer and fine (Al) as the fuel and sensitizer, mixed in a binary composition without additional explosives or binders. Typical ratios range from 80–95% to 5–20% by weight, selected to balance , , and cost; lower content (e.g., 5%) suits for controlled fragmentation, while higher (e.g., 20%) boosts energy in contexts via the exothermic oxidation of to alumina. The is usually in prilled or powdered form for uniform mixing, with particle size under 10–20 μm to ensure rapid reaction initiation upon . This simple mixture relies on the chemical incompatibility of components for insensitivity under normal conditions but high reactivity under shock, distinguishing it from sensitized variants.

Variants and Modifications

A primary variant of ammonal incorporates trinitrotoluene () to enhance and , forming what is known as T-ammonal; this modification addresses limitations in the shattering effect of basic ammonium nitrate-aluminum mixtures by leveraging 's higher explosive power. Early formulations for , developed in around 1915, typically comprised 65% , 17% aluminum powder, 15% , and 3% , with the charcoal serving to improve ignition reliability and mixture homogeneity. Commercial variants often derive from aluminized amatol, blending , , and aluminum powder; an 80/20 amatol base (80% , 20% ) with added aluminum exemplifies this approach, yielding explosives like Ammonal B or Ripping Ammonal tailored for rock fragmentation in quarrying. These modifications prioritize cost-effective while maintaining relative , though they require careful proportioning to avoid reduced performance from excess aluminum, which can lower if exceeding optimal levels around 10-20% by weight. Further adaptations in research include substituting aluminum with aluminum-magnesium to boost energy release and characteristics, as powders exhibit higher reactivity in mixtures, potentially increasing heat and velocity over pure aluminum variants. Some industrial formulations add waxy binders to mitigate moisture absorption, a common issue with hygroscopic , thereby extending shelf life in applications without altering core .

Physical and Chemical Properties

Detonation Characteristics

Ammonal, a mixture primarily of ammonium nitrate and aluminum powder, detonates as a non-ideal with performance highly sensitive to charge , , and . Detonation velocities measured in expansion tests range from 2.6 to 3.8 km/s, increasing with larger charge diameters due to reduced divergence effects; for instance, tests in 50.8 mm inner cylinders yielded 3.82 km/s, compared to 3.52 km/s in 25.4 mm cylinders. These values reflect partial inert behavior of aluminum particles in the initial reaction zone, with subsequent afterburning contributing to expanded wall velocities up to 0.925 mm/μs at larger radial displacements. Detonation velocity also varies with ammonium nitrate grain size and aluminum content; finer AN grains (<100 μm) achieve up to 3.07 km/s at densities of 0.89 g/cm³, while coarser grains (400–710 μm) yield as low as 1.92 km/s at 0.82 g/cm³. Adding 5–15% aluminum to AN increases velocity modestly, from 2.64 km/s (pure AN) to 2.96 km/s at 10% aluminum and 0.82 g/cm³ density, though higher aluminum fractions (e.g., 7% flaked) can reduce it due to agglomeration effects. Detonation pressures for ammonal compositions typically fall between 1.16 and 1.56 GPa, peaking at intermediate AN grain sizes (200–300 μm) owing to optimal reaction kinetics and gas production; finer grains reduce pressure to 1.16 GPa via altered products. The inclusion of aluminum enhances relative to non-aluminized ammonium nitrate explosives like , as the metal's exothermic oxidation post- wave elevates temperatures and fragment velocities, though initial brisance is lower than high explosives like due to the slower-reacting aluminum phase. Gurney energies from cylinder tests range from 1.59 to 1.97 kJ/g, underscoring ammonal's utility in applications requiring sustained blast effects over sharp shock.

Stability and Sensitivity

Ammonal exhibits relatively low sensitivity to impact, shock, and friction, characteristics primarily derived from the stability of its component, rendering it safer for handling than primary explosives or highly sensitive secondaries like . Impact sensitivity, assessed via drop hammer tests, yields a 50% initiation height of 76 cm to over 320 cm for loose powder formulations, with pelleted variants showing heights exceeding 320 cm; this positions Ammonal as less sensitive than and roughly equivalent to . Contaminants such as metals or moisture do not substantially elevate impact sensitivity, and added moisture in fact enhances insensitivity by increasing the required drop height beyond 320 cm. Friction and shock sensitivities remain low, necessitating a detonator or booster—such as —for reliable initiation rather than propagation from mild mechanical insult alone. sensitivity requires a minimum of approximately 0.5 joules for 50% initiation probability, rendering it less prone to accidental sparking than PETN but more so than under optimal conditions of 50 mils at 4.0 kV. Thermally, Ammonal demonstrates stability suitable for storage and transport, with cook-off temperatures initiating around 700°F and vacuum stability tests showing rapid decomposition only above 250°C; however, ammonium nitrate's polymorphic phase transitions, particularly near 32°C, can introduce variability in performance, though not directly increasing sensitivity. Overall, these properties contributed to its adoption in large-scale military applications despite inherent batch-to-batch inconsistencies.

Historical Development

Origins and Early Experiments

Ammonal, an explosive mixture combining as an oxidizer with aluminum powder as a , originated in in 1915 for applications. This development addressed the need for a high-performance, cost-effective blasting agent, leveraging ammonium nitrate's availability and the energy release from aluminum to achieve greater than ammonium nitrate alone. Early formulations typically comprised 65% ammonium nitrate, 15% trinitrotoluene (), 17% aluminum powder, and 3% wax to improve homogeneity and reliability. These mixtures were tested in controlled mining blasts to evaluate , power output, and sensitivity, confirming superior fragmentation compared to traditional black powder or . The addition of served to enhance initiation and stability, while aluminum increased the heat of explosion, making ammonal suitable for excavation. By early 1916, British military engineers adapted ammonal for tunneling and mine warfare during , conducting initial experiments with large-scale charges under enemy lines. The first significant deployment occurred at Hawthorn Ridge during the on 1 July 1916, where approximately 18,000 kg of ammonal detonated in an underground mine, creating a over 30 meters deep and displacing vast amounts of earth. These experiments demonstrated ammonal's effectiveness in confined spaces but also revealed challenges such as variable detonation due to charge size and confinement, informing refinements for subsequent operations like the Messines mines in 1917.

World War I Adoption

Ammonal, initially developed for civilian mining applications in England around 1915, saw military adoption by the British Army for tunnel warfare explosives from early 1916 onward. Its selection stemmed from desirable properties including high brisance and effectiveness in confined detonations, making it suitable for underground charges in trench stalemates. British tunneling companies, including Royal Engineer units, integrated ammonal into operations to counter German mining efforts and disrupt enemy positions. The first documented combat use occurred at during the on 1 July 1916, where approximately 40,000 pounds of ammonal were detonated in a single , creating a crater over 30 meters deep. This early application highlighted ammonal's capacity for massive disruption, though premature detonation timing drew tactical criticism for alerting German forces. Subsequent refinements led to widespread employment, notably in the Battle of Messines on 7 1917, where British forces exploded 19 ammonal-filled mines totaling 454 tons beneath German lines, generating seismic effects registered as far as 150 kilometers away and inflicting around 10,000 casualties in an instant. These charges, often mixed with gun cotton for enhanced reliability, represented the war's largest coordinated mining operation. Ammonal's role extended to other fronts, including the Canadian Corps' use at Vimy Ridge on 9 April 1917, where 25-pound bags were incorporated into demolition charges. Its aluminum content boosted and fragmentation effects compared to pure mixes, aiding in crater formation and shockwave propagation through soil. By war's end, ammonal had become a staple in doctrine, with production scaled to meet demands for both offensive mines and improvised trench weapons, though handling risks from sensitivity prompted strict protocols. Allied forces valued its cost-effectiveness amid TNT shortages, yet post-battle analyses noted inconsistencies in performance due to moisture absorption in damp tunnels.

Post-War Decline and Legacy

Following the , Ammonal's applications declined precipitously, as the trench-bound tunneling warfare of the Western Front gave way to more mobile conflict doctrines in interwar planning and subsequent wars, eliminating the need for large-scale charges. use in quarrying and continued sporadically into the , valued for its high shattering power from the aluminized , but high costs—driven by aluminum's expense and scarcity —and handling sensitivities limited its adoption compared to simpler nitrate-based blends. By the mid-20th century, Ammonal was largely supplanted in civilian blasting by economical alternatives like ammonium nitrate-fuel oil (ANFO), which offered comparable oxygen balance and detonation velocity at lower cost and reduced sensitivity to initiation, reflecting a broader shift toward non-metallized explosives for bulk mining operations. Ammonal's enduring legacy lies in its pivotal role during the Battle of Messines on 7 June 1917, where British forces detonated 19 mines containing roughly 454 metric tons of the explosive beneath German positions, generating seismic effects registered as far as London and contributing to an estimated 10,000 enemy casualties in the initial blasts—events that remain among the largest conventional detonations in history. Surviving craters, such as Lochnagar (detonated with 60,000 pounds of Ammonal), serve as preserved memorials to mine warfare, underscoring the tactic's tactical shock value despite its ultimate failure to decisively alter the war's course. Contemporary studies of Ammonal variants persist in academic research, examining detonation scaling and non-ideal behavior to inform safer modern aluminized formulations, though practical deployment remains rare due to inherited stability concerns.

Applications

Military Uses

Ammonal saw extensive military application by the British Army during World War I, particularly in underground mining warfare aimed at collapsing German trench lines. From early 1916, it served as the primary explosive for tunnel bombs, offering a potent mixture that enhanced blast effects through aluminum's incendiary properties combined with ammonium nitrate's oxygen supply. The first significant deployment occurred at during the on July 1, 1916, where approximately 40,000 pounds (18,000 kg) of Ammonal were detonated in a beneath positions, creating a over 30 meters deep but alerting defenders due to a premature ten minutes before the . Subsequent uses included a second at the same site on November 13, 1916, with 30,000 pounds of Ammonal fired without delay to support advances. In the Battle of Messines on June 7, 1917, the British detonated 19 mines charged with a total of 454 tons of Ammonal and gun cotton beneath the Messines Ridge, producing seismic shocks registered as far as and contributing to an estimated 10,000 German casualties in one of history's largest non-nuclear explosions. Individual charges, such as one under Hill 60, contained 53,300 pounds of Ammonal, dug through challenging blue clay to reach German lines. These operations by Royal Engineer tunnelling companies demonstrated Ammonal's suitability for large-scale, deep-buried charges, though its sensitivity required careful handling to prevent premature detonation. Post-World War I, Ammonal's military use declined sharply due to the development of more stable high explosives like and , limiting its role to legacy contexts rather than ongoing applications.

Industrial and Mining Uses

Ammonal, a mixture primarily of and aluminum powder, was originally developed in in 1915 for applications, offering enhanced explosive power through the thermitic of aluminum that increases temperature and for effective rock fragmentation. Its high made it suitable for blasting in hard rock formations, where the aluminum component contributed to superior shattering compared to alone. In early 20th-century operations, Ammonal saw extensive use in open-cast , quarrying, and seam blasting, particularly for softer and thicker seams, as it provided reliable with lower to than nitroglycerin-based dynamites. Typical formulations, such as 95% with 5% aluminum, were loaded into boreholes for controlled blasts, balancing cost-effectiveness with performance in projects like tunnel excavation and aggregate production. Post-World War I, Ammonal's industrial application persisted in specialized blasting but declined with the rise of cheaper, less sensitive alternatives like , though research into its detonation parameters continues for optimizing non-ideal explosive behavior in cylinders. Modern instances include combinations with boosters like Anfex in horizontal and vertical boreholes for enhanced fragmentation in , demonstrating ongoing niche utility in regions with challenging .

Safety Considerations

Inherent Risks

Ammonal, typically composed of 80–95% and 5–20% aluminum powder, possesses moderate impact sensitivity, with 50% initiation heights exceeding 76 cm for loose powder and over 320 cm for pelleted forms in standardized drop-weight tests, indicating lower risk of accidental detonation from mechanical shock compared to highly sensitive explosives like PETN (12 cm initiation height) but comparable to (187 cm). This relative insensitivity facilitates handling but does not eliminate hazards from high-velocity impacts or misuse, particularly in unconfined or low-density charges where initiation thresholds remain achievable. Thermal stability is compromised by the aluminum additive, as vacuum stability tests at 150–250°C reveal faster gas evolution and decomposition than pure , increasing the likelihood of reactions under heat exposure. experiments demonstrate ignition in 80% of trials at 700°F and 100% at 1000°F, with molten Ammonal exhibiting heightened sensitivity to subsequent stimuli, potentially transitioning to if confined or contaminated. Slow heating poses additional risks of spontaneous ignition without full , releasing toxic fumes and partial energy output. As a non-ideal , Ammonal's performance depends critically on charge diameter, confinement, and , leading to potential low-order detonations or to propagate, which leave undetonated as a persistent hazard. Aluminum enhances and afterburning, extending times (up to 2.5-fold increase with additives) and elevating secondary blast pressures, though excessive aluminum can desensitize mixtures, preventing reliable initiation. The base introduces hygroscopicity, promoting moisture ingress that degrades stability and may sensitize the mixture to contaminants like organics or chlorates. Electrical initiation risks arise from low thresholds (30–3500 volts depending on configuration), susceptible to stray currents or static from aluminum powder.

Regulatory and Handling Protocols

Ammonal, as a recognized mixture, is regulated in the United States under the Bureau of Alcohol, Tobacco, Firearms and Explosives (ATF) as part of the annual list of explosive materials, subjecting its manufacture, storage, distribution, and use to federal licensing requirements per 18 U.S.C. Chapter 40 and 27 CFR Part 555. Entities handling Ammonal must secure federal explosives licenses or permits, maintain detailed records of inventory and transactions, and ensure facilities meet security standards to prevent theft or unauthorized access. Storage occurs in ATF-approved magazines (Types 1 through 5, depending on quantity and class), with mandatory separation distances from inhabited buildings, highways, and other explosives to mitigate risks—typically 50 feet for up to 100 pounds of high explosives like Ammonal, increasing with quantity per ATF tables. Occupational Safety and Health Administration (OSHA) guidelines under 29 CFR 1910.109 govern workplace handling, classifying Ammonal as a high and prohibiting co-storage with detonators, flammable liquids, or contaminants such as acids, chlorates, or organic materials that could accelerate . Protocols emphasize trained personnel, non-sparking tools, grounding to prevent static , and to avoid accumulation, as components are hygroscopic and sensitive to heat exceeding 130°F upon storage entry. , including gloves, safety goggles, and masks, is required to address and contact hazards from aluminum powder and . No , open flames, or impact-prone operations are permitted within 50 feet of storage or handling areas. In mining contexts, the (MSHA) mandates clean handling equipment and procedures to prevent introduction of foreign materials that could alter sensitivity, with misfires treated akin to incidents—requiring evacuation and professional disposal. Transportation complies with (DOT) rules as a Class 1 Division 1.1 , demanding compatible packaging, vehicle placarding, and driver certification; internationally, it aligns with UN Model Regulations for (Class 1), including IMDG Code provisions for maritime bulk transport prohibiting under-deck stowage without emergency venting capabilities.

Notable Incidents Involving Similar Mixtures

On July 7, 2023, an explosion at the Promsintez explosives manufacturing plant in Chapayevsk, , , resulted in the deaths of six workers and injuries to two others. The facility specializes in producing ammonal, along with nitric and sulfuric acids for industrial and military applications. Preliminary investigations indicated the blast occurred during operations, highlighting risks associated with handling sensitizing agents like aluminum powder in proximity to . This incident underscores the potential for unintended in production environments despite established protocols. Mixtures akin to ammonal, such as those combining ammonium nitrate with aluminum powder for binary exploding targets like Tannerite, have led to civilian accidents due to improper mixing or initiation. In one documented case from 2016, a user suffered severe blast injuries, including mangled extremities and shrapnel wounds, from handling a Tannerite mixture without adhering to impact-only detonation guidelines, demonstrating heightened sensitivity when components are prematurely combined. Similarly, on June 8, 2024, a bystander in Benton County, Minnesota, sustained serious injuries from a Tannerite explosion during recreational shooting, where witnesses reported the detonation occurring in a field setting. These events illustrate the hazards of unregulated access to ammonium nitrate-aluminum formulations outside controlled industrial or military contexts. Such incidents with similar mixtures emphasize the need for strict separation of oxidizer and components until intentional use, as aluminum's as a sensitizer can amplify rates under or mechanical . While ammonal's and applications have historically minimized public accidents through oversight, parallels with civilian analogs reveal broader vulnerabilities in , , and amateur experimentation.

Comparative Analysis

Advantages Over Other Explosives

Ammonal exhibits superior thermal output compared to many conventional explosives due to the highly exothermic oxidation of its aluminum component, which enhances rock fragmentation and blasting efficiency in operations. This increased heat of , derived from the between ammonium nitrate's oxygen and aluminum powder, provides greater energy release per unit mass than ammonium nitrate alone or standard mixtures like without metallic additives. In military applications, particularly during , ammonal's formulation allowed for the economical production and deployment of massive charges, such as the approximately 40,000 pounds detonated at Hawthorn Ridge on July 1, 1916, enabling effective cratering under enemy lines where pure high explosives like were cost-prohibitive at scale. Its non- detonation behavior facilitates energy buildup in large-diameter charges, outperforming ideal explosives in unconfined or scaled-up scenarios by sustaining and over extended volumes. Relative to TNT, ammonal offers cost advantages stemming from the inexpensive ammonium nitrate base, which comprised the bulk of wartime production needs, while the aluminum augmentation boosts and pressure beyond baseline ammonium nitrate explosives. This combination rendered it preferable for industrial blasting where high and thermal effects were prioritized over the consistent velocity of manufactured aromatics.

Limitations and Alternatives

Ammonal exhibits non-ideal detonation behavior, with performance strongly dependent on charge diameter and confinement, leading to potential failure in smaller or poorly confined charges where steady propagation may not occur reliably. This variability arises from the mixture's reliance on ammonium nitrate's decomposition kinetics, which can result in incomplete energy release or dead-pressing in suboptimal geometries, increasing the risk of misfires in mining blasts or military applications. Additionally, its detonation velocity of approximately 4,400 m/s is lower than that of trinitrotoluene (6,900 m/s), limiting brisance and fragmentation efficiency in hard rock blasting or cratering operations. The inclusion of aluminum powder enhances energy output through exothermic oxidation but elevates costs compared to simpler ammonium nitrate-based mixtures, as aluminum comprises a significant portion of the (typically 5-20%) and requires precise particle sizing for optimal reactivity. Ammonal also inherits nitrate's hygroscopicity, reducing and performance in humid environments unless sealed, and poses handling risks due to sensitivity variations with fuel-oxidizer ratios—mixtures near 95:5 nitrate to aluminum can detonate from moderate shock but suffer oxygen imbalance, yielding incomplete and toxic byproducts like nitrogen oxides. Regulatory restrictions further limit its use, mandating permits for and due to these sensitivities and potential for misuse. In mining, alternatives like ammonium nitrate-fuel oil (ANFO) predominate for bulk blasting due to lower cost (often 20-50% cheaper per unit energy) and simpler logistics, though ANFO shares water resistance issues and requires larger primers for reliable initiation in non-ideal conditions. Water-resistant emulsions or slurries, such as those based on with polymer-thickened fuels, offer superior stability in wet environments and reduced sensitivity, enabling safer deployment in underground operations without sacrificing velocity (up to 5,000-6,000 m/s). For military cratering or demolition, high explosives like (RDX/TNT) provide consistent high-velocity performance (around 8,000 m/s) and better , minimizing residue and enhancing predictability over Ammonal's historical formulations. T-ammonal variants, incorporating , mitigate some deficits but introduce manufacturing complexity akin to pure military-grade melts.

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