Reaction Model and Optimization of the Alkaline Hydrolysis of SF-3 Double-Base Propellant Wastes Using Analysis of Response Surface Methodology

The alkaline hydrolysis process is a promising method for treating SF-3 double-base propellant waste. This study aimed to validate the SF-3 waste alkaline hydrolysis reaction model and optimize its reaction conditions, thereby promoting the industrial application of alkaline hydrolysis treatment of double-base propellant wastes. Thus, the SF-3 alkaline hydrolysis reaction model was developed based on theoretical assumptions, derivations, and experimental validation. A central composite design coupled with response surface methodology was used to optimize the operational conditions, including reaction temperature, liquid–solid ratio, and reaction time. The results showed that the SF-3 alkaline hydrolysis conformed to a shrinking particle reaction model. The relationship between the x_SF and the t is x_SF = [(α + 2)t/(αt_e′) − 2t²/(αt_e′²)] × 100, where the limiting step is the alkaline hydrolysis process on the particle surface. In addition to reaction temperature and reaction time, the liquid–solid ratio influenced the SF-3 alkaline hydrolysis process. Furthermore, the results of Pareto and analysis of variance analyses revealed that the regression model equation was obtained as x_SF = 48.91 + 8.32₁ + 13.11X₃ − 3.49X₁² − 2.162X₂² − 4.179X₃² + 2.78X₁X₂. Meanwhile, the optimal reaction temperature, time, and liquid–solid ratio were 86.5 °C, 70.8 min, and 6.0, respectively. Under the optimal reaction conditions, the predicted x_SF using the regression model was 99.80%, while the experimental value was 95.01 ± 1.87%, demonstrating the accuracy of the regression model. Therefore, this study provides theoretical and technical support for the industrial-scale safe disposal and resource utilization of waste double-base propellants.