Method for preparing anhydrous tetrazole gas generant compositions

A method for preparing anhydrous gas generants comprising the steps of:

• (a) preparing a mixture of oxidizer particles having a number average particle size of about 1 micron to about 20 microns and fuel particles having a number average particle size of about 10 microns to about 40 microns wherein the oxidizer is selected from the group consisting of a metal peroxide, an inorganic nitrate, an inorganic nitrite, a metal oxide, a metal hydroxide, an inorganic chlorate, an inorganic perchlorate, or a mixture thereof, the fuel is at least one tetrazole selected from the group consisting of (i) 5-aminotetrazole, a salt thereof, or a complex thereof, (ii) bis-(1(2)H-tetrazol-5-yl)-amine, a salt thereof, or a complex thereof, and (iii) a mixture thereof in at least about 20% by weight and up to about 40% by weight water;
• (b) granulating the mixture to obtain granules having a weight average particle size of about 100 mesh to about 14 mesh;
• (c) drying the granules to obtain anhydrous granules;
• and
• (d) pelletizing the anhydrous granules into pellets.