ARMAMENT RESEARCH, DEVELOPMENT AND ENGINEERING CENTERARMAMENT RESEARCH, DEVELOPMENT AND ENGINEERING CENTER

PLASMA ORDNANCE DEMILITARIZATION SYSTEMPLASMA ORDNANCE DEMILITARIZATION SYSTEM(PODS)(PODS)

FOR THE DESTRUCTION OF PYROTECHNIC ORDNANCEFOR THE DESTRUCTION OF PYROTECHNIC ORDNANCE

Presented by:Presented by:Dan FlynnDan Flynn

Energetics, Warheads, & Environmental Technology DirectorateEnergetics, Warheads, & Environmental Technology DirectorateProducibility for Production Readiness DivisionProducibility for Production Readiness Division

Picatinny, NJPicatinny, NJ

2007 Global Demilitarization Symposium & Exhibition2007 Global Demilitarization Symposium & ExhibitionReno, NV Reno, NV

1414--18 May 200718 May 2007

U.S. ARMY RESEARCH, DEVELOPMENT AND ENGINEERING COMMANDU.S. ARMY RESEARCH, DEVELOPMENT AND ENGINEERING COMMAND

PRESENTATION OUTLINEPRESENTATION OUTLINEProgram ObjectiveProgram ObjectiveBackgroundBackgroundPODS System DescriptionPODS System DescriptionTesting OverviewTesting OverviewProject StatusProject StatusTechnical SolutionsTechnical SolutionsProgram ScheduleProgram ScheduleItems to be ProcessedItems to be ProcessedOperating Cost EstimateOperating Cost EstimateSummarySummary

PROGRAM OBJECTIVEPROGRAM OBJECTIVE

To develop an effective/efficient alternative method of To develop an effective/efficient alternative method of demilitarization for small, fully assembled, smoke and demilitarization for small, fully assembled, smoke and pyrotechnic ordnance pyrotechnic ordnance -- a task which had previously a task which had previously

been accomplished by Open Burning/Open been accomplished by Open Burning/Open Detonation (OB/OD) and conventional incineration.Detonation (OB/OD) and conventional incineration.

BACKGROUNDBACKGROUNDThe Surgeon General Imposed a Moratorium on OB/OD of Smoke The Surgeon General Imposed a Moratorium on OB/OD of Smoke and Dye Munitionsand Dye Munitions

Problems Have Been Reported with the Use of Existing IncineratorProblems Have Been Reported with the Use of Existing Incinerators s for the Demilitarization of Smoke and Pyrotechnic Items for the Demilitarization of Smoke and Pyrotechnic Items

•• Heat damage to incinerators from flaresHeat damage to incinerators from flares•• Filters clogging with particulate matterFilters clogging with particulate matter•• Incinerator ash has been classified as a hazardous wasteIncinerator ash has been classified as a hazardous waste•• Fugitive emissionsFugitive emissions

In general, the DOD is Reducing Dependence on OB/OD and is In general, the DOD is Reducing Dependence on OB/OD and is Increasing the Use of Closed Disposal Technologies (CDT), Increasing the Use of Closed Disposal Technologies (CDT), Including R3Including R3

BACKGROUND (cont.)BACKGROUND (cont.)

Plasma Arc Technology Offers Several Advantages Over Plasma Arc Technology Offers Several Advantages Over Conventional Incineration:Conventional Incineration:

•• NonNon--hazardous solid slag output instead of hazardous ash hazardous solid slag output instead of hazardous ash •• Clean gaseous effluents at lower mass flows Clean gaseous effluents at lower mass flows •• No fugitive emissionsNo fugitive emissions•• Capability to demilitarize the assembled end item without Capability to demilitarize the assembled end item without

furnace damagefurnace damage•• More uniform and reliable DREMore uniform and reliable DRE

CANDIDATE ITEMSCANDIDATE ITEMSOther Items:Other Items:

Riot ControlRiot ControlIncendiaryIncendiaryPhosphorousPhosphorousPropellant & Cartridge Propellant & Cartridge IncrementsIncrementsCartridge an Propellant Cartridge an Propellant Actuated DevicesActuated DevicesByBy--Products of RProducts of R3 3 (e.g. (e.g. Mortar Ignition CartridgesMortar Ignition CartridgesFuzesFuzesSmall High Explosive Small High Explosive Components & ItemsComponents & Items

Major Focus: Pyrotechnic ItemsMajor Focus: Pyrotechnic Items

PODS PROCESS FLOW DIAGRAMPODS PROCESS FLOW DIAGRAM

Q U E N C H E R

S LA GC O L LE C TIO NC H A M B E R

S E C O N D A R YC O M B U S TIO NC H A M B E R

P A C K E D -B E DA B S O R BE R

S C R U B B E RLIQ UIDC H ILLE R

N O xC A TA LY TICR E A C TO R

PLASMA

PCFRPT1

ELR 4/21/95LAST MODIFIEDGSM 8/25/99

P R IM A R YC H A M B E R

FE E D E R SR E H E A TE R

D E M IS TE R

B A G H O U S EN O xA N A LY ZE RSA M PL IN GPO R T

TOW A T ERTR EA TM E N TSY ST EM

H 2O

D IE SELFU EL &O X YG EN

P L A S M AT O R C H E S(SE C O N D TO R C H N O T SH O W N )

20 ,000 oF

SC RU B B E DG A S TOST A C K

B LO W E R

H IG H E N E R G YP A R T IC U LA TES C R U B B E R

C O N TIN U O U SEM IS SIO N SM O N ITO R IN GPO R T

R E H E A TE R

O X YG E N(IN J E C T E D )

H2O

2 ,00 0oF

3 ,0 00 oF

PLASMA ARC PLASMA ARC FURNACE FURNACE

SLAG: PLASMA FURNACE OUTPUTSLAG: PLASMA FURNACE OUTPUT

PODS FACILITYPODS FACILITYHAWTHORNE ARMY DEPOT, HAWTHORNE, NVHAWTHORNE ARMY DEPOT, HAWTHORNE, NV

Ordnance UpOrdnance Up

Soil InSoil In Ordnance InOrdnance In

Ordnance/Soil Ordnance/Soil Conveyors & PODS Conveyors & PODS FurnaceFurnace

Slag Collection Chamber Slag Collection Chamber & Slag Crane& Slag Crane

Pollution Abatement Pollution Abatement EquipmentEquipment

Cooling Towers Cooling Towers & Water Storage & Water Storage

PondPond

Water Treatment Water Treatment System & System &

Evaporation PondEvaporation Pond

PODS TESTING OVERVIEWPODS TESTING OVERVIEWOperational Verification Testing (OVT): 7/7 Weeks Completed

Preliminary Testing (PT) aka “Miniburns”:Establishes reliable operation in preparation for the Comprehensive Performance Test (CPT). 6/10 Weeks Completed

Feed Rate Determination 5/6 Weeks Completed

Feed Rate Verification 1/1 Weeks Completed

CEMS/COMS 0/2 Weeks Completed

CPT/Risk Burn Pre-Run 0/1 Weeks Completed

Performance Verification Testing (PVT):1 week-long, 24 hour per day test with ordnance.Verifies duration performance. 1/2 Weeks Completed

CPT / Risk Burn Test:3 replicate 1-day tests.Establishes environmental compliance under MACT & RCRA. 0/1 Weeks Completed

PODS TESTING ACCOMPLISHMENTSPODS TESTING ACCOMPLISHMENTS

Performance Verification Testing (Sept. 2006):Performance Verification Testing (Sept. 2006):–– ~100 Hours of Torch Operation~100 Hours of Torch Operation–– 24,697 lbs. of HC Smoke Canisters Processed24,697 lbs. of HC Smoke Canisters Processed–– Sustained Ordnance Feed Rate: 735 lbs./hrSustained Ordnance Feed Rate: 735 lbs./hr–– Highlighted Key Technical Issues Attributable to Highlighted Key Technical Issues Attributable to

Continuous Operation (i.e. Plugging, Tapping Continuous Operation (i.e. Plugging, Tapping Efficiency)Efficiency)

Feed Rate Determination Testing (April 2007):Feed Rate Determination Testing (April 2007):–– 67 Hours of Torch Operation67 Hours of Torch Operation–– 16,511 lbs. of HC Smoke Canisters Processed16,511 lbs. of HC Smoke Canisters Processed–– Sustained Ordnance Feed Rate: 1368 lbs./hrSustained Ordnance Feed Rate: 1368 lbs./hr–– Evaluated 4 Different Solutions to Mitigate Plugging.Evaluated 4 Different Solutions to Mitigate Plugging.–– Evaluated Slag Mold RedesignEvaluated Slag Mold Redesign

TEST ITEMSTEST ITEMS

DODICDODIC NOMENCLATURENOMENCLATURE TYPETYPED450D450 Canister, 155mm HC M2 SmokeCanister, 155mm HC M2 Smoke Pyro. (Smoke)Pyro. (Smoke) 62,45562,455

L592L592 TOW Missile Blast Simulator AssemblyTOW Missile Blast Simulator Assembly Pyro. (Simulator)Pyro. (Simulator) 42.85 lbs. 42.85 lbs. ~710 (items)~710 (items)

M30/31, XM34/35 Blast SimulatorsM30/31, XM34/35 Blast Simulators

Riot ControlRiot ControlPyro. (Smoke)Pyro. (Smoke)Pyro. (Smoke)Pyro. (Smoke)

Pyro. (Smoke)Pyro. (Smoke)Pyro. (Simulator)Pyro. (Simulator)

Pyro. (Simulator)Pyro. (Simulator)

HE FuzeHE Fuze

G960G960 Grenade, Hand Riot, CN,M7Grenade, Hand Riot, CN,M7 660660G930G930 Grenade, Hand Smoke HC ANGrenade, Hand Smoke HC AN--M8M8 70.470.4G932G932 Grenade, Hand Smoke Red M48Grenade, Hand Smoke Red M48 5757

Canister, 155mm HC M1 SmokeCanister, 155mm HC M1 SmokeSimulator, Projectile, Airburst, Simulator, Projectile, Airburst,

M74A1/M74M74A1/M74Simulator, Flash, Artillery, M21Simulator, Flash, Artillery, M21

Fuze, Bomb, Tail, M905 Fuze, Bomb, Tail, M905

>> Additional Items TBD <<>> Additional Items TBD <<

Weight (lbs.)Weight (lbs.)

L602L602

F989F989

D445D445L366L366

Technical SolutionsTechnical SolutionsSlag Mold Evolution:Slag Mold Evolution:

Technical Solutions Technical Solutions (cont.)(cont.)

Pollution Abatement Equipment Pollution Abatement Equipment Modifications:Modifications:

AIR INJECTION /AIR INJECTION /STAINLESS STEEL ELBOWSTAINLESS STEEL ELBOW

Technical Solutions Technical Solutions (cont.)(cont.)

Pollution Abatement Equipment Pollution Abatement Equipment Modifications:Modifications:

KAOLIN INJECTIONKAOLIN INJECTION

Technical Solutions Technical Solutions (cont.)(cont.)

Pollution Abatement Equipment Pollution Abatement Equipment Modifications:Modifications:

MECHANICAL RAMMERMECHANICAL RAMMER

PROGRAM SCHEDULEPROGRAM SCHEDULEFY 2007 FY 2008

TASK

Apr

May

Jun

JulA

ugA

ug

SepO

ctN

ov

Dec

JanFebM

arA

prM

ay

Preliminary Testing & Performance Verification Testing

Comprehensive Performance Test/Risk Burn Test

Data Analysis, Report, & Obtain NDEP/RIX Approval

Initial Workloading

PODS PLANNED WORKLOADPODS PLANNED WORKLOAD

PROJ., 155MM, SMOKE, HC, M116A1PROJ., 155MM, SMOKE, HC, M116A1

CANISTER 155MM SMK HC M1 & M2CANISTER 155MM SMK HC M1 & M2 CANISTER 105MM SMK HC M1CANISTER 105MM SMK HC M1

CARTRIDGE, 105MM, SMOKE, HC, M84 SERIESCARTRIDGE, 105MM, SMOKE, HC, M84 SERIES

One Million CanistersOne Million Canisters1.2 Years at 24/5 Shift1.2 Years at 24/5 Shift

WORKLOAD ITEMSWORKLOAD ITEMS

ADDITIONAL POTENTIAL ADDITIONAL POTENTIAL WORKLOADWORKLOAD

TOW Missile Blast Simulator AssemblyTOW Missile Blast Simulator AssemblyApproximately 54,000 currently located at HWADApproximately 54,000 currently located at HWADAMCOM priority to demilAMCOM priority to demilWill demonstrate synergy between conventional ammo Will demonstrate synergy between conventional ammo and tactical missile demiland tactical missile demil

$0

$1,000

$2,000

$3,000

$4,000

$5,000

$6,000

$7,000

250 500 750 1000 1250 1500 1750 2000 2250 2500

Item Weight= 92% of PROWT(for White Smoke Canisters)

Item Weight= 50% of PROWT (for typical pyrotechnic items)

PODS OPERATING COST ESTIMATEPODS OPERATING COST ESTIMATE

Note: PROWT = “Prorated Weight”, the weight of an item plus it’s portion of packaging materials.

Ope

ratin

g C

ost (

$/sh

ort t

on)

Item Feed Rate (lb/hr)

SUMMARYSUMMARYThe Plasma Ordnance Demilitarization System at Hawthorne Army The Plasma Ordnance Demilitarization System at Hawthorne Army Depot Will Provide the US Army with a StateDepot Will Provide the US Army with a State--ofof--thethe--Art Art Demilitarization Capability for Completely Assembled, Small SmokDemilitarization Capability for Completely Assembled, Small Smoke e and Pyrotechnic Ordnance, as well as a Variety of Other Ordnanceand Pyrotechnic Ordnance, as well as a Variety of Other Ordnance. .

PODS:PODS:

•• Is safeIs safe•• Is an environmentally compliant alternative to OB/ODIs an environmentally compliant alternative to OB/OD•• Captures hazardous constituents of the ordnance in a Captures hazardous constituents of the ordnance in a

lowlow--leachable, nonleachable, non--hazardous final waste formhazardous final waste form•• Is cost effectiveIs cost effective