The simulated waste materials that were treated in the MPT were these:

• Actual butyl rubber toxic agent protective gear: M3 suits, aprons, boots, gloves;

• Surrogate demilitarization protective ensemble material (30 mil poly sheet) and poly drum liners;

• Ethylene propylene diene monomer chemical hose (non-PVC [LSS] air hose surrogate);

• Spill pillows saturated with ethylene glycol (hydraulic fluid stimulant);

• Simulated EBH rocket warhead debris (fuze mockups, cut-to-length steel tubes, poly tube);

• Scrap piping components (large dense valves and pipe); and

• Simulated equipment test hardware rocket shipping and firing tube sections and cut aluminum rocket bulkheads from the rocket-cutting machine TRRP.

Waste was fed on mini-waste incineration container (mini-WIC) trays, half the length but otherwise identical to the baseline-design WICs. WIC trays were “stacked” using fabricated tray inserts to test the concept of “double-decking.”

The testing at Kennewick was limited to nonhalogenated materials and did not include EBH energetic materials because of permitting considerations. Waste feeds were limited to 20 lb of organic constituents per tray since the CATOX capacity was equivalent to the VOC loading from 30 lb/h of waste.

The results indicated the following:⁵

• Chamber oxygen content consistently fell from the initial value at tray insertion to less than detectable (<0.01 percent) within minutes after tray insertion. The process logic controller, which recorded O₂ levels to 0.0001 percent, indicated that the O₂ level continued to drop, stabilized, and eventually rose rapidly back above the 0.01 percent level. This duration was generally on the order of 60 minutes.⁶

• The BPBGT pyrolysis study concluded that VOC/total organic carbon monitors are not appropriate for determining the completion of pyrolysis when treating organic-containing materials such as secondary waste (BPBGT, 2007d).

• The off-gas treatment CATOX experienced temperature rises that exceeded the CATOX operating limits. The temperature spikes varied for different types of waste. This was not considered a concern by the committee because the full-scale BOX has a higher temperature rating.

• Sharp, but low-level, spikes of VOCs and carbon monoxide were measured in the outlet air lock. These spikes are believed to be contributors to the rises in CATOX noted in the preceding observation and are not considered a concern for the BOX unit. Also, since nitrogen purge is used in the outlet air lock, ignition of these materials did not occur.

• Wood and cotton cloth waste did not flame when the tray was removed. Most treated waste appeared reduced to nonorganic constituents and was readily removed from the WIC by vacuum or brush and pan.

• The mini-WICs showed very little thermal deformation.

• All dosimeters indicated that treatment at 1000°F for 15 minutes was met within the 120-minute standard residence time. Oxygen level response indicated that all organic material was gone after 75 minutes.

• Remaining issues of concern included steam flow into the air locks immediately on door opening, and smoking of some types of waste shortly after the tray was placed in the chamber.

• Estimated weekly secondary waste processing rates were developed using an ASPEN⁷ model, projecting BGCAPP waste generation rates to estimate weekly process time anticipated in the MPT.

• Inspection of duct interiors during disassembly of the off-gas treatment system showed no buildup of tars or chars that would be indicative of full-scale operational cleanout or downtime issues. However, the amount and rate of surrogate material processed was much lower than will be experienced in the full-scale MPT.

Finding. The range of secondary waste materials tested was limited in comparison to the anticipated range of waste to be treated in the full-scale MPT. Furthermore, halogenated materials were excluded because the TRRP MPT permit could not be readily changed to allow such materials.

Recommendation 3-5a. The BPBGT should perform more-comprehensive testing prior to systemization, drawing from operator experience at prior operating plants. This testing should include waste materials and waste flow rates representative of those encountered during closure, as well as miscellaneous secondary waste from operations and maintenance and any possible residual energetics.

Recommendation 3-5b. The use of halogenated materials should be minimized in operations and maintenance activities wherever possible, and selection of materials should