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Review and Assessment of Developmental Issues Concerning the Metal Parts Treater Design for the Blue Grass Chemical Agent Destruction Pilot Plant 6 General Findings and Recommendations The following general findings and recommendations are based on the discussions and the detailed findings in Chapters 2 through 5 of this report. Finding. The full-scale MPT as currently designed for BGCAPP can decontaminate projectile bodies and secondary and closure waste, and it will be able to achieve its target throughput rates provided that the BPBGT is able to resolve the following issues: Successful implementation of new designs for door closure and seals, for roller bearings on conveyors, and for the superheated steam header; Effective thermal treatment of secondary waste without excessive fouling of the duct work leading to the bulk oxidizer; Successful integration of the MPT with its flameless thermal oxidizer (i.e., the bulk oxidizer) and cyclone; and Complete destruction of energetic materials in the waste stream of the energetics batch hydrolyzer without adversely affecting the MPT. Finding. The current range of heat-up times of munitions in the MPT should not affect the overall schedule of BGCAPP operations. Heat-up times in the TRRP tests are close to target and appear to be capable of being improved by raising the wall temperature of the full-scale MPT. CFD modeling predicts correct trends in temperaturetime profiles and locations of cold spots and should be useful in guiding the design and testing of the full-scale MPT. The processing rate of projectile bodies in the MPT is not on the critical path of the process throughput. The design calls for two MPTs. The second is intended to be used for secondary waste, but it could also be used for treating munitions bodies in an emergency. Finding. The MTU could be substituted for the MPT at BGCAPP; however, it would be necessary to do the following: Use supplemental decontamination units and autoclaves to treat secondary waste, Find another means of treating the detonators in the M417 rocket fuzes, Modify the MTU design to accommodate 8-in. projectiles, Modify the footprint of the building to accommodate the units, and Modify the existing permits. Finding. For BGCAPP, the TRRP testing did not address a method to thermally treat the fuzes and a limited number of igniters from contaminated propellant that are not decomposed in the energetics batch hydrolyzers. Recommendation 6-1. The BPBGT needs to develop a method to collect and pop the igniters and fuzes that will not adversely affect the operation of the MPT. Recommendation 6-2. To reduce the technical risks in treating secondary waste in the MPT, the BPBGT should continue to strive to send secondary waste off-site whenever possible and minimize the use of halogenated materials. Recommendation 6-3. To reduce the load on the off-gas treatment system, the BPBGT should consider obtaining permits that allow the use of the Airborne Exposure Limit Guidelines to operate the MPT at lower temperatures for the thermal treatment of secondary waste whenever possible. Finding. TRRP testing demonstrated the validity of using an MPT for thermal decontamination. It also identified many changes and design improvements that will be necessary to achieve an acceptable throughput rate and control maintenance and operating costs. Further testing with var-
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Review and Assessment of Developmental Issues Concerning the Metal Parts Treater Design for the Blue Grass Chemical Agent Destruction Pilot Plant ied secondary waste materials including halogenated waste is still required. These changes and improvements may require several iterations before satisfactory results are achieved. Recommendation 6-4. A test plan should be prepared for all design changes identified for the MPT but not verified in the TRRP tests. This test plan should be conducted at the fabrication facility and should include time for the repeated trials needed to arrive at acceptable performance for the overall full-scale MPT. A similar test plan should be prepared for testing the integrated full-scale off-gas treatment system for the MPT at BGCAPP. This test plan should include the testing of a full range of secondary, energetics batch hydrolyzer, and closure waste at the full-scale design rates.