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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6 General Findings and recommendations Finding. The MTU could be substituted for the MPT The following general findings and recommendations are based on the discussions and the detailed findings in at BGCAPP; however, it would be necessary to do the Chapters 2 through 5 of this report. following: Finding. The full-scale MPT as currently designed for • Use supplemental decontamination units and auto- BGCAPP can decontaminate projectile bodies and secondary claves to treat secondary waste, and closure waste, and it will be able to achieve its target • Find another means of treating the detonators in the throughput rates provided that the BPBGT is able to resolve M417 rocket fuzes, the following issues: • Modify the MTU design to accommodate 8-in. projectiles, • Successful implementation of new designs for door • Modify the footprint of the building to accommodate closure and seals, for roller bearings on conveyors, the units, and and for the superheated steam header; • Modify the existing permits. • Effective thermal treatment of secondary waste with- Finding. For BGCAPP, the TRRP testing did not address a out excessive fouling of the duct work leading to the bulk oxidizer; method to thermally treat the fuzes and a limited number of • Successful integration of the MPT with its flameless igniters from contaminated propellant that are not decom- thermal oxidizer (i.e., the bulk oxidizer) and cyclone; posed in the energetics batch hydrolyzers. and Recommendation 6-1. The BPBGT needs to develop a • Complete destruction of energetic materials in the waste stream of the energetics batch hydrolyzer method to collect and pop the igniters and fuzes that will not without adversely affecting the MPT. adversely affect the operation of the MPT. Finding. The current range of heat-up times of munitions in Recommendation 6-2. To reduce the technical risks in treat- the MPT should not affect the overall schedule of BGCAPP ing secondary waste in the MPT, the BPBGT should continue operations. to strive to send secondary waste off-site whenever possible and minimize the use of halogenated materials. • Heat-up times in the TRRP tests are close to target Recommendation 6-3. To reduce the load on the off-gas and appear to be capable of being improved by rais- ing the wall temperature of the full-scale MPT. treatment system, the BPBGT should consider obtaining • CFD modeling predicts correct trends in temperature- permits that allow the use of the Airborne Exposure Limit time profiles and locations of cold spots and should Guidelines to operate the MPT at lower temperatures for the be useful in guiding the design and testing of the thermal treatment of secondary waste whenever possible. full-scale MPT. Finding. TRRP testing demonstrated the validity of using • The processing rate of projectile bodies in the MPT is not on the critical path of the process throughput. The an MPT for thermal decontamination. It also identified design calls for two MPTs. The second is intended many changes and design improvements that will be neces- to be used for secondary waste, but it could also be sary to achieve an acceptable throughput rate and control used for treating munitions bodies in an emergency. maintenance and operating costs. Further testing with var- 0

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 geNeRal FiNdiNgS aNd ReCOMMeNdaTiONS ied secondary waste materials including halogenated waste TRRP tests. This test plan should be conducted at the fabrica- is still required. These changes and improvements may tion facility and should include time for the repeated trials require several iterations before satisfactory results are needed to arrive at acceptable performance for the overall achieved. full-scale MPT. A similar test plan should be prepared for testing the integrated full-scale off-gas treatment system for Recommendation 6-4. A test plan should be prepared for all the MPT at BGCAPP. This test plan should include the test- design changes identified for the MPT but not verified in the ing of a full range of secondary, energetics batch hydrolyzer, and closure waste at the full-scale design rates.