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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
REVIEW AND ASSESSMENT OF DEVELOPMENTAL ISSUES CONCERNING THE METAL PARTS TREATER DESIGN FOR THE BLUE GRASS CHEMICAL AGENT DESTRUCTION PILOT PLANT
Committee to Review and Assess Developmental Issues Concerning the Metal Parts Treater Design for the Blue Grass Chemical Agent Destruction Pilot Plant
Board on Army Science and Technology
Division on Engineering and Physical Sciences
NATIONAL RESEARCH COUNCIL OF THE NATIONAL ACADEMIES
THE NATIONAL ACADEMIES PRESS
Washington, D.C.
www.nap.edu
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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
THE NATIONAL ACADEMIES PRESS
500 Fifth Street, N.W. Washington, DC 20001
NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competences and with regard for appropriate balance.
This study was supported by Contract No. W911NF-06-C-0184 between the National Academy of Sciences and the U.S. Army. Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the views of the organizations or agencies that provided support for the project.
International Standard Book Number -13: 978-0-309-11515-5
International Standard Book Number -10: 0-309-11515-9
Limited copies of this report are available from:
Board on Army Science and Technology
National Research Council
500 Fifth Street, N.W., Room 940
Washington, DC 20001
(202) 334-3118
Additional copies are available from:
The National Academies Press
500 Fifth Street, N.W. Lockbox 285 Washington, DC 20055 (800) 624-6242 or (202) 334-3313 (in the Washington metropolitan area) Internet, http://www.nap.edu
Copyright 2008 by the National Academy of Sciences. All rights reserved.
Printed in the United States of America
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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
THE NATIONAL ACADEMIES
Advisers to the Nation on Science, Engineering, and Medicine
The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences.
The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. Charles M. Vest is president of the National Academy of Engineering.
The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of Medicine.
The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. Charles M. Vest are chair and vice chair, respectively, of the National Research Council.
www.national-academies.org
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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
COMMITTEE TO REVIEW AND ASSESS DEVELOPMENTAL ISSUES CONCERNING THE METAL PARTS TREATER DESIGN FOR THE BLUE GRASS CHEMICAL AGENT DESTRUCTION PILOT PLANT
ROBERT A. BEAUDET,
University of Southern California, Los Angeles (retired),
Chair
RICHARD J. AYEN,
Waste Management Inc. (retired), Jamestown, Rhode Island
JOAN B. BERKOWITZ,
Farkas Berkowitz and Company, Washington, D.C.
WILLARD C. GEKLER,
ABS Consulting Inc., Los Alamitos, California
DAVID A. HOECKE,
Enercon Systems Inc., Elyria, Ohio
JOHN R. HOWELL,
University of Texas at Austin
NELLINE KOWBEL,
Malcolm Pirnie Inc., Emeryville, California
JOHN E. MORRAL,
Ohio State University, Columbus
DERRICK K. ROLLINS,
Iowa State University, Ames
Staff
MARGARET N. NOVACK, Study Director
NIA JOHNSON, Senior Program Associate
JAMES C. MYSKA, Senior Research Associate
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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
BOARD ON ARMY SCIENCE AND TECHNOLOGY
MALCOLM R. O’NEILL,
Lockheed Martin Corporation (retired), Vienna, Virginia,
Chair
ALAN H. EPSTEIN,
Pratt & Whitney, East Hartford, Connecticut,
Vice Chair
RAJ AGGARWAL,
Rockwell Collins, Cedar Rapids, Iowa
SETH BONDER,
The Bonder Group, Ann Arbor, Michigan
JAMES CARAFANO,
The Heritage Foundation, Washington, D.C.
ROBERT L. CATTOI,
Rockwell International Corporation (retired), Dallas, Texas
DARRELL W. COLLIER,
U.S. Army Space and Missile Defense Command (retired), Leander, Texas
JAY C. DAVIS,
Lawrence Livermore National Laboratory (retired), Livermore, California
PATRICIA K. FALCONE,
Sandia National Laboratories, Livermore, California
RONALD P. FUCHS,
The Boeing Company, Seattle, Washington
WILLIAM R. GRAHAM,
National Security Research Inc. (retired), San Marino, California
PETER F. GREEN,
University of Michigan, Ann Arbor
CARL GUERRERI,
Electronic Warfare Associates Inc., Herndon, Virginia
M. FREDERICK HAWTHORNE,
University of Missouri, Columbia
MARY JANE IRWIN,
Pennsylvania State University, University Park
ELLIOT D. KIEFF,
Channing Laboratory, Harvard University, Boston, Massachusetts
LARRY LEHOWICZ,
Quantum Research International, Arlington, Virginia
EDWARD K. REEDY,
Georgia Tech Research Institute (retired), Atlanta
DENNIS J. REIMER,
DFI International (retired), Arlington, Virginia
WALTER D. SINCOSKIE,
Telcordia Technologies Inc., Morristown, New Jersey
MARK J.T. SMITH,
Purdue University, West Lafayette, Indiana
MICHAEL A. STROSCIO,
University of Illinois, Chicago
JUDITH L. SWAIN,
University of California at San Diego, La Jolla
WILLIAM R. SWARTOUT,
Institute for Creative Technologies, Marina del Rey, California
EDWIN L. THOMAS,
Massachusetts Institute of Technology, Cambridge
ELLEN D. WILLIAMS,
University of Maryland, College Park
Staff
BRUCE A. BRAUN, Director
CHRIS JONES, Financial Associate
DEANNA P. SPARGER, Program Administrative Coordinator
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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
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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
Preface
The Committee to Review and Assess Developmental Issues Concerning the Metal Parts Treater Design for the Blue Grass Chemical Agent Destruction Pilot Plant (Appendix A) was appointed by the National Research Council in response to the following request from the Program Manager for Assembled Chemical Weapons Alternatives:
Statement of Task
Review the design and thermal modeling of the metal parts treater (MPT) for BGCAPP;
Review testing results that have become available in the course of Technical Risk Reduction Program activity 5c for the metal parts treater;
Develop means to address the longer-than-expected heat-up times of munitions casings in the MPT in view of considerations of the effect this has on the throughput capabilities for overall BGCAPP operations;
Review the Pueblo Chemical Agent Destruction Pilot Plant (PCAPP) Munitions Treatment Unit (MTU) design and test data, compare the MPT and MTU and make any recommendations regarding the MTU’s application to BGCAPP;
Produce a report with findings and recommendations concerning first-of-a-kind developmental issues and possible options concerning the MPT design for BGCAPP.
The committee is the latest in a series of committees assembled to provide scientific and technical advice to the Army as it seeks alternatives to the existing baseline incineration programs being used at five of the remaining eight chemical weapons stockpile locations.
The committee met three times (see Appendix B for the meeting agendas). At the first meeting, the committee visited the Parsons facility in Kennewick, Washington, to be briefed on the full Assembled Chemical Weapons Alternatives (ACWA) designs, the specifications for the metal parts treater (MPT), and the MPT Technical Risk Reduction Program (TRRP). The committee members also inspected the TRRP MPT used in testing. On September 20, 2007, representatives of the committee visited the Abbott Furnace Company in St. Marys, Pennsylvania, to receive presentations from the munitions treatment unit (MTU) manufacturer and to inspect the MTU being constructed and tested for the Pueblo Chemical Agent Destruction Pilot Plant (PCAPP). The second full meeting was held on October 16-18, 2007, at the National Academies’ Beckman Conference Center in Irvine, California. The first half-day was devoted to discussions with the Program Manager for Assembled Chemical Weapons Alternatives and the Bechtel Parsons Blue Grass Team to clarify any remaining questions, and the remainder of the 3-day meeting was devoted to discussions and to writing the report. At the last meeting, on November 6-8, 2007, also at the Beckman Conference Center, the committee focused on refining the report for peer review.
This was a very challenging study, in part because of the short time frame allowed the committee and in part because the delivery of sufficiently detailed written information necessary to inform the committee was delayed owing to security vetting. Such vetting, which appears to be an artifact of the September 11, 2001 attacks, continues to have a negative effect on the ability of committees to provide the type of technically detailed advice that is expected of them. The January 2008 date originally requested for delivery of the report required the committee to complete its data gathering before its third meeting, which took place November 6-8, 2007. Unfortunately, the Bechtel Parsons Blue Grass Team’s final report, Technical Risk Reduction Program Metal Parts Treater Final Study Report, Revision B, containing 763 pages of information and describing the testing of the MPT, was not made available to the committee until November 2, 2007, owing to an extensive operational security review. Thus, although the committee did spend considerable time during its final meeting examining this information, it based the majority of its deliberations on the oral presentations of test results and discussions with the Program Manager for Assembled Chemical Weapons Alternatives and contractor representatives.
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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
As the chair of this committee, I commend the diligent work and the contributions to the preparation of this report by the writing team leaders, Bill Gekler, John Howell, Joan Berkowitz, and Richard Ayen. Their efforts are particularly appreciated.
The entire committee, in turn, is grateful to the Program Manager for Assembled Chemical Weapons Alternatives Kevin Flamm and his staff, particularly Joseph Novad and Darren Dalton, for their considerable efforts to provide the needed information. The committee understands the challenges that these hard-working professionals encountered in assembling and gaining operational security clearances for the information and test results requested.
The committee also greatly appreciates the support and assistance of National Research Council staff members Bruce Braun, Margaret Novack, Nia Johnson, and Jim Myska, who ably assisted the committee in its fact-finding activities and in the production of the report.
The members of the Board on Army Science and Technology (BAST), listed on page v, were not asked to endorse the committee’s conclusions or recommendations, nor did they review the final draft of this report before its release, although board members with appropriate expertise may be nominated to serve as formal members of study committees or as report reviewers. The BAST was established in 1982 by the National Research Council at the request of the U.S. Army. It brings broad military, industrial, and academic scientific, engineering, and management expertise to bear on Army technical challenges and other issues of importance to senior Army leaders. The BAST also discusses potential studies of interest; develops and frames study tasks; ensures proper project planning; suggests potential committee members and reviewers for reports produced by fully independent, ad hoc study committees; and convenes meetings to examine strategic issues.
Robert A. Beaudet, Chair
Committee to Review and Assess Developmental Issues Concerning the Metal Parts Treater Design for the Blue Grass Chemical Agent Destruction Pilot Plant
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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
Acknowledgment of Reviewers
This report has been reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the National Research Council’s (NRC’s) Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the institution in making its published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their review of this report:
Martin Gollin, Carmagen Engineering Inc.,
Gary S. Groenewold, Idaho National Laboratory,
Elizabeth A. Holm, Sandia National Laboratories,
Peter B. Lederman, New Jersey Institute of Technology (retired),
James F. Mathis, NAE, Exxon Corporation (retired),
George J. Quarderer, Dow Chemical Company (retired),
W. Leigh Short, Principal and Vice President of Woodward-Clyde (retired), and
Michael K. Stenstrom, University of California, Los Angeles.
Although the reviewers listed above have provided many constructive comments and suggestions, they were not asked to endorse the conclusions or recommendations, nor did they see the final draft of the report before its release. The review of this report was overseen by Harold Forsen, NAE. Appointed by the National Research Council, he was responsible for making certain that an independent examination of this report was carried out in accordance with institutional procedures and that all review comments were carefully considered. Responsibility for the final content of this report rests entirely with the authoring committee and the institution.
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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
Contents
SUMMARY
1
1
INTRODUCTION
7
Background,
7
The BGCAPP Design and the Metal Parts Treater,
8
The PCAPP Design and the Munitions Treatment Unit,
10
Scope and Organization of the Study,
10
2
METAL PARTS TREATER SYSTEM
11
Overview,
11
Metal Parts Treater,
11
System Description,
11
System Operation,
13
Prototype Testing of the Metal Parts Treater Technology,
14
Off-Gas Treatment System,
16
System Description,
16
System Operation,
18
3
ASSESSMENT OF METAL PARTS TREATER TESTING ACTIVITIES
20
Mechanical Issues,
20
New Door Closure Mechanism and Seals,
20
Bearings for the Conveyer Rollers,
21
Heating Zones,
21
Secondary and Closure Waste Treatment,
22
Waste to Be Treated in the MPT,
22
Pyrolysis Testing of Secondary Waste Simulants,
24
Technical Risk Reduction Program Testing of MPT Treatment of Secondary Waste,
24
Alternative Treatment and Disposition of Secondary Waste,
26
4
THERMAL TESTING, MODELING, AND PREDICTED THROUGHPUT OF THE METAL PARTS TREATER
27
Experimental Temperature Measurements,
27
Temperature Prediction by Computational Fluid Dynamics Thermal Modeling,
28
Comparison of Temperature Measurements and Modeling,
30
Ability to Scale Up and Meet Throughput Requirements,
32
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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
5
APPLICABILITY OF PCAPP MUNITIONS TREATMENT UNIT AT BGCAPP
34
Munitions Treatment Unit Design and Operation at PCAPP,
34
Testing of the Munitions Treatment Unit for PCAPP,
35
Comparison of the Metal Parts Treater and Munitions Treatment Unit for BGCAPP,
35
Treatment of Energetics Batch Hydrolyzers and Secondary and Closure Waste at BGCAPP,
38
6
GENERAL FINDINGS AND RECOMMENDATIONS
40
REFERENCES
42
APPENDIXES
A BIOGRAPHICAL SKETCHES OF COMMITTEE MEMBERS
45
B COMMITTEE MEETINGS AND SITE VISITS
47
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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
Tables, Figures, and Box
TABLES
S-1
Comparison of the Metal Parts Treater and the Munitions Treatment Unit,
5
1-1
Inventory of the Chemical Weapons in the Blue Grass Army Depot Stockpile,
8
1-2
Pueblo Chemical Depot Chemical Weapons Stockpile of HD- or HT-filled Munitions,
8
3-1
Solid Waste Generation and Processing Rate in the Metal Parts Treater,
24
3-2
Summary of Results from Secondary Waste Testing Carried Out in 2005,
24
4-1
Metal Parts Treater Unit’s Material Properties,
30
4-2
Computational Fluid Dynamics Model Boundary Conditions for the Technical Risk Reduction Program,
31
4-3
Computational Fluid Dynamics Model 070806 Boundary Conditions,
32
4-4
Computational Fluid Dynamics Model 070806 Component Masses,
32
4-5
Metal Parts Treater/Metal Parts Treater Cooling System Projectile Throughput Rates,
33
5-1
Comparison of the Metal Parts Treater and the Munitions Treatment Unit,
37
FIGURES
1-1
Process flow diagram for the Blue Grass Chemical Agent Destruction Pilot Plant,
9
2-1
Simplified flow diagram of the metal parts treater system,
12
2-2
Current design of the off-gas treatment system for the metal parts treater,
12
2-3
First-of-a-kind full-scale metal parts treater system,
13
2-4
Technical Risk Reduction Program metal parts treater system (without staging conveyors, air lock doors, and cooling chamber),
15
2-5
Bulk oxidizer in the off-gas treatment system for the metal parts treater,
17
4-1
Location of thermocouples (X) and computational fluid dynamics model “cold spots” on test rounds and in tray for June 14 testing,
28
4-2
Comparison of computational fluid dynamics (CFD) model predictions with experimental results for thermocouples 4 and 6 on projectile 14 with CFD predictions,
29
4-3
Thermocouple installation on the projectile,
30
4-4
Variation of specific heat and emissivity with temperature,
31
5-1
The Abbott Furnace Company munitions treatment unit,
36
BOX
3-1
The Technical Risk Reduction Program (TRRP) 05c Heat Transfer Test,
22
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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
Abbreviations and Acronyms
ACWA Assembled Chemical Weapons Alternatives
BGAD Blue Grass Army Depot
BGCAPP Blue Grass Chemical Agent Destruction Pilot Plant
BOX bulk oxidizer (flameless thermal oxidizer)
BPBGT Bechtel Parsons Blue Grass Team
CATOX catalytic oxidizer
CFD computational fluid dynamics
DOD Department of Defense
EBH energetics batch hydrolyzer
ENS energetics neutralization system
GB nerve agent (sarin)
H Levinstein mustard agent
HD distilled mustard agent
HT distilled mustard mixed with bis(2-chloroethylthioethyl) ether
HVAC heating, ventilation, and air conditioning
LSS Lab Safety Supply
MDB munitions demilitarization building
MPT metal parts treater
MTU munitions treatment unit
MWS munitions washout system
NAE National Academy of Engineering
NRC National Research Council
OTM off-gas treatment for the MPT
OTS off-gas treatment system
PCAPP Pueblo Chemical Agent Destruction Pilot Plant
PCD Pueblo Chemical Depot
PMACWA Program Manager for Assembled Chemical Weapons Alternatives
PMD projectile mortar disassembly
PTFE polytetrafluoroethylene
PVC polyvinylchloride
SCWO supercritical water oxidation
SDU supplemental decontamination unit
TRRP Technical Risk Reduction Program
VOC volatile organic compound
VSL vapor screening level
VX nerve agent
WCL waste control limit
WIC waste incineration container
