Interim Design Assessment for the Pueblo Chemical Agent Destruction Pilot Plant (2005) / Chapter Skim
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3 Selected Pueblo Chemical Agent Destruction Pilot Plant Design Issues
3 Selected Pueblo Chemical Agent Destruction Pilot Plant Design Issues
Pages 27-47
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From page 27... ...
largely on the initial design for the Pueblo Chemical Buffer storage is needed for situations in which singleAgent Destruction Pilot Plant (PCAPP)
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From page 28... ...
The Bechtel Pueblo team de- are novel. Moreover, the PCAPP design is a first-of-asigning the Pueblo Chemical Agent Destruction Pilot kind pilot plant, and, consequently, overall integration Plant should seek clarification on the regulations for of the unit processes presents additional challenges.
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From page 29... ...
Although the implementation of the risk result in explosion. It would seem that the con- assessment methodology in the preliminary technical sequences of explosion in both instances or lo- risk assessment for the Pueblo Chemical Agent De cations should be the same, since the impact of struction Pilot Plant is sometimes inconsistent, the investigation delays would be similar.
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From page 30... ...
requirement for maintenance, with moderate schedule impact. Closure criteria not adequately defined, causing minimal to Add experienced closure expert from Johnston Atoll Chemical moderate impacts on closure costs and schedule due to extra time Agent Disposal System to design-build team to participate and and equipment requirements.
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From page 31... ...
sessment (TRA) scoring process for the Pueblo Chemi- For example, higher risks in the public's perception cal Agent Destruction Pilot Plant is continued, the may relate mainly to worker and public safety, whereas Army and the Bechtel Pueblo team should more clearly the Bechtel Pueblo team may see those risks as mandefine each of the weighting factors used in the initial ageable and less of a challenge than other technical TRA for probability and consequences.
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From page 32... ...
concept for the Pueblo Chemical Agent Destruction In a typical workday (daytime only) , one vePilot Plant (PCAPP)
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From page 33... ...
The Bechtel Pueblo team propellant cardboard cases, and the boxes, are collected should evaluate the hazards associated with the two- in bins for transport to the dunnage shredding and hanway traffic pattern within the restricted area in the vi- dling system and continuous steam treater. cinity of the energetics processing building at the The reconfiguration room is designed so that perPueblo Chemical Agent Destruction Pilot Plant and sonnel in the room can safely open and reconfigure the should consider revising this pattern to maintain a one- munitions.
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From page 34... ...
Based on preliminary testing, a high efforts for the munitions washout system design of the water temperature minimizes water usage and is more Pueblo Chemical Agent Destruction Pilot Plant should effective for the removal of agent heels from the pro- ensure that the design is forgiving of misalignment and jectiles. The design must optimize water wash tempera- misplacement of munitions in trays, and that proceture and volume for both the washout process itself and dures are in place to effectively deal with off-normal the downstream processing.
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From page 35... ...
If the tests of the munitions after all nonleaking 4.2-inch mortars have been pro- washout system/cavity access machine to be used at cessed. the Pueblo Chemical Agent Destruction Pilot Plant still The committee understands that the PCAPP refrig- indicate problems with frothing agent from munitions, eration unit, if used, would be installed in the unpack the committee recommends solving these problems area of the EPB before the start of the campaigns for without the application of refrigeration for leakers and processing leakers and rejected munitions.
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From page 36... ...
Achieving a rate of energetics transfer equivato locate and overpack individual leakers at Pueblo lent to the design rate established for the overChemical Depot and other storage sites should be con- head monorail conveyor system. sidered for continued use during operations of the Pueblo Chemical Agent Destruction Pilot Plant.
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From page 37... ...
The hydrolysis of energetic materials at the beginning of May 2004. Because testing prior to the Pueblo Chemical Agent Destruction Pilot Plant is 2003 had been done at or below 105°C, the DCD tests expected to be substantially completed in the energetwere planned to verify that the bulk of the reaction of ics rotary hydrolyzers.
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From page 38... ...
Design decisions for the sion cracking can occur in 304 or 316 stainless steel at Pueblo Chemical Agent Destruction Pilot Plant regardtemperatures as low as 120°C for 35 percent caustic ing the appropriate material for use in caustic service solutions. As this is the approximate operating range of should take into account temperatures, concentrations the ERH, the use of 304 or 316 stainless steel must be of caustics, and contaminants.
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From page 39... ...
In designing the Pueblo for the biological treatment process should be capable Chemical Agent Destruction Pilot Plant, the Bechtel of handling these contaminants. As the pH of the hyPueblo team should establish the toxicity of the efflu- drolysates is reduced to ranges suitable for biotreatment ent from biotreatment of TNT and tetryl hydrolysates, (i.e., pH 6 to 9)
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From page 40... ...
The with aluminum hydroxide precipitates and other prebench-scale testing of the ICBs at the Battelle Memo cipitates and their effect on the biotreatment process at rial Institute in Columbus, Ohio, is not evaluating the the Pueblo Chemical Agent Destruction Pilot Plant. effects of aluminum and will not observe the effects of The Bechtel Pueblo team is addressing the problem, phosphorus depletion.
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From page 41... ...
some problems discovered at full scale that were not This TRRP activity will not test the offgas treatment found at the lower scale of the TRRP. Some of these system because the Bechtel Pueblo team believes that factors may include (1)
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From page 42... ...
of the public. Pueblo Chemical Agent Destruction Pilot Plant, should Under the updated rules, a material can be released be used to determine if repeated cycles of parking hot unconditionally under any of the following three cirtrays on the MPT exit hardware will cause excessive cumstances (U.S.
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From page 43... ...
with respect to the chemical composition of the gases- for example, corrosion and the possibility of dioxin and Prior to issuance of the new guidance by the Army, furan formation in the CST offgas treatment system the Bechtel Pueblo team was constrained to treat dun- (OTS)
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From page 44... ...
Finding 3-19. The continuous steam treaters for the The new CST design is expected to allow the solid Pueblo Chemical Agent Destruction Pilot Plant will be feed material to reach 1000°F in the first chamber required to treat a wide range of feed materials, includquickly, while the second chamber provides assurance ing organic liquids.
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From page 45... ...
at the Pueblo Chemical process stream within the critical temperature range of Agent Destruction Pilot Plant should provide for char400°C to 750°C, metal dusting can be severe (Baker et acterizing the CST offgas feed to the offgas treatment al., 2004)
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From page 46... ...
Army, 2004b. Offgas Treatment System of the are 100 microns and larger, while the second cyclone Continuous Steam Treater removes more than 99 percent of particulates that are 10 microns and larger.
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From page 47... ...
The venturi scrubber also removes hydro- nificant restriction of plant operation if the OTSs of the chloric acid. In the venturi section, the hot process Pueblo Chemical Agent Destruction Pilot Plant prove gases are cooled and condensed using a spray of to have lower-than-expected reliability.
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