Final Report

Environmental Security Technology Certification Program (ESTCP) Final Report Project Number: DACA87-02-C-0014 Project Title: Non-Thermal, On-Site Decontamination and Destruction of Practice Bombs Date of Submittal: 12 June 2006 Distribution Statement A: Approved for Public Release, Distribution is Unlimited ESTCP/SERDP Contract No.: DACA72-02-C-0014 Non-Thermal, On-Site Decontamination and UXB International, Inc. Destruction of Practice Bombs Table of Contents 1 ABSTRACT ........................................................................................................................... 1 2 INTRODUCTION................................................................................................................. 2 2.1 BACKGROUND .................................................................................................................. 2 2.2 OBJECTIVES OF THE DEMONSTRATION ............................................................................. 2 2.3 REGULATORY DRIVERS.................................................................................................... 3 2.4 STAKEHOLDER/END-USER ISSUES.................................................................................... 3 3 TECHNOLOGY DESCRIPTION....................................................................................... 4 3.1 TECHNOLOGY DEVELOPMENT AND APPLICATION ............................................................ 4 3.2 PREVIOUS TESTING OF THE TECHNOLOGY........................................................................ 7 3.2.1 Red Phosphorus....................................................................................................... 9 3.2.2 KC-4 Cartridges...................................................................................................... 9 3.2.3 BDU-33 Practice Bombs with Installed KC-4 Smoke Cartridges......................... 10 3.3 FACTORS AFFECTING COST AND PERFORMANCE............................................................ 10 3.4 ADVANTAGES AND LIMITATIONS OF THE TECHNOLOGY ................................................ 11 4 DEMONSTRATION DESIGN .......................................................................................... 11 4.1 PERFORMANCE OBJECTIVES ........................................................................................... 11 4.2 SELECTING TEST SITE(S)................................................................................................ 12 4.3 TEST SITE HISTORY/CHARACTERISTICS ......................................................................... 12 4.4 PRESENT OPERATIONS.................................................................................................... 12 4.5 PRE-DEMONSTRATION TESTING AND ANALYSIS ............................................................ 13 4.6 TESTING AND EVALUATION PLAN .................................................................................. 13 4.6.1 Demonstration Set-Up and Start-Up..................................................................... 13 4.6.1.1 Mobilization ...................................................................................................... 13 4.6.1.1.1 Trailer Setup................................................................................................ 13 4.6.1.1.2 Supplies ....................................................................................................... 13 4.6.2 Period of Operation – Major Project Milestones ................................................. 14 4.6.3 Scope of Demonstration ........................................................................................ 14 4.6.4 Residuals Handling ............................................................................................... 14 4.6.5 Operating Parameters For The Technology ......................................................... 14 4.6.6 Demobilization ...................................................................................................... 16 4.7 SELECTION OF ANALYTICAL/TESTING METHODS........................................................... 16 4.8 SELECTION OF ANALYTICAL TESTING LABORATORY ..................................................... 17 5 PERFORMANCE ASSESSMENT.................................................................................... 17 5.1 PERFORMANCE CRITERIA ............................................................................................... 17 5.2 DATA ANALYSIS, INTERPRETATION, AND EVALUATION................................................. 18 6 COST ASSESSMENT ........................................................................................................ 20 i ESTCP/SERDP Contract No.: DACA72-02-C-0014 Non-Thermal, On-Site Decontamination and UXB International, Inc. Destruction of Practice Bombs 6.1 COST REPORTING ........................................................................................................... 20 6.2 COST ANALYSIS ............................................................................................................. 21 6.2.1 Cost Comparison................................................................................................... 22 6.2.2 Cost Basis.............................................................................................................. 22 6.2.3 Cost Drivers .......................................................................................................... 22 6.2.4 Life Cycle Costs..................................................................................................... 23 7 IMPLEMENTATION ISSUES.......................................................................................... 23 7.1 ENVIRONMENTAL CHECKLIST ........................................................................................ 23 7.2 OTHER REGULATORY ISSUES ......................................................................................... 23 7.3 END-USER ISSUES .......................................................................................................... 23 8 REFERENCES.................................................................................................................... 24 9 POINTS OF CONTACT .................................................................................................... 24 10 ATTACHMENTS ............................................................................................................... 26 List of Figures SM FIGURE 1: UXBASE MOBILE BDU TREATMENT UNIT (SEE ATTACHMENT 1) .............................. 5 FIGURE 2: PROCESS FLOW DIAGRAM............................................................................................... 6 FIGURE 3: KC-4 CARTRIDGE: BEFORE AND AFTER....................................................................... 10 FIGURE 4: LOCATIONS OF THE SAMPLING POINTS ......................................................................... 16 FIGURE 5: EXAMPLE OF PROCESSED CARTRIDGE PROPELLANT RESIDUE LOCATION..................... 19 List of Tables TABLE 1: TEST RESULTS ................................................................................................................. 8 TABLE 2: PERFORMANCE OBJECTIVES........................................................................................... 11 TABLE 3: SAMPLING POINTS AND FREQUENCIES ........................................................................... 15 TABLE 4: PERFORMANCE CRITERIA............................................................................................... 17 TABLE 5: PERFORMANCE CONFIRMATION METHODS .................................................................... 18 TABLE 7: COST TRACKING ............................................................................................................ 21 TABLE 6: POTENTIAL COST SAVINGS ............................................................................................ 22 ii ESTCP/SERDP Contract No.: DACA72-02-C-0014 Non-Thermal, On-Site Decontamination and UXB International, Inc. Destruction of Practice Bombs List of Appendices Appendix A: Analytical Methods Supporting Project Appendix B: Quality Control Plan Appendix C: Site-Specific Health and Safety Plan Appendix D: Test Results: Laboratory Tests of BDU-33 Practice Bombs with Installed KC-4 Smoke Cartridges Appendix E: Test Results for the Disposal of Neutralized Process Solutions List of Acronyms BDU Bomb Dummy Unit DOD Department of Defense EOD Explosive Ordnance Disposal SOP Standard Operating Procedure UXO Unexploded Ordnance iii ESTCP/SERDP Contract No.: DACA72-02-C-0014 Non-Thermal, On-Site Decontamination and UXB International, Inc. Destruction of Practice Bombs 1 Abstract The process was evaluated to determine required process variables. Following treatment the clean scrap was evaluated to determine its value. After neutralization, the liquid by-products were analyzed for explosive content, metals, and pH. During operations, gasses evolved were analyzed for hydrogen, carbon monoxide, carbon dioxide, and phosphine. Overall the process failed to achieve its objectives. The failure was due to the inability of the caustic fluid to penetrate certain blockages of some dropped, but still live, BDU’s so that the propellant was not always destroyed. The fact that propellant does remain in some cases means that inspection would be required to verify that the process has worked as intended for each and every BDU treated, which largely negates the projected cost savings from the process, and does not decrease the hazards associated with recycling

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