Sampling and Analysis at PCAPP During Pilot Test DemonstrationDr. Reza Karimi, Andrew Shaffer, and Clara Galbis-ReigMay 2017 CWD

OPSEC/ITAR Review Completed: 22 May 2017

Agenda

Introduction

• PCAPP basics

Pilot Test Objectives

Pilot Test Blocks and Results

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PCAPP Facility is in Agent Operations

Designed to destroy 2,611 tons of mustard agent (HD) in mortar and projectiles stored at PCD

• Completed construction and systemization phases

Destruction operations began on 7 Sep 2016

• Destroyed more than 25,000 155mm HD projectiles

• Completed multiple pilot tests

Began feeding agent hydrolysate to biomass in April 2017

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Pilot Test Objectives

Pilot testing provides the data to:

• Define critical operating parameters

• Demonstrate safe operations

• Validate environmental compliance

• Demonstrate efficient operations of the PCAPP

• Provide data for the Multiple Pathway Health Risk Assessment (MPHRA)

Pilot Testing uses a stepped-approached to characterizing plant impacts

• Testing is organized into “blocks” to incrementally assess system impacts

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DEMONSTRATE THE PROCESS CRITERIA AND OPERATINGCONDITIONS THAT ENSURE THE PROTECTION OF HUMAN

HEALTH AND THE ENVIRONMENT

PCAPP Block Functions

Block 1 - Projectile Mortar Disassembly (PMDs) machines and associated and air monitoring systems

• Separate energetic components from chemical munitions

Block 2 – Munitions Washout System (MWS) and Munition Treatment Unit (MTU) operations

• Access mustard agent from munitions and washout munition bodies

• Thermally treat munition bodies to U.S. Army standard of 1,000°F for 15 minutes

Block 3 – Chemical Agent Collection and Neutralization Systems

• Collect and separate chemical agent and washwater

• Neutralize/Hydrolyze mustard agent, converting it to thiodiglycol

Block 4 – Hydrolysate Treatment and Water Recovery

• Treat thiodiglycol using immobilized cell bioreactors (ICBs)

• Recover water for reuse in PCAPP systems

Block 5 – Supplemental Decontamination

• Treat chemical agent contaminated secondary waste to levels that will allow for off-site disposition using a supplementary decontamination unit (SDU) and/or an autoclave

Block 6 – Off-gas Treatment System and Agent Filtration Area

• Control PCAPP facility emissions through an active off-gas treatment system and activated charcoal filtration systems

Pilot Test Blocks

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Block 1 – Munitions Receipt and Enhanced Reconfiguration

Purpose

• Demonstrate energetics removal, handling, and disposition

• Demonstrate the Projectile Mortar Disassembly (PMD) machine can support the operating schedule

• Define critical operating parameters

• Disposition munition pallets

Status – testing complete!

Results

• Determined daily munitions rate

• Determined average throughput (meets ops schedule)

• No adverse findings in air monitoring for munitions/energetics

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Block 2 – Munitions Body Treatment

Purpose is to

• Demonstrate throughput supports the ops schedule

• Control paint chips, ash, dust

• Collect data on agent Recycle munitions bodies

• solids treatment emissions

Status – 75% complete

Completed

• Munition Washout System (MWS) optimization test

– Set points ID’ed to maximize effectiveness while minimizing use of resources

• Munitions Treatment Unit (MTU) loss of Paint Residue Removal System (PRRS) test (paint chips/ash/dust are controlled)

• Munitions Treatment Unit heel (agent solids) test – results within safe limits

• Need to complete optimization confirmation and 100% ramp-up tests.

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Block 2 – Munitions Body Treatment:AFA Sampling

Facility Emission Analyses Conducted

• HD (destruction efficiency)

• Dioxins and furans

• VOCs

• SVOCs

• Acid gases

• Metals/mercury

• Nitrogen oxides

• Sulfur dioxide

• Particulates

Outcome for the MPHRA

• MWS/MTU only test runs show MPHRA impacts below threshold levels

• Results for samples collected to date are within regulator identified thresholds

Block 3 – Agent Collection and Neutralization

Purpose

• Control mustard agent concentration in the agent neutralization reactor (ANR) and produce hydrolysate

• Demonstrate mustard agent destruction with:

– Up to 15 wt% agent concentrate

– No agitator

Status – 75% complete

Completed

• Agent/Water Separator

• High agent load test

• ANR no agitator test

Final report pending (in review)

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Block 3 – Agent Collection and Neutralization: AFA Sampling

Facility Emission Analyses Conducted

• TDG

• 1,4-dithiane

• 1,4-oxathiane

• VOCs

• SVOCs

• Anions

• Cations

• Ammonia

• Metals

• COD

• TOC and DOC

• TDS and TSS

• Conductivity

• Dioxins and furans

Outcome for the MPHRA

• MWS/MTU only test runs show MPHRA impacts below threshold

• Results for samples collected to date are within regulator identified thresholds

Block 4 – Hydrolysate Treatment and Water Recovery

Purpose

• Demonstrate thiodiglycol removal from hydrolysate via immobilized cell bioreactors (ICBs)

• Produce recovered water that is acceptable for reuse in the facility via Brine Recovery System (BRS)

• Control chemical of potential concern and odor emissions

Status – 10% complete

Began feeding hydrolysate to biomass in April 2017

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Block 4 – Hydrolysate Treatment and Water Recovery: Bio Treatment Area Emissions

Analyses Conducted

• TDG

• 1,4-dithiane

• 1,4-oxathiane

• VOCs

• SVOCs

• Anions

• Cations

• Ammonia

• Metals

• COD

• Dioxins and furans

Outcome for the MPHRA

• Sampling not conducted yet

• Preliminary MPHRA estimates used for current projections

Block 5 – Supplemental Decontamination

Purpose

• Demonstrate decontamination operations, waste handling, and disposition

Status – testing complete!

• Supplemental Decontamination Unit (SDU) demonstration

• Autoclave demonstration

Analyses

• Air monitoring for HD off-gassing from waste

Results

• SDU and autoclave systems are capable of reducing mustard agent contamination levels below client/regulatory thresholds

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Block 6 – Off-gas Treatment System –Agent Filtration Area

Purpose

• Evaluate contributions of individual systems on emissions (previous block test descriptions)

• Demonstrate agent destruction and removal efficiency

• Evaluate performance with respect to acid gases, particulates, and control Chemicals of Potential Concern

• Determine relationship of THC monitoring to emissions

Status – 75% complete

Completed

• MWS/MTU OTS/AFA demo

• OTS/AFA - ANR demo

• OTS/AFA demo

Integrated Facility Demonstrationremains

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OTS = Off-Gas Treatment SystemAFA = Agent Filtration Area

Block 6 – Off-gas Treatment System –Agent Filtration Area: Emissions

Analyses Conducted

• HD

• VOCs

• SVOCs

• Metals

• Mercury

• Acid gases

• Particulates

• Dioxins and furans

• Nitrogen oxides

• Sulfur dioxide

• Butane adsorption

• Ammonia

Outcome for the MPHRA

• Maximum values across all tests to date show MPHRA impacts below threshold

• Dioxin/Furans and metals present challenges in modeling – alternative evaluation pathways are under consideration

• Results for samples collected to date are within regulator identified thresholds

Integrated Facility Demonstration (IFD)

Purpose

• Demonstrate integrated facility operations at the maximum achievable rate

– While remaining compliant with procedures, permits and regulations

• Collect site-wide emissions data at the maximum achievable rate

– Supports development of RCRA Part B permit conditions

Status – Upcoming in July and August 2017

Chemical Limited Area Integrated Facility Demonstration : AFA Emissions

Analyses Conducted

• HD

• VOCs

• SVOCs

• Metals

• Mercury

• Acid gases

• Particulates

• Dioxins and furans

• Nitrogen oxides

• Sulfur dioxide

• Butane adsorption

• Ammonia

How data will be used

• Sample data is converted into emission rates

• Emissions rates will be input into the dispersion and exposure model MPHRA to evaluate health impact

• Plant operations conditions (throughput rates via emissions criteria) established

• Conditions codified in Part B RCRA permit

Biotreatment Area Integrated Facility Demonstration

Analyses Conducted

• TDG

• VOCs

• SVOCs

• Anions

• Cations

• Ammonia

• Chemical oxygen demand

• Dioxins and furans

How data will be used

• Sample data is converted into emission rates

• Emissions rates will be input into the dispersion and exposure model MPHRA to evaluate health impact

• Plant operations conditions (throughput rates via emissions criteria) established

• Conditions codified in Part B RCRA permit

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