An Overview of PCAPP’s Pilot Demonstration Testing

Presented by: Kim Jackson, PCAPP Operations Manager & George Lecakes, PCAPP Chief Scientist

Timeline – Pilot Test Demonstration

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PCAPP Pilot Test DemonstrationObjectives1

1. Demonstrate agent removal, agent neutralization, and related agent neutralization sampling and analysis.

2. Demonstrate munition body treatment (washout, thermal treatment).3. Establish bounding operating ranges and set points for operating

parameters critical to agent removal, munition body treatment, and agent neutralization operations.

4. Demonstrate energetics removal and establish bounding operating ranges and set points for operating parameters critical to ensuring energetics removal operations.

5. Validate monitoring protocols for all equipment and work areas in the ERB and APB.

6. Validate treatment and monitoring protocols for disposition of dunnage, energetics, and miscellaneous waste (e.g., OPP, PME, SDU, Autoclave as designated for each waste material)

7. Demonstrate removal of TDG and document removal of other organic compounds from hydrolysate waste stream (e.g., ICB, BRS)

8. Demonstrate processing systems can operate at a ramp rate that safely supports the operating schedule.

1DERIVED FROM THE TEST CONCEPT PLAN, APPENDIX D; 3/21/2011

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PCAPP Pilot Test DemonstrationObjectives (CONT.)

9. Demonstrate integrated facility operations with agent and energetics to verify the following:

a) Compliance with safety requirementsb) Compliance with surety and security requirements c) Integrated system operabilityd) Plant-wide operations while remaining within emissions requirements (as stated in the Multiple

Pathway Health Risk Assessment Report for PCAPP Project [MPHRA], 24852-RD-3RC-000-V0004)e) Handling and movement of munitions for current munitions campaignf) Sampling and analysis protocols (e.g., agent, hydrolysate, brine, emissions)g) Decontamination operationsh) Ability to perform routine and selected off-normal maintenance activitiesi) Waste handling and disposition, including dust and odor control

10.Validate agent monitoring protocols for detecting agent (e.g., MINICAMS, Depot Area Air Monitoring System [DAAMS]).

11.Demonstrate off-gas treatment performance. This will include demonstration of agent destruction and removal at the OTS and AFA, odor control at the BTA.

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Finally, the collection of site-wide emissions data for finalization of the RCRA Part B Permit

Block 1 – Systems, Fit, and Function

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Systems: Block 1 – Baseline and Enhanced Reconfiguration includes OPP Monitoring, Munitions Monitoring Table (Baseline Reconfiguration), PMD Operations and MME/PME Operations Fit: After transport and receipt of munitions at PCAPP and prior to agent removal activitiesFunction: Prepares munitions for access and removal of agent by separating packing material (e.g., wooden pallets, strapping, boxes) and energetics/miscellaneous parts from the munitions bodies

Explosion ContainmentRoom

MWS

MTU

Block 2 – Systems, Fit, and Function

Systems: Block 2 – Munitions Body Treatment includes Munitions Washout System (MWS) and Munitions Treatment Unit (MTU) Fit: After Baseline and Enhanced Reconfiguration and prior to Agent Collection and NeutralizationFunction: Drains and washes agent from energetics-free munitions bodies and thermally treats munitions bodies to Clean Unrestricted, Releasable to the General Population (Clean Unrestricted)

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Block 3 – Systems, Fit, and Function

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Systems: Block 3 – Agent Collection and Neutralization includes the Agent Water Separators, Wash Water Holding Tanks, Agent Hydrolyzers, Hydrolysate Hold Tanks and 30-Day Storage TanksFit: After Agent Collection and prior to Bio-Treatment of the cleared hydrolysateFunction: Separates the MWS agent drained and rinse water, hydrolyzes the mustard agent, and verifies destruction prior to treatment in the Immobilized Cell Bio Reactors

Block 4 – Systems, Fit, and Function

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Systems: Block 4 – Hydrolysate Treatment and Water Recovery includes the Bio-Treatment System, Water Recovery System (Brine Concentrate Feed Tanks), and the Brine Reduction System plus associated off-gas treatment unitsFit: After agent neutralization and clearing in Block 3 and prior to process water recycle or to off-site shipment of secondary wastes (salt cake / bio sludge)Function: Removes thiodiglycol (TDG) and other organics through biodegradation, recovers process water, de-waters sludge for disposal and treats off-gasses for discharge.

Block 5 – Systems, Fit, and Function

Systems: Block 5 – Supplemental Decon Units and AutoclaveFit: Receives materials, equipment, components, and waste materials from other process areas including ERB, APB, ESM, MSM.Function: Reduces agent contamination levels to acceptable levels for either reuse and/or off-site disposal

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Block 6 – Systems, Fit, and Function

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Systems: Block 6 – Off-gas treatment system including thermal oxidizer and scrubbers, the agent filtration area (including particulate & HEPA filtration, granulated activated carbon and sulfur impregnated carbon) and the AFA stackFit: Receives process off-gas from the OTS and HVAC exhaust from ERB and APB ventilation systems Function: Treat process off-gasses and HVAC exhaust from engineering controlled spaces to remove agent and other COC’s to prescribed levels before releasing to the atmosphere.

Process Layout by BlocksPCAPP PROCESS DIAGRAM

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EDT REMOVED FROM PCAPP SCOPECONTAMINATED ENERGETICS AND IN-PROCESS

LEAKERS & REJECTS SENT TO G-BLOCK FOR SUBSEQUENT PROCESSING IN A GOVERNMENT

SYSTEM

Test SequencePilot Testing (155mm) Block 1 Block 2 Block 3 Block 4 Block 5 Block 6

Changeover Testing 105mm Campaign 4.2in Campaign

• Testing ≡ to define optimized operating parameters

• Ramp-up ≡ capability of personnel and equipment to sustain operations

• Demonstration ≡ capability of each process system within the facility to process munitions for 4-hour periods per shift

Block 1 – Munitions Receipt and Enhanced Reconfiguration is to support the testing, ramp-up and demonstration of the other systems within Blocks 2, 3, 4 and 6.Block 5 – Secondary Waste Treatment

OperatingPermit

INTEGRATED FACILITY DEMONSTRATION TEST

• Emissions Sampling

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QUESTIONS