Demilitarization by Open Burning and Open Detonation for National Academy of Sciences October 2017 John F. McFassel PD Demil (973) 724-8759 john.f.mcfassel.civ@mail.mil
Purpose Describe Reasons that certain munitions are Open Burned or Open Detonated Describe alternate methods that have been investigated for these items 2
Demilitarization by Open Burning Placed Directly in Burning Pans D541 Charge, Propelling D533 Charge, Propelling D675 Charge, Propelling D676 Charge, Propelling D681 Flash Reducer C511 and C520 105-mm Training Rounds Cartridges are pulled apart Propellant removed for Open Burning Inert warhead has a tracer so they are flashed in OB pans, if Depot does not have a Flashing Furnace Inert warhead is then recycled 3
Demilitarization by Open Burning Alternatives Until recently, no safe, efficient, and effective alternative process had been demonstrated several attempts made No Single Location that could justify expense of system like one used at Camp Minden (Which was only Demonstrated for one type of Propellant) Multiple Items at multiple locations D533 (3400 tons total) stored at four of the seven organic sites. TEAD and HWAD each have over 1000 tons, CAAA over 800 tons RDT&E Project looking at Bulk Energetics Demilitarization System Commercial Contract Planned in FY 18 to Determine State of Commercial Industrial Base Sources Sought Indicate Multiple Companies Interested 4
Open Burning Alternatives (Past Challenges) Thermal Incineration of Bulk Propellants (Rotary Kiln): Challenges associated with managing propellant burn dynamics including premature ignition of material at feed system resulting in damage to equipment and injury of personnel. Base Hydrolysis of Bulk Propellants: Challenges associated with heavy metal contamination and controlling chemical reaction rates resulting in damage to equipment and risks of environmental contamination from process spillage. Blasting Slurry Agent Manufacturing from Bulk Propellants: Challenges associated with unpredictability of commercial slurry markets (demand vs total supply vs yearly government funding), speculative accumulation cost of operations, and loss of Ammunition Lot traceability leading to inability to validate propellant stability levels for stored material. Reuse & Recovery of Bulk Propellants: Challenges associated with energetic removal, recovery and separation operations resulting in damage to equipment and injury of personnel. Inability to establish predictable commercial or military reuse markets for recovered materials. 5
Static Firing Recent History of Static firing Motor Hazard Class Propellant Weight AP Based Honest John (H365) 1.1/1.3 ~2,000 N Maverick (PA33) 1.3 ~65 Y Chaparral(V511) 1.3 ~60 Y Phoenix (V885) 1.3 ~360 Y Standard (V284) 1.3 ~385 Y Sparrow (V378) 1.3 ~135 Y Sidewinder (V888) 1.3 ~60 Y When fully operational, LEMC ARMD facility will be ale to process all AP based motors shown above Static Fire will be Phased Out at other Depots Double base motor inventory (i.e. Honest John, Nike Herc, Standard MK12, etc) Static fire most viable option Propellant safety risk from impact (mass detonating/explosion); nitroglycerin diffusion to threads and seals (disassembly risk) Low quantities and tend to be oldest stocks in missile demil inventory Other alternatives researched (size reduction, chemical conversion, closed chamber, etc.) but not currently viable to implement given overall quantities and safety considerations 6
High Explosive Rounds B632 CTG 60-mm C256 and C868 Cartridge 81-mm C463 105mm (Rocket Assist) C508 105mm (Shaped Charge) C995 CTG and Launcher AT-4 (Shaped Charge) D544 155mm D624 8 in Smaller items (60mm and 81mm) candidates for Static detonation Chamber Energetics could possibly be removed by washout or melt out, but cost would be high given relatively small Net Explosive Weight of Each Item D510 Copperhead Projectile is disassembled, hazardous components removed, only warhead is detonated 7
Cluster Munitions D563 155mm Projectile or just M42/M46 submunitions E890 Dispenser and Bomb C462 CTG 105mm Projectile/Bomb is typically downloaded and only submunitions are subject to Open Detonation Shell casings from the D563 (over 100,000 per year) are collected for reuse at organic government facilities 8
Alternatives for Cluster Munitions GD-OTS using automated facility for Multiple Launch Rocket System (MLRS) as well as D563 and D864 155-mm Projectiles At GD-OTS facility CBUs are downloaded, cut to remove fuze and fed into rotary kiln EXPAL proposes to use Static Detonation Chamber and is Considering Reclamation of Energetics Automated Facility for MLRS Warheads at Anniston is in Low Rate Initial Production Automated Facilities must be Designed for each specific munition Disassembly is required Detonations Occur on a Regular Basis 9
2.75 and 5 Inch Rockets J147 2.75in Rocket Motor H842 2.75 in Warhead J106 2.75 in Rocket Motor J143 5 in Rocket Motor (for Mine Clearing Line Charge) Energetics could possibly be removed by washout or melt out, but cost would be high given small Net Explosive Weight of Each Item and their low total numbers Investigating Static Fire Within Contained Detonation Chamber at Blue Grass Army Depot 10
K045 Mine Canister K143 Anti-Personnel Mine Mines and Fuzes Disassembly is required for these items prior to other Demilitarization methods There are safety issues with handing these items since they are antipersonnel mines K068 Mine Fuze N285 Artillery Fuze N335 Artillery Fuze N340 Artillery Fuze Thermal treatment is a possibility for these items, although they would require disassembly first These items contain plastics which cause Build up in the APE 1236 11
Other B104 30mm cartridge High explosive Incendiary Round, Much slower feed rate in APE 1236 than other medium caliber items E485 500 lb Bomb Unusual shape and small quantity made melt out much more expensive than other bombs M158 Engine Starter Cartridge Looking at the potential to static fire this item and recycle casing C601 and C410 90mm Anti-Personnel Cartridges Rounds are pulled Apart, Projectile Detonated, Propellant Burned, Case recycled Donor Material M757 Demolition Kit M591 TNT Block 8W77 Sonobuoy - Disassembled SW37 Underwater Sound Signal - Disassembled 12
Summary Demilitarization Enterprise is continuously researching methods for safe and compliant handling of new munitions Open Burning and Open Detonation are compliant within regulated permit limits and only used when safe alternatives have not been proven 13