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U.S. ARMY ARMAMENT RESEARCH, DEVELOPMENTU.S. ARMY ARMAMENT RESEARCH, DEVELOPMENTAND ENGINEERING CENTERAND ENGINEERING CENTER
CRYOFRACTURE DEMILITARIZATION PROGRAM UPDATE
Committed to Excellence
PRESENTED BY:
Florence Elie-DelacruzArmament Engineering and Technology Center
Energetics, Warheads, and Environmental Technology Directorate
John F. FollinGeneral AtomicsSan Diego , CA
2007 Global Demilitarization Symposium & ExhibitionReno, NevadaMay 16, 2007
AMC
U.S. ARMY RESEARCH, DEVELOPMENT, AND ENGINEERING COMMANDU.S. ARMY RESEARCH, DEVELOPMENT, AND ENGINEERING COMMAND
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2Committed to Excellence
ACKNOWLEDGEMENTS
• Project Sponsors:» Product Manager for Demilitarization» US Army Defense Ammunition Center
• Project Team:» PM Demil - Project Oversight» DAC – Project Integration and Coordination
– Robotics Integration» ARDEC – Project Execution and Technical Supervision» MCAAP – Facility Support and Process Operations» GA – Process Design, Construction/Installation, and Proveout
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3Committed to Excellence
PRESENTATION OUTLINE
• Background
• Project History
• Prototype Facility» Process Design Basis» Facility Development» Equipment Upgrade Status» Schedule» Summary
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4Committed to Excellence
BACKGROUND
• There is a potential requirement to demilitarize 6 to 9 million ADAM antipersonnel landmines as well as a variety of other small explosive loaded munitions in the demil inventory (e.g., grenades, mines and submunitions in ICMs and CBUs)
• Conventional methods are not acceptable for the ADAM mine:» Components include explosives (in the overlay/kill mechanism, gas
generator, Safe & Arming Device), an ammonia battery and an epoxy housing containing a small amount of DU
» OB/OD yields DU/explosives mixed waste which contaminates the soil, air and water and is not exempted under Federal Regulation10CFR40
» Disposal sites will require long-term care, monitoring and maintenance to protect the public health and safety
» Incineration in a deactivation furnace will result in contamination of the furnace and ultimately require its disposal
• For other small explosive-loaded munitions, there is a hazard associated with detonation in the furnace.
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5Committed to Excellence
OBJECTIVE
• Develop a safe, cost effective, environmentally sound technology for the demilitarization of the ADAM mine and other small, explosive-loaded munitions in order to:
» Phase out Open Burning/Open Detonation» Increase the throughput in deactivation furnaces » Minimize risk to personnel and equipment» Reduce operator exposure to DU/explosive materials during
the demilitarization operation» Demonstrate automated projectile download operations
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6Committed to Excellence
TECHNICAL APPROACH
• Use an existing large-scale cryofracture test facility at Dugway Proving Ground (DPG) to determine feasibility of process and confirm the proposed prototype design
• Design, procure, install and proveout a high rate prototype cryofracture demil facility at McAlester Army Ammunition Plant (MCAAP), Oklahoma
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7Committed to Excellence
CRYOFRACTURE PROJECT HISTORY
• Project has evolved through 5 phases• Phase I: Proof of Principle for Conventional Ammunition
» 1994-1999: Inert and live testing of various munitions at DPG» 1997: ADAM mine selected as primary candidate item
• Phase II: Design of Prototype Facility at McAlester AAP» 1997: Cryofracture process conceptual design completed» 1999: Detailed process design completed» 2000: Building and support equipment design completed
• Phase III: Facility Construction and Equipment Procurement/Fabrication/Installation/Proveout and Manual Demonstration/Validation
» 2000-2004• Phase IV: Addition of Automated Robotically-Based Projectile
Disassembly/Downloading Capability» 2001-2005
• Phase V: Process Equipment and Safety Upgrades/Integrated(including robotics) Dem/Val
» 2004-Present
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8Committed to Excellence
MCAAP MCDF DevelopmentCryofracture Process Design Basis
• Process ADAM mines
• Process other munitions tested at DPG or at YPG
• Process other “yet-to-be identified” munitions
• Throughput is one fracture per minute
• Each fracture processes multiple munitions
• Interface with existing APE-1236 Deactivation Furnace
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9Committed to Excellence
MCAAP MCDF DevelopmentProjectile Download Design Basis
• Accept fully loaded M732 and M692 projectiles containing 36 ADAM mines
• Remove the ADAM mines from the projectiles
• Collect/segregate all scrap material (metal projectile, spacers, projectile base plate, ogive, pushout rod, etc.)
• Place the ADAM mines in cryofracture transport fixtures for introduction to the cryofracture process
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10Committed to Excellence
PROPELLANT OVERLAY
ELECTRONICS SUBSYSTEM
S&ADETONATING
CORD ASSEMBLY
KILL MECHANISM
Area Denial Artillery Munition (ADAM) Mine
SENSOR MANIFOLD
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11Committed to Excellence
ADAM Mine Cryofracture/Thermal Treatment PFD
UnpackProjectiles
Cryo-cool/CryofractureADAM mines
Recycle Shell,Inserts, and
Spacers
RemoveMines
StandardMetal
Recycler
DischargeO/KMs intoAPE-1236
Discharge Mine Housing
Debris with DU
Thermally Treat S&A andGG in Debris
ThermallyTreat O/KMs
Recycle O/KMMetal Scrap
Treated MineHousing debris
in drums
StandardMetal
Recycler
Recycle Goldand other
Precious metals
Precious MetalsRecycler
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12Committed to Excellence
MCAAP Cryofracture Facility
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13Committed to Excellence
Cryofracture Demilitarization Facility Animation Video
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14Committed to Excellence
Manual Loading of ADAM Mines on Conveyor
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15Committed to Excellence
Automated Download of ADAM Mines
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16Committed to Excellence
ADAM Mines Cooling in Cryobath
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17Committed to Excellence
ADAM Mines Ready for Cryofracture
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ADAM Mines after Cryofracture
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19Committed to Excellence
Cryofracture Debris Discharge – Tilt Table
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20Committed to Excellence
Cryofractured Overlay Kill/Mechanisms
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21Committed to Excellence
RKS Feed of Accessed O/KMs
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22Committed to Excellence
Deactivation by Induction Heating
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23Committed to Excellence
ADAM Mine Debris in Drum
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24Committed to Excellence
Control Room Workstations
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25Committed to Excellence
MCDF Munitions Processed To-Date
• 958 Simulants (plastic inerts)
• 1,832 Previously functioned ADAM QA mines from YPG
• 2,655 ADAM QA mines
• 9,384 ADAM AP mines
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26Committed to Excellence
Project Status
DEM/VAL TestDEM/VAL TestMishapMishap
O/KM Accessing EvaluationO/KM Accessing Evaluation
-- Repair and Continue or Repair and Continue or -- Investigate Improved Accessing MethodInvestigate Improved Accessing Method
ADAM AP Mine TVTADAM AP Mine TVT
Process UpgradesProcess Upgrades
-- Dust CollectionDust Collection-- CCTV CamerasCCTV Cameras-- Conveyor ModificationsConveyor Modifications
Safety EnhancementsSafety Enhancements
-- Updated SOPsUpdated SOPs-- Improved Training ProgramsImproved Training Programs
DesignDesign
-- SafetySafety-- ReviewsReviews-- HazopHazop
Installation and Checkout of the PDWC EquipmentInstallation and Checkout of the PDWC Equipment
Complete ProjectComplete Project
-- ProcureProcure-- Install Install -- StartupStartup-- Dem/ValDem/Val
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27Committed to Excellence
MCAAP MCDF DEVELOPMENT Accomplishments Since 2004 Mishap
● Design Effort (Press tooling and process upgrades)
● Design Reviews
● Detonation Analysis - Detonations are not likely due to controlled orientation of O/KM on toolset- Detonations are possible and the press and frame are designed to survive - Fragment shields and tooling are designed to survive (blast analysis
simulation) but can easily be replaced
● HAZOP (process is safe)- No design changes- A number of changes to the SOPs
● Procurement
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MCAAP MCDF DEVELOPMENT Current Schedule
Mar 07 Procure Safety and Upgrade Equipment for Cryofracture
Jul 07 Equipment Installation
Sep 07 Checkout/Startup complete
Nov 07 Integrated tests complete
Dec 07 Dem/Val Testing Complete (MCDF and PDWC)
Feb 08 Transition to Support ADAM mine demil workload
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29Committed to Excellence
SUMMARY
• Cryofracture technology has been shown to be an effective means for demilitarizing a variety of small explosive-loaded conventional munitions
• Cryofracture provides a solution to the ADAM mine mixed waste demilitarization problem
• Automated robotic process will demonstrate an effective means for disassembling/downloading cargo-carrying 155mm projectiles
• The SEAS press incident, while disappointing and impacting the schedule, has led to operational and safety improvements
• Prototype facility at MCAAP will provide a safe, cost effective and environmentally sound alternative to OB/OD and significantly enhance deactivation furnace processing