Review of the Design of the Dynasafe Static Detonation Chamber (SDC) System for the Anniston Chemical Agent Disposal Facility Letter Report (2010) / Chapter Skim
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This SDC system is being acquired as an efficient means to destroy mustard agent projectiles and mortar rounds at Anniston Army Depot that could present problems for processing through the existing Anniston Chemical Agent Disposal Facility. The committee's general findings and recommendations are given below.
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3 The cited reference refers to the NRC report, Assessment of Explosive Destruction Technologies for Specific Munitions at the Blue Grass and Pueblo Chemical Agent Destruction Pilot Plant s (NRC, 2009a)
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The Army should use the Dynasafe system to destroy the reject mustard agent munitions from the Anniston Chemical Agent Disposal Facility, provided that the factory acceptance testing at Kristinehamn and the preoperational testing at Anniston are satisfactorily completed and the system receives a Resource Conservation and Recovery Act permit modification from the Alabama Department of Environmental Management for operation at Anniston Army Depot and Department of Defense Explosives Safety Board approvals. General Finding 2.
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System for the Anniston Chemical Agent Disposal Facility Attachments A Statement of Task B Abbreviations and Acronyms C Committee on Review of the Design of the Dynasafe Static Detonation Chamber (SDC) System for the Anniston Chemical Agent Disposal Facility D Acknowledgement of Reviewers -4
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The heating of the explosives in the munitions and/or the pressure generated from the heated liquid agent contents eventually cause the munitions to rupture and add to the scrap bed, which is periodically reduced by a chamber tipping procedure. The complete SDC system contains a munitions handling and loading system and a detonation chamber with a pollution abatement system (PAS)
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," presentation to the committee, March 30, 2010. customer requirements have been implemented in each project.4 Also, the Army has two Dynasafe chambers not complete explosive destruction technology systems installed at its Munitions Assessment and Processing System facility at the Aberdeen Proving Ground in Maryland (NRC, 2009a)
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Under the regulations, RCRA regulations concerning hazardous air emissions do not apply to hazardous waste incinerators that demonstrate compliance with the Hazardous Waste Combustor Maximum Achievable Control Technology (MACT) requirements by conducting a comprehensive performance test, submitting to the ADEM a notification of compliance, and documenting compliance under the ADEM air quality regulations.7 As stated in the application for modification, ANAD will comply with National Emission Standards for Hazardous Pollutants Hazardous Waste Combustor MACT 5 Public Notice-424, Alabama Department of Environmental Management, Notice of Request for Comments and Announcement of Public Hearing for Modification of the Operating Permit under t he Alabama Hazardous Wastes Management and Minimization Act (AHWMMA)
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. 9 Tim Garrett, Site Project Manager, ANCDF, and Charles Wood, ANCDF Deputy Operations Manager, URS, "Static detonation chamber (SDC)
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ANAD will submit a request to modify the permit to include numerically specified data for the above parameters not later than 90 days following the emissions test.15 As part of the application for a RCRA permit modification, ANAD filed a proposed emissions test plan. The test plan defines operating conditions and munitions feed rates that will be used to determine SDC performance in accordance with ADEM hazardous waste incinerator standards.
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18 According to Department of the Army Pamphlet 385 -61, Toxic Chemical Agent Safety Standards, Section 5-6, agent is destroyed and materials contaminated by agent are considered clean and may be released for unrestricted use to the public if heated to an internal temperature of 538°C (1000°F) for at least 15 minutes (U.S.
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FIGURE 2a Process flow diagram for front components of Dynasafe SDC1200 installation for Anniston Army Depot. SOURCE: Adapted from personal communication between Holger Weigel, Vice President, Dynasafe International, and Managing Director, Dynas afe Germany, and Richard Ayen, committee chair, May 12, 2010.
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FIGURE 2b Process flow diagram for back-end pollution abatement system components of Dynasafe SDC1200 installation for Anniston Army Depot. SOURCE: Adapted from personal communication between Holger Weigel, Vice President, Dynasafe International, and Managing Director, Dynasafe Germany, and Richard Ayen, committee chair, May 12, 2010.
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20 Personal communication between Harley Heaton, Vice President, Research, UXB International, Inc.; Richard Ayen, committee chair; and Douglas Medville, committee member, May 5, 2010.
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22 Personal communication between Holger Weigel, Vice President, Dynasafe International, and Managing Director, Dynasafe Germany; Richard Ayen, committee chair; and Douglas Medville, committee member, May 5, 2010. 23 Personal communication between Harley Heaton, Vice President, Research, UXB International, Inc., and Harrison Pannella, NRC, study director, May 19, 2010.
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Loading chamber 1 is vented to a process ventilation system. This system is kept under negative pressure by means of induction fans, and the air it collects is passed through particulate filters and activated carbon beds, 24 Personal communication between Gene Wells, SDC Area Supervisor, ANCDF ; Richard Ayen, committee chair; and Douglas Medville, committee member, May 4, 2010.
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Boxed munitions are pushed into the loading chambers with hydraulic arms. They move from one chamber to the next and are then dropped onto the detonation chamber's heated scrap bed, about 2 m below the second loading chamber.
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However, relatively few munitions, several tens as opposed to hundreds or thousands, had been fed through that system as this report was being developed. Therefore, extended operation of the rotating cradle, including the fragment valve, should be carried out during the preoperational testing at Anniston Army Depot, using overpacks that will be fed during subsequent munition destruction operations.
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Extended operation of the rotating cradle with overpacked munitions and operation of the hydraulic fragment valve at the interface between loading chamber 2 and the top of the detonation chamber under realistic (hot) conditions should be demonstrated in preoperational testing at Anniston Army Depot.
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The heated air passes into the upper part of the chamber and is directed downward toward the scrap bed by means of a nozzle. The heater is in operation whenever munitions are being fed.32 As the munitions heat up, the burster charge in the projectile or mortar will either deflagrate or detonate and burst the projectile open.
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34 Personal communication between Harley Heaton, Vice President, Research, UXB International, Inc., and Harrison Pannella, NRC, study director, June 27, 2010 . 35 Personal communication between Holger Weigel, Vice President, Dynasafe International, and Managing Director, Dynasafe Germany, and Richard Ayen, committee chair, May 6, 2010.
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Each conveyor overlaps the next and the scrap thus drops from one conveyor to 37 Personal communication between Holger Weigel, Vice President, Dynasafe International, and Managing Director, Dynasafe Germany, and Richard Ayen, committee chair, May 6, 2010.
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38 Personal communication between Gene Wells, SDC Area Supervisor, ANCDF ; Richard Ayen, committee chair; and Douglas Medville, committee member, May 4, 2010. 39 Personal communication between Harley Heaton, Vice President, Research, UXB International, Inc.; Richard Ayen, committee chair; and Douglas Medville, committee member, May 5, 2010.
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a Personal communication between Holger Weigel, Vice President, Dynasafe International, and Managing Director, Dynasafe Germany; Richard Ayen, committee chair; and Douglas Medville, committee member, May 5, 2010. SOURCE: Adapted from Harley Heaton, Vice President, Research, UXB International, Inc., "Similarities and differences between the SDC installations at GEKA and ANCDF," presentation to the committee, March 30, 2010.
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.41 Both the pressure equalization tank and the 3.94-inch diameter lines connecting it to the SDC are electrically heat traced to maintain wall temperatures above 300°C (572°F) at all times, including nights and weekends,42 to prevent internal condensation of liquids or any unburned energetics or chemical agents.
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43 Personal communication between Holger Weigel, Vice President, Dynasafe International, and Managing Director, Dynasafe Germany; Richard Ayen, committee chair; and Douglas Medville, committee member, May 5, 2010. 44 Personal communication between Harley Heaton, Vice President, Research, UXB International, Inc., and Harrison Pannella, NRC, study director, May 19, 2010.
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Computational fluid dynamics (CFD) modeling should be performed for the thermal oxidizer in the pollution abatement system for the Dynasafe SDC1200 for Anniston to ensure that oxidation of all trace organics, including dioxin and furan precursors, will be sufficiently complete.
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Spray Dryer Processing at Anniston The purpose of the spray dryer is to cool hot gases without generating a liquid discharge by reducing salts in the spent scrubber brine to dry, flowable solids. The goal of avoiding liquid discharges eliminates the need to transport liquid waste from the process offsite.52 The temperature of the gas from the thermal oxidizer at the inlet to the spray dryer is 1100°C.
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Finding 9. The spray dryer to be used in the pollution abatement system for the Dynasafe SDC1200 system to be installed at Anniston Army Depot might not in itself adequately minimize dioxin and furan formation.
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. 58 Personal communication between Harley Heaton, Vice President, Research, UXB International, Inc., Holger Weigel, Vice President, Dynasafe International, and Managing Director, Dynasafe Germany; Richard Ayen, committee chair; and Douglas Medville, committee member, May 5, 2010.
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The neutral scrubber is maintained at a pH of 6.7 in the same way.62 Both scrubbers operate at 78°C and are constructed from fiberglass reinforced polyester. Blowdown of spent scrubber solution from both scrubbers is sent to the same tank, then to the spray dryer for 61 Personal communication between Holger Weigel, Vice President, Dynasafe Inter national, and Managing Director, Dynasafe Germany; Richard Ayen, committee chair; and Douglas Medville, committee member, May 4, 2010.
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The IONEX CD2000 includes two activated carbon filter banks to adsorb trace concentrations of species remaining in the off-gas, with the first bank containing sulfurimpregnated activated carbon. Sulfur-impregnated activated carbon is a widely used approach for removing mercury from gaseous combustion streams and has been utilized for this purpose during mustard agent destruction at the Tooele, Utah, chemical agent disposal facility (TOCDF)
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The chemical agent monitoring systems used for the Dynasafe SDC1200 system to be installed at Anniston are similar to the systems that have been in use at all other chemical agent disposal facilities and that have been found to adequately protect personnel and the environment. As discussed earlier in this report in the sections on the spray dryer and the baghouse, the committee cautions that the solids collected from the baghouse (and the solids that precipitate in the spray dryer)
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2009a. Assessment of Explosive Destruction Technologies for Specific Munitions at the Blue Grass and Pueblo Chemical Agent Destruction Pilot Plants.
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2010. Anniston Chemical Agent Disposal Facility Static Detonation Chamber Emissions Test Plan.
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