Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Blue Grass Army Depot (2002) / Chapter Skim
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4 Eco Logic Technology Package
4 Eco Logic Technology Package
Pages 71-98
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From page 71... ...
system. Foster Wheeler is the technology provider for the transpiring-wall supercritical water oxidation (SCWO)
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From page 73... ...
Area 30~supercritical Multiple parallel SCWO reactors are used to process the accumulated hydrolysate held in the SCWO water oxidation (SCWO) feed tank.
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From page 74... ...
Upon removal by the PMD, projectile lifting plug/ fuze adapter assemblies and fuze well cups are transferred by the MPRS conveyor of the PMD machine to the projectile component discharge hopper. Bursters from 1 55-mm, M 1 10 mustard agent projectiles are transferred by the PMD burster transfer conveyor to the burster size-reduction machine.
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From page 75... ...
A PWS is to be incorporated into the technology provider's design to ensure the removal of mustard agent heels or gelled GB nerve agent from projectiles. This has been a recent addition to the Eco Logic process design; consequently, the design of the equipment had only begun when this report was prepared, and only a few details were available.
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From page 76... ...
COINS The COINS process uses an overhead conveyor system that collects metal parts containing explosive energetics components (fuzes and bursters) into baskets that are moved through a tank containing a caustic bath that hydrolyzes the energetic materials in the metal parts.
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From page 77... ...
The planned operation of the three reactors will stagger the batch cycles such that at any time one reactor is filling, one is being used for reaction or undergoing analysis of reaction products and one is discharging to Area 300. At the completion of the batch operation, the hydrolysate is discharged into a buffer storage tank prior to processing through the SCWO reactor.
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From page 78... ...
The Eco Logic design for a Blue Grass facility uses five transpiring-wall SCWO reactors (Eco Logic, 2001a)
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From page 79... ...
When processing mustard agent hydrolysate, the total aluminum content is expected to be less than 400 ppm, which the technology provider considers to be an acceptable level to prevent scale buildup in the SCWO reactors. When processing VX and GB, an aluminum removal system will be needed to reduce aluminum in the energetics hydrolysate feed to less than 500 ppm so that the total in the combined hydrolysate feed is less than 400 ppm (Eco Logic, 2001a)
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From page 80... ...
The reactor liner is fabricated from multiple layers of Inconel 600 assembled in sheets of what the technology provider refers to as "platelets" to produce transpiration pores. Deionized water is added to the SCWO reactor through transpiration pores in the liner
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From page 81... ...
The organic waste vapors are removed from the TRBP by a flow of sweep gas and are conveyed into the GPCR™ reactor for destruction. The sweep gas may be hydrogen and/or recycled product gas from the GPCR™ reactor.
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From page 82... ...
Carbon monoxide formation is expected by the technology provider but has not been studied. GPCRrM Reactor Feet' Preheater System The preheater system includes all of the equipment required to heat any combination of the gaseous inputs to the GPCR™ reactor (including hydrogen, steam, the offgas from Areas 100 and 200, and recycled GPCR™ product gas from storage)
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From page 83... ...
The 16 utilities provided by Area 500 are summarized as follows: aqueous NaOH caustic solution at both 50 percent and 20 percent concentration primary cooling water used in the heat exchangers in Areas 300, 400, and 500, i.e., those with essentially no possibility of agent on the hot side saturated steam produced from demineralized water natural gas provided by the depot infrastructure liquid oxygen compressed and heated to 4,500 psig and 75°F for use by the SCWO reactors recycle water received from the Area 300 evaporation system and the Area 400 stack gas condensate propylene glycol for supply to the SCWO reactors · liquid nitrogen compressed and heated to 4,500 psig and 75°F for use in the SCWO reactors or used as a medium-pressure stream delivered to Areas 100, 200, 400, and 500 for purging demineralized and deionized water produced from recycle · process water provided by the depot infrastructure hydrogen produced on-site by an off-the-shelf catalytic steam reformer carbon dioxide supplied to Area 400 electrical equipment · hot water circulated through a closed system to Area 100 and 200 heat exchangers · secondary cooling water circulated through a closed system to Area 100 and 200 heat exchangers instrument and plant air provided by the depot infrastructure electricity provided by the depot infrastructure i?
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From page 84... ...
On the upper floor of the facility, some conveyors are modified from the baseline system in length, width, or both, whereas conveyors on the lower floor are also modified to accommodate the heavier loads of the TRBP bins and projectile racks. The drained projectile bodies On December 14, 2001, Eco Logic issued a final draft of the EDP for a full-scale pilot plant implementing its technology package at Blue Grass Army Depot (Eco Logic, 2001a)
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From page 85... ...
The EDS test program was designed to specifically address these questions. The study plans from Eco Logic and Foster Wheeler were organized to investigate the following areas: methods development explosivity testing metallurgy testing elastomers testing - grinder tests - transpiring-wall SCWO reactor tests The overall testing objective included generating all required design/operating data to facilitate the development of a full-scale design, preliminary hazards analysis, and a detailed, accurate, full-scale cost estimate and schedule.
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From page 86... ...
Seven energetic materials representative of those found in the Blue Grass stockpile were selected: five explosives (RDX, tetryl, TNT, Composition B and tetrytol)
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From page 87... ...
Demonstrate the ability of grinding equipment to safely process foreign objects such as detached antiresonance rods and igniter cables. Results: During tests of the grinder, Eco Logic fed simulated antiresonance rods and igniter cables that would be intrinsic to the M28 propellant grains.
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From page 88... ...
However, Foster Wheeler concluded that the test did indicate the upper 2. During early tests, the technology provider found it difficult to initiate the SCWO oxidation reaction from cold conditions with propylene glycol as the initiating fuel.
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From page 89... ...
Separation of the propellant from the rocket motor case may also be problematic. That is, once the case is cut, the propellant grain is pushed out of the case to separate the energetic materials from the inert materials.
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From page 90... ...
- , ~ ~ Supercritical Water Oxidation (Area 300) The design and operation of the transpiring-wall SCWO reactor developed by Foster Wheeler were covered extensively in previous reports (NRC, 1999, 2001b)
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From page 91... ...
3. The technology provider resolved the loss of reaction caused by the less-than-optimum reactivity of propylene glycol by continuing the flows of the initiating fuel (kerosene)
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From page 92... ...
However, the first run with DPE suit material was stopped prematurely because the reactor input line plugged. Reactor product gases were effectively treated in the two-stage scrubber system and product gas burner.
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From page 93... ...
The first is Area 300, where the operability of the Foster Wheeler transpiring-wall SCWO reactor remains a significant and incompletely resolved problem. The transpiring-wall design is meant to minimize both corrosion and salt deposition, which would plug the reactor.
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From page 94... ...
However, this test was not performed under stable operating conditions, and at stable operating conditions, the tests might have been more or less favorable. If problems of corrosion and salt deposition occur, as they did with other SCWO reactors, or if liner cracks develop, as occurred during Demo II testing, significant maintenance and downtime would be required.
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From page 95... ...
Although the committee knows of no previous accidents that would raise safety questions unique to the transpiring-wall SCWO reactor, it has expressed gen
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From page 96... ...
That report's conclusion that the health and environmental impacts are minimal and the supporting information it contains are unchanged. Effluent Characterization The committee's report on Demo II testing of the Eco Logic technology package found as follows (NRC, 2001b)
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From page 97... ...
EFKE-1. The occurrence of frequent spikes in hydrocarbon and CO emissions in the 97 gaseous effluent from the transpiring-wall SCWO reactor is a serious problem that must be resolved before the Eco Logic technology can be implemented.
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From page 98... ...
Any unexposed energetic remaining in the fuzes and bursters following the COINS operation will be destroyed in the TRBP, which can withstand the explosion of the small amounts of energetic materials that remain (see Finding EFKE-2~. Finding (Blue Grass)
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