DESIGN FOR DEMILITARISATION Presented by Dr David M Stalker BSc, PhD, C Chem, MRSC BAE SYSTEMS RO DEFENCE
Mar 29, 2015
DESIGN FOR DEMILITARISATION
Presented by
Dr David M Stalker BSc, PhD, C Chem, MRSC
BAE SYSTEMS
RO DEFENCE
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INTRODUCTIONDuring 1999 and 2000 a consortium of Royal Ordnance plc,United Kingdom (RO) and DEMEX Consulting Engineers A/S,
Denmark (DEMEX), undertook a research contract WEAO EUCLID Reference Number 98/EF 14.6/004 on behalf of the
Western European Armaments Organisation (WEAO) Research Cell, CEPA-14. This joint study entitled
“A Study into the Demilitarisation of Advanced Conventional Munitions” resulted in six separate reports:
•Review of Demilitarisation State of the Art
Life Cycle Analysis
Demilitarisation Technologies
Biodegradation
Environmental Impact & Cost Benefit Analysis
Procurement Specification
In this presentation one of the principal conclusions relates to “DESIGN FOR DEMILITARISATION”.
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Definition of Demilitarisation
Demilitarisation is the Process whereby the Military Characteristics of Munitions are removed:
•Unsuited for continued storage•Obsolete•Excess to Service requirements
“…the act of removing or otherwise neutralising the military potential of a munition. Such neutralisation is to be carried out in a safe, cost effective, practical and environmentallyresponsible manner. Demilitarisation is a necessary step for military items prior to their release to a non-military setting.”
Definition of Demilitarisation from STANAG 4518
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The need for Demilitarisation
As Munitions become older there are a number of issues that face the custodians:
Increasing Hazards due to:
Corrosion
Loss of ID
Chemical Instability
Electonic Component Deterioration
•Surplus Stocks•Obsolence•Storage •No Longer Required•Deterioration•Possible Sale•Use for Training Purposes•Conversion
}
Security/Safety Risks due to:TheftAttractiveness to TerroristsNeed for Continued StorageAccidents
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The need for DemilitarisationR
isks
/ Cos
ts
Retention
Increasing Hazards due to:
Corrosion
Loss of ID
Chemical Instability
Electronic Component Deterioration
Increasing Security/Safety Risks due to:TheftAttractiveness to TerroristsNeed for Continued StorageAccidents
Progressive reductionof stocks through disposal
Today TimeYears
100% Demil
The choice is to assume greater risks and costs with continued storage or
proceed with destruction
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Examples of Demilitarisation Problem Areas
Fungicide Impregnated Pallets eg Pentachlorophenols
Case Bonding of Energetic Fillings
Toxic Metal Salts in Propellants eg Lead
Filling Ports which are too small to use for Emptying Out
Electronics encased in Epoxy Resin with addedDU Salt
Self destruct mechanisms
Anti-tamper devices and mechanisms
Adhesives
Asbestos and Asbestos Impregnated Resins
No formulated Dis-assembly or Demilitarisation methods
Water or air sensitive species Pyrophoric Metals
Radioactive Kinetic Energy Projectiles
Radioactive Sighting DevicesChlorinated Plastic Components
Mixed Plastic Components
Corrosive Materials
Caustic Materials
Oxidising Materials
Hypergolic MaterialsInterference Fit of Components
Pyrotechnics - heavy metal species
Potentially Incompatible Materials
Volatile Materials
Toxic Materials
Stability of Aged Explosives
Leaching or Weeping of Energetics
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Demilitarisation Options
Munition Assembly
Controlled Incineration or Detonation
Open Burn Open Detonation
Controlled Incineration or Detonation
Sale
Use for Training, Targetry etc
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Demilitarisation Options
Munition Assembly
Open Burn Open Detonation
Controlled Incineration or Detonation
Sale
Use for Training, Targetry etc
Removal from packaging
Disposal of Packaging
Re-use of Packaging
Strip and Separate packaging Components eg Wood/Plastics/Metal etc
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Demilitarisation Options
Munition Assembly
Removal from packaging
Disposal of Packaging
Re-use of Packaging
Controlled Incineration or Detonation
Strip and Separate packaging Components eg Wood/Plastics/Metal etc
DisassemblyRe-use of Hardware
Upgrade Hardware
Destroy/Mutilate Hardware
Separate Components
Scrap
Open Burn Open Detonation
Controlled Incineration or Detonation
Sale
Use for Training, Targetry etc
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Demilitarisation Options
Munition Assembly
Disassembly
Removal of Energetics
Removal from packaging
Disposal of Packaging
Re-use of Packaging
Recovery of Energetics
Conversion to anotherEnergetics Application
Conversion to alternate non-energetic use
Fertiliser
Chemical Feedstock
Open Burn Open Detonation
Controlled Incineration or Detonation
Energetics Re-use
Eg Mining Open Burn
Open Detonation
Controlled Incineration or Detonation
Disposal of Non-Energetics eg Fillers, Binders etc
Re-use of Hardware
Upgrade Hardware
Destroy/Mutilate Hardware
Separate Components
Scrap
Strip and Separate packaging Components eg Wood/Plastics/Metal etc
Sale
Use for Training, Targetry etc
Separation of Chemical components
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Demilitarisation Areas for The Future
Munition Assembly
Disassembly
Removal of Energetics
Removal from packaging
Disposal of Packaging
Re-use of Packaging
Recovery of Energetics
Conversion to anotherEnergetics Application
Conversion to alternate non-energetic use
Fertiliser
Chemical Feedstock
Open Burn Open Detonation
Controlled Incineration or Detonation
Energetics Re-use
Eg MiningOpen Burn
Open Detonation
Controlled Incineration or Detonation
Disposal of Non-Energetics eg Fillers, Binders etc
Re-use of Hardware
Upgrade Hardware
Destroy/Mutilate Hardware
Separate Components
Scrap
Strip and Separate packaging Components eg Wood/Plastics/Metal etc
Sale
Use for Training, Targetry etc
Separation of Chemical components
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The overall drive is towards source reduction, re-use and recycling - basicallyWaste Minimisation and Pollution Prevention throughout the life of the storeleading to the concepts of:
The Changing Emphasis of Demilitarisation
Cost Effective
Safe
Practical
ealth Hazards
Environmentally Acceptable
Physically Safe
Maximisation of Recovery and Reuse
Free from H
Cost Effective
Efficient
Increasingly Demilitarisation contracts are stipulating•No Open Burning (OB)•No Open Detonation (OD)•Encouragement to Recycle or Convert into other products•Maximum levels of Recycle
R3 Resource Recovery and Re-use
R4 Resource Recovery Re-use and Recycle
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Examples of Existing Technologies
1. Disassembly and Opening Up•Mechanical Disassembly and Reverse Engineering•Mechanical Saw•Mechanical Separation - eg abrasive water jet cutting•Cryofracture
Review of Demilitarisation Technologies and Techniques
In the CEPA 14.6 Project a survey of Demilitarisation Technologies and Techniques was made
Usually leading to destruction of the hardware and scrapping with no re-use.
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3. Disposal of Energetics•OB/OD•Contained Detonation Chamber •Propellant and HE Conversion to Fertilizer & Mining Explosives•Incineration
Less easy to deal with energetics– Usually destroyed– Increasing conversion to mining Explosives– No processes for Recovery and Recycle of PBXs in use yet– No easy means of removal from hardware– Still contain hazardous and toxic species
2. Removal of Energetics and Fillings•Meltout•Steamout •Dry Machining •High Pressure Water Washout •Hot Water Washout•Water Washout of Class Rkt Motors
Review of Demilitarisation Technologies and Techniques
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Planned and Emerging Demilitarisation Technologies
Confined Burn Pyrotechnic Reclaim/ReuseHot Gas Decontamination Reuse of Gun Propellant Biodegradation HMX Recovery Contained Detonation Chamber RDX Recovery Contained Burn with Scrubber Propellant Conversion to FertilizerTunnel Burn Liquid Ammonia Reclamation of Tactical Rocket Motors & IMTunnel Detonation Induction Heating Molten Salt Oxidation Microwave Meltout of HE Loaded Munitions Cryocycling of Energetic Materials Base Hydrolysis Water Washout of Rkt Motors Hydrothermal Oxidation Laser Cutting Plasma Arc System (PODS)Supercritical Water Oxidation Explosive Rework Process for Cast Loaded MunitionsAbrasive Waterjet Cutting Explosive D Conversion to Picric AcidRobotic Disassembly Electrochemical Techniques (eg Silver II))Biochemical Techniques
Review of Demilitarisation Technologies and Techniques
The thrust of most of these applications is towards •more efficient removal and destruction or conversion•recovery of materials (hardware and chemical components)•re-use and recovery
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Design for DemilitarisationIn the CEPA 14.6 Project a survey of Munitions’ development was madeencompassing:
•Projectiles and Warheads
• Ammunition of all calibres• Fuzing and Firing Devices• Guns and Artillery Systems• Mines and Demolition Systems• Armour and Anti-Armour• Rocket Motors
•Energetics
• High Explosives• Gun Propellants and Charges• Rocket Propellants• Pyrotechnics
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Design for Demilitarisation
Environmental Pressures will only increase:•need to understand nature of all chemical species in munition from outset•need to understand chemistry of all species involved
•conversion to other species•breakdown of binders•build in breakdown mechanisms at start
•eg hydrolysable binders•means of removal of chemical mixtures/admixtures from hardware
Little effort is made towards "Design for Demilitarisation” in forthcoming Munitions Designs
• Ease of energetics removal is paramount•fortuitous designs faciliatate removal
•for example Steel Strip Laminate Rocket Bodies
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Insensitive Munitions and R3Executive Order 13101 -- Greening the Government through Waste Prevention, Recycling,…Consider:
• elimination of virgin material requirements• reuse of product
•A recent advance is in reclamation and re-use of TNT from 8” HE projectiles in new production of AF bombs in US
• effect of reducing demil cost per round• necessary to decrease the moisture content in the reclaimed TNT• new NSN for reclaimed TNT has been established: 1376- 01- 479- 1067
• life- cycle cost• recyclability• disposal
USD( AT& L) , December 2000:
• view demil stockpile as asset, not liability• maximise resource recovery and reuse• recycle energetics & reformulate in less- sensitive fills• apply to munitions acquisition process
Extracts from US Executive Orders on Demilitarisation and on Insensitive Munitions
Design for Demilitarisation
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Design for Demilitarisation
Designers and Procurers should be encouraged to:– Design in components that can be recovered – Recycle and Re-use recovered components– look at means of reusing energetics
– re-visit specifications
Demilitarisation provides a valuable resource for raw materials and resources
MIDAS provides a means of Characterisation of Munitions and enables and allows for the determination of all the chemical constituents at the outset. There is a need to develop a MIDAS type database in Europe - a model database(EICAD) has been developed as part of the CEPA 14 Project and efforts are now needed to populate the model and demonstrate its usefulness. Thismodel also encompasses whole life costing and not only the Demilitarisation stages.
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Munitions’ Characterisation & Creation of Munitions Database Library
Munition/Store
Existing Environmental, Safety and Health Regulations and Impact
Health Effects and Impact•COSHH•Carcinogen•Neurotoxin•Acute•Teratogen•etc
Environmental Impact Effects•Water Release •Air Release•Ground Release
Safety/Health & Environmental Effects
•Define materials into categories•Toxic•Flammable•Corrosive•Oxidiser•etc
Bulk Items Materials ie Packagingand
Component Parts
Inert Materialsand Compounds
PEP Materialsand
PEP Ingredients(Energetic and Non-Energetic)
Manufacture•Processes
•e.g. Plating, Alloys, •Materials used•Resources used•Resources Consumed
Define natures of all materials present and used: refer to
• CAS No and Synonyms Dictionaries•Hazard Data Sheets•Manufacturers’ Information•etc
Inventory
Quantities/Amounts Present or Consumed
Munitions Database Library
Demilitarisation Process Design Process
Identify Components/Parts including all Packaging and Specific Transportation Equipment
DrawingsDiagramsSpecificationsStandards
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Conclusions1. Design for Demil
Ease of disassembly and removal of energetics Design in safe and easy access for disassembly Design in safe means and effective means of material extraction
• Consider and apply latest/best applicable technologies
Maximise recovery of Materials Energetics Packaging Hardware Non-energetics
Maximise potential for reuse of components and materialsConfigure in ease of component and packaging reuse or recycling
2. Create Inventories of Substances and Components including packaging
Minimise environmental impactSelect materials that minimise hazards to personnel and the environment at the end of the munition’s life
•Build in “demil switches” – eg hydrolysable binders
Aspects highlighted in yellow incorporated in STANAG 4518 and OB Proc P115(2)
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3. Design for Mid Life Improvement Potential Design for Life Extension Design for reuse or conversion of the munition through limited modification or remanufacture
4. Design in life extension through conversion to training use Maximise Service LifeDesign for Life Extension Select materials and design features that enable stocks to be used in training
5. Configure packaging to maximise recycle, re-useConfigure in ease of packaging reuse or recycling
6. Minimise environmental impact from packaging
8. Provide detailed procedures and information on munition’s demilitarisation
Conclusions
Aspects highlighted in yellow incorporated in STANAG 4518 and OB Proc P115(2)
7. Incorporate components identified from demil inventory available for re-use