Saudi Conventional Ammunition and Chemical Warfare Disposal

1. www.eisenmann.com
© Eisenmann AG 2014
Thermal disposal of conventional ammunition and chemical
warfare agents
Overview about the different technologies of EISENMANN; Germany
Dr. Ing. Uwe Neumann, Eisenmann Anlagenbau GmbH & Co. KG

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Agenda
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Introduction
Thermal disposal technologies for conventional ammunition
- Full steel rotary kiln, brick lined rotary kiln and the moving bed reactor
Thermal disposal technologies for chemical warfare agents
- TURAKTOR® technology, shuttle/chamber kiln and full steel rotary kiln
Overview of EISENMANN‘s references of thermal ammunition disposal
Conclusions and summary

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About Eisenmann
Eisenmann is a leading international systems supplier for finishing technology, material flow automation,
and for environmental and thermal process technology.
Plant design and construction experts
Highly flexible systems integrator
Market and technology leader in components as well as in complete systems
Service provider with a broad range of service products
Family-owned company with a very sound financial foundation and sustainable economic management
Innovative high-tech company due to a wide range of R&D activities as well as testing facilities & laboratories

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Fact Sheet
No.1 in the world market for paint shops for plastic parts
No.1 in the world market for ammunition disposal plants
€789 million in sales revenue in 2012
More than 1,500 engineers and technicians
3,700 employees (2012)
21 locations worldwide

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Range of Products and Services
AUTOMOTIVE SYSTEMS
Surface finishing, body shell conveyor systems, final assembly lines
GENERAL FINISHING
Paint shops for metal parts, paint shops for plastic parts, paint shops for wooden parts, new materials
Pretreatment and coating systems, high-temperature technology, firing lines for ceramics, heat treatment, carbon
fiber ovens
PROCESS & HIGH TEMPERATURE TECHNOLOGY
CONVEYOR SYSTEMS
Electrified monorail systems, inverted electrified conveyors, Power & Free conveyors, peripheral conveyor
systems
SERVICE
Customer service, spare parts management, plant renewal, advisory services, full-service & BOT models
ENVIRONMENTAL TECHNOLOGY
Exhaust air purification, waste water treatment, waste disposal, ammunition disposal, biogas plants

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Locations
Paris
Crystal Lake
São Paulo
Fuzhou
Kunshan
Shanghai
Cruzeiro
Chennai
DelhiThane
Country with Eisenmann location
Country with Eisenmann sales representatives
Changchun
Puebla
Pune
Moscow
Saronno
Göttingen (Ruhstrat)
Böblingen
Holzgerlingen
Erftstadt (intec)
Stafford
Barcelona

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Agenda
1
2
3
4
5
Introduction
Thermal disposal technologies for conventional ammunition
- Full steel rotary kiln, brick lined rotary kiln and the moving bed reactor
Thermal disposal technologies for chemical warfare agents
- TURAKTOR® technology, shuttle/chamber kiln and full steel rotary kiln
Overview of EISENMANN‘s references of thermal ammunition disposal
Conclusions and summary

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Thermal disposal technologies for conventional ammunition
Full steel rotary kiln incinerator: theoretical backgrounds
suitable for small caliber ammunition (l < 250mm, d < 50mm, m < 0,7 kg)
M input > 150 kg/h of ammunition
maximum 300 g TNT equivalent / single load
transportation through the kiln:
- spirally arranged flights
ideal retention time for complete destruction:
- variable flights pitch
- rotation speed
operation mode:
- co current / countercurrent
a) 3D drawing of a full steel rotary kiln

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Thermal disposal technologies for conventional ammunition
Full steel rotary kiln incinerator: practical example
location : Hottendorf, Germany
start of construction : 09/2009
commissioning : 08/2010
throughput : 150 kg/h
a) armor grenade
d) location of the facility
b) 30 mm grenade c) hand grenade
a, b, c) Input materials

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Thermal disposal technologies for conventional ammunition
Full steel rotary kiln incinerator: practical example
a) input materials (hand grenades)
b) beginning of the assemblage of the Hottendorf Facility

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Thermal disposal technologies for conventional ammunition
Full steel rotary kiln incinerator: practical example
a) assembling of the rotary kiln on the Hottendorf site

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Thermal disposal technologies for conventional ammunition
Full steel rotary kiln incinerator: practical example
a) view of the Hottendorf facility

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Thermal disposal technologies for conventional ammunition
Full steel rotary kiln incinerator: practical example
a) view of the Hottendorf facility
Rotary kiln

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Thermal disposal technologies for conventional ammunition
Bricklined rotary kiln incinerator: theoretical backgrounds
suitable for non explosive ammunition (e.g. rocket propellant)
M input < 1 500 kg/h of propellant
transportation through the kiln:
- rotational movement
- inclination of the kiln
ideal retention time for complete destruction:
- rotation speed / inclination
operation mode:
- co-current
a) example of a bricklined rotary kiln

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Thermal disposal technologies for conventional ammunition
Bricklined rotary kiln incinerator: practical example
location : Pavlograd, Ukraine
awarding : 05/2011
start of installation : 12/2011
turnover : 06/2012
a) location of the facility

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Thermal disposal technologies for conventional ammunition
Bricklined rotary kiln incinerator: practical example
input : propellant and empty motor cases of
the SS-24 intercontinental rockets
throughput amount : 850 kg/h
c) example of an SS-24 rocket
a) propellant crumb with emulsion
before the thermal treatment
b) propellant crumb with emulsion
after the thermal treatment

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Thermal disposal technologies for conventional ammunition
Bricklined rotary kiln incinerator: practical example
a) 3D drawing of the Pavlograd facility

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Thermal disposal technologies for conventional ammunition
Bricklined rotary kiln incinerator: practical example
a) view of the building of the Pavlograd facility b) view of the rotary kiln of the Pavlograd facility

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Thermal disposal technologies for conventional ammunition
Bricklined rotary kiln incinerator: practical example
b) view of the wet deslagger of the Pavlograd facilitya) view of the feeding area of the Pavlograd facility

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Thermal disposal technologies for conventional ammunition
Bricklined rotary kiln incinerator: practical example
a) view of the waste water treatment unit of the Pavlograd facility b) screenshot control panel of the Pavlograd facility

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Thermal disposal technologies for conventional ammunition
Bricklined rotary kiln incinerator: practical example
b) burner unit of the Pavlograd facilitya) view of the rotary kiln and PCC of the Pavlograd facility

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Thermal disposal technologies for conventional ammunition
Moving bed reactor incinerator: theoretical backgrounds
designed for unexploded ordnances (UXOs)
maximum 5.1 kg TNT equivalent
transportation through the reactor:
- by gravity
- geometry of the reactor
operation mode:
- co-current
a) view of the moving bed reactor

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Thermal disposal technologies for conventional ammunition
Moving bed reactor incinerator: practical examples
First plant
location : Hottendorf, Germany
start of construction : 2001
commissioning : 2002
throughput : 2.4 kg TNTequivalent / UXO
Second plant
location : Hünxe, Germany
start of construction : 2009
commissioning : 2010
throughput: : 5.1 kg TNTequivalent / UXO
a) location of the facilities

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Thermal disposal technologies for conventional ammunition
Moving bed reactor incinerator: practical example
a) 105 mm grenade before
treatment
b) 105 mm grenade after treatment

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Thermal disposal technologies for conventional ammunition
Moving bed reactor incinerator: practical example Hottendorf
a) view of the Hottendorf facility in winter b) view of the Hottendorf facility in summer

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Thermal disposal technologies for conventional ammunition
Moving bed reactor incinerator: practical example Hünxe
a) view of the Hünxe facility b) view of the post combustion chamber

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Thermal disposal technologies for conventional ammunition
Moving bed reactor incinerator: practical example Hünxe
a) view of the wet flue gas cleaning system b) view of the additive dosing

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Agenda
1
2
3
4
5
Introduction
Thermal disposal technologies for conventional ammunition
- Full steel rotary kiln, brick lined rotary kiln and the moving bed reactor
Thermal disposal technologies for chemical warfare agents
- TURAKTOR® technology, shuttle/chamber kiln and full steel rotary kiln
Overview of EISENMANN‘s references of thermal ammunition disposal
Conclusions and summary

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Thermal disposal technologies for chemical warfare agents
The Turaktor® technology: theoretical backgrounds
suitable for warfare agents in liquid phase and/or suspensions
due to the special injection design of the waste stream high turbulences are created:
- very good burn out properties
- uniform retention time
no post combustion chamber required
operation mode:
- co current
- counter current
a) example of a Turaktor® unit

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 1
location : Kambarka, Russia
contract award : 2003
start of disposal : 2007
end of disposal : 2009
processed agent : Lewisit
total amount to be processed : ~ 6 000 tons
hourly throughput : 600 kg/h
a) location of the facility

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 1
a) 3D drawing of the of the Kambarka complex
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3
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6
Turaktor
Quench
Centrifugal separator
Wet scrubber 1
Wet scrubber 2
Wet electrostatic precipitator
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Turaktor
Quench
Centrifugal separator
Wet scrubber 1
Wet scrubber 2
Wet electrostatic precipitator
b) top view of the Kambarka installation

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 1
a) 3D drawing of the of the waste water unit of the Kambarka complex
b) view of the waste water unit of the Kambarka complex
1. Waste water tanks
2. Reaction tanks
3. High performance sludge clarifier
4. Filter press
5. Gravel filter
6. Sludge thickener
7. Tanks for chemicals
8. Storage tanks

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 1
a) view of the Kambarka complex
the plant was successfully operated for three years
in 2009 the total amount of chemical warfare agents in Kambarka were disposed

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 2
location : Potschep, Russia
start of construction : 2007
commissioning : 2010
start of disposal : 2011
processed agents : - Vx ~ 4 850 tons
- Soman ~ 2 450 tons
- Sarin ~ 250 tons
total throughput amount : 7 450 tons
hourly throughput per line : 1 000 kg/h
number of lines : 2
a) location of the facility

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 2
a) 3D drawing of the complex of the Potschep complex
1. Storage reaction masses
2. Incineration of the liquid
residuals of reaction masses
3. Roller hearth kiln for
solid residuals
4. Waste water treatment
plant
5. Vacuum plant
6. Social area
1
5
3
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2
4

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 2
a, b, c) view of the Potschep complex preinstalled at EISENMANN’s preassembly hall

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 2
start of disposal operation for Vx in 2011
currently the plant is prepared for the disposal of the next chemical warfare agent Sarin
a) view of the Potschep complex

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 3
location : Tirane, Albania
contract award : 2004
start of disposal : 2006
end of disposal : 2007
processed agents : the exhaust gas generated at the
shuttle/chamber kiln by treating:
- Sulfur Mustard ~ 13 700 kg
- Chloroacetophenone ~ 1 050 kg
- Lewisite ~ 920 kg
- Adamsite ~ 330 kg
a) location of the facility

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 3
total amount to be processed : ~ 16 000 kg
throughput per charge : ~ 500 kg
type of the facility : semimobile
operation mode : batchwise
a) barrels with input material stored at the Albanian disposal
facility

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 3
a) schematical flow sheet of the Albanian facility

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Thermal disposal technologies for chemical warfare agents
The Turaktor technology: practical example nr. 3
a) treatment unit of the Albanian facility preinstalled at
EISENMANN’s preassembly hall
b) picture of the Albanian facility on site

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Thermal disposal technologies for chemical warfare agents
The shuttle/chamber kiln technology: theoretical backgrounds
suitable for contaminated equipment and empty shells
batchwise and semi-batchwise operation is possible
post combustion chamber is required
flue gas cleaning system is required
a) example of a shuttle/chamber kiln

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Thermal disposal technologies for chemical warfare agents
The shuttle/chamber kiln technology : practical example nr. 1
location : Potschep, Russia
start of construction : 2007
commissioning : 2010
start of disposal : 2011
input material : - empty shells from detoxification
- solid residues from detoxification
total throughput amount : 1 300 kg/batch
thermal performance : 3 000 kW
a) location of the facility

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Thermal disposal technologies for chemical warfare agents
The shuttle/chamber kiln technology : practical example nr. 1
a) rockets to be disposed of in the shuttle kiln of the Potschep complex b) view into the shuttle kiln of the Potschep complex

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Thermal disposal technologies for chemical warfare agents
The shuttle/chamber kiln technology : practical example nr. 2
location : Tirane, Albania
contract award : 2004
start of disposal : 2006
end of disposal : 2007
processed agents : - Sulfur Mustard ~ 13 700 kg
- Chloroacetophenone ~ 1 050 kg
- Lewisite ~ 920 kg
- Adamsite ~ 330 kg
total amount to be processed : ~ 16 000 kg
throughput per charge : ~ 500 kg
type of the facility : semimobile
operation mode : batchwise
a) location of the facility

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Thermal disposal technologies for chemical warfare agents
The shuttle/chamber kiln technology : practical example nr. 2
a) view of the chamber kiln unit of the Albanian facility

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Thermal disposal technologies for chemical warfare agents
The full steel rotary kiln technology: theoretical backgrounds
designed for As containing warfare agents with the purpose of As recovery
post combustion chamber is required
transportation through the kiln:
- through the inclination of the kiln
ideal retention time for complete destruction:
- rotation speed
operation mode:
- co-current

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Thermal disposal technologies for chemical warfare agents
The full steel rotary kiln technology: practical example
location : Fukuoka, Japan
contract award : 2004
start of disposal : 2005
end of disposal : 2006
processed agents : grenades containing
- Lewisit
- Sulfur Mustard
- Dyphenyl Cyanoarsine
throughput amount : 30 kg/h
type of the facility : semimobile
a) location of the facility

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Thermal disposal technologies for chemical warfare agents
The full steel rotary kiln technology: practical example
a) 3D drawing of the Fukuoka facility

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Thermal disposal technologies for chemical warfare agents
The full steel rotary kiln technology: practical example
a) view of the full steel rotary kiln of the Fukuoka facility preassembled at EISENMANN’s assembly hall

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Thermal disposal technologies for chemical warfare agents
The full steel rotary kiln technology: practical example
a) view of the facility
b, c) loading the kiln d) view of the kiln

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Agenda
1
2
3
4
5
Introduction
Thermal disposal technologies for conventional ammunition
- Full steel rotary kiln, brick lined rotary kiln and the moving bed reactor
Thermal disposal technologies for chemical warfare agents
- TURAKTOR® technology, shuttle/chamber kiln and full steel rotary kiln
Overview of EISENMANN‘s references of thermal ammunition disposal
Conclusions and summary

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Overview of EISENMANN‘s references of thermal ammunition disposal
Fukuoka (I.a.)
Legend
I. – chemical warfare agents
II. – conventional ammunition
a. – semi -mobile facility
b. – stationary facility
EPC*
subcontractor*
engineering*
delivery of parts*
* -regarding exclusively the thermal
treatment facility
Gorny (I.b.)
Albania (I.a.)
Kambarka (I.b.)
Kizner (I.b.)
Potschep (I.b.)
Pavlograd (II.b.)
Leonidowka (I.b.)
Hünxe (II.b.)
Hottendorf (II.b.)
Möckern (I.a.)
Wulfen (I.b.)
Marokko (II.a.)

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Agenda
1
2
3
4
5
Introduction
Thermal disposal technologies for conventional ammunition
- Full steel rotary kiln, brick lined rotary kiln and the moving bed reactor
Thermal disposal technologies for chemical warfare agents
- TURAKTOR® technology, shuttle/chamber kiln and full steel rotary kiln
Overview of EISENMANN‘s references of thermal ammunition disposal
Conclusions and summary

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Conclusions and summary
EISENMANN has worldwide experience with the thermal disposal of both conventional and chemical
ammunition
EISENMANN offers the following technologies for the thermal disposal of conventional ammunition:
- full steel rotary kiln
- brick lined rotary kiln
- moving bad reactor
EISENMANN offers the following technologies for the thermal disposal of chemical ammunition:
- Turaktor®
- shuttle/chamber kiln
- full steel rotary kiln
EISENMANN offers state of the art technology, controlled disposal methods in accordance with the
environmental regulations
EISENMANN offers tailor suited solutions in accordance to clients requirements

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Contacts
Dr. Uwe Neumann
Senior Expert
Environmental Technologies
Phone: +49 7031 78-2918
E-Mail: uwe.neumann@eisenmann.com
Tübinger Straße 81, 71032 Böblingen, Germany