3. demilitarzn & melt out.pptx

Most of the countries procure more conventional ammunition than they use.
Despite other disposal initiatives, much of a nation’s surplus ammunition
stockpile eventually require demilitarization—a process by which ammunition is
safely dismantled or destroyed while, ideally, its valuable materials are
recovered. This con measure is a component of conventional ammunition
stockpile management and features prominently in the UN International
Ammunition Technical Guidelines (IATG). In many countries, excess stockpiles of
obsolete or unserviceable munitions have reached a level require
demilitarization on an industrial scale, often in a race against time, because the
ammunition tends to become unsafe with age. This chapter will provide an
intro snapshot of the ammunition demilitarization.

History Development of Demilitarization
Demilitarization came into existence much later stage of disposal of ammunition. In
earlier days, the disposal technical was only by destroying ammunition. Due to
development of technical now a day’s various recycling methods are being adopted.
The chronological development of demilitarization are as following:
a. 1st Stage. Before 1950s the only disposal method was dumping in sea or
land in remote places.
b. 2nd Stage. From 1950 to 1970 the disposal method was burning and
demolition instead of dumping.
c. 3rd Stage. From 1970 till now the main disposal method is Disassy and
Emptying keeping in view the concept of recycling. Disassy and Emptying method
are supplemented by burning and demolition in only require cases.

Significance of Demilitarization
The significance of demilitarization are as following:
a. Reduce military and econ burden.
b. Reduce mistakes and risks of ammunition sup and using.
c. Safety of ammunition depot.
d. Increase the value of ammunition. Normally the WA lost its original value but
still most of its source elms might be still useful. So, by recycling the value of WA can
be increased.

Many munitions and propellants are harmful to the environment, so demilitarizing
large quantities of ammunition requires the rigorous control and processing of toxic
substances. The packaging material can also require handling and treatment to
contain the heavy metals and persistent organic pollutants that were often used as
preservatives in wooden ammunition packaging before it was banned. Some of the
demilitarization processes them-selves generate additional environmental hazards,
such as air pollutants, pink water and other hazardous secondary materials. All of
these substances have been the subject of regional or national environmental
regulation covering noise, air, water, and land emissions, as well as waste
management and recovery
Environmental Issues Versus Cost-effectiveness

Any demilitarization process must ensure that there is appropriate control of the
materials at all stages, and particularly the final disposal of any hazardous waste
stream. Yet strict adherence to these standards is not always possible, given
countries’ local demilitarization capacities and national legislation, which may be
less demanding. Environmental legislation has largely spurred the development of
recovery, recycling, and reuse (R3) processes to reduce the reliance on OB/OD,
which remains a common, yet controversial, practice, even when combined with
industrial dismantling. (R3) proceases have become an important requirement in
the demilitarization industry.

Yet the environmental compliance process, often involving multiple licensing
requirements, has also made demilitarization systems more complex and expensive
to develop and operate thereby increasing the costs of demilitarization for cash-
strapped client governments and prospective donor countries. The current debates
surrounding the environmental impact of OB/OD and the extent to which (R3)
revenues can offset overall demilitarization costs reflect the underlying need for
cost-effectiveness in industrial ammunition demilitarization.

a. Ensure Safety. This relates to the safety of persons and equipment. In short,
adopt various measures to avoid accidents or reduce the harm of accidents by
implementing proper plan and suitable process. Standing and regulations are
achieved through long term practice experience which has to be following as
regulation criterion of safety measures. Ensuring safety should meet following two
imp aspects:
(i) The unity of safety and its effect on efficiency of work output.
(ii) Safety measures must meet the standing and regulations.
General Principles of Demilitarization

b. Increase Economic Benefits. Ways of economic benefits are either to
increase output or to decrease input. It can be shown as under:
(i) Economic benefits = Output – Input (Absolute Value). Or,
(ii) Economic benefits= Output / Input (Relative Value).

c. Dispose thoroughly and not to Leave Hidden Trouble. Measures for
removing hidden troubles are as following:
(i) Sep energy materials from non-energy materials and ensure there are no
energy materials in non-energy materials (Commonly known as FFE – Free From
Explosives).
(ii) Dumping into sea water and earth is environmentally not
supported.
(iii) Proper accountability of ammunition; list of ammunition and stock must
correspond each other.
(iv) In selling or auctioning of non-energy materials strict check must be done
before leaving depot, so as to ensure there are no energy materials.
(v) The site should be checked strictly so that no residue of energy materials is left
behind.

d. Reducing Pollution to Environment. WAD procedures are generally
environment friendly. It is mainly the waste water which cause little pollution where
TNT is the main constituent. However, careful disposal of waste water might reduce
the magnitude of pollution.

Demilitarization is defined as ‘the complete range of processes that render
weapons, ammunition and explosives unfit for their originally intended purpose’.
The term applies equally to serviceable and unserviceable surplus material or
equipment. Many demilitarization techniques are available, categorized by the stage
of the demilitarization process in which they are applied
Demilitarization Stages

Not all of these steps are systematically required and some can be
combined. Demilitarization is considered complete once all residues from the
reverse engg or destruction process have been destroyed or recycled. Many
countries use a mix of open burning and open detonation (OB/OD) with other, more
environmentally friendly methods that aim to recover valuable materials. The
decision to choose any particular tech is based on cost, safety, environmental
considerations, customer preference and timeframe, log, available, the type and
quantity of ammunition being destroyed, the physical or chemical condition of the
ammunition and the value of recovered material. Countries also modify technical to
be mobile or transportable so that they can be moved from stockpile to stockpile.

Process Stage Description
1. Transport Compliance with dangerous goods or hazardous waste
regulations that apply to the transportation of
ammunition and explosives earmarked for
demilitarization
2. Storage until demilitarization Compliance with relevant quantity-distance standards
3. Manual unpacking and preparation Sorting and unpacking
4. Pre-processing and disassembly Separation of projectiles, propellants, and casings;
exposure of energetic material prior to removal
5. Energetic removal Physical removal of energetic materials from their
housing or casing
6. Energetic disposal (primary destruction) Decommissioning or destruction of energetic materials
7. Energetic disposal (secondary
destruction)
Production of scrap material ‘Free From explosives’
8. Pollution control system Compliance with regional or national environmental
regulations covering noise, air, water, and land
emissions, as well as waste management and recovery

The demilitarization industries are mostly based in Western Europe and the
United States. A core group of approximate 30 major companies with proven
operation capable occupy the international market. Many of them are former or
active ammunition producers that have re-engineered their production lines for
demilitarization. For instance, Nammo Buck GmbH in Germany was an ammo
factory before the reunification of East and West Germany, and has been involved in
demilitarization since 1991. Other companies focus exclusively on manufacturing
and marketing demilitarization equipment industry contractors operation under
private, government, or mixed ownership. Indeed, public–private partnerships are
common. The contractors demilitarize all types of ammunition under normal
competitive tendering rules. National procurement and log agencies publication
requirement for proposals (RP), and often use regional organization to issue them
for large disposal programme.
Demilitarization Scenario Around the Globe

The NATO Support Agency, for example, manages RPs for the disposal of
surplus ammunition holdings on behalf of NATO Ammunition Support Partnership
and Partnership for Peace (PP) countries, monitoring these contracts until
completion. A well-document PP trust fund case study is Albania, where three
successive project significantly increased the country’s indigenous demilitarization
capacity. The contracts usually cover ammo receipt; storage; internal move;
demilitarization processes; the processing of by-products, such as explosives and
metals; and the disposal of all scrap materials. In 2012 TRZK estimated its
demilitarization costs on behalf of the Serbian Ministry of Defence at EUR 780 (USD
1,000) per ton and claimed that they would fall below EURO 500 (USD 650) per ton
following the upcoming installation of an explosive waste incinerator and new
disassy machines.

The United States is the largest market for demilitarization services and will
remain so for the foreseeable future. US figures from the 2010 Demilitarization
Symposium in Tulsa indicate a demilitarization stockpile of 587,000 tons, with
annual funding of approximate USD 146 million. Large quantity of surplus munitions
are disposed of each year, but a similar quantity is declared surplus. Cluster
munitions, especially multiple-launch rocket system rockets, still represent an
important segment of US demilitarization activity. In Western Europe,
demilitarization stockpiles are generally growing at a much slower rate. In Eastern
European and Commonwealth of independent states countries, industrial
demilitarization remains a domestic activity largely inaccessible to open,
international tender competition.

Bangladesh Army being an age old army for about 44 yrs having lot of
conventional munitions in its inventory. There are lot of shelf life expired and phase
out ammunition in its stock. So long main disposal method following were burning
and demolition. During burning and demolition the reuse, recycle and resale value
of the metallic part of the ammunition could not be achieved. At this backdrop a
high lvl BofO visited few European and Asian countries to ascertain the modus
operand of demilitarization of waste ammunition in Bangladesh. Accordingly the
BofO recommendation to construction an ammunition lab in CAD of Bangladesh
Army with a view to demilitarize the large number of waste ammunition and
recycling them in effective way. This may be termed as the genesis of
demilitarization of waste ammunition in Bangladesh Army.
Demilitarization Scenario in Bangladesh Army

When appropriate risk mgt processes are applied, industrial demilitarization
is not inherently risky. Yet the nature of the activities involved means that
explosions can occur during processing or storage, even in NATO-standard facilities.
When built according to strict quantity–distance standards, facilities confine all
explosive damage to the workshop where an incident might occur. The buildings
used to store or process munitions are self-contained, often partially buried, and
designed to send any blast upward and not outward, to minimize damage. In
countries where industrial demilitarization is less developed, involving contractors
that do not meet relevant standards, there is greater potential for accidents.
Lab Condition

According to technical characters and using conditions, demilitarization can
be carry out in four ways:
a. Disassy.
b. Emptying.
c. Burning.
d. Demolition.
GEN METHODS OF DEMILITARIZATION

Disassy
It is the tech process of removing the original structure and function of the
ammunition by certain technical means, so that the ammunition returns to the
source element state.
a. Advantage.
(i) Recycling and out ratio of source element is high.
(ii) Easy to meet environmental requirements.
b. Disadvantage.
(i) Need complete equipment and installations and initial input is
high.
(ii) Safety requires is higher.

Emptying
The technical process in which the propel and explosive in the shell case are poured
out to sep the energy materials from the casing. Emptying of prop is comparatively
easier than the explosive from shell:
a. Advantage.
(i) Recycling ratio is high.
(ii) Demolition can be avoided in case of many WA.
b. Disadvantage.
(i) Need technical equipment, initial input is high.
(ii) Too much consumption of power.
(iii) Additional treatment require for the wastes.

Burning
Burning is the technical process to burn the energy materials to release their energy
in the given way. Open and closed burning are the widely used technical in many
countries.
a. Advantage. Universal applicability.
b. Disadvantage. Certain air pollution and consumption
of fuel (in closed burning).

Demolition
It is the technical process in which the explosive or the elements with explosive are
exploded to release the energy of the explosives in the form of explosion or
detonation.
a. Advantage. Widely applicable and low cost as there is no need for
complex and costly equipment.
b. Disadvantage. Low recycling ratio, air-noise pollution and strict
require for explosion site.

Criterion to Choose Demilitarization Method. Considering following points
demilitarization method can be chosen:
a. Object of Treatment. Basing on the degree of disassy, elements or materials
to be recycled (according to values) and the elements to be disposed of the
demilitarization method can be deter.
b. Technical Conditions. Available of mechanical equipment and tools,
technical site and technical ability of person also helps to deter demilitarization
method.
c. Environmental Conditions. Environmental site, condition also dictates to
deter the demilitarization method.

Emptying is the disposal method in which some technical means are used to pour
out energy materials such as black powder or explosives from the ammunition or
elements of ammunition and thus sep the energy materials from the cases. Now a
days, this method is widely used in most of the countries of the world keeping in
view the popular Recycling Concept of the ammo and its various elms.
Emptying Method

Application
Project filled with HE and also special project like smoke, incendiary, Illuminate,
tracer, jammer and carrier project can be disposed of by emptying method. Gen,
TNT, RDX, mixture of TNT – Dinitronapthaline (DNN), TNT – RDX, mixture of RDX – al
etc are the commonly used HE filling. HE project, Hollow charge project and AP
shells are having a wide variety and qty which can be effectively disposed of by
emptying method.
Emptying Method

Main Emptying Methods
Several different methods are being used by many countries of the world. The most
common methods are listed below :
a. Steam Heating Method.
b. Hot Air Heating Method.
c. Water Boiling and Vapor Swilling Method.
d. Pre Heating and Scooping Method.
e. Hot Water Sep Method.
f. Soaking Method.
g. High Pressure Water Jet Method.
Emptying Method

. The instruction manual aims at helping the user to familiarize himself with the
machine and to utilize it for in intended purposes. The instruction manual contains
important notes with regard to safe, appropriate and economic operation of the
machine. Observing these notes helps to avoid dangers, to reduce repair costs and
down times and to increase the reliability and the life time cycle of the ma‐
chine/installation.
EXPLOSIVE MELT OUT INSTRUCTION MANUAL

Notes on precautions to be taken by the operator (in many countries required by
law).
a. Entrust working activities on/with the machine/installation only to personnel
that is sufficiently qualified for this type of work.
b. Clearly define responsibilities of operating and servicing personnel.
c. Add stipulations to the instruction manual as they result from national
regulations on occupational safety and health and environmental protection (e.g.
organization of work).
d. Instruct the personnel to observe the instruction manual and its
supplements and make controls at periodic intervals. Make sure that a copy of the
instruction manual always is available at the machine.
e. Operate the machine/system only when it is in perfect working condition
and make sure to maintain that standard.

Safety Instructions
Operator. Owner/proprietor of the machine/install action or per son authorized by
him providing the machine / installation to be utilized by his employees (operating
personnel) within the framework of the working system.
Supervising Personnel. One or more persons authorized by the operator, to
supervise the (technical) utilization and operation of the machine /installation and
to give the required work instructions
Operating Personnel. The person/persons who is/are entrusted with immediate
operation of the ma chine/installation (e.g. turning on and shutting down, feeding
and retraction o f work pieces, if need be also simple activities with regard to
maintenance, upkeep and troubleshooting during operation).
Maintenance Personnel. The person/persons who is/are exclusively or mainly active
in maintenance and trouble shooting and w ho has/have the qualifications required
for this job.

Purpose
The melt out plant has been intended for removal of explosives from large caliber
projectiles/shells. For this purpose the parameters indicated in Chapter 4 of these
operating instructions have to be observed. All variations regarding these
parameters have to be defined and confirmed by provider Yugo import SDPR. Fuse,
supplement explosive charge (booter), fin assembly and propellant charges (ignition
cartridge and incremental charges) of the shells have to be dismantled. Dismantled
shells have to be free of grease, oil, accumulated filths, and bonded foreign parts on
the surf ace before processing by the explosive melt out equipment. The
manufacturer is not responsible for damage resulting from any misuse. The risk lies
entirely with the user.

Technical description
Layout.
Feed Section of Conveyor
Melt out vessel
Collecting tank
Cooling section of Conveyor
Platform
Boiler
Pump melt
Unpack table
Removal section of Conveyor

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