Presented to: Chemical Destruction Community Advisory Board’s Explosive Destruction Technology Working Group Presented by: Jeff Brubaker, ACWA Site Manager John McArthur, Systems Contractor Environmental Manager

1. Explosive Destruction Technology
30 Percent Design Update
May 6, 2014
Presented to:
Chemical Destruction Community
Advisory Board’s Explosive Destruction
Technology Working Group
Presented by:
Jeff Brubaker, ACWA Site Manager
John McArthur, Systems Contractor
Environmental Manager

2. A Partnership for Safe Chemical Weapons Destruction
Bechtel Parsons Joint Venture team

3. A Partnership for Safe Chemical Weapons Destruction
3
Agenda
 EDT Facility Layout
 Munitions Processing Steps
 Equipment Layout
 Other Materials
 Questions/Discussion

4. A Partnership for Safe Chemical Weapons Destruction
EDT Facility Layout
4

5. A Partnership for Safe Chemical Weapons Destruction
O2SF Outside Operations Support Facility
ESB EDT Support Building
MH Monitoring House
ESM EDT Service Magazine
EEB EDT Enclosure Building
CON Control Room
TOF Treaty Office Facility
5
EDT and OPS Facilities

6. A Partnership for Safe Chemical Weapons Destruction
6
ESM
ESB
EEB
MH
O2
SF
O2SF
BGCAPP Site Plan / EDT Site Location

7. A Partnership for Safe Chemical Weapons Destruction
7
TOF
BGCAPP Site Plan / EDT Site Facility
ESM
ESBEEB
MH

8. A Partnership for Safe Chemical Weapons Destruction
 Function: The purpose of the O2SF will be a primary location for
support functions related to the start and end of daily and shift
activities and routine facility support
 O2SF will consist of the following areas to support the Project:
 7 offices and 12 cubicles
 A Mask Issue, fit and test area
 First Aid Area (with a blood draw area and a small Laboratory for Medical personnel)
 Hazmat/decon Storage Area
 Toxicological Area Protective (TAP) gear storage
 Lunch Room
 Restrooms and Showers
 Locker Areas (with approximately 150 lockers)
 A Cotton Goods Issue Room
 An IT Help Desk and a small Communication Equipment Room
8
O2SF – Facility Design Description

9. A Partnership for Safe Chemical Weapons Destruction
 Function: The purpose of the ESB is the primary support functions
directly related to the operation of the EDT to support the disposal of
the Mustard agent inventory at Blue Grass Army Depot (BGAD)
 The ESB houses and supports the EDT operational crews and the
direct support crew functions
 ESB will have 6 offices, 10 cubicles, a Conference Room, a TAP
Gear / Tool / Parts Storage Area, a Lunch Room / Crew
briefing/training area, Restrooms, an Electrical Room, a
Communications Room, and a small Custodial Utility Room
 The offices are for general purpose and direct support services use,
and planned to accommodate Plant Management, Engineering,
Automation and personnel that directly support the EDT operations
 It will support approximately 20 people on Day Shift and
approximately 90 people on rotating shift that are part of the
operational crews that work within the EDT Complex
ESB – Facility Design Description

10. A Partnership for Safe Chemical Weapons Destruction
 A Conference Room will provide space for crew training, turn-
overs, and meetings
 The Lunch Room/Crew Room contains approximately 40
lockers. This area will have a seating area for approximately
27 personnel. This area also serves as a meeting area to be
used for shift turn-over, crew training, meetings and
presentations. It will also contain several computer
workstations for general crew use (e.g. timekeeping, complete
computer based training, complete Read and Sign
requirement, etc.)
 The building’s HVAC system can be shut down to utilize the
ESB as a shelter-in-place facility
 The ESB will not house any Chemical Weapons Convention
(CWC) Treaty personnel
 Adjacent to the ESB is the EDT Control Room (CON)
ESB – Facility Design Description

11. A Partnership for Safe Chemical Weapons Destruction
 Function: The purpose of the EDT Process Monitoring House
(MH) is a centralized area which contains the air monitoring
equipment and some process monitoring equipment to
support operator safety and verify environmental compliance
during 24/7 processing operations of the EDT Facility.
 The MH consist of a 16 by 36 foot raised structure,
MiniCAMS, DAAMS, CEMS, and other air monitoring
equipment.
11
MH – Facility Design Description

12. A Partnership for Safe Chemical Weapons Destruction
 Function: The purpose of the ESM will be to hold a reserve of
Mustard munitions to support 24/7 processing operations of the EDT
Facility
 The ESB consist of a 30 by 30 foot Non-Standard Storage Structure
(NSS) with an HVAC unit, a Monitoring Shack, a Bottle Storage Area
with overhead cover, and a 1,000 CFM Filter Unit mounted on a
trailer.
 ESM Capability:
– Maximum explosive capability = 500 pound Net Explosive Weight (NEW) (1,206
projectiles)
– Site Plan Safety Submittal (SPSS) Limit = 1,128 projectiles
 Pallet stacking within the ESM is limited to two high
 The floor is designed with secondary containment and water stops
 The Monitoring Shack contains MiniCAMS and DAAMS to support air
monitoring of the ESM, EONCs, and the 1,000 CFM Filter Unit
12
ESM – Facility Design Description

13. A Partnership for Safe Chemical Weapons Destruction
13
EONC Transport of Chemical Weapons

14. A Partnership for Safe Chemical Weapons Destruction
 Function: The purpose of the EEB is to house the SDC and OTS
process equipment
 The EEB consist of a 77 by 120 foot building (approx.)
 The building has an A, B, C, D Agent Areas with a Cascading
Ventilation System and a Munitions Delivery Airlock
 The SDC consist of a:
– Loading Conveyor and Elevator Lift
– Loading Chamber #1 and #2
– The Detonation Chamber (DC)
– A Buffer Tank
– A Scrap Chute, Scrap Cooling Conveyor, Belt Conveyor, and a Scrap
Bin
14
EEB – Facility Design Description

15. A Partnership for Safe Chemical Weapons Destruction
 The Off-Gas Treatment System (OTS) consist of a:
– Thermal Oxidizer
– Spray Dryer
– Bag House Filter
– Quench
– Acid & Neutral Scrubber
– ID Fans
– Heat Exchanger and Cooler
– A Re-Heater
 The building has a 16,000 CFM IONEX Carbon Filter Unit
 And the OTS has a 4,000 CFM IONEX Carbon Filter Unit
15
EEB – Facility Design Description

16. A Partnership for Safe Chemical Weapons Destruction
16
EDT Enclosure Building (EEB)
Layout is based
on the Vendor’s
Preliminary
Design and Equipment
Layout Drawings

17. A Partnership for Safe Chemical Weapons Destruction
17
Airlock
OTS
Gears
Switch
Monitoring
House
4000
IONEX
16000
DC
ChillerScrap
Conveyor
Lift
Feed
Conveyor
THO
Air Tank
Air
Compressors
Layout is based
on the Vendor’s
Preliminary
Design and Equipment
Layout Drawings
BT
EDT Enclosure Building (EEB) Layout

18. A Partnership for Safe Chemical Weapons Destruction
18
EDT Enclosure Building (EEB)
SDC
OTS
Monitoring
House
Airlock
IONEX
4000
Layout is based
on the Vendor’s
Preliminary
Design and Equipment
Layout Drawings

19. A Partnership for Safe Chemical Weapons Destruction
Agent
Area
Category
Color
Code
Purpose Areas Included Remarks
A Red Primary Containment of liquid and
vapor agent
Detonation Chamber (DC) and off-gas
piping to the Thermal Oxidizer (THO)
Most negative pressure
B Orange Secondary Containment of vapor
agent
Around the DC, off-gas piping to the
THO, and the THO itself
More negative pressure
C Yellow Tertiary Containment providing an
area under ventilated engineering
controls
Munition Handling and loading areas
within the building and around the
Secondary Containment areas
Slight negative pressure. Will
require both MHE and personnel
air lock(s) from the D area
D Green No containment. Provides weather
protection to EDT equipment and
crew
The outer building No negative pressure on this
structure
THO OTSDCLoading Area
Category D area
Category C area
Filter / Stack
4,000
Vestibule
No Scale is given to any component of this concept drawing
19
Category B area
EEB – Agent Containment Areas
Carbon Filter
16,000
Air is pulled from atmosphere pressure through process areas with progressing decreasing (negative) pressure as
an engineering control measure

20. A Partnership for Safe Chemical Weapons Destruction
 Function: The purpose of the CON is to serve as the Commend and
Control (C2), and the operational center for EDT Facility.
 The CON consist of a 16 by 20 foot structure.
 Process Equipment include:
– DC HMI stations 1 and 2
– OTS MHI stations 1 and 2
– Dynamic Pressure Sensing Station
– CCTV HMI station with multiple monitors
 The CON will be staffed by:
– Shift Plant Manager (SPM)
– Control Room Operators (CRO) (2 each)
– Operations Support Tech
– Automation Specialist (Day Shift only) 20
EDT CON – Facility Design Description

21. A Partnership for Safe Chemical Weapons Destruction
 EDT Enclosure Building (EEB)
– On a concrete pad
– Personnel Entry/Exit
– Emergency Exits
– Munition Delivery Airlock
– Scrap Handling Area
 SDC System
– Feed Conveyor
– Lift
– Loading Chamber 1
– Loading Chamber 2
– Detonation Chamber (DC)
– Scrap Conveyor
– Inspection Conveyor
– Belt Conveyor
– Scrap Bin
– Buffer Tank
– Dust Handling System
• Off-Gas Treatment System (OTS)
– Thermal Oxidizer
– Spray Dryer
– Bag House Filter
– Quench
– Acid & Neutral Scrubber
– ID Fans
• IONEX Carbon Filter Units (two)
– OTS Filter Unit
– Building Filter Unit
• Utilities
– Natural Gas
– Electrical
– Water
– Emergency Generator
– Air Compressor
– Hydraulics 21
EDT Equipment Components

22. A Partnership for Safe Chemical Weapons Destruction
Munitions Processing Steps
22

23. A Partnership for Safe Chemical Weapons Destruction
23
EDT Munitions Processing Steps
(Based on the Preliminary 30% Design)
BGCA CW
Storage Igloo
Wooden Pallets
Steel Banding
CW Munitions
are un-banded
CW placed in
Staging Area
EDT CW
Service
Magazine
CW placed in
Feed Tray
SDC
CW enters the
Detonation
Chamber
CW moved via
Conveyor /
Elevator
CW moved
through
Air-Locks
SDC
LC1 - 112
LC2 - 114
LFT
104
COV
101
Information Sources: Updated Vendor PFD and P&ID drawings received 18 February 2014.
Disclaimer: The above illustrated Process Steps are based on the general preliminary design information provided.
Equipment abbreviation code and ID number that
relates to those on the PFDs and Mass Balance

24. A Partnership for Safe Chemical Weapons Destruction
24
EDT Munitions Processing Steps
(Based on the Preliminary 30% Design)
Page 2 of 4
Dust
Metal - Oxide
Volatile / Semi-Volatile
Heavy Metals (Pb, Be, Cr)
Dosing
Station
Dry Salts &
Particulates
Ash
Large Particulates
Spray
Dryer
Bag
House
Filter
Sodium
Bicarbonate
Detonation
Chamber
Buffer
Tank /
Cyclone
Separator
Scrap Metal Recycled to DC
(for 5X treatment)
THO
310
BHF
330
SPD
320
BT
160
Process
Water Tank
Air
Nature Gas
Air
Water
IBC
Air
DC
120
PWT
424
ADS
470 (NaOH)
NAS
480
Bleed Water
Information Sources: Updated Vendor PFD and P&ID drawings received 18 February 2014.
Disclaimer: The above illustrated Process Steps are based on the general information provided.
Scrap Conveyor 2
5X
Scrap Metal
for Recycle
Air
Heater
Emergency Water
Water
Process
Vent
Filter
Dust
Thermal
Oxidizer
Air
PVF
171
PVC
170
Cyclone

25. A Partnership for Safe Chemical Weapons Destruction
25
EDT Munitions Processing Steps
(Based on the Preliminary 30% Design)
Information Sources: Updated Vendor PFD and P&ID drawings received 18 February 2014.
Disclaimer: The above illustrated Process Steps are based on the general preliminary design information provided.
Quench
Tower
Acid
Scrubber
Neutral
Scrubber
Water
Feed/Recycle loops
Heat
Exchanger
NaOH
AC
366
SEP
367
QUE
340
HX
362
NSC
360
ASC
350
Emergency Water
Tank
Separ
ator
Air
Cooler
EWT
322
BWT
430
Bleed
Water Tank
Condensate
Tank
COT
363
NaOH
Bleed Water
Emergency Water
Dust
Chlorine, Hydrogen chloride
SOx
SOx
Chlorine
Heavy Metals
Heater
AH
370
Air

26. A Partnership for Safe Chemical Weapons Destruction
26
EDT Munitions Processing Steps
(Based on the Preliminary 30% Design)
Information Sources: Updated Vendor PFD and P&ID drawings received 18 February 2014.
Disclaimer: The above illustrated Process Steps are based on the general preliminary design information provided.
ID Fan
1
ID Fan
2
Pre
Filter
HEPA
Filter
HEPA
Filter
Carbon
Filter
SIC
Carbon
Filter
Filter Bank
(five filter element)
Carbon Filter
Elements
STACK
Monitoring
House
ION
400
IDF1
370
IDF2
371
Exhaust Stack
Laboratory
Monitoring
House
Water Vapor
MiniCAMS
DAAMS
CEMS
CO
O2
ID Fan
Sample
Ports

27. A Partnership for Safe Chemical Weapons Destruction
Equipment Layout
27

28. A Partnership for Safe Chemical Weapons Destruction
28
Note: Our Scrap Conveyor
is turned 90 degrees from
the Cool Down Conveyor
Feed
Conveyor
Munitions
Lift
Dust
Collection
Scrap
Bin
Belt
Conveyor
Secondary
Containment
Buffer Tank
EDT Process Equipment Layout

29. A Partnership for Safe Chemical Weapons Destruction
29
Tilting Cradle
Fragment
Shield
Loading
Chamber 1
Gate 2
Secondary
Containment
Loading
Chamber 2
Gate 1
EDT Process Equipment

30. A Partnership for Safe Chemical Weapons Destruction
30
Fragment
Liner
Destruction
Chamber
Heating
Elements
DC Empting
Arrangement
Locking RingInsulation
EDT Process Equipment

31. A Partnership for Safe Chemical Weapons Destruction
31
1
4
3
2
EDT Feeding Cycle

32. A Partnership for Safe Chemical Weapons Destruction
Air
Heater
32
DC Empting Cycle / Scrap Removal &
Cooling

33. A Partnership for Safe Chemical Weapons Destruction
33THO QUE ASC
NSC
BHFSPD HXIDF1
IDF2
 Upgraded / Larger THO & OTS
– Limiting Throughput (Pacing Station) for the Anniston unit
 The THO is 98% larger:
– Anniston unit is: 162 ft3
– BGCAPP unit will be: 321 ft3
 The OTS is 75% larger
 Closed Loop Process Water System
OTS - Key Design Elements

34. A Partnership for Safe Chemical Weapons Destruction
Reverse angle
Spray Dryer Dosing Station
Spray Dryer Waste Drum
Quench Venturi
Bag House Waste Drum
Emergency
Water Tank
Bag House Filter
Spray Dryer
Thermal
Oxidizer
Scrubbers
34
OTS Process Equipment Layout

35. A Partnership for Safe Chemical Weapons Destruction
35 15B
1S
3 4
2
5 6
15A
98
7 12 13
10
14
11
C/N Host
SP
SP
P
1
P
2
1 EONC Unload
2 Service Magazine
3 Carbon Midbed
4 Fixed Perimeter
5 Perimeter Trailer
6 Perimeter Trailer
7 Air Lock
8 Loading Area
9 Buffer Tank
Enclosure
10 D/C Enclosure
11 Scrap Exit Area
12 HVAC Midbed
13 HVAC Stack
14 OGT Carbon
Midbed
15 OGT Stack A/B
EDT Personnel Safety Monitoring
Locations

36. A Partnership for Safe Chemical Weapons Destruction
Other Materials
36

37. A Partnership for Safe Chemical Weapons Destruction
37
• Processing Rates - without Overpack
– M110 155mm H Projectiles
– At Peak and Normal Processing Rates:
• Peak Rate estimated: 6.1 projectiles per hour
• Peak Rate actual: To be determined during the
Factory Acceptance Test (FAT)
• Normal Rate estimated: 4.8 projectiles per hour (81%
availability)
Processing Rates

38. A Partnership for Safe Chemical Weapons Destruction
Activity Date
EDT CW Operations Jan – Oct 2017
Ramp-Up Period
Full Rate Period
Regulatory Testing
Over-Pack Processing
EDT Closure and Turn-Over Nov 2017 – May 2018
Decontamination
Restoration
De-staffing
System / Facility Turn Over
Main Plant CW Operations (forecasted Start date) Jan 2018
38
EDT Schedule and Key Milestones

39. A Partnership for Safe Chemical Weapons Destruction
39
• Day Crew arrive at O2SF – Change Out / Draw Mask / Transport to the EDT Complex
• Crew Turn-Over / POD Briefing
• Daily RCRA inspections (AM)
• Verify FPIs and LCOs are completion and approval
• Routine Activities:
Open, complete, and print Feed Sheets
Establish TCEAs – as required (EONC delivery / Munition transfer / EEB processing)
Conduct munitions transfer from the ESM to the EEB Loading Area (twice per shift)
Load Munitions in Feed Trays (twice per shift)
Begin CW Processing - Feed Trays to the SDC
Scrap inspection and removal – as required
Dump Scrap Bin – as required
Daily Operational Report
• Night Crew arrive at O2SF / – Change Out / Draw Mask / Transport to the EDT Complex
• Crew Turn-Over
• Repeat the above Routine Activities
• Munitions Accountability paperwork
• Midnight – Perform a Daily Munition Inventory – develop the COD packet for the prior 24 hrs
• Equipment PM Checks are performed
• Lab Perform equipment challenges (AM)
• Resume CW Processing
Typical EDT Operational Day

40. A Partnership for Safe Chemical Weapons Destruction
Location: Anniston BGCAPP
Description SDC 1200 CM (Chemical Mobile) SDC 1200 C (Chemical)
Transportable unit Fix Facility unit
CW Net Explosive Wt. (NEW) 2.2 lb HE / 6.61 Propellant TBD (min, 2.2 lb HE / 6.61 Propellant)
Fragment Shield: Tube Shaped (sides only) Bowl Shaped (sides with a bottom)
DC Heater: 3 on the bottom of the DC 3 on the bottom plus additional on sides
Cooling Fan for Locking Ring: None Yes (added to minimize binding at high temps.)
LC1 and LC2 Vents to THO: No Yes
(to minimize/prevent agent migration to the Process Ventilation)
Bypass valve around off-gas No Yes
orifice: (to minimize press in the chamber to minimize agent migration to LC2)
Off-Gas Treatment System (OTS): Has a SDC 1200 sized OTS Has a larger SDC 2000 OTS (75% larger)
Thermal Oxidizer (THO): 162 ft3 321 ft3 (98% larger)
Bleed Water Tank: No Yes (added to support 24/7 operations)
Chiller to remove Condensate: No (collection pump to recycle H2O) Yes (added after the Neutral Scrubber)
Re-Heater after Chiller: None initially – installed later Included
Carbon Filter System: IONEX CD2000 IONEX CD4000
Building Type: Sprung Structure Steel Building
Building HVAC: No - Portable AC unit added Yes
Cascading Ventilation System: Vapor containment only Yes (with Category A, B, C, and D areas)
Number of Mustard Projectiles: 2,737 CW munitions processed Approx. 16,000 munitions to be processed
Agent Types: HD and HT Mustard H Mustard (with solids and heels)
DOT Bottles: None processed Two (2) are planned
40
EDT Unit Differences
(Anniston vs. BGCAPP)

41. A Partnership for Safe Chemical Weapons Destruction
Questions/Discussion
41