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DESIGN FOR DEMILITARISATION

DESIGN FOR DEMILITARISATION. Presented by Dr David M Stalker BSc, PhD, C Chem, MRSC BAE SYSTEMS RO DEFENCE. INTRODUCTION. During 1999 and 2000 a consortium of Royal Ordnance plc,United Kingdom (RO) and DEMEX Consulting Engineers A/S,

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DESIGN FOR DEMILITARISATION

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  1. DESIGN FOR DEMILITARISATION Presented by Dr David M Stalker BSc, PhD, C Chem, MRSC BAE SYSTEMS RO DEFENCE

  2. INTRODUCTION • During 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”. AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  3. “…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 environmentally responsible manner. Demilitarisation is a necessary step for military items prior to their release to a non-military setting.” Definition of Demilitarisation from STANAG 4518 Definition of Demilitarisation • Demilitarisation is the Process whereby the Military • Characteristics of Munitions are removed: • Unsuited for continued storage • Obsolete • Excess to Service requirements AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  4. Surplus Stocks • Obsolence • Storage • No Longer Required • Deterioration • Possible Sale • Use for Training Purposes • Conversion Security/Safety Risks due to: Theft Attractiveness to Terrorists Need for Continued Storage Accidents } Increasing Hazards due to: Corrosion Loss of ID Chemical Instability Electonic Component Deterioration The need for Demilitarisation As Munitions become older there are a number of issues that face the custodians: AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  5. Retention Risks/ Costs Increasing Security/Safety Risks due to: Theft Attractiveness to Terrorists Need for Continued Storage Accidents Progressive reduction of stocks through disposal Increasing Hazards due to: Corrosion Loss of ID Chemical Instability Electronic Component Deterioration Today Time Years 100% Demil The need for Demilitarisation The choice is to assume greater risks and costs with continued storage or proceed with destruction AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  6. Examples of Demilitarisation Problem Areas No formulated Dis-assembly or Demilitarisation methods Potentially Incompatible Materials Stability of Aged Explosives Case Bonding of Energetic Fillings Interference Fit of Components Hypergolic Materials Chlorinated Plastic Components Radioactive Sighting Devices Toxic Materials Anti-tamper devices and mechanisms Radioactive Kinetic Energy Projectiles Volatile Materials Self destruct mechanisms Pyrotechnics - heavy metal species Corrosive Materials Electronics encased in Epoxy Resin with added DU Salt Toxic Metal Salts in Propellants eg Lead Caustic Materials Fungicide Impregnated Pallets eg Pentachlorophenols Leaching or Weeping of Energetics Oxidising Materials Filling Ports which are too small to use for Emptying Out Mixed Plastic Components Adhesives Asbestos and Asbestos Impregnated Resins Water or air sensitive species Pyrophoric Metals AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  7. Demilitarisation Options Controlled Incineration or Detonation Controlled Incineration or Detonation Sale Open Detonation Open Burn Munition Assembly Use for Training, Targetry etc AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  8. Demilitarisation Options Controlled Incineration or Detonation Disposal of Packaging Sale Open Burn Open Detonation Munition Assembly Strip and Separate packaging Components eg Wood/Plastics/Metal etc Use for Training, Targetry etc Removal from packaging Re-use of Packaging AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  9. Demilitarisation Options Controlled Incineration or Detonation Controlled Incineration or Detonation Disposal of Packaging Sale Open Burn Open Detonation Munition Assembly Strip and Separate packaging Components eg Wood/Plastics/Metal etc Use for Training, Targetry etc Removal from packaging Re-use of Packaging Disassembly Re-use of Hardware Upgrade Hardware Separate Components Destroy/Mutilate Hardware Scrap AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  10. Demilitarisation Options Controlled Incineration or Detonation Disposal of Packaging Sale Open Burn Open Detonation Munition Assembly Strip and Separate packaging Components eg Wood/Plastics/Metal etc Use for Training, Targetry etc Chemical Feedstock Removal from packaging Re-use of Packaging Conversion to alternate non-energetic use Disassembly Re-use of Hardware Fertiliser Removal of Energetics Upgrade Hardware Conversion to another Energetics Application Separate Components Recovery of Energetics Separation of Chemical components Open Burn Eg Mining Destroy/Mutilate Hardware Open Detonation Disposal of Non-Energetics eg Fillers, Binders etc Controlled Incineration or Detonation Energetics Re-use Scrap AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  11. Demilitarisation Areas for The Future Controlled Incineration or Detonation Disposal of Packaging Sale Open Burn Open Detonation Munition Assembly Strip and Separate packaging Components eg Wood/Plastics/Metal etc Use for Training, Targetry etc Chemical Feedstock Removal from packaging Re-use of Packaging Conversion to alternate non-energetic use Disassembly Re-use of Hardware Fertiliser Removal of Energetics Upgrade Hardware Conversion to another Energetics Application Separate Components Recovery of Energetics Separation of Chemical components Open Burn Eg Mining Destroy/Mutilate Hardware Open Detonation Disposal of Non-Energetics eg Fillers, Binders etc Controlled Incineration or Detonation Energetics Re-use Scrap AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  12. Cost Effective Environmentally Acceptable Safe Physically Safe Practical Maximisation of Recovery and Reuse Free from H ealth Hazards Cost Effective Efficient The Changing Emphasis of Demilitarisation • 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 The overall drive is towards source reduction, re-use and recycling - basically Waste Minimisation and Pollution Prevention throughout the life of the store leading to the concepts of: R3 Resource Recovery and Re-use R4 Resource Recovery Re-use and Recycle AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  13. Usually leading to destruction of the hardware and scrapping with no re-use. Review of Demilitarisation Technologies and Techniques In the CEPA 14.6 Project a survey of Demilitarisation Technologies and Techniques was made • Examples of Existing Technologies • 1. Disassembly and Opening Up • Mechanical Disassembly and Reverse Engineering • Mechanical Saw • Mechanical Separation - eg abrasive water jet cutting • Cryofracture AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  14. 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 Review of Demilitarisation Technologies and Techniques • 2. Removal of Energetics and Fillings • Meltout • Steamout • Dry Machining • High Pressure Water Washout • Hot Water Washout • Water Washout of Class Rkt Motors • 3. Disposal of Energetics • OB/OD • Contained Detonation Chamber • Propellant and HE Conversion to Fertilizer & • Mining Explosives • Incineration AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  15. Review of Demilitarisation Technologies and Techniques Planned and Emerging Demilitarisation Technologies Confined Burn Pyrotechnic Reclaim/Reuse Hot Gas Decontamination Reuse of Gun Propellant Biodegradation HMX Recovery Contained Detonation Chamber RDX Recovery Contained Burn with Scrubber Propellant Conversion to Fertilizer Tunnel Burn Liquid Ammonia Reclamation of Tactical Rocket Motors & IM Tunnel 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 Munitions Abrasive Waterjet Cutting Explosive D Conversion to Picric Acid Robotic Disassembly Electrochemical Techniques (eg Silver II)) Biochemical 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 AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  16. Design for Demilitarisation • In the CEPA 14.6 Project a survey of Munitions’ development was made • encompassing: • 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 AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  17. Design for Demilitarisation • 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 • 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 AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  18. Design for Demilitarisation Extracts from US Executive Orders on Demilitarisation and on Insensitive Munitions • 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 • Insensitive Munitions and R3 • Executive 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 AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  19. 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. This model also encompasses whole life costing and not only the Demilitarisation stages. AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  20. Drawings Diagrams Specifications Standards Identify Components/Parts including all Packaging and Specific Transportation Equipment Bulk Items Materials ie Packaging and Component Parts Safety/Health & Environmental Effects • Define natures of all materials present and used: refer to • CAS No and Synonyms • Dictionaries • Hazard Data Sheets • Manufacturers’ Information • etc Existing Environmental, Safety and Health Regulations and Impact PEP Materials and PEP Ingredients (Energetic and Non-Energetic) • Environmental Impact Effects • Water Release • Air Release • Ground Release • Define materials into categories • Toxic • Flammable • Corrosive • Oxidiser • etc Inert Materials and Compounds • Health Effects and Impact • COSHH • Carcinogen • Neurotoxin • Acute • Teratogen • etc • Manufacture • Processes • e.g. Plating, Alloys, • Materials used • Resources used • Resources Consumed Inventory Quantities/Amounts Present or Consumed Munitions Database Library Demilitarisation Process Design Process Munitions’ Characterisation & Creationof Munitions Database Library Munition/Store AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  21. Conclusions 1. 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 materials • Configure in ease of component and packaging reuse or recycling • Minimise environmental impact • Select materials that minimise hazards to personnel and the environment • at the end of the munition’s life • Build in “demil switches” – eg hydrolysable binders 2. Create Inventories of Substances and Components including packaging Aspects highlighted in yellow incorporated in STANAG 4518 and OB Proc P115(2) AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

  22. Conclusions • 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 Life • Design for Life Extension • Select materials and design features that enable stocks to be used in training • 5. Configure packaging to maximise recycle, re-use • Configure in ease of packaging reuse or recycling 6. Minimise environmental impact from packaging 7. Incorporate components identified from demil inventory available for re-use 8. Provide detailed procedures and information on munition’s demilitarisation Aspects highlighted in yellow incorporated in STANAG 4518 and OB Proc P115(2) AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

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