Assembled Chemical Weapons Alternatives Program Update 20 May 2009

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					Assembled Chemical Weapons
Alternatives Program Update

20 May 2009



Presented to:
CWD 2009
12th International Chemical Weapons Demilitarisation Conference


Presented by:
Mr. Kevin J. Flamm
Program Manager
       Chemical Demilitarization
       Program
       A Partnership for Safe Chemical Weapons Destruction

Impetus: Established in 1986 by Public Law 99-145 and directed by several succeeding
laws; designated an ACAT-1D program
Mission: Eliminate chemical warfare materiel and former production facilities, while
ensuring maximum protection to the workforce, the public, and the environment and
meeting requirements specified in the Chemical Weapons Convention
Public Law 104-208 established ACWA to conduct a pilot program to identify and
demonstrate at least two alternatives to the baseline incineration process, followed by
several more laws supporting this separate Chem Demil program


                   U.S. Chemical Demilitarization Program Components
                                                                 Assembled Chemical Weapons
               U.S. Army Chemical Materials Agency
                                                                         Alternatives

• Destruction facilities at Johnston Atoll; Tooele, UT;       • Destruction facilities in
  Anniston, AL; Umatilla, OR; Pine Bluff, AR; Aberdeen, MD;     Richmond, KY; Pueblo, CO
  and Newport, IN
• Non-Stockpile Chemical Materiel Project
• Chemical Stockpile Emergency Preparedness Program




                                                                                              2
               ACWA’s Mission in the Chemical
               Demilitarization Program
               A Partnership for Safe Chemical Weapons Destruction




Pueblo Chemical Agent
Destruction Pilot Plant (PCAPP)
Colorado
Mustard: 2,371 Metric Tons in
cartridges and projectiles
                                                         1
                                                                     2




                                                                         3
    ACWA Key Background
     A Partnership for Safe Chemical Weapons Destruction


ACWA program mandated by Congress in 1996 to research and
demonstrate alternatives to incineration for assembled chemical
weapons that meet the applicable safety and environmental
requirements

ACWA program mandated by Congress in 1998 to continue
development of alternatives and meet public outreach and public
participation requirements

Neutralization followed by biotreatment selected for Pueblo in
2002; neutralization followed by supercritical water oxidation
selected for Blue Grass in 2003

Revised Program Baseline established January 2007

US Army Element Assembled Chemical Weapons Alternatives
established November 2007
                                                                  4
              ACWA Leadership
               A Partnership for Safe Chemical Weapons Destruction


    Program Manager, ACWA reports directly to the Under Secretary of
    Defense for Acquisition, Technology and Logistics
    The ACWA Program Office is officially U.S. Army Element, ACWA, a
    Separate Reporting Activity under the U.S. Army Materiel Command




Dr. Ashton B. Carter
  Under Secretary of Defense
                                Mr. Andrew C. Weber
  for Acquisition, Technology
                                    Assistant to the Secretary        Mr. Jean D. Reed
         and Logistics
                                of Defense for Nuclear and Chemical                                    Mr. Kevin J. Flamm
                                                                         Deputy Assistant to the
                                 and Biological Defense Programs                                           Program Manager
                                                                          Secretary of Defense
                                                                                                          Assembled Chemical
                                                                      (Chemical & Biological Defense
                                                                                                          Weapons Alternatives
                                                                      and Chemical Demilitarization)

                                                                                                                                 5
Safety is Our Top Priority
A Partnership for Safe Chemical Weapons Destruction

                                      The 12-month Recordable Incident Rate (RIR)
                                      as of 30 April 2009 was 1.39
                                      ACWA facilities continue their focus of safe
                                      construction and each have achieved
                                      excellent records for hours worked without a
                                      lost-time incident
                                      PCAPP systems contractor
                                      awarded the OSHA VPP Star
                                      Status – first CWDF to achieve
                                      this while in construction




                                                                                 6
PCAPP Construction Progress
A Partnership for Safe Chemical Weapons Destruction




                                                      7
BGCAPP Construction Progress
A Partnership for Safe Chemical Weapons Destruction




                                                      8
                  First of A Kind (FOAK) Equipment
                  Factory Acceptance Testing
                  A Partnership for Safe Chemical Weapons Destruction

                                        PCAPP
                                        – MTU – Oct 08
                                        –       LPMD
                                            •   LPMD #1 – Jan 09;
                                                – Mustard Munition Demo - Jul 09
    Metal Parts Treater (MPT)
                                            •   LPMD #2 - Mar 10                   Linear Projectile Mortar Disassembly (LPMD)

                                            •   LPMD #3 - Dec 10
                                        –       MWS
                                            •   CAM (155) - May-Jun 09
                                            •   CAM (4.2) - Sep-Oct 09
                                            •   CAM (105) - Jan-Feb
Energetics Batch Hydrolyzer (EBH)
                                                                                    Munition Washout System (MWS)

                                        BGCAPP
                                        –   MPT - Jun-Aug 09
                                        –   EBH - Jun-Nov 09
                                        –   SCWO - Jan-Sep 12*
                                        –   RCM/RSM - Jan-Jun 12*
Super Critical Water Oxidation (SCWO)
                                        –   MWS - Jul-Dec 12*                             Rocket Cutter Machine (RCM)

                                                                                                                             9
        Destruction Progress:
        Operation Swift Solution
         A Partnership for Safe Chemical Weapons Destruction

GB Steel Container Treatment at the Blue Grass Army Depot

   Three corroding containers stored a                  Key Milestones
   mixture of GB nerve agent and                        Nov. 10, 2008 – Operations begin
   breakdown products                                   Dec. 18, 2008 – All liquid GB mixture successfully
                                                        drained and destroyed
   Leak occurred within igloo in August
                                                        Jan. 17, 2009 – Container clean-out completed
   2007 that required response                          Feb. 26, 2009 - Hydrolysate disposal completed
   ACWA solution: Employment of the
   CHATS glove box technology coupled
   with Nonstockpile support facilities
   With community concurrence, all wastes
   shipped to a licensed treatment, storage
   and disposal facility

                                                                 Chemical Agent Transfer System




                                                                                                         10
     FY08 Congressional Mandate
      A Partnership for Safe Chemical Weapons Destruction

Section 8119 of Public Law 110-116, Department of Defense
Appropriations Act of FY 2008
 – Complete destruction of the U.S. chemical weapons stockpile by
   the Chemical Weapons Convention deadline (29 April 2012), and
   in no circumstances later than 31 December 2017
 – Submit initial report not later than 31 December 2007, and every 180
   days thereafter on progress toward compliance
 – Include projected annual funding levels necessary to achieve full
   compliance of Congressional direction
Section 922 of Public Law 110-181, National Defense Authorization
Act for FY 2008
 – Submit initial report not later than 15 March 2008, and every 180 days
   thereafter on progress
 – Include anticipated schedule, options/alternatives for acceleration, and
   funding required for options



                                                                              11
     Acceleration Assessment
     (June 2008 Semi-Annual Report)
      A Partnership for Safe Chemical Weapons Destruction


Option 1: Baseline. Maintain the program on its current track
under the April 2007 Acquisition Program Baseline and the FY 2009
President’s Budget request, with complete destruction slated for
Colorado and Kentucky in 2020 and 2023, respectively
Option 2: Cross-level Destruction Capacity. Transfer Colorado
and Kentucky stockpiles to operational U.S. chemical weapons
destruction sites
Requires legislative changes to meet federal and state environmental and
permitting requirements and relief from Public Law 103-337 prohibiting
transport of chemical weapons across state borders
Option 3: Accelerate the ACWA Program. Accelerate ACWA
program by increasing staff, re-phasing schedule and conducting
24/7 destruction operations and using an explosive destruction
technology to destroy Kentucky mustard munitions
Colorado stockpile destruction by 2017 appears possible; Kentucky requires
some additional time
                                                                             12
    Program Funding Adjustments
    A Partnership for Safe Chemical Weapons Destruction


ACWA Program funding guidance as of April 2008 showed
downward trend beyond FY 2009 with a significant dip in FY
2011
 – Totaled $2.0B for FY10-15

January 2009 funding guidance for the ACWA Program
reverses the downward trend and eliminates the dip
 – Demonstrates DoD commitment to Chem Demil Program
 – Enables acceleration




                                                             13
         ACWA Program Cost and
         Schedule Comparison
          A Partnership for Safe Chemical Weapons Destruction




                                                                Destruction Operation
                                                                      End Dates

                                                                BGCAPP       PCAPP
Options

1.   Baseline                                                    Oct 23      Nov 20

2.   Cross-Leveling – Transportation of Blue Grass Stockpile
                                                                 Mar 15      Sep 17
     and Accelerate Pueblo Stockpile
3.   Accelerated – Current Course of Action
                                                                May 21       Sep 17
     (FY10 President’s Budget Request)
3a. Accelerated
     (Assumed BGCAPP Balance of Construction contract           May 20       Sep 17
     award by 1QFY10)




                                                                                        14
                       ACWA Current Course of Action
                       A Partnership for Safe Chemical Weapons Destruction

          Demonstrates DoD commitment to chemical demilitarization program
          Accelerates Destruction of the Kentucky and Colorado Stockpiles:
             – Pueblo: 38 months
             – Blue Grass: 29 months
          Neither site able to achieve CWC 100% destruction milestone
          PCAPP is able to achieve Congressional 2017 milestone
          Additional acceleration of Blue Grass and Pueblo might be possible in the
          future

                                                                                                                         38 months
                                                                                                                                       Baseline Destruction
                                                                                                                                       Operations Complete
  Pueblo, CO

                                                                                                                                               29 months

  Blue Grass, KY
                                                                                                                                           Baseline Destruction
                                                                                                                                           Operations Complete

                                                     Chemical Weapons Convention                         Congressional 2017 Deadline
                                                      100% Destruction Milestone                          Public Laws 110-116 & 181
* - There is a 7 month overlap with the end of the Operations Phase and beginning of the Closure Phase

                                                                                                                                                                  15
    Conclusion…
    A Partnership for Safe Chemical Weapons Destruction

ACWA Program is committed to destroying the chemical
weapons stockpiles in Kentucky and Colorado as quickly as
possible.

We have incorporated the lessons learned from the other U.S.
chemical weapons destruction facilities, however, challenges
are expected given the ACWA destruction facilities are pilot
plants employing unique processes and equipment.

Hydrolysate will be treated on-site. However, should technical
difficulties arise which could delay stockpile destruction
efforts, off-site hydrolysate treatment will be considered.

Safety of the workforce is and will continue to be the
cornerstone of ACWA Program.
                                                                 16
                       Questions?
A Partnership for Safe Chemical Weapons Destruction




                                                      17
            Projectile Processing Comparison

            A Partnership for Safe Chemical Weapons Destruction

                                                                                              MDM
                                                  PMD                                 (agent removal)

                   Unpack                (explosives removal)                                                        Munition                      MPF
                                                                                              MDM
 Baseline           Area                          PMD                                 (agent removal)                 Bodies               (metal decontamination)

Projectile                               (explosives removal)                                 MDM
                                                                                      (agent removal)
Processing
                                                Explosives                                    Agent
                                                                                                                                            Off-Site Disposal
                                                  DFS                                         LIC
                                       (explosives destruction)                     (agent destruction)



                                                              CAM              CAM             CAM         CAM           CAM
                                      LPMD                    (agent          (agent           (agent      (agent        (agent
                                (explosives removal)         removal)        removal)         removal)    removal)      removal)


                                                                                                                        MWS*
  PCAPP           Unpack              LPMD                                                                                            Munition             MTU
                                                                                                                                                          (metal
                   Area         (explosives removal)                                                                                   Bodies
Projectile                                                                                                              MWS*                          decontamination)



Processing                            LPMD                    CAM
                                                              (agent
                                                                               CAM
                                                                              (agent
                                                                                               CAM
                                                                                               (agent
                                                                                                           CAM
                                                                                                           (agent
                                                                                                                         CAM
                                                                                                                         (agent
                                (explosives removal)
                                                             removal)        removal)         removal)    removal)      removal)
                                                                                                                                                         Off-Site
                        Contaminated       Uncontaminated                             Agent                                                              Disposal
                                                                                                         Recycled Water
  CAMs per MWS*          Explosives          Explosives
                                                                              ANS                                    Bio Treatment
   105mm    8/2
                             EDT                                        (agent destruction)                      (Disposal Pretreatment)
   4.2-in   8/2
   155mm    6/2      (explosives destruction)
                    (contaminated explosives)

                                                                                                                                                                     18
       M55 Rocket Processing Comparison

       A Partnership for Safe Chemical Weapons Destruction

                                              RSM
                 Unpack          (agent & energetics separation)
                                                                                    Agent
                  Area                        RSM
 Baseline                        (agent & energetics separation)

  Rocket                            Energetics Metal Parts

Processing
                                              DFS                                    LIC
                                    (explosives destruction &                                                       Off-Site Disposal
                                                                           (agent destruction)
                                   residual agent destruction)




                          RCM                       RSM                                                                       MPT
                      (uncontaminated        (agent & energetics                                            Metal
                                                                                        ANS                                  (metal
        Unpack         motor removal)            separation)                                                Parts
                                                                        Agent          (agent                            decontamination)
         Area             RCM                       RSM                              destruction)
                      (uncontaminated        (agent & energetics
                       motor removal)            separation)                                         Recycled
                                                                                                      Water                Off-Site
 BGCAPP               Uncontaminated
                                              Explosives and
                                              Contaminated
                                                                                                                           Disposal
                                                                                       Buffer
  Rocket                  Motors                  Motors
                                                                                      Storage
Processing                              EBH
                                                                   Hydrolysate
                               (energetics destruction)

                                                    ENR                          SCWO (3 units)
                                         (residual agent destruction)           (Disposal Pretreatment)



                                                                                                                                            19
A Partnership for Safe Chemical Weapons Destruction




              Construction Photographs




                                                      20
   Pueblo Chemical Destruction Pilot Plant (PCAPP)
Pueblo Chemical AgentAgent Destruction Pilot Plant
                     March 2009
                    April 2009
                                                     21
Enhanced Reconfiguration Building (ERB)
 Explosive Containment Rooms (ECRs)
                                          22
Autonomous Guided Vehicle (AGV) Corridor

                                           23
        Munitions Treatment Unit (MTU) #1
being installed in Agent Processing Building (APB)
                                                     24
                  Agent Processing Building (APB)
Munitions Washout System (MWS) wash water collection tanks (left) and
                    agent-water separator tanks
                                                                        25
        Utility Area
Process Water Storage Tanks
                              26
Biotreatment Area

                    27
Blue Grass Chemical Agent Destruction Pilot Plant (BGCAPP)
                       March 2009
                                                             28
Munitions Demilitarization Building (MDB)
       non-blast horizontal rebar
                                            29
Munitions Demilitarization Building (MDB)
non-blast horizontal concrete placement
                                            30
    Munitions Demilitarization Building (MDB) non-blast horizontal
concrete placement, Control Support Building (CSB) slab in background
                                                                        31
Personnel Support Building (PSB)

                                   32
Maintenance Building (MB)

                            33
Control Support Building (CSB) foundation slab

                                                 34