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Building a Clean & Secure FutureBuilding a Clean and Secure Future
PIKA International, Inc.
Innovative Range Management/Scrap Sorting System
Mr. Paul Ihrke
Vice President, Federal Programs
PIKA International, Inc.
Environment, Energy, Security, & Sustainability Symposium & Exhibition
June 2010
2
Segregation and Inspection of Range Residue
Decontamination
Thermal Convection
Explosive Demilitarization of MEC/MPPEH/MDEH
Final Inspection and Certification of MPPEH as Material
Documented as an Explosives Hazard (MDEH) or
Material Documented as Safe (MDAS)
Offsite shipment and recycling as appropriate of MDEH
and MDAS
PIKA’s Range Management Process
3
Separate, clear, desensitize and remove dangerous items including
MEC, MPPEH and range related debris (RRD) from the site
Excavation and mechanical sorting of oversized stockpiles to
segregate the soils from MEC/MPPEH/RRD
Burn residue inspection, certification and disposal in accordance
with DOD standards.
Onsite processing and offsite disposal of earthen material including
the sampling of all sorted soil, onsite treatment of soil exceeding
requirements specified in the SOW and offsite disposal of soil
Sample, stabilize (if necessary) and dispose of lead contaminated
soil
Restoration of the site
Why?
4
Removal of Oversize Stockpile (Mt. Molle
at Seneca AD)
CPC of Former Naval Training Range
Vieques Island, Puerto Rico (VNTR)
Case Studies
6
MEC/MD Segregation and Removal of ~20,000 CY of Oversize Materials that
remained after approximately 120,000 CY of soil were sifted and removed from
the Open Burning Grounds
During prior sifting operations, Oversize Material was sifted three or more times
to reduce its volume
Scope of Work
Mt.
Molle
8
Munitions & Explosives of Concern
Large number and variety of MEC items found
The smallest and most numerous - 20mm projectile
Hundreds of larger projectiles
Inert-filled 3 inch and 4.2 inch stokes mortars
2.36 inch white phosphorous (WP) warheads (without bursters)
25mm, 37mm, 40mm, 57mm, 75 mm, and 105 mm projectiles
Various fuzes/ other munitions components
Munitions Debris (MD)
Non-MD Metal Scrap
12
Initial Sorting of Large Debris
Hardened Long Arm Excavator
used to Load Soil into Trommel
Separation of Larger Items
Some Degree of Dewatering
Uniform Flow of Similar Sized
Items through Conveyor System
13
Ferrous Metal Separation
Suspended Electromagnet Cross belt Separator
Magnetic Pulley
Vibratory Feeder
Rare Earth Drum
Separator
Trommel
14
Non-Ferrous Metal Separation
Eddy Current Separator
Non-Ferrous Items e.g. Fuzes,
Aluminum, Brass, Copper
15
Final Inspection
Soil Free of MEC and MD
being taken to Staging Area
for Sampling
Blast Wall
Metal Detector
QC by UXO Techs
Eddy Current
18
Other Project Activities
Decontamination Station
Offsite Disposal of Soils > 500ppm
Screened Soils Awaiting Lab Results
19
MPPEH Processing at ViequesCentral Processing Center (CPC) for
Management of MD, RRD and MPPEHat
Former Vieques Naval Training Range (VNTR)Vieques, Puerto Rico
Project Objective- To shred, mutilate, deform, flash, crush, ship, and 5X certify all scrap prior to releasing it to a qualified recycler
20
Secure CPC Area
Technologies and Equipment Selected for VNTR
100%
QC
Shear
HammerMill
Water Jet
Petrogen
5X Furnace100%
QC
Non-Energetic
Targets/RRD
Recovery
MD
Recovery
Navy
QA
Process Flow Diagram
29
5X Flashing Furnace
MD, non-MD Scrap
Scrap flashed in the furnace is 5x
certified and is ready to be QA
inspected by visual/physical
inspection and review of the electronic
time/temperature tabular data.
This certifies that the material
potentially presenting an explosive
hazard has been properly processed
and 100% QA inspected and to the
best of our knowledge and belief is
inert and / or free of explosive hazards.
Material Documented as Safe (MDAS)
has replaced the 5X terminology.
30
QC and MDAS Certification
Core Temperature
0
100
200
300
400
500
600
700
800
900
1000
9:2
6:5
8 A
M
9:2
8:2
8 A
M
9:2
9:5
8 A
M
9:3
1:2
8 A
M
9:3
2:5
8 A
M
9:3
4:2
8 A
M
9:3
5:5
8 A
M
9:3
7:2
8 A
M
9:3
8:5
8 A
M
9:4
0:2
8 A
M
9:4
1:5
8 A
M
9:4
3:2
8 A
M
9:4
4:5
8 A
M
9:4
6:2
8 A
M
9:4
7:5
8 A
M
9:4
9:2
8 A
M
9:5
0:5
8 A
M
9:5
2:2
8 A
M
9:5
3:5
8 A
M
9:5
5:2
8 A
M
9:5
6:5
8 A
M
9:5
8:2
8 A
M
9:5
9:5
8 A
M
10:0
1:2
8 A
M
10:0
2:5
8 A
M
10:0
4:2
8 A
M
10:0
5:5
8 A
M
10:0
7:2
8 A
M
Time
Tem
pera
ture
(F
)
Core Temp Basket 1
Core Temp Basket 2
Monitoring & Recording Core Temperatures using Computers
Chart showing the Time/Temperature profile
Documentation Prepared for Each Cycle of Flashing Operations
31
Scrap Recycling
All processed MD/RRD is MDAS certified and 100% QA inspected before being loaded into
containers to be transported to a scrap recycling facility. In addition any MD that is thermally
processed must be placed into a secure container until it is ready to be loaded into the
shipping container. This eliminates any chance of commingling with non-processed material.
Loading of 5X Material Securing/Sealing the Containers
Final Inspection by NAVY
Containers Staged for Transportation
Containers Loaded onto Ferry
32
Remote Vegetation Clearance in the
Submunition Area
We have been given the task to remotely clear 75 acre’s of submunitions by means of
the NEMESIS a remote controlled skid steer with mulcher attachment. To date we
have cleared 30% of the area reducing the risk to our vegetation and MEC teams
and allowing for safe demo operations. Attached are a couple of photo’s.
33
Central Processing Center
Hardened Excavator
Snellar Brush Clearance
Locked Storage Bins
Loading Ramps
Hydraulic Shear
Water Jet Cutter
HammerMill Pulverizer
5X Flashing Furnace
Generator & Fuel Tanks
Forklift and Lull
10-ton Truck
Petrogen Torch
Proven Cradle to Grave Solution
More than 15 Million Pounds Processed and Recycled from 2006 - 2009
34
Summary To Date
MPPEH Recovered at VNTR, Vieques, PR
Processing Technology Items Weight (Tons)
Inspection, Recovery and Processing of Munitions Debris (MD)
Crushing w Hammermill 155mm, 75mm, 90mm, 81mm, 60mm, 2.75", MK-23, MK-118, BDU-33, BDU-48244.95
Shearing of MD GBU Practice, M117, MK-81, MK-82, MK-83 and MK-84 1190.81
Waterjet Cutting/ Petrogen
Torch Cutting155mm, 152mm, 120mm, 105mm, 75mm, 90mm, 16", 5" and 3"
303.50
Flashing of MD All the above items and scrap 2,639.57
Inspection, Recovery and Processing of Range Residue Debris (RRD)
Inspection, Downsizing and Recovery of RRD 4,133.33
MD Inspected and Recovered 3600.09
MK series bombs recovered 4937
Total material inspected and stockpiled 7,733.42
Total Scrap shipped offsite till date 6,335.02
Total Scrap awaiting processing to be shipped 1398.40
35
TCS Applications
MD, Process Equipment
and Piping
Unstable Energetics
Underground Ovens
Washout Stations Process Buildings
36
Swaging Process
Combines Thermal Treatment and Demilitarization
– eliminates need for shredding, crushing, flashing…
Swaging - Heats the MD to Target Temperatures and Presses it into Metal Ingots
Shredding
Crushing
Flashing
37
Swaging Process
Can Process Munitions of Various Sizes and Metal Compositions
TCS Used to Heat Metal to Temperatures Where Metal Becomes
Malleable
Metal is Then Put Into a Press and Reshaped into Ingots of
Manageable Sizes and Weights
39
Contact Information
PIKA International, Inc.
12723 Capricorn Drive, Suite 500
Stafford, TX 77477
(866) 472-8595
(281) 340-5533 fax
Paul Ihrke
VP, Federal Programs
(281)814-2038 (C)