Presented by: Kim Jackson, PCAPP Operations Manager & George Lecakes, PCAPP Chief Scientist

1. An Overview of PCAPP’s
Pilot Demonstration Testing
Presented by:
Kim Jackson, PCAPP Operations Manager &
George Lecakes, PCAPP Chief Scientist

2. Timeline –
Pilot Test Demonstration
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3. PCAPP Pilot Test Demonstration
Objectives1
1. Demonstrate agent removal, agent neutralization, and related agent
neutralization sampling and analysis.
2. Demonstrate munition body treatment (washout, thermal treatment).
3. Establish bounding operating ranges and set points for operating
parameters critical to agent removal, munition body treatment, and agent
neutralization operations.
4. Demonstrate energetics removal and establish bounding operating ranges
and set points for operating parameters critical to ensuring energetics
removal operations.
5. Validate monitoring protocols for all equipment and work areas in the ERB
and APB.
6. Validate treatment and monitoring protocols for disposition of dunnage,
energetics, and miscellaneous waste (e.g., OPP, PME, SDU, Autoclave as
designated for each waste material)
7. Demonstrate removal of TDG and document removal of other organic
compounds from hydrolysate waste stream (e.g., ICB, BRS)
8. Demonstrate processing systems can operate at a ramp rate that safely
supports the operating schedule.
1DERIVED FROM THE TEST CONCEPT PLAN, APPENDIX D; 3/21/2011
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4. PCAPP Pilot Test Demonstration
Objectives (CONT.)
9. Demonstrate integrated facility operations with agent and energetics to verify
the following:
a) Compliance with safety requirements
b) Compliance with surety and security requirements
c) Integrated system operability
d) Plant-wide operations while remaining within emissions requirements (as stated in the Multiple
Pathway Health Risk Assessment Report for PCAPP Project [MPHRA], 24852-RD-3RC-000-V0004)
e) Handling and movement of munitions for current munitions campaign
f) Sampling and analysis protocols (e.g., agent, hydrolysate, brine, emissions)
g) Decontamination operations
h) Ability to perform routine and selected off-normal maintenance activities
i) Waste handling and disposition, including dust and odor control
10.Validate agent monitoring protocols for detecting agent (e.g., MINICAMS, Depot
Area Air Monitoring System [DAAMS]).
11.Demonstrate off-gas treatment performance. This will include demonstration of
agent destruction and removal at the OTS and AFA, odor control at the BTA.
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Finally, the collection of site-wide emissions data for
finalization of the RCRA Part B Permit

5. Block 1 –
Systems, Fit, and Function
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Systems: Block 1 – Baseline and Enhanced Reconfiguration includes OPP Monitoring, Munitions Monitoring
Table (Baseline Reconfiguration), PMD Operations and MME/PME Operations
Fit: After transport and receipt of munitions at PCAPP and prior to agent removal activities
Function: Prepares munitions for access and removal of agent by separating packing material (e.g., wooden
pallets, strapping, boxes) and energetics/miscellaneous parts from the munitions bodies
Explosion Containment
Room

6. MWS
MTU
Block 2 –
Systems, Fit, and Function
Systems: Block 2 – Munitions Body Treatment includes Munitions Washout System (MWS) and Munitions
Treatment Unit (MTU)
Fit: After Baseline and Enhanced Reconfiguration and prior to Agent Collection and Neutralization
Function: Drains and washes agent from energetics-free munitions bodies and thermally treats munitions
bodies to Clean Unrestricted, Releasable to the General Population (Clean Unrestricted)
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7. Block 3 –
Systems, Fit, and Function
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Systems: Block 3 – Agent Collection and Neutralization includes the Agent Water Separators, Wash Water Holding
Tanks, Agent Hydrolyzers, Hydrolysate Hold Tanks and 30-Day Storage Tanks
Fit: After Agent Collection and prior to Bio-Treatment of the cleared hydrolysate
Function: Separates the MWS agent drained and rinse water, hydrolyzes the mustard agent, and verifies destruction
prior to treatment in the Immobilized Cell Bio Reactors

8. Block 4 –
Systems, Fit, and Function
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Systems: Block 4 – Hydrolysate Treatment and Water Recovery includes the Bio-Treatment System, Water Recovery
System (Brine Concentrate Feed Tanks), and the Brine Reduction System plus associated off-gas treatment units
Fit: After agent neutralization and clearing in Block 3 and prior to process water recycle or to off-site shipment of
secondary wastes (salt cake / bio sludge)
Function: Removes thiodiglycol (TDG) and other organics through biodegradation, recovers process water, de-
waters sludge for disposal and treats off-gasses for discharge.

9. Block 5 –
Systems, Fit, and Function
Systems: Block 5 – Supplemental Decon Units and Autoclave
Fit: Receives materials, equipment, components, and waste materials from other process areas including ERB, APB,
ESM, MSM.
Function: Reduces agent contamination levels to acceptable levels for either reuse and/or off-site disposal
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10. Block 6 –
Systems, Fit, and Function
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Systems: Block 6 – Off-gas treatment system including thermal oxidizer and scrubbers, the agent filtration area
(including particulate & HEPA filtration, granulated activated carbon and sulfur impregnated carbon) and the AFA stack
Fit: Receives process off-gas from the OTS and HVAC exhaust from ERB and APB ventilation systems
Function: Treat process off-gasses and HVAC exhaust from engineering controlled spaces to remove agent and other
COC’s to prescribed levels before releasing to the atmosphere.

11. Process Layout by Blocks
PCAPP PROCESS DIAGRAM
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EDT REMOVED FROM PCAPP SCOPE
CONTAMINATED ENERGETICS AND IN-PROCESS LEAKERS &
REJECTS SENT TO G-BLOCK FOR SUBSEQUENT PROCESSING
IN A GOVERNMENT SYSTEM

12. Test Sequence
Pilot Testing (155mm)
 Block 1
 Block 2
 Block 3
 Block 4
 Block 5
 Block 6
Changeover Testing
 105mm Campaign
 4.2in Campaign
• Testing ≡ to define optimized
operating parameters
• Ramp-up ≡ capability of
personnel and equipment to
sustain operations
• Demonstration ≡ capability
of each process system
within the facility to process
munitions for 4-hour periods
per shift
Block 1 – Munitions Receipt and Enhanced Reconfiguration is to
support the testing, ramp-up and demonstration of the other
systems within Blocks 2, 3, 4 and 6.
Block 5 – Secondary Waste Treatment
Operating
Permit
INTEGRATED FACILITY DEMONSTRATION TEST
• Emissions Sampling
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13. 13
QUESTIONS