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

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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

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Removal of Oversize Stockpile (Mt. Molle)

at

Seneca Army Depot Activity

Romulus New York

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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

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Physical Composition of Stockpile

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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

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Separation Technologies Researched

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Design of Semi-Automated Sorting System

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Gross Removal of Ferrous Metal

Electromagnet

Sorting by UXO Techs

Hardened Equipment

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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

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Ferrous Metal Separation

Suspended Electromagnet Cross belt Separator

Magnetic Pulley

Vibratory Feeder

Rare Earth Drum

Separator

Trommel

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Non-Ferrous Metal Separation

Eddy Current Separator

Non-Ferrous Items e.g. Fuzes,

Aluminum, Brass, Copper

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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

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Panoramic View

Seneca Army Depot Activity (SEDA) Operation

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MD Shredding/Recycling

Slow-Speed, High-Torque,

Shear-Type Shredder Smelter

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Other Project Activities

Decontamination Station

Offsite Disposal of Soils > 500ppm

Screened Soils Awaiting Lab Results

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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

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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

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Vegetation Clearance

Manual

Mechanized

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Removal, Venting/3X and Accumulation

MEC Surface Clearance

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Inspection and Recovery of MD

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MK 80 Series Bombs

Inspection and Recovery of MD

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Petrogen Torch

Inspection and Recovery of RRD

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Inert Bombs, RRD

Hydraulic Shear

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Pulverizer

Before

After

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Water Jet Cutter

155MM, Armor Piercing

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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.

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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

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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

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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.

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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

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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

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TCS Applications

MD, Process Equipment

and Piping

Unstable Energetics

Underground Ovens

Washout Stations Process Buildings

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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

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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

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Swaging Process

Press

Metal Ingots

Heat Source

Input Material

Handling System

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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

pihrke@pikainc.com

(281)814-2038 (C)