DESIGN FOR DEMILITARISATION [Note: The tone of this presentation needs to: be plain English, direct, pragmatic, business like be factual, frank, `telling it like it is’ give employees the feeling that they’ve heard the same as managers be externally focused, set in the `real’ world. Set the external context so that people understand the context for the strategy and actions taken.] [Welcome group] The last year has been very challenging for all of us. Change is always difficult, and we have gone through - and still are going through in some areas - significant change. What I want to do over the next 45 minutes or so is take you through where we are now in that change process, outline the opportunities for growth and success that we now have as a group, look specifically at our role within that process, and share with you the messages and themes that John Weston and other members of the Group Executive briefed at a management conference in London on 24 May. The aim is to ensure that all 100,000 BAE SYSTEMS people worldwide receive this briefing - with the relevant local input - so we are all clear about the performance challenge we need to meet if we are to deliver the success we are capable of. 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, 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"

Definition of Demilitarisation Demilitarisation is the Process whereby the Military Characteristics of Munitions are removed: Unsuited for continued storage Obsolete Excess to Service requirements “…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 AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

The need for Demilitarisation As Munitions become older there are a number of issues that face the custodians: 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 AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

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

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"

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

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"

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"

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 Recovery of Energetics Separate Components 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"

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 Recovery of Energetics Separate Components Separation of Chemical components Open Burn Eg Mining Destroy/Mutilate Hardware Open Detonation Disposal of Non-Energetics eg Fillers, Binders etc Energetics Re-use Controlled Incineration or Detonation Scrap AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

The Changing Emphasis of Demilitarisation ealth Hazards Environmentally Acceptable Physically Safe Maximisation of Recovery and Reuse Free from H Cost Effective Efficient Cost Effective Safe Practical 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"

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 Usually leading to destruction of the hardware and scrapping with no re-use. AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

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 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 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"

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"

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"

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"

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"

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"

Munitions’ Characterisation & Creation of Munitions Database Library Identify Components/Parts including all Packaging and Specific Transportation Equipment Drawings Diagrams Specifications Standards Munition/Store Bulk Items Materials ie Packaging and Component Parts Inert Materials and Compounds PEP Materials PEP Ingredients (Energetic and Non-Energetic) Manufacture Processes e.g. Plating, Alloys, Materials used Resources used Resources Consumed 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 Health Effects and Impact COSHH Carcinogen Neurotoxin Acute Teratogen etc Environmental Impact Effects Water Release Air Release Ground Release Safety/Health & Environmental Effects Munitions Database Library Define materials into categories Toxic Flammable Corrosive Oxidiser etc Inventory Quantities/Amounts Present or Consumed Demilitarisation Process Design Process AVT - 115 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

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"

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"