Tactical Missile Recycling at the ANMC MRC BRIEFING AMCOM Wes Thompson by:

Army Tactical Missile Systems Class 1.1 Propellants Clean Burning/Detonable HELLFIRE TOW CHAPARRAL Class 1.3 Propellants Smoky/Nondetonable HAWK MLRS PATRIOT

Recycling is the Alternative to OB/OD

What is a Missile Recycling Capability? • >98% of TOW missile components are recyclable - Missile Warheads - Guidance & Control Packages - Rocket Motor Propellants - Airframe Components - Rocket Motor Cases - Shipping Containers Warhead Explosive S&A System Actuator Gyro Batteries Electro Optics Launch Motor Igniter Flight Motor Electronics • Major MRC Modules - Missile Disassembly - Energetics Processing - Rocket Motor Denozzling - Slurry Explosive Manufacturing - Propellant Removal - Hardware Decontamination - Warhead Explosive Removal - Material Handling & Shredding Equipment - Energetics Size Reduction Environmental Compliance: “Recycling is the Future, and the Future is Now”

ANMC – MRC Module Locations Building 381 Missile Disassembly Processes N EPM Site Ingredient Extraction & Recovery Building 65 Slurry Explosives Manufacturing

Existing vacant building accommodate MRC modules ANMC – MRC Building 381 Existing vacant building has been upgraded to accommodate MRC modules Work cells for Missile Disassembly Propellant & Warhead Separations Hardware Recovery

ANMC - Building 381

MRC Disassembly Module Disassembly of TOW Missile Major Hardware Components Disassembles missile into major subsystem components Segregates rocket motors, warheads, and inert hardware components for recycling operations

MRC Disassembly Module

MRC Disassembly Module Air Frame Components from TOW Disassembly Electronic Units from TOW Disassembly Launch Tubes from TOW Disassembly > 98% of TOW Missile Components are Recovered for Recycling

MRC Denozzling Module Launch Motor Denozzling Flight Motor Denozzling TOW Launch Motor TOW Flight Motor Launch Motor with Nozzle Removed Flight Motor with Nozzle Removed Removes aft closure (nozzle) from forward motor section Provides access to rocket motor propellants Damage free recovery of motor hardware

MRC Denozzling Module TOW Launch Motor Denozzling Machine TOW Launch Motor Denozzling Bay TOW Launch Motor Denozzling Machine Launch Motor Components

TOW Flight Motor Denozzling Bay TOW Flight Motor Denozzling Machine MRC Denozzling Module TOW Flight Motor Denozzling Bay TOW Flight Motor Denozzling Machine

MRC Propellant Removal Modules Squib & Retaining Nut Removal Machine Vertical Milling Machine Provides low cost/high rate method for efficient propellant removal Recovers cartridge loaded and case bonded propellants for recycling

MRC Propellant Removal Module TOW Squib & Retaining Nut Removal Machine TOW Squib & Retaining Nut Removal Machine TOW Double Base Cartridge-Loaded Grain

MRC Propellant Removal Module TOW Igniter Assembly Removal Machine TOW Igniter Assembly Removal Machine Squib and Igniter Assembly Components

MRC Propellant Removal Modules Motor Case Holding Fixture Cutting Head Typical Propellant Chips Vertical Milling Machine

MRC Propellant Removal Module

MRC Warhead Explosive Removal Module Warhead Billet Splitting Machine Warhead Billet Removal Machine Removes entire explosive warhead billet from outer casing Separates warhead explosive from shaped charge liner

MRC Warhead Explosive Removal Module Warhead Billet Removal Machine

MRC Warhead Explosive Removal Module Warhead Billet Splitting Machine

MRC Warhead Explosive Removal Module LX-14 Split from Cone Warhead Billet in Contact with Knives Aluminum Warhead Casing Recovered Shaped-Charge Copper Cone Recovered

MRC Energetics Size Reduction Module Before Size Reduction Energetics Size Reduction After Size Reduction Reduces the size of recovered bulk energetic materials Provides granulated feedstock for energetic material recycling

MRC Energetics Size Reduction Module

Energetics Processing Module (EPM) Redstone Pilot Plant Energetics Processing Module (EPM) EPM extracts, separates, and recovers propellant and warhead oxidizers Located at Redstone Arsenal Pilot plant provides technical basis for full-scale engineering development

Oxidizers Recovered from Propellants and Warheads Recovered RDX Recovered HMX Recovered AP

MRC Energetics Processing Module On-going EPM Construction Extraction Vessel On-going EPM Construction Vertical EPM Tower Recovers high value, energetic oxidizers (HMX, RDX, & AP) from propellant and warhead feedstocks Recovers and recycles liquid ammonia processing solvent within a closed-loop system

MRC Energetics Processing Module Installation of the EPM Ammonia Charging Hopper

MRC Slurry Explosive Manufacturing Module Mining Explosive Product Slurry Mixer Mining Explosive Product Incorporates ~20% of a low value energetic material into a commercial Ammonium Nitrate Fuel Oil (ANFO) mining explosive

MRC Slurry Explosive Manufacturing Module

Slurry Explosive Manufacturing ANMC – Building 65 Slurry Explosive Manufacturing Planned MRC Slurry Explosive Manufacturing Site

MRC Hardware Decontamination Module Flashing furnace decontaminates missile hardware components Decontaminates non-combustible metal to 5X cleanliness Limited to 5 pounds of net explosive weight (NEW)

MRC Material Handling and Shredding Equipment Module Provides for material transport and shredding of inert missile components

MRC STATUS AT THE ANMC • Installation of the following modules at the ANMC was completed 30 September 02 - Missile Disassembly Workstations (QTY:3) - Warhead Billet Splitting Machines (QTY: 4) - Launch Motor Denozzling Machines (QTY:4) - Squib Removal Machines (QTY: 4) - Flight Motor Denozzling Machines (QTY:4) - Igniter Assembly Removal Machines (QTY: 4) - Warhead Billet Removal Machines (QTY: 4) • Installation of the remaining MRC modules will occur during FY 04-05 - Vertical Milling Machine (QTY: 2) - Hardware Decontamination Module (QTY:1) - Energetics Size Reduction Machines (QTY: 2) - Energetics Processing Module (QTY: 1) - Slurry Explosive Manufacturing (QTY: 1) During this current LRIP phase, 5,000 TOW missiles are scheduled to be processed by 30 SEP 03 THE FULLY INTEGRATED ANMC MRC WILL HAVE A CAPABILITY TO RECYCLE >15,000 TOW MISSILES PER YEAR

Thank you for the opportunity to tell you about our team capabilities US Army Aviation and Missile Command Research, Development, and Engineering Center Redstone Arsenal POC: Dr. William Melvin Technical Program Manager for R3 Technologies Phone: DSN 746-4096 E-mail: william.melvin@rdec.redstone.army.mil 500 Wynn Drive, Bldg 300, Suite 314 Huntsville, AL 35816 POC: Wesley Thompson Director of Engineering Services Phone 256-722-7200 E-mail: wesley.thompson@rdec.redstone.army.mil