1. 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

2. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

3. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

4. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

5. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

6. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

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

8. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

9. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

10. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

11. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

12. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

13. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

14. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

15. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

16. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

17. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

18. 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 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:
• life- cycle cost
• recyclability
• disposal
AVT Warsaw 9/10 October 2003 Demilitarisation of Munitions"

19. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

20. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

21. 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 Warsaw 9/10 October 2003 Demilitarisation of Munitions"

22. 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
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
Configure packaging to maximise recycle, re-use
Configure in ease of packaging reuse or recycling
Minimise environmental impact from packaging
Incorporate components identified from demil inventory available for re-use
Provide detailed procedures and information on munition’s demilitarisation
Aspects highlighted in yellow incorporated in STANAG 4518 and OB Proc P115(2)
AVT Warsaw 9/10 October 2003 Demilitarisation of Munitions"