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Blue Grass Chemical Agent-Destruction Pilot Plant

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Coordinates: 37°43′02″N 84°12′28″W / 37.7171°N 84.2077°W / 37.7171; -84.2077
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BGCAPP Logo

The Blue Grass Chemical Agent-Destruction Pilot Plant (BGCAPP) is a facility built to destroy the chemical weapons stockpile at the Blue Grass Army Depot (BGAD), near Richmond, Kentucky.

Since 1944, the Army has stored 523 short tons (474 t) of nerve agents sarin (GB) and VX and mustard agent in 155mm projectiles, 8-inch projectiles and M55 rockets at BGAD. That was about 2% of the nation’s original chemical weapons stockpile.

Now, BGCAPP is using neutralization to destroy the stockpile in the main plant and Static Detonation Chamber technology to augment the main plant.

Destruction of this stockpile is a requirement of the Chemical Weapons Convention, an international treaty to which the United States is a party. The Organisation for the Prohibition of Chemical Weapons is the implementing body of the Chemical Weapons Convention and monitors the progress of the nation's chemical weapons destruction programs. The Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA) oversees the destruction of the Blue Grass chemical weapons stockpile.

BGCAPP

Planning and organization

A systems contract was awarded in June 2003 to a joint venture team composed of Bechtel National, Inc., and Parsons Corporation. The Bechtel Parsons Blue Grass team is contracted to develop a design-build plan and then design, construct, systemize, operate and close BGCAPP.

In March 2005 the design-build-operate-close schedule was extended to make the program more affordable on an annual basis. Site preparation work and the construction of support buildings continued and final designs for the remaining BGCAPP facilities were completed in 2010. In June 2019, the Static Detonation Chamber began destroying mustard agent-filled projectiles. In January 2020, the BGCAPP main plant facility began processing nerve agent-filled projectiles. The destruction operations are expected to be complete by 2023. The plant will operate until all the chemical weapons have been destroyed. Closure activities (shut-down, dismantling, and restoration of site) are slated to be wrapped up by 2026. This schedule exceeds the terms of the Chemical Weapons Convention deadline of April 29, 2012.

Legislation enacted by the U.S. Congress in 2007 (Public Laws 110-116 and 110-181) mandates the destruction of the remaining U.S. national chemical stockpile in accordance with the April 2012 date, but in no circumstances later than Dec. 31, 2017.[1] This deadline was subsequently extended to Dec. 31, 2023, by the National Defense Authorization Act for Fiscal Year 2016 (Public Law 114-92).[2]

History of chemical demilitarization in Kentucky

Decade Milestones
1940s
  • BGAD begins storage of chemical weapons containing mustard agent.
1960s
  • BGAD begins storage of chemical weapons containing nerve agent.
1980s[3]
  • Public Law 99-145 designates the U.S. Army responsible for the destruction of the U.S. chemical weapons stockpile.
1990s[4]
  • Congress establishes the ACWA program to identify and demonstrate alternatives to incineration.
  • Congress ratifies the Chemical Weapons Convention treaty, which directs all member nations to destroy their chemical weapons and production facilities.
2000s
  • Public Law 107-248[5] assigns ACWA responsibility for destruction of chemical weapons stored in Kentucky if an alternative technology is chosen.
  • Department of Defense selects neutralization followed by supercritical water oxidation (SCWO) as the destruction method for the Kentucky stockpile.
  • Bechtel Parsons Blue Grass awarded the contract to design, build, and operate BGCAPP.
  • The Secretary of Defense affirms to Congress that there are no options by which the U.S. can destroy 100 percent of its chemical stockpile by the extended Chemical Weapons Convention treaty deadline of April 29, 2012.
  • BGCAPP Groundbreaking is held.
  • Public Laws 110-116[6] and 110-181[7] are enacted, mandating destruction of the chemical stockpile by April 2012 or in no case later than December 31, 2017.
  • Site preparation and basic facility infrastructure (perimeter fencing, lighting and underground utilities) is complete.
  • Vertical construction of the personnel support building, the maintenance building and the badging facility is complete.
  • Construction activities progress focusing on the facility's Munitions Demilitarization Building, Utility Power Centers, Fire Water Pump House, Utility Building and SCWO Building.
2010s
  • BGCAPP surpasses 4 million job hours worked without a lost-time injury.[8]
  • Construction activities progress focusing on the facility's Munitions Demilitarization Building, Utility Power Centers, Fire Water Pump House, Utility Building, SCWO Processing Building and Control and Support Building.
  • The Department of Defense accepts the final BGCAPP design.
  • The systemization phase begins at BGCAPP. Construction teams turn over the first subsystems to the start-up groups for systemization testing and commissioning to begin preparing the facilities for chemical weapons destruction operations. The construction teams turn over the first building, the Fire Water Pump House, and the first system, the 138 kV Power Center, to the systemization team.[9]
  • BGCAPP partners with the Blue Grass Chemical Activity to conduct an X-ray assessment of the mustard agent stockpile. The assessment shows that removal of mustard agent from projectiles would be difficult using the current BGCAPP design. The Blue Grass team evaluates the feasibility of utilizing Explosive Destruction Technology (EDT) to destroy this segment of the stockpile.[10]
  • BGCAPP is designated as a Voluntary Protection Program Star Status site by the U.S. Department of Labor's Occupational Safety and Health Administration.[4]
  • In June 2013, BGAD and PEO ACWA completed an environmental assessment to meet the requirements of the National Environmental Policy Act, or NEPA, and Title 32 Code of Federal Regulations Part 651, to address any potential impacts of the installation and operation of EDT at the depot. The environmental assessment concluded that the installation and operation of an EDT will have no significant environmental impacts. A draft Finding of No Significant Impact was prepared and provided for public comment for a 60-day period. It was concluded that no additional analysis was necessary for the proposed action under NEPA.[11]
  • Bechtel Parsons Blue Grass received approval from PEO ACWA to begin initial work on an EDT system at the Blue Grass plant. Following a competitive procurement process, Bechtel Parsons selected the Static Detonation Chamber.[12]
  • The Blue Grass Chemical Agent-Destruction Pilot Plant received approval from the Kentucky Department for Environmental Protection in 2014 to begin initial construction activities of an EDT facility.
  • In 2014, systemization reached 25 percent completion at the BGCAPP.[4]
  • In 2015, the Bechtel Parsons Blue Grass Team earned recertification of Star Status in the Occupational Safety and Health Administration's Voluntary Protection Program.[4]
  • In June 2015, the Static Detonation Chamber (SDC) completed Factory Acceptance Testing at the Dynasafe workshop in Kristinehamn, Sweden. The SDC arrived at BGCAPP in August to be assembled, tested and installed.[13]
  • The SDC was assembled and installed at BGCAPP in early 2016.
  • In July 2017, the BGCAPP team began systemization or testing activities on the Energetics Batch Hydrolyzers and Metal Parts Treaters.[14]
  • In August 2017, 25 percent (i.e., 15 systems) of the systems and facilities at BGCAPP were turned over from the systemization team to the operations team.[14]
  • In September 2017, the BGCAPP team began systemization or testing activities on the Rocket Handling System.
  • In November 2017, the team began pre-systemization activities in the Explosive Destruction Technology facility.
  • In late 2017, ACWA Test Equipment (ATE) was introduced in the plant to test and calibrate equipment.[15]
  • In December 2017, Kentucky Department for Environmental Protection opened a 45-day public comment period[16] on the GB Sampling and Research, Development & Demonstration permit modifications.
  • In January 2018, the BGCAPP team successfully completed the Systemization Demonstration Procedure[17] for the Energetics Neutralization System.
  • In February 2018, the BGCAPP team tested pre-filter banks for proper filtration and air flow[18] and the team introduced nitrogen[19] into the plant for the first time.
  • In March 2018, the BGCAPP systemization team turned over 21 of 59 Blue Grass plant systems to operations.[20]
  • By July 2018, the BGCAPP systemization team turned over more than half of the 59 systems to operations.[21]
  • In October 2018, plant workers were fitted for and received M40 masks as part of their standard personal protective equipment.[22]
  • In November 2018, the Blue Grass plant received 44 M60 training rockets from the Blue Grass Army Depot.[23]
  • On May 29, 2019, an event was held to mark the start of chemical weapons destruction operations.[24]
  • In June 2019, the Static Detonation Chamber entered the operations phase with the successful destruction of the first mustard agent-filled munition on June 7.[25]
  • On June 7, 2019, the Static Detonation Chamber, now called the Static Detonation Chamber 1200, entered the operations phase with the successful destruction of the first mustard agent–filled munition.
  • In July 2019, the Blue Grass Army Depot commander signed a document verifying no significant impact to the environment is anticipated from the proposed additional Static Detonation Chamber for the Blue Grass plant.[26]
2020s
  • On Jan. 17, 2020, the BGCAPP main plant entered the operational phase with the destruction of the first 8-inch projectile containing GB nerve agent.
  • In March 2020, the first concrete foundation was placed for a support building for the new, larger Static Detonation Chamber 2000 facility, which was added to augment the main plant processing.
  • In May 2020, the first destruction campaign at BGCAPP was completed when all 8-inch projectiles containing GB nerve agent were destroyed using neutralization.[27]
  • In August 2020, the decision was made to not use the supercritical water oxidation system to process hydrolysate, the product of the neutralization process.[28]
  • On Jan. 10, 2021, BGCAPP destroyed 155mm projectiles containing VX nerve agent for the first time.[29]
  • In March 2021, program officials announced hydrolysate, the product of nerve-agent neutralization at BGCAPP, will be destroyed at Veolia North America near Port Arthur, Texas.[30]
  • On May 28, 2021, the second destruction campaign was completed as the final VX 155mm projectiles were destroyed.[31]
  • On July 9, 2021, BGCAPP destroyed M55 rockets containing VX nerve agent for the first time, marking the start of the fourth of five destruction campaigns.[32]
  • On Sept. 4, 2021, the third destruction campaign was completed as the final mustard 155mm projectiles in Kentucky were destroyed.[33]
  • On Oct. 7, 2021, BGCAPP shipped the first tankers of hydrolysate for destruction at Veolia North America near Port Arthur, Texas.
  • On Nov. 1, 2021, BGCAPP shipped the first boxes of non-contaminated rocket motors to Anniston Army Depot for destruction in a Static Detonation Chamber.
  • On April 19, 2022, BGCAPP destroyed the last M55 rocket containing VX nerve agent, thus completing the fourth and penultimate destruction campaign.[34]
  • On July 6, 2022, the fifth and final destruction campaign began when the first M55 rocket containing GB nerve agent was destroyed.[35]
  • As of Sept. 9, 2022, 50% of the original stockpile of chemical agent at BGCAPP has been destroyed.[36]
  • On Jan. 27, 2023, the Static Detonation Chamber 2000 entered the operations phase with the successful destruction of the first containerized rocket warhead previously drained of GB nerve agent in the main plant. [37]
  • On Feb. 17, 2023, BGCAPP reached 50% destruction of the M55 rockets containing GB nerve agent, in the plant’s fifth and final destruction campaign.
  • As of Feb. 24, 2023, 75% of the original stockpile of chemical agent at BGCAPP has been destroyed.
  • On Apr. 12, 2023, the last VX nerve agent rocket motor has been destroyed.[38]
  • As of Apr. 14, 2023, approximately 84% of the chemical agent stockpile has been destroyed.[38]

Technology

The Department of Defense conducted studies[39] to evaluate potential impacts of the elimination of these weapons using incineration and non-incineration methods for the plant. Four technologies were considered:

  • Incineration
  • Chemical neutralization followed by supercritical water oxidation (SCWO)
  • Chemical neutralization followed by supercritical water oxidation and gas phase chemical reduction
  • Electrochemical oxidation

Neutralization

The Department of Defense initially selected neutralization followed by supercritical water oxidation for use at the depot. In 2020, the decision was made to not use the supercritical water oxidation system and instead ship the nerve agent hydrolysate to a permitted treatment, storage and disposal facility.[40]

The neutralization method consists of the following steps:

  • Munitions are disassembled by modified reverse assembly.[41]
  • The chemical agent is drained from the munitions. The liquid agent is chemically mixed with caustic and water to destroy the chemical agent using hydrolysis. The resulting chemical compound is known as hydrolysate.
  • Hydrolysate is held and tested to ensure agent destruction.
  • The agent hydrolysate is shipped to Veolia North America near Port Arthur, Texas, for further processing.
  • Metal parts are thermally decontaminated by heating them to 1,000 °F (538 °C) for a minimum of 15 minutes. The metal parts can then be safely recycled.
  • Gas effluents are filtered through a series of HEPA and carbon filters before being released to the atmosphere.

Explosive Destruction Technology (EDT)

After an X-ray assessment of the mustard munitions stockpile showed that the agent had significantly solidified in the rounds[11]—making removal of mustard agent from projectiles difficult using neutralization—ACWA decided to explore use of Explosive Destruction Technology (aka Explosive Demolition Technology, Explosive Detonation Technology, EDT) for these projectiles.

EDT uses heat/pressure from explosion or just heat to destroy the munitions; it is not considered incineration and does not require disassembly of the weapons.[13] There are three general types of technologies that can destroy chemical weapons:

  • Detonation Technology – destroys the majority of the agent and explosive in the munition by detonating donor explosives wrapped around the munition. The resulting off-gasses are processed through secondary treatment to ensure agent destruction. Examples of detonation technology include the Transportable Detonation Chamber, or TDC, and the DAVINCH (Detonation of Ammunition in a Vacuum-Integrated Chamber).
  • Neutralization Technology – uses small explosive shaped charges to open the munition and consume the explosive in the burster and fuze. The agent is destroyed by subsequent neutralization. The U.S. Army's Explosive Destruction System, or EDS,[42] is an example.
  • Thermal Destruction – uses the heat of the electrically heated containment vessel to deflagrate the munition and destroy the agent and energetics. The resulting gases are treated in an off-gas treatment system. The Static Detonation Chamber, or SDC, is an example of thermal destruction technology.

Bechtel Parsons Blue Grass received approval from PEO ACWA to begin initial work on an Explosive Destruction Technology system at the Blue Grass plant. Following a competitive procurement process, Bechtel Parsons selected the Static Detonation Chamber.[43]

In June 2015, the SDC completed Factory Acceptance Testing at the Dynasafe workshop in Kristinehamn, Sweden. The SDC was assembled and installed at BGCAPP in 2016.[44]

In May 2018, EDT technicians brought the air filtration system online for the first time.[45]

In July 2018, construction substantially completed and testing began on EDT plant equipment in remote operations mode.[46]

In February 2019, a total of 24 B586 conventional munitions were processed in the Static Detonation Chamber as part of systemization activities.[47]

On June 7, 2019, the Static Detonation Chamber, now called the Static Detonation Chamber 1200, entered the operations phase with the successful destruction of the first mustard agent-filled munition.

On Sept. 4, 2021, the final mustard 155mm projectiles in Kentucky were destroyed in the Static Detonation Chamber 1200.[33]

Static Detonation Chamber (SDC)

In September 2019, BGCAPP received state approval to begin work on a second, larger SDC, called the SDC 2000. Workers broke ground Jan. 22, 2020. The site includes the main structure housing the detonation chamber, a storage magazine and support buildings.

It began operations on Jan. 27, 2023, destroying the first containerized rocket warhead containing residual amounts of GB nerve agent.

BGCAPP is using the new, larger SDC 2000 to destroy containerized, drained and undrained rocket warheads, as well as M55 rocket overpacks and rockets not suitable to be processed in the main plant.

In September 2021, after the final mustard munition was destroyed at BGCAPP, the original SDC, now known as the SDC 1200, began a changeover process. Once the changeover is completed, this SDC will process drained, containerized, rocket warheads containing residual VX nerve agent and potentially, undrained rocket warheads containing GB nerve agent. SDC 1200 operations are expected to begin by late 2023.

Public outreach

The Blue Grass Chemical Stockpile Outreach Office was established to serve as the community's primary information resource on chemical weapons destruction in Kentucky.[48] The office responds to inquiries, provides information materials and coordinates guest speakers for a variety of different civic groups and organizations and interfaces with the governor-appointed Kentucky Chemical Demilitarization Citizens' Advisory Commission and its Chemical Destruction Community Advisory Board.[49]

References

  1. ^ "National Defense Authorization At for Fiscal Year 2016" (PDF). gpo.gov. Retrieved July 3, 2017.
  2. ^ "Public Law 114-92" (PDF). Archived (PDF) from the original on 2016-04-13.
  3. ^ "Public Law 99-145" (PDF). uscode.house.gov. Retrieved July 3, 2017.
  4. ^ a b c d Program Executive Office, Assembled Chemical Weapons Alternatives. "Program Timeline". peoacwa.army.mil. Retrieved April 3, 2017.
  5. ^ "Public Law 107-248" (PDF). www.congress.gov. October 23, 2002. Retrieved July 3, 2017.
  6. ^ "Public Law 110-116" (PDF). www.congress.gov. Retrieved July 3, 2017.
  7. ^ "Public Law 110-181" (PDF). www.congress.gov. Retrieved July 3, 2017.
  8. ^ "Design of chemical weapons destruction facility concludes". Richmond Register. August 2, 2010. Retrieved April 3, 2017.
  9. ^ Clemons, Becca (May 31, 2011). "First building operational at Richmond's chemical agent destruction plant". Lexington Herald-Leader. Retrieved April 3, 2017.
  10. ^ U.S. Army Chemical Materials Agency. "U.S. Army Chemical Materials Agency: Project Manager for Non-Stockpile Chemical Materiel: X-Ray Assessment of 155mm Mustard Projectiles Stored at Blue Grass Army Chemical Activity, Richmond, Kentucky" (PDF). peoacwa.army.mil. Retrieved April 3, 2017.
  11. ^ a b Front Matter | Assessment of Explosive Destruction Technologies for Specific Munitions at the Blue Grass and Pueblo Chemical Agent Destruction Pilot Plants | The National Academies Press. doi:10.17226/12482.
  12. ^ "Facts: Static Detonation Chamber (SDC) | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". Retrieved April 3, 2017.
  13. ^ a b "BGCAPP Explosive Destruction Technology | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved April 3, 2017.
  14. ^ a b "Facts: Blue Grass-Specific Equipment | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved 2017-09-26.
  15. ^ "Experts Renew Efforts at Blue Grass Mustard Destruction Project | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved 2017-12-21.
  16. ^ "State Agency Opens Permit Public Comment Period | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved 2018-03-28.
  17. ^ "Team Completes Demonstration of Key System | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved 2018-03-28.
  18. ^ "Technicians Use Mist and Light to Test Filters | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved 2018-03-28.
  19. ^ "Nitrogen Introduced into Blue Grass Plant for First Time | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved 2018-03-28.
  20. ^ "Experts: 21 Systems Turned Over to Operations | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved 2018-06-18.
  21. ^ "More Than Half of Blue Grass Systems Turned Over to Operations".
  22. ^ "Protective Masks Issued Ahead of Plant Operations".
  23. ^ "Plant Receives Army Training Rockets".
  24. ^ "Stakeholders Recognize Start of Kentucky Chemical Weapons Destruction at Event".
  25. ^ Six, Taylor (June 12, 2019). "30 Munitions Destroyed at BGAD". Richmond Register. Archived from the original on 2019-06-13.
  26. ^ "Recommend Approval of the Finding of No Significant Impact for the Referenced Environmental Assessment, May 2019" (PDF). Archived (PDF) from the original on 2020-07-26.
  27. ^ Six, Taylor. "BGCAPP destroys all 8-inch projectiles". Richmond Register. Archived from the original on 2020-06-05.
  28. ^ Chisenhall, Jeremy. "Tanker trucks may move Kentucky nerve agent waste that can't be disposed of on site". Lexington Herald Leader. Archived from the original on 2020-09-11.
  29. ^ "VX nerve agent destruction begins at Blue Grass Army Depot". Richmond Register. Jan 11, 2021. Archived from the original on 2021-01-12.
  30. ^ Johnson, Stu (March 3, 2021). "Disposal of Nerve and Mustard Agent Moves Forward in 2021". www.weku.org. Retrieved 2021-07-06.
  31. ^ "Plant completes destruction of projectiles with nerve agent". AP NEWS. June 4, 2021. Retrieved 2021-07-06.
  32. ^ report, Register staff. "First nerve agent rockets destroyed at Blue Grass Army Depot". Richmond Register. Retrieved 2021-09-29.
  33. ^ a b "Projectiles containing mustard agent destroyed". AP NEWS. 2021-09-09. Retrieved 2021-09-29.
  34. ^ "Entire U.S. Stockpile of VX Nerve Agent Eliminated". PEO ACWA. 2022-04-20. Retrieved 2022-04-20.
  35. ^ "Work begins on last chemical weapons stockpile in Kentucky". AP NEWS. 2022-07-07. Retrieved 2022-09-30.
  36. ^ "Half of Blue Grass Chemical Agent Stockpile Destroyed - Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". 2022-09-12. Retrieved 2022-09-30.
  37. ^ https://www.weku.org/interviews/2023-01-31/ramp-up-of-new-nerve-munition-detonation-chamber-continues-this-week
  38. ^ a b "Anniston Destroys All VX Rocket Motors from Kentucky". 2023-04-19. Archived from the original on 2023-04-19. Retrieved 2023-04-24.
  39. ^ Council, National Research (2006-07-12). Letter Report of Review and Assessment of the Proposals for Design and Operation of Designated Chemical Agent Destruction Pilot Plants (DCAPP-Blue Grass).
  40. ^ Chisenhall, Jeremy (September 5, 2020). "Tanker trucks may move Kentucky nerve agent waste that can't be disposed of on site". Lexington Herald Leader. Archived from the original on 2020-09-11.
  41. ^ "Facts: Chemical Weapons Destruction at Blue Grass | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". Retrieved April 3, 2017.
  42. ^ "Explosive Destruction System Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved April 3, 2017.
  43. ^ Program Executive Office, Assembled Chemical Weapons Alternatives (2013). "How the Static Detonation Chamber Will Augment the Blue Grass Chemical Agent-Destruction Pilot Plant" (PDF). peoacwa.army.mil. Retrieved April 3, 2017.
  44. ^ The National Academies of Science Engineering and Medicine (2010). "Review of the Design of the Dynasafe Static Detonation Chamber (SDC) System for the Anniston Chemical Agent Disposal Facility". nap.edu. Retrieved April 3, 2017.
  45. ^ "Technicians Start Air Filtration System for First Time | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved 2018-06-18.
  46. ^ "BGCAPP Monthly Recap – July 2018 | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". www.peoacwa.army.mil. Retrieved 2018-09-19.
  47. ^ "Crew Tests Equipment Procedures with Conventional Munitions".
  48. ^ "Facts: Blue Grass Chemical Stockpile Outreach Office | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". Retrieved April 3, 2017.
  49. ^ "Facts: Kentucky Chemical Demilitarization Citizens' Advisory Commission and Chemical Destruction Community Advisory Board | Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)". Retrieved April 3, 2017.

Public Domain This article incorporates public domain material from the United States Army

37°43′02″N 84°12′28″W / 37.7171°N 84.2077°W / 37.7171; -84.2077

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