WO1998030861A2 - Method and apparatus for the destruction of articles - Google Patents

Method and apparatus for the destruction of articles Download PDF

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Publication number
WO1998030861A2
WO1998030861A2 PCT/US1998/000020 US9800020W WO9830861A2 WO 1998030861 A2 WO1998030861 A2 WO 1998030861A2 US 9800020 W US9800020 W US 9800020W WO 9830861 A2 WO9830861 A2 WO 9830861A2
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WO
WIPO (PCT)
Prior art keywords
enclosure
hazmat
destruction
chamber
breaching
Prior art date
Application number
PCT/US1998/000020
Other languages
French (fr)
Other versions
WO1998030861A3 (en
Inventor
J. Mark Loizeaux
Original Assignee
Loizeaux Group Int'l Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Loizeaux Group Int'l Ltd. filed Critical Loizeaux Group Int'l Ltd.
Priority to AU66467/98A priority Critical patent/AU6646798A/en
Publication of WO1998030861A2 publication Critical patent/WO1998030861A2/en
Publication of WO1998030861A3 publication Critical patent/WO1998030861A3/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F42AMMUNITION; BLASTING
    • F42BEXPLOSIVE CHARGES, e.g. FOR BLASTING, FIREWORKS, AMMUNITION
    • F42B33/00Manufacture of ammunition; Dismantling of ammunition; Apparatus therefor
    • F42B33/06Dismantling fuzes, cartridges, projectiles, missiles, rockets or bombs
    • F42B33/067Dismantling fuzes, cartridges, projectiles, missiles, rockets or bombs by combustion
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F42AMMUNITION; BLASTING
    • F42BEXPLOSIVE CHARGES, e.g. FOR BLASTING, FIREWORKS, AMMUNITION
    • F42B33/00Manufacture of ammunition; Dismantling of ammunition; Apparatus therefor
    • F42B33/06Dismantling fuzes, cartridges, projectiles, missiles, rockets or bombs

Definitions

  • the present invention is directed to an apparatus and method for the destruction of articles and, particularly, a method and apparatus for destroying biological and chemical components of weaponry by breaching or exposing the components followed by treating the products of the breaching step for safe disposal.
  • Hazmat contents are to be handled in a disposal facility, projectiles or other containers are most often opened under environmental containment by drilling, puncturing, or cutting often with complex, remotely operated equipment with little or no backup or redundancy.
  • the Hazmat contents are removed and disposed of afterward under a separate method by a variety of means including neutralization and incineration,
  • the method of removing the contents and decontaminating the containers is complex and generates significant real and potential risks as well as large quantities of byproducts and contaminated materials, called dunnage, which must be disposed of or treated at additional risk and expense.
  • dunnage which must be disposed of or treated at additional risk and expense.
  • the efficiency and completeness of the opening method affects the certainty of complete destruction of the Hazmat and decontamination of the containers. This is a time-consuming and expensive multistep method.
  • the present art for destruction of explosive-containing projectiles includes detonation with an excess of explosive which is intended to destroy the Hazmat chemicals rather than disperse them.
  • the containers are often opened by the use of shaped explosive charges in conjunction with detonation of the excess explosive charge.
  • This prior art application has been performed in open air, and has been proposed to be performed, under containment in conjunction with neutralizers.
  • the explosives destruction method often yields less than 100% efficiency of destruction, dispersing dangerous residues which are unacceptable. Incomplete explosives destruction of Iraqi chemical weapons has been claimed by experts to be responsible for "Gulf War Syndrome".
  • Explosion containment chambers are in use in various industries for testing and evaluation of explosives, and have been proposed for the explosive destruction of hazardous materials.
  • the use of such chambers addresses only a few of the problems associated with that prior art, leaving many unsolved, creating risk to the technicians involved, the public and the environment.
  • the prior art is also severely limited in terms of productivity due to the size and consideration limitations of explosion containment chambers.
  • shock absorbent foam molds and injected foams to insulate and protect various articles is widespread in the packaging and shipping industries.
  • Such protection of Hazmat for storage or shipping is also known and has been practiced throughout many areas of the Hazmat industry.
  • the present invention provides environmentally acceptable techniques and apparatus to destroy and, if necessary, dispose of these weapon related contaminants.
  • Another object of the invention is the destruction of the unwanted components of weaponry using explosive techniques followed by treatment of the products of such explosions to render the products safe for handling and/or disposal.
  • the present invention provides a method of destroying at least one article comprising the steps of providing at least one article containing at least one of a biological and chemical component and charging the at least one article into a sealable breaching chamber.
  • the at least one article is breached or opened using at least one energy releasing charge such as a heat generating or explosive device to form a contaminated product.
  • the contaminated product is then transferred to a treatment apparatus to substantially destroy the contaminated product in the treatment apparatus.
  • the inventive apparatus for destroying at least one article containing at least one of a chemical and biological component comprises a sealable breaching chamber sized to receive the at least one article.
  • the breaching chamber has an entry door and a discharge door.
  • the treatment apparatus is in communication with the breaching chamber when the discharge door is in an open position to permit transfer of the article thereto.
  • the treatment chamber and its ancillary attachments and peripherals includes means for completely destroying all contaminated products emanating from the breaching chamber after breaching of the at least one article, e.g., a high temperature furnace and/or afterburner, agitator, bubblers, comminution devices or the like.
  • the apparatus is preferably enclosed in a containment structure which is essentially sealed from atmosphere to control egress of contaminants therefrom, e.g., via air locks or the like.
  • the articles, preferably weapons, can be encased individually or in groups prior to charging into the breaching chamber to facilitate safe handling and offer more control over the breaching step.
  • the dunnage or other non-hazardous byproducts e.g., gasses
  • the dunnage or other non-hazardous byproducts can be disposed and/or vented to atmosphere.
  • Figure 1 is a perspective view of one embodiment of the invention
  • Figure 2 is a top view of a mold arrangement for use in connection with the invention
  • Figure 3 is an end view of the arrangement of Figure 2;
  • Figure 4 is a end view of a bundled mold arrangement
  • Figure 5 is a side view of the breaching chamber of the embodiment depicted in Figure 1;
  • Figure 6 is a schematic view of a gate for use in the embodiment of Figure l;
  • Figure 7 is a flow sheet of one mode of the invention.
  • Figure 8 is a flow sheet of a second mode of the invention. Description of the Preferred Embodiments
  • the inventive method and invention advances the art by making the handling of the chemical and biological component-containing containers, e.g. weaponry, from storage point to destruction point far safer for technicians, and greatly reduces the risk to the public and the environment.
  • the chemical and biological components referred to above are termed Hazmat hereinafter.
  • the advances noted above make the opening and destruction of the Hazmat and decontamination of the containers more automated and certain, and reduce byproducts and dunnage.
  • This method and apparatus through the combination of alternative/optional components, is able to handle projectiles from which explosives have been removed at far higher rates than the prior art, can destroy explosive containing projectiles (which are currently being set aside or incompletely destroyed) without modification to the method, can employ high temperatures, neutralization, or a combination of both to yield an optimum method for handling each Hazmat product in consideration of the style and condition of its container.
  • the various embodiments of the invention accomplish the advantages noted above by: (1) providing for early and complete envelopment of hazardous material containers in a sealed enclosure of material selected to resist escape of, or decomposition by, the hazardous material.
  • This enclosing method makes handling of the hazardous materials safer, far less time consuming and, therefore, less expensive; (2) making the enclosure out of materials which are consumed as an integral component of and step in the destruction method, thereby reducing the number of steps required to support the destruction method, creating less dunnage, reducing risk and expense; (3) using the enclosure as a shock absorbent medium, protecting the breaching chamber against damage during opening of the containers and increasing its through-put capacity; (4) including an integral, pre-neutralizer or other Hazmat destroying method or means as part of the enclosure to ensure contamination-free operation of the breaching chamber, facilitate subsequent destruction of the Hazmat and enhance safety of operations for technicians; (5) making the breaching chamber of such simple construction that in the event the opening method inside the sealed breaching chamber violates an enclosure and contaminates the inside of the breaching chamber
  • the destruction facility is designed to be completely enclosed within a containment structure operating under controlled negative pressure to preclude the escape of hazardous materials throughout the destruction method.
  • all method air used in the destruction method is introduced from within the containment structure. The only discharge is made through a single chimney following redundant passage through a Hazmat destruction method. Feed materials enter the containment structure through air locks and solid byproducts leave the containment structure through air locks.
  • the destructive apparatus designated by the reference numeral 10 comprises a breaching chamber followed by a furnace into which the Hazmat-containing enclosures are fed, as described below.
  • the breaching chamber 1 has an entry breach door 5 and an exit or discharge gate 7.
  • the breaching chamber is in communication with a primary chamber 9 of the furnace 3.
  • the furnace 3 rests on a refractory base 11 and has a lower discharge tap 13 and an upper discharge chimney 15.
  • the chimney 11 is in communication with an afterburner or the like.
  • the furnace 3 is preferably water cooled and includes a secondary chamber 17 having a blast door 19.
  • the breaching chamber can be used to feed other Hazmat treatment and destruction methods.
  • containers of hazardous chemicals can be retained within an enclosure made of consumable materials specifically selected to resist attack by, and contain, the particular hazardous materials in question, on a case by case basis, see Figures 2 through 4. This will be done most efficiently at the Hazmat storage site by placing the hazardous materials container within a mold and injecting or filling the mold with a fluid or foaming substance which envelops the container and sets.
  • the outside of the mold can be shelled, lined or bagged as particular circumstances require to facilitate handling and future functions the enclosure will be put through.
  • the container can alternatively be placed in a preformed enclosure or encased or sealed in a rigid or flexible outer envelope.
  • the matrix of the mold, injected foam outer enclosure shell and a swab containing a neutralizer back up to subsequently neutralize the breaching chamber may also be inserted.
  • This complete enclosure will be consumable later in the destruction method.
  • the enclosure components can be made of, or contain, additional fuel, fluxes, pre-neutralizers, purging devices and/or catalysts to facilitate the destruction of chemicals, containers and/or dunnage, as a particular Hazmat, container or circumstance requires. These components are well known in the art, e.g., a solvent, activated charcoal, or the like as neutralizers, a metal oxide as a catalyst, etc.
  • FIGS 2 and 3 depict an exemplary mold arrangement (without a bursting charge) as reference numeral 20.
  • the mold arrangement includes a mold 21 having hinged doors 23 and 25, the hinges designated as 22. Door 23 is shown with slot 27 and door 25 has tongue 29, the slot and tongue useful for interconnecting other enclosures after molding is completed.
  • the chemical and/or biological component-containing projectile 31 is sandwiched between a pair of two piece plastic cradles 33.
  • the mold 31 has sockets 35 to accept the cradles which support the projectile 31.
  • the projectile 31 includes thermal and/or shaped charges 37, each connected to the detonator line 39.
  • the mold 21 can be filled to form the enclosure with the Hazmat therein for subsequent breaching and treatment.
  • a dowel 38 interconnects the cradle pairs 33.
  • mold arrangements include preforming or premolding could be employed so that the preformed enclosure readily receives the article containing the Hazmat.
  • the preformed enclosure could be combined with an injection molding to assure an integral fit between the enclosure and the article.
  • an outer shell could be employed to encase the article which is not form fit or the outer shell could be combined with the injection molding step to provide a tight fit with the article.
  • Multiple layers could be employed as part of the enclosure for safety purposes.
  • an outer shell could be employed to encase an article surrounded by one of the arrangements described above.
  • the material or materials used for the enclosure should not only be consumable but should be resistant to detonation and degradation by the Hazmat. These materials should also not create any other environmental concerns when consumed.
  • the enclosure can also contain devices to open the container(s), and a means for conveying a signal to activate the devices which open the container(s) inside the enclosure once inside the breaching chamber.
  • the devices will be redundantly applied to ensure the intended effect. They may be standard, sheet or open or closed back linear or conical shaped explosives charges, explosives- activated mechanical perforators, and/or heat-generating compositions like Thermite. These opening devices can also be used to detonate, deflagrate or "fume-off dispersal charges if they cannot be pre-removed.
  • the opener signaling and triggering device may be electrical or non-electrical detonators or initiators activated by electricity, impact, heat, radiation or other methods.
  • the triggering system should be redundant to the extent that the probability of an unopened container or significant quantities of undetonated explosives leaving the chamber is not a credible event. Notwithstanding such probability, the furnace is designed to resist failure from detonation of multiple explosives opening devices, thermal opening devices, purging devices, BLEVE's, or delayed detonation of high explosives dispersal (burster) charges if they could not be pre- removed.
  • the explosives opening devices can also be used to drive single or binary pre-neutralization and/or container pre-purging devices or materials which would generate preliminary heat destruction, neutralization and/or displacement of the Hazmat from the container while surrounded by the enclosure in the breaching-chamber.
  • the outer shell or envelope of the enclosure can be designed with directional venting to direct gases from the opening or intra-enclosure pre- neutralization/purging heat pre-destruction method or detonation/fume-off of dispersal charges through a vent into the furnace or other downstream destruction method.
  • the enclosure can be formed or bundled to conform to the shape of the opening to the breaching chamber.
  • Figure 4 illustrates a round configuration for multiple charges to be introduced into a round breaching chamber.
  • a plurality of enclosures 40 are interconnected so that a plurality of projectiles 31 can be breached and treated simultaneously.
  • the breaching chamber can be designed as an explosive containment chamber, see Figures 5 and 6.
  • the preferred method is to make such chambers cylindrical in shape, but it is possible that for specific needs other shapes might be preferred, such as an elongated or rectangular profile for controlling the placement of thermite-type, heat generating opening or pre-destruction devices, or an expansion chamber to accommodate pressure rises from purge/neutralization or other devices inside the enclosure.
  • the breaching chamber 1 has a ram extending through the breach door 5.
  • the enclosures 40 are surrounded by swabs 43.
  • the swabs 43 neutralize the breaching chamber, if necessary.
  • the breaching chamber 1 also has vents 45 to the furnace 3 to direct any contaminants thereto for destruction.
  • Bolts 47 and flange 49 are shown to facilitate attachment of the breaching chamber 1 to the furnace 3.
  • the discharge gate as a knife gate is more fully illustrated in Figure 6.
  • the gate 7 includes the knife 51 driven by the hydraulic drive cylinder 53, the drive 53 enclosed by the sealed drive housing 54.
  • the knife seal 52 has a venting perforation 55 to allow communication between the downstream furnace and the breaching chamber to allow the negative pressure to draw Hazmat fumes into the furnace when the knife 51 is partially raised. A plurality of perforations can be used.
  • the number of containers that can be placed in the enclosure at any time will be controlled by the size of the chamber and the chamber's ability to withstand the potential explosive or other forces that might be generated by the containers and/or their contents during the opening, purging or dispersal charge detonation method. That ability, and the construction that governs it, will be determined by economic and logistic concerns for fixed/portable construction of the facility and in consideration of a particular intended use.
  • the design and capacity of the breaching chamber will be determined by intended use. With the discharge gate 7 of the breaching chamber 1 in a position to expose the venting perforation 55 i.e., partially raised, the breach door 5 will be opened and the enclosure 40, with an optional following swab 43 of neutralizer as a back up against contamination of the chamber, will be placed in the breaching chamber 1.
  • the chamber 1 operates under negative pressure, air flow being drawn from inside the containment structure through the air lock (both not shown), into the breaching chamber 1 through orifice(s), e.g., the venting perforation(s) and the vents 45 to the furnace, used to relieve pressures generated by the opening method and the discharge gate.
  • This negative pressure ensures air flow toward the destruction system, e.g., the furnace and associated apparatus, at all times.
  • the breach door 5 will be closed, the discharge gate 7 completely closed, and the opening devices and other devices attached to the Hazmat containers in the enclosure can then be activated.
  • the gasses with entrained liquids generated by the opening method which may escape the enclosure will be pre-treated in transit within the system and vented into the destruction system, e.g., a primary combustion furnace or to the furnace/afterburner or other treatment method in a controlled manner.
  • the discharge end of the chamber will then be opened and the enclosure, with its contents, will be fed into the downstream device (furnace in this case) mechanically.
  • the following swab 43 may remain in the chamber for ejection with the next enclosure charge.
  • the preferred method is to mechanically move the enclosure 40 into the downstream device by positive means of the ram 41 (less hazardous materials can be fed by gravity, reducing the complexity of the chamber), see Figure 5.
  • the ram 41 can be an integral part of the breach door 5 of the chamber 1, can have a detachable rod and/or contain a hollow annulus for the introduction of fluids to treat the chamber.
  • the ram 41 when withdrawn can seal the annulus, and the discharge gate can close. Throughout this operation, the overall system is closed and under negative pressure to ensure absolute control of all Hazmat.
  • the breaching chamber is ready for another enclosure 40 according to the rate of consumption in the furnace or other downstream device. Fuels, fluxes, or catalysts for following destruction methods may be added in the same manner, as needed.
  • the discharge gate is preferably a knife-type gate and capable of cutting a portion of the following swab 43 if the decision is made for it to remain in the discharge opening until introduction of the next enclosure.
  • the chamber may be used to feed any type of high temperature furnace, incinerator, agitator, or comminution device as is acceptable for a particular Hazmat container or situation.
  • the breaching chamber's most efficient mode with extremely hazardous materials is to feed a high temperature blast resistant furnace capable of melting most metals included in certain chemical weapon projectiles. Numerous designs for furnaces exist within the industry. Several variations on these could be placed downstream of the blast resistant furnace if needed, or in place of it if justified by a lack of explosion risk.
  • the furnace sides and top can be constructed of steel, may be hollow, and can be typically water or otherwise cooled as is customary of blast furnaces. At the bottom is a refractory bath designed to contain molten metals. Tuyeres (induction fed under negative pressure) are provided in the furnace walls for air flow control.
  • the design of the furnace is robust and intended to withstand blast pressures in the unlikely event that an unintended detonation, from any source, occurs within it.
  • the furnace operates with a downward increasing temperature gradient. Material introduced at the top is gradually heated as it descends to the combustion zone, liquids or solids, including previously pre-treated Hazmat, are volatilized and these gasses are drawn off to afterburner(s). Solids or molten metals can only exit the system by passing through the combustion zone to the lower furnace discharge.
  • the temperature of the combustion zone is determined by the needs of a particular application and is controlled by throughput rates, input of fuel, feed, and oxygen and the fuel selected. If containers are fabricated with high temperature components which will not be consumed, the furnace may be operated on continuous tap with higher air demand and lower efficiency so that solids can be safely removed at the lower furnace discharge.
  • the tap orifice size and bath slope can be used to control flow.
  • the afterburner may be a gas combustion chamber or fluidized bed as appropriate for the materials being destroyed, a particular chemical feed, or the requirements of applicable environmental regulations.
  • Between the furnace and the afterburner can be a blast door with a high temperature expansion bag designed to accept the gasses from any accidental detonation after the enclosure and its contents have passed through the breaching-chamber.
  • the discharge from the afterburner is fed into an auxiliary chamber which is designed to accommodate any increased flows resulting from an accidental detonation or BLEVE within the furnace.
  • less expensive, higher production units in the form including, but not limited to, log washers, grinders, agitators, bubblers, or other neutralization and purging methods could be used in place of a furnace.
  • a log washer would tumble and spin the containers in a neutralizer bath to ensure complete destruction of the Hazmat product.
  • a grinder or comminution device would progressively destroy, or render the containers.
  • Agitators, bubblers and other purging/sterilization methods are less certain but may be adequate depending on the nature of the hazardous material involved..
  • dunnage/debris from either method would be passed out of the system while a combustion chamber would be used to destroy all volatiles.
  • the complete facility is enclosed within a containment structure under negative pressure.
  • the negative pressure is generated by extracting feed air for the tuyeres which service the furnace or provide oxygen for the incinerator if the latter is used.
  • Scrubbers or other pollution control equipment may be added following the afterburner and auxiliary chamber to clean byproduct gases as may be required in consideration of feed products (e.g. arsenicals), applicable regulations, and environmental requirements.
  • Tapped-out metal or unrendered containers will have been exposed to temperatures in excess of those required to guarantee complete destruction of the hazardous materials according to the nature of a particular feed product.
  • the complete system would be electronically monitored using state-of-the- art equipment operated by trained professionals as required for safety of personnel and protection of the environment during a Hazmat destruction method.
  • Figures 7 and 8 illustrate two exemplary modes and systems of the invention.
  • the enclosure can be modified with a one or more of a neutralizer, fuels, catalysts, opening devices, e.g., shaped charges or the like.
  • any volatiles and/or neutralizers can pass either directly to the afterburner or pass through the furnace prior to afterburner treatment.
  • the remnants of the projectile then pass into the furnace, are converted to a molten form, cast and disposed.
  • the afterburner products are sent to scrubbers and safely discharged to the environment.
  • an alternative to the furnace is shown as an agitation or comminution device.
  • the remnants of the breaching step which do not pass to the afterburner are treated by agitation or comminution, with or without solvents.
  • the product of this treatment step can then be separated and incinerated for disposal. Monitors control these processes and materials or volatiles can be recycled as necessary.

Abstract

A high production method for the safe opening of containers of hazardous materials (HAZMAT), including chemical weapons with or without burster explosives charges, and the complete destruction of their hazardous contents and rendering of the resultant dunnage. This method embodies enclosing the Hazmat containers in materials which facilitate and ensure safety of their initial handling/transport from their point of origin (original storage location) to the destruction site, during opening and destruction. This method calls for the placing of the enclosure in a sealed breaching-chamber (1) for opening and prepurging of the Hazmat containers and pre-neutralization of the Hazmat. The enclosure containing the opened or breached containers is then mechanically transferred or gravity fed directly into a furnace (13), agitator or communition device for the final and complete destruction of the Hazmat, and the destruction or decontamination of the Hazmat containers. The entire opening and destruction method is performed in a sealed environment with redundancy in every step in the operation. An afterburner (15) is provided for volatilies. The complete method is enclosed in a containment structure. Any fugitive gases which might escape into the containment structure would be recycled through a furnace and/or afterburner to ensure complete Hazmat destruction. The entire facility is blast resistant, operates under negative pressure and is electronically/chemically monitored by qualified professionals to ensure complete destruction of all Hazmat.

Description

Method and Apparatus for the Destruction of Articles
Field of the Invention
The present invention is directed to an apparatus and method for the destruction of articles and, particularly, a method and apparatus for destroying biological and chemical components of weaponry by breaching or exposing the components followed by treating the products of the breaching step for safe disposal.
Background Art
Chemical/biological projectiles (bombs, warheads and shells) are stockpiled in large numbers at facilities in many locations by many governments, worldwide. Due to the effects of aging, poor storage conditions and/or the corrosive nature of the contents of many of these containers, they are often in deteriorated condition. Historically, this deteriorated condition has made handling and disposal difficult and dangerous when done by hand.
Complex prior art systems are prone to system breakdown and jamming of mechanical methods, creating even greater risk for technicians and the environment when freeing such jams. Problems arising out of deteriorated containers are prevalent with all types of hazardous materials (Hazmat). In the case of munitions, the projectiles (shells, warheads, bombs) are sometimes preloaded and stored with high explosive dispersal ("burster") charges and fuses in place. Frequently, these cannot be removed prior to destruction because of the deteriorated condition of the projectiles. Such circumstances complicate the destruction method used in prior art techniques.
Currently, if the Hazmat contents are to be handled in a disposal facility, projectiles or other containers are most often opened under environmental containment by drilling, puncturing, or cutting often with complex, remotely operated equipment with little or no backup or redundancy. The Hazmat contents are removed and disposed of afterward under a separate method by a variety of means including neutralization and incineration, The method of removing the contents and decontaminating the containers is complex and generates significant real and potential risks as well as large quantities of byproducts and contaminated materials, called dunnage, which must be disposed of or treated at additional risk and expense. The efficiency and completeness of the opening method affects the certainty of complete destruction of the Hazmat and decontamination of the containers. This is a time-consuming and expensive multistep method. With every additional step or complex mechanical operation of prior art techniques, increased expense and risk are added for the technicians, the public and the environment. U.S. Patent No. 5,430,228 to Ciambrone et al., herein incorporated by reference, discloses a method of destroying chemical weapons using neutralizers.
When explosive fuses and/or dispersal charges (called "bursters") are present in munitions, they must be manually removed before the projectile can be opened or destroyed under most applications of the prior art. Corrosion and/or leakage of a container makes it impossible to do this without increased risk to the technician and his equipment when dealing with Hazmat, such risk extends to the public and the environment.
The present art for destruction of explosive-containing projectiles (or seriously deteriorated Hazmat containers) includes detonation with an excess of explosive which is intended to destroy the Hazmat chemicals rather than disperse them. The containers are often opened by the use of shaped explosive charges in conjunction with detonation of the excess explosive charge. This prior art application has been performed in open air, and has been proposed to be performed, under containment in conjunction with neutralizers. However, when performed, the explosives destruction method often yields less than 100% efficiency of destruction, dispersing dangerous residues which are unacceptable. Incomplete explosives destruction of Iraqi chemical weapons has been claimed by experts to be responsible for "Gulf War Syndrome". Many deteriorated or explosive containing projectiles are presently being set aside during the application of prior art destruction methods because of the inability of these methods or apparatus to effectively and safely destroy them. This is not an exact science and is subject to variable efficiency which is environmentally unacceptable with extremely hazardous materials.
Chemical and physical methods for destroying most hazardous chemicals suitable for prior art applications are relatively straightforward. Failures of current destruction methods are usually related to lack of efficiency (insufficient mixing or lack of contact of chemicals with the destructive method), not from a deficiency in the concept of method itself.
Explosion containment chambers are in use in various industries for testing and evaluation of explosives, and have been proposed for the explosive destruction of hazardous materials. The use of such chambers addresses only a few of the problems associated with that prior art, leaving many unsolved, creating risk to the technicians involved, the public and the environment. The prior art is also severely limited in terms of productivity due to the size and consideration limitations of explosion containment chambers.
The use of shock absorbent foam molds and injected foams to insulate and protect various articles is widespread in the packaging and shipping industries. Such protection of Hazmat for storage or shipping is also known and has been practiced throughout many areas of the Hazmat industry.
High temperatures have proven effective in prior art for the destruction of Hazmat. However, the heating of Hazmat liquids within a sealed or inadequately vented container can cause an explosion called a "BLEVE", an acronym for boiling liquid expanding vapor explosion. Any method to heat liquid containing vessels should embody safeguards against such an occurrence. The risks associated with this method and potential of BLEVE's have precluded acceptance of the use of high temperatures as an environmentally acceptable method of destruction of exceptionally hazardous materials.
In view of the deficiencies in the prior art techniques described above, a need has developed to provide improved methods and apparatus to dispose of chemical and biological components of weapons. In satisfaction of this need, the present invention provides environmentally acceptable techniques and apparatus to destroy and, if necessary, dispose of these weapon related contaminants.
Summary of the Invention
Accordingly, it is a first object of the invention to effectively and safely destroy the biological and chemical components of weapons.
Another object of the invention is the destruction of the unwanted components of weaponry using explosive techniques followed by treatment of the products of such explosions to render the products safe for handling and/or disposal.
Other objects and advantages will become apparent as a description of the invention thereof proceeds.
In satisfaction of the foregoing objects and advantages, the present invention provides a method of destroying at least one article comprising the steps of providing at least one article containing at least one of a biological and chemical component and charging the at least one article into a sealable breaching chamber.
The at least one article is breached or opened using at least one energy releasing charge such as a heat generating or explosive device to form a contaminated product. The contaminated product is then transferred to a treatment apparatus to substantially destroy the contaminated product in the treatment apparatus.
The inventive apparatus for destroying at least one article containing at least one of a chemical and biological component comprises a sealable breaching chamber sized to receive the at least one article. The breaching chamber has an entry door and a discharge door. The treatment apparatus is in communication with the breaching chamber when the discharge door is in an open position to permit transfer of the article thereto. The treatment chamber and its ancillary attachments and peripherals includes means for completely destroying all contaminated products emanating from the breaching chamber after breaching of the at least one article, e.g., a high temperature furnace and/or afterburner, agitator, bubblers, comminution devices or the like.
The apparatus is preferably enclosed in a containment structure which is essentially sealed from atmosphere to control egress of contaminants therefrom, e.g., via air locks or the like.
The articles, preferably weapons, can be encased individually or in groups prior to charging into the breaching chamber to facilitate safe handling and offer more control over the breaching step.
Other components or redundant systems can be employed during the breaching step, e.g., neutralizers, fuels, catalysts, or the like, besides the opening or explosive devices depending on the type of hazardous material being destroyed.
Once the biological and chemical components are destroyed, the dunnage or other non-hazardous byproducts, e.g., gasses, can be disposed and/or vented to atmosphere.
Brief Description of the Drawings
Reference is now made to the drawings of the invention wherein:
Figure 1 is a perspective view of one embodiment of the invention;
Figure 2 is a top view of a mold arrangement for use in connection with the invention;
Figure 3 is an end view of the arrangement of Figure 2;
Figure 4 is a end view of a bundled mold arrangement;
Figure 5 is a side view of the breaching chamber of the embodiment depicted in Figure 1;
Figure 6 is a schematic view of a gate for use in the embodiment of Figure l;
Figure 7 is a flow sheet of one mode of the invention; and Figure 8 is a flow sheet of a second mode of the invention. Description of the Preferred Embodiments
The inventive method and invention advances the art by making the handling of the chemical and biological component-containing containers, e.g. weaponry, from storage point to destruction point far safer for technicians, and greatly reduces the risk to the public and the environment. The chemical and biological components referred to above are termed Hazmat hereinafter. The advances noted above make the opening and destruction of the Hazmat and decontamination of the containers more automated and certain, and reduce byproducts and dunnage. This method and apparatus, through the combination of alternative/optional components, is able to handle projectiles from which explosives have been removed at far higher rates than the prior art, can destroy explosive containing projectiles (which are currently being set aside or incompletely destroyed) without modification to the method, can employ high temperatures, neutralization, or a combination of both to yield an optimum method for handling each Hazmat product in consideration of the style and condition of its container.
The various embodiments of the invention accomplish the advantages noted above by: (1) providing for early and complete envelopment of hazardous material containers in a sealed enclosure of material selected to resist escape of, or decomposition by, the hazardous material. This enclosing method makes handling of the hazardous materials safer, far less time consuming and, therefore, less expensive; (2) making the enclosure out of materials which are consumed as an integral component of and step in the destruction method, thereby reducing the number of steps required to support the destruction method, creating less dunnage, reducing risk and expense; (3) using the enclosure as a shock absorbent medium, protecting the breaching chamber against damage during opening of the containers and increasing its through-put capacity; (4) including an integral, pre-neutralizer or other Hazmat destroying method or means as part of the enclosure to ensure contamination-free operation of the breaching chamber, facilitate subsequent destruction of the Hazmat and enhance safety of operations for technicians; (5) making the breaching chamber of such simple construction that in the event the opening method inside the sealed breaching chamber violates an enclosure and contaminates the inside of the breaching chamber, it can be easily and safely decontaminated; (6) providing a method which contains the opening and destruction method within a single apparatus with few moving parts, and minimal human interaction, eliminating risk preserved under more complex transfer logistics, and (7) purging and/or neutralizing or destroying containers, Hazmat chemicals, and most dunnage within a continuous, contained method, backed up by a redundancy appropriate for the Hazmat products being destroyed.
The destruction facility is designed to be completely enclosed within a containment structure operating under controlled negative pressure to preclude the escape of hazardous materials throughout the destruction method. To ensure the effectiveness of the containment structure, all method air used in the destruction method is introduced from within the containment structure. The only discharge is made through a single chimney following redundant passage through a Hazmat destruction method. Feed materials enter the containment structure through air locks and solid byproducts leave the containment structure through air locks. In one embodiment, referring to Figure 1, the destructive apparatus, designated by the reference numeral 10 comprises a breaching chamber followed by a furnace into which the Hazmat-containing enclosures are fed, as described below. The breaching chamber 1 has an entry breach door 5 and an exit or discharge gate 7. With the gate 7 in the open position, the breaching chamber is in communication with a primary chamber 9 of the furnace 3. The furnace 3 rests on a refractory base 11 and has a lower discharge tap 13 and an upper discharge chimney 15. Although not shown, the chimney 11 is in communication with an afterburner or the like.
The furnace 3 is preferably water cooled and includes a secondary chamber 17 having a blast door 19. As will be described, the breaching chamber can be used to feed other Hazmat treatment and destruction methods. In accordance with the invention, containers of hazardous chemicals can be retained within an enclosure made of consumable materials specifically selected to resist attack by, and contain, the particular hazardous materials in question, on a case by case basis, see Figures 2 through 4. This will be done most efficiently at the Hazmat storage site by placing the hazardous materials container within a mold and injecting or filling the mold with a fluid or foaming substance which envelops the container and sets. The outside of the mold can be shelled, lined or bagged as particular circumstances require to facilitate handling and future functions the enclosure will be put through. If the Hazmat container size or shape is of a particular configuration or condition, the container can alternatively be placed in a preformed enclosure or encased or sealed in a rigid or flexible outer envelope. The matrix of the mold, injected foam outer enclosure shell and a swab containing a neutralizer back up to subsequently neutralize the breaching chamber may also be inserted. This complete enclosure will be consumable later in the destruction method. The enclosure components can be made of, or contain, additional fuel, fluxes, pre-neutralizers, purging devices and/or catalysts to facilitate the destruction of chemicals, containers and/or dunnage, as a particular Hazmat, container or circumstance requires. These components are well known in the art, e.g., a solvent, activated charcoal, or the like as neutralizers, a metal oxide as a catalyst, etc.
Figures 2 and 3 depict an exemplary mold arrangement (without a bursting charge) as reference numeral 20. The mold arrangement includes a mold 21 having hinged doors 23 and 25, the hinges designated as 22. Door 23 is shown with slot 27 and door 25 has tongue 29, the slot and tongue useful for interconnecting other enclosures after molding is completed. The chemical and/or biological component-containing projectile 31 is sandwiched between a pair of two piece plastic cradles 33. The mold 31 has sockets 35 to accept the cradles which support the projectile 31. The projectile 31 includes thermal and/or shaped charges 37, each connected to the detonator line 39. As stated above, the mold 21 can be filled to form the enclosure with the Hazmat therein for subsequent breaching and treatment. A dowel 38 interconnects the cradle pairs 33.
Other mold arrangements include preforming or premolding could be employed so that the preformed enclosure readily receives the article containing the Hazmat. In yet another embodiment, the preformed enclosure could be combined with an injection molding to assure an integral fit between the enclosure and the article. Alternatively, an outer shell could be employed to encase the article which is not form fit or the outer shell could be combined with the injection molding step to provide a tight fit with the article. Multiple layers could be employed as part of the enclosure for safety purposes. For example, an outer shell could be employed to encase an article surrounded by one of the arrangements described above.
The material or materials used for the enclosure should not only be consumable but should be resistant to detonation and degradation by the Hazmat. These materials should also not create any other environmental concerns when consumed.
The enclosure can also contain devices to open the container(s), and a means for conveying a signal to activate the devices which open the container(s) inside the enclosure once inside the breaching chamber. The devices will be redundantly applied to ensure the intended effect. They may be standard, sheet or open or closed back linear or conical shaped explosives charges, explosives- activated mechanical perforators, and/or heat-generating compositions like Thermite. These opening devices can also be used to detonate, deflagrate or "fume-off dispersal charges if they cannot be pre-removed. The opener signaling and triggering device may be electrical or non-electrical detonators or initiators activated by electricity, impact, heat, radiation or other methods. The triggering system should be redundant to the extent that the probability of an unopened container or significant quantities of undetonated explosives leaving the chamber is not a credible event. Notwithstanding such probability, the furnace is designed to resist failure from detonation of multiple explosives opening devices, thermal opening devices, purging devices, BLEVE's, or delayed detonation of high explosives dispersal (burster) charges if they could not be pre- removed. The explosives opening devices can also be used to drive single or binary pre-neutralization and/or container pre-purging devices or materials which would generate preliminary heat destruction, neutralization and/or displacement of the Hazmat from the container while surrounded by the enclosure in the breaching-chamber.
The outer shell or envelope of the enclosure can be designed with directional venting to direct gases from the opening or intra-enclosure pre- neutralization/purging heat pre-destruction method or detonation/fume-off of dispersal charges through a vent into the furnace or other downstream destruction method.
The enclosure can be formed or bundled to conform to the shape of the opening to the breaching chamber. Figure 4 illustrates a round configuration for multiple charges to be introduced into a round breaching chamber. In this embodiment, a plurality of enclosures 40 are interconnected so that a plurality of projectiles 31 can be breached and treated simultaneously.
The breaching chamber can be designed as an explosive containment chamber, see Figures 5 and 6. The preferred method is to make such chambers cylindrical in shape, but it is possible that for specific needs other shapes might be preferred, such as an elongated or rectangular profile for controlling the placement of thermite-type, heat generating opening or pre-destruction devices, or an expansion chamber to accommodate pressure rises from purge/neutralization or other devices inside the enclosure. In the Figure 5 embodiment, the breaching chamber 1 has a ram extending through the breach door 5. The enclosures 40 are surrounded by swabs 43. The swabs 43, as described below, neutralize the breaching chamber, if necessary. There is a neutralizer feed 44 to add raw neutralizer to the chamber 1 if the swabs prove inadequate. The breaching chamber 1 also has vents 45 to the furnace 3 to direct any contaminants thereto for destruction. There is a sensor 46 to ensure that the breaching chamber is free of Hazmat material from the previous sequence before the breach is opened to allow insertion of the next enclosure. Bolts 47 and flange 49 are shown to facilitate attachment of the breaching chamber 1 to the furnace 3.
The discharge gate as a knife gate is more fully illustrated in Figure 6. The gate 7 includes the knife 51 driven by the hydraulic drive cylinder 53, the drive 53 enclosed by the sealed drive housing 54. The knife seal 52 has a venting perforation 55 to allow communication between the downstream furnace and the breaching chamber to allow the negative pressure to draw Hazmat fumes into the furnace when the knife 51 is partially raised. A plurality of perforations can be used.
The number of containers that can be placed in the enclosure at any time will be controlled by the size of the chamber and the chamber's ability to withstand the potential explosive or other forces that might be generated by the containers and/or their contents during the opening, purging or dispersal charge detonation method. That ability, and the construction that governs it, will be determined by economic and logistic concerns for fixed/portable construction of the facility and in consideration of a particular intended use.
The design and capacity of the breaching chamber will be determined by intended use. With the discharge gate 7 of the breaching chamber 1 in a position to expose the venting perforation 55 i.e., partially raised, the breach door 5 will be opened and the enclosure 40, with an optional following swab 43 of neutralizer as a back up against contamination of the chamber, will be placed in the breaching chamber 1. The chamber 1 operates under negative pressure, air flow being drawn from inside the containment structure through the air lock (both not shown), into the breaching chamber 1 through orifice(s), e.g., the venting perforation(s) and the vents 45 to the furnace, used to relieve pressures generated by the opening method and the discharge gate. This negative pressure ensures air flow toward the destruction system, e.g., the furnace and associated apparatus, at all times. The breach door 5 will be closed, the discharge gate 7 completely closed, and the opening devices and other devices attached to the Hazmat containers in the enclosure can then be activated. In the event that the enclosure is breached, the gasses with entrained liquids generated by the opening method which may escape the enclosure will be pre-treated in transit within the system and vented into the destruction system, e.g., a primary combustion furnace or to the furnace/afterburner or other treatment method in a controlled manner. The discharge end of the chamber will then be opened and the enclosure, with its contents, will be fed into the downstream device (furnace in this case) mechanically. The following swab 43 may remain in the chamber for ejection with the next enclosure charge.
For highly hazardous materials, the preferred method is to mechanically move the enclosure 40 into the downstream device by positive means of the ram 41 (less hazardous materials can be fed by gravity, reducing the complexity of the chamber), see Figure 5. The ram 41 can be an integral part of the breach door 5 of the chamber 1, can have a detachable rod and/or contain a hollow annulus for the introduction of fluids to treat the chamber. The ram 41 when withdrawn can seal the annulus, and the discharge gate can close. Throughout this operation, the overall system is closed and under negative pressure to ensure absolute control of all Hazmat.
Once the gate 7 is closed, the breaching chamber is ready for another enclosure 40 according to the rate of consumption in the furnace or other downstream device. Fuels, fluxes, or catalysts for following destruction methods may be added in the same manner, as needed.
The discharge gate is preferably a knife-type gate and capable of cutting a portion of the following swab 43 if the decision is made for it to remain in the discharge opening until introduction of the next enclosure.
The chamber may be used to feed any type of high temperature furnace, incinerator, agitator, or comminution device as is acceptable for a particular Hazmat container or situation. The breaching chamber's most efficient mode with extremely hazardous materials is to feed a high temperature blast resistant furnace capable of melting most metals included in certain chemical weapon projectiles. Numerous designs for furnaces exist within the industry. Several variations on these could be placed downstream of the blast resistant furnace if needed, or in place of it if justified by a lack of explosion risk. The furnace sides and top can be constructed of steel, may be hollow, and can be typically water or otherwise cooled as is customary of blast furnaces. At the bottom is a refractory bath designed to contain molten metals. Tuyeres (induction fed under negative pressure) are provided in the furnace walls for air flow control. The design of the furnace is robust and intended to withstand blast pressures in the unlikely event that an unintended detonation, from any source, occurs within it.
The furnace operates with a downward increasing temperature gradient. Material introduced at the top is gradually heated as it descends to the combustion zone, liquids or solids, including previously pre-treated Hazmat, are volatilized and these gasses are drawn off to afterburner(s). Solids or molten metals can only exit the system by passing through the combustion zone to the lower furnace discharge. The temperature of the combustion zone is determined by the needs of a particular application and is controlled by throughput rates, input of fuel, feed, and oxygen and the fuel selected. If containers are fabricated with high temperature components which will not be consumed, the furnace may be operated on continuous tap with higher air demand and lower efficiency so that solids can be safely removed at the lower furnace discharge. The tap orifice size and bath slope can be used to control flow.
The afterburner may be a gas combustion chamber or fluidized bed as appropriate for the materials being destroyed, a particular chemical feed, or the requirements of applicable environmental regulations. Between the furnace and the afterburner can be a blast door with a high temperature expansion bag designed to accept the gasses from any accidental detonation after the enclosure and its contents have passed through the breaching-chamber. The discharge from the afterburner is fed into an auxiliary chamber which is designed to accommodate any increased flows resulting from an accidental detonation or BLEVE within the furnace.
Depending on the type of the Hazmat and containers involved, less expensive, higher production units in the form including, but not limited to, log washers, grinders, agitators, bubblers, or other neutralization and purging methods could be used in place of a furnace. A log washer would tumble and spin the containers in a neutralizer bath to ensure complete destruction of the Hazmat product. A grinder or comminution device would progressively destroy, or render the containers. Agitators, bubblers and other purging/sterilization methods are less certain but may be adequate depending on the nature of the hazardous material involved..
The dunnage/debris from either method would be passed out of the system while a combustion chamber would be used to destroy all volatiles.
The complete facility is enclosed within a containment structure under negative pressure. The negative pressure is generated by extracting feed air for the tuyeres which service the furnace or provide oxygen for the incinerator if the latter is used.
Scrubbers or other pollution control equipment may be added following the afterburner and auxiliary chamber to clean byproduct gases as may be required in consideration of feed products (e.g. arsenicals), applicable regulations, and environmental requirements.
Tapped-out metal or unrendered containers will have been exposed to temperatures in excess of those required to guarantee complete destruction of the hazardous materials according to the nature of a particular feed product.
The complete system would be electronically monitored using state-of-the- art equipment operated by trained professionals as required for safety of personnel and protection of the environment during a Hazmat destruction method.
Figures 7 and 8 illustrate two exemplary modes and systems of the invention. In Figure 7, the enclosure can be modified with a one or more of a neutralizer, fuels, catalysts, opening devices, e.g., shaped charges or the like. Once the enclosure is breached, any volatiles and/or neutralizers can pass either directly to the afterburner or pass through the furnace prior to afterburner treatment. The remnants of the projectile then pass into the furnace, are converted to a molten form, cast and disposed. The afterburner products are sent to scrubbers and safely discharged to the environment. In Figure 8, an alternative to the furnace is shown as an agitation or comminution device. In this embodiment, the remnants of the breaching step which do not pass to the afterburner are treated by agitation or comminution, with or without solvents. The product of this treatment step can then be separated and incinerated for disposal. Monitors control these processes and materials or volatiles can be recycled as necessary.
By virtue of the invention, higher throughput rates and greater safety for workers, the public and the environment are achieved by eliminating the need for human interaction once the materials are enclosed and placed in the breaching chamber. The inventive method and apparatus also reduce the need for intermediate steps used in many prior-art methods which required isolation and separate handling/destruction of Hazmat components. Reliability of the facility is distinctive and functional by virtue of its robust simple construction, inherent redundancy and few moving mechanical parts to fail or jam. The variable size and modular construction of the facility allows it to be constructed for portable or fixed base applications.
As such, an invention has been disclosed in terms of preferred embodiments thereof which fulfills each and every one of the objects of the present invention as set forth above and provides a new and improved method and apparatus for the destruction of articles.
Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. It is intended that the present invention only be limited by the terms of the appended claims.

Claims

What Is Claimed Is:
1. A method of destroying at least one article comprising the steps of: a) providing at least one article containing at least one of a biological and a chemical component; b) charging the at least one article into a sealable breaching chamber; c) breaching the at least one article using at least one energy releasing charge to form a contaminated product; d) transferring the contaminated product to a treatment apparatus; and e) substantially destroying the contaminated product in the treatment apparatus.
2. The method of claim 1, wherein the at least one article is encased in an enclosure prior to the charging step.
3. The method of claim 2, wherein a pre-neutralizer and the energy releasing device are included as part of the enclosure.
4. The method of claim 2 wherein a pre-neutralizer, a pre-purging device and the energy releasing device are included as part of the enclosure.
5. The method of claim 2, wherein the enclosure is formed by molding a material around the article.
6. The method of claim 2, wherein the enclosure comprises a foam material.
7. The method of claim 1, wherein the at least one article is a weapon component.
8. The method of claim 1, wherein a plurality of articles are charged to the breaching chamber.
9. The method of claim 2, wherein a plurality of articles are encased in the enclosure.
10. An apparatus for destroying at least one article containing at least one of a chemical and a biological component comprising: a) a sealable breaching chamber sized to receive the at least one article and having an entry door and a discharge door; and b) a treatment apparatus in communication with the breaching chamber when the discharge door is in an open position, the treatment chamber containing means for destroying contamination in all products emanating from the breaching chamber after breaching of the at least one article.
11. The apparatus of claim 10, further comprising an enclosure sized to encase at least one of the articles, the enclosure sized to fit within the breaching chamber.
12. The apparatus of claim 11, wherein the enclosure includes the energy releasing device.
13. The apparatus of claim 11, wherein the enclosure includes the energy releasing device and at least one of a pre-purging device and a pre-neutralization device.
14. The apparatus of claim 11, wherein the enclosure is sized to encase a plurality of articles.
15. The apparatus of claim 11, wherein the enclosure is made of a material consumable in the treatment apparatus.
16. The apparatus of claim 15, wherein the enclosure is a foam material.
17. The apparatus of claim 11, wherein the enclosure is a one of an outer shell and a preformed casing.
18. The apparatus of claim 10, wherein the apparatus is sized to be portable.
19. The apparatus of claim 17, wherein the outer shell or the preformed casing is combined with an injected foam.
PCT/US1998/000020 1997-01-10 1998-01-09 Method and apparatus for the destruction of articles WO1998030861A2 (en)

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