Secondary wastes and high explosive residues generated during production of main high explosive charges for nuclear weapons. Revision 1 Page: 4 of 13
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facilities and equipment requires that estimates of the amounts of HE residues and wastes and their characteristics
be available.
This study identified the major sources of solid, liquid, and gaseous secondary wastes and HE residues generated
during actual past production of HE main charges at the Pantex facility. We estimated the amounts and characteristics
of these wastes and residues on the basis of the currently constructed Pantex facility. These estimates were developed
by establishing a reference HE production flowsheet, by interviewing Pantex staff experienced in actual HE
production operations, by walking through the Pantex facility production lines, and by using engineering judgment.
To facilitate the systematic development of these estimates, we defined and used a three-step estimating
methodology.
This report summarizes the results of the study and provides the methodology and major assumptions used to
estimate the secondary wastes and HE residues. The estimates can be used both to prepare design criteria and identify
candidate process areas for waste minimization. In addition, since a primary goal of the lead laboratory effort is to
treat all HE residual materials as an asset, assessments must be made to consider recycle and reuse of HE residues,
even though some residues must be destroyed. With this information, the design bases for a new HE main-charge
production facility can be prepared.
METHODOLOGY FOR DEVELOPING
ESTIMATES OF WASTES AND HE RESIDUES
We used a three-step approach to prepare the estimates. In step one, a reference process flowsheet and facility layout
were defined on the basis of the Pantex facility HE main-charge production processes. We then divided the production
process and facility layout into ten discrete, major, unit-operations areas. Figure 1 summarizes these ten areas.
[Place Fig. 1 here.] In addition, we defined four areas for support or ancillary operations, which are shown at the
bottom of Fig. 1. Each area was established on the basis of past HE production process operations or current Pantex
facility layouts. All areas were selected so as to be correlated with discrete groups of process operations known to
create major quantities of secondary wastes and HE residues.
In step two, we studied each area in sufficient detail to identify the major equipment and operations required to carry
out the functional operations. We used this information to develop process flow diagrams that show the detailed
subactivities for each of the blocks in Fig. 1. Figure 2 shows an example of these diagrams. [Place Fig. 2
here.] We used these levels of greater detail to estimate the actual secondary wastes and HE residues that require
collection and treatment in all facility designs.
In step three, we examined all activities or operations individually in order to develop estimates of solid, liquid, or
gaseous waste characteristics and quantities. Where insufficient Pantex production staff experience existed, or where
Pantex production records of waste and HE generation were incomplete, we used engineering judgment to develop the
estimates. We then estimated the total volumes resulting from the HE main-charge production processes by
tabulating the results from each of the ten discrete areas and four support areas for each waste and HE residue type.
Reference HE Production Facility and Operations
The Pantex production site is located about 18 miles northeast of Amarillo in the panhandle region of northwest
Texas. The site is located on U.S. DOE property and has rail and truck access. The feed materials required for the HE
production process are received and stored in storage igloos at the on-site receiving and storage area.
The main-charge HE production facilities at the Pantex site are housed in four buildings. All of these facilities are
assessed in this study. They are (1) the HE and materials staging facility, (2) the main HE pressing areas, (3) the
radiography/x-ray facility, and (4) the HE machining areas. The building that houses the main HE pressing areas also
contains the isostatic press control room, the rotoclone ventilation scrubber system, and the isostatic press fluid
equipment room.
The major activities performed in the building that houses the HE and materials staging facility include the receipt
and staging of HE process feed materials from the storage igloos and from other staging operations, the staging of
intermediate products, and the staging of HE residues from the production processes. HE process feed materials are
stored in one of seven magazines until required by the production process. Intermediate HE production process
products are also stored in sealed cans containing a desiccant and are staged during various phases of the HE
production process. Production wastes, HE residues, and other materials are placed in cans until final disposition is
determined.
In examining the HE main-charge pressing operations, we looked at both the pressing operations and associated
materials-handling operations. The HE main-charge pressing operations are conducted as follows. HE materials are
prepared and then sent to undergo heat treatment and subsequent materials loading into the HE mandrels/liners. The
main HE charges are then isostatically pressed. The pressed HE mold breakout and initial shadowgraph product
inspections are then carried out. HE products passing the shadowgraph inspections are sent in sealed cans to the
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Jardine, L.J. & McGee, J.T. Secondary wastes and high explosive residues generated during production of main high explosive charges for nuclear weapons. Revision 1, article, January 1, 1995; California. (https://digital.library.unt.edu/ark:/67531/metadc684149/m1/4/: accessed April 23, 2024), University of North Texas Libraries, UNT Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.