A.3.5 High Explosives Fabrication

The HE fabrication mission requires explosives synthesis, formulation, pressing, machining, testing, evaluation, and component manufacturing. In addition to these fundamental capabilities, a variety of support activities is required. 

The explosives fabrication activity is important to the overall mission of the future DOE Complex. Over the past several years, economic trends have dictated a significant reduction in the domestic commercial support for this technology. In today's marketplace it is difficult to secure the small quantities of products necessary to sustain the reduced workload from commercial sources. The meticulous quality required of the explosives and components placed in nuclear weapons also disqualifies most commercial vendors. 

Assumptions. In addition to the general assumptions used in preparing this PEIS, the following assumptions apply specifically to the HE fabrication mission: 

• Baseline technologies will be used except where alternatives can be shown to meet requirements and be more cost effective. 
• All production operations can be housed in existing facilities. 
• Raw materials required to manufacture explosive charges are available either from within DOE or from commercial manufacturers. 

• Solvents and wipes for manual cleaning operations 
• Adhesives and bonding agents for manual assembly operations 
• Glycerin fluid for preparing the isostatic pressing fluid 
• Release agents for coating the inside of mechanical die sets used in pressing operations 
• Dye for the penetrant test 
• Shipping and packaging materials 
• X-ray film 
• Bottled nitrogen for extrusion loading 
• Bottled argon for laser welding 
• Solvents and feedstocks for the synthesis of hexanitrostilbene and triaminotrinitrobenzene powders 
• Other miscellaneous materials required for routine operations 

• Bulk HE machining scrap 
• Off-specification HE components 
• HE-contaminated materials, such as gloves and wipes, from manual cleaning operations 
• Glycerin pressing fluid 
• Developing materials from x-ray and neutron radiography film processing 
• Hazardous contaminated materials from chemical bonding operations, packaging/


repackaging, storage/staging, and shipment for ultimate disposal 

A.3.5.1 Downsize at Pantex Plant

Pantex is the current DOE site for HE main charge manufacturing, small HE component manufacturing, HE formulation and synthesis, and HE testing and characterization. To efficiently meet the expected Complex workload, Pantex can downsize current HE fabrication operations. The following description assumes a downsized HE production mission at Pantex along with the A/D functions. 

Significant downsizing actions at Pantex focus on functional consolidation. This can be achieved by reducing the number of facilities operating in the explosives area to 11 or 12 and decreasing the direct, direct support, and direct operations support personnel to about 50. There are no processes to be transferred from offsite. All facilities identified under this plan meet Federal regulations and DOE orders as they pertain to explosives manufacturing. Table A.3.5.1-1 indicates specific products and capabilities that comprise the HE fabrication mission at Pantex. 

Table A.3.5.1-1.-- Pantex Plant High Explosives Fabrication Products 
and Capabilities

Products	Capabilities
High Explosives	Manufacturing Process Development
	Stockpile stewardship support
	Formulation
	Synthesis
	Surveillance
Binders	Main Charge Manufacturing
	Pressing
	Machining
	Subassembly
	Receiving/storage
	QA-mechanical/chemical/test fire
	Disposition
Main Charge Formulations	Energetic Component Manufacturing
	Pressing
	Machining
	Subassembly
	Receiving/storage
	QA-mechanical/chemical/test fire
Initiation High Explosives	Detonators
Mock High Explosives Formulations	Testing

Note: QA - quality assurance.
Source: PX DOE 1995e.

Assumptions. Requirements are based on an annual production rate of 150 replacements or retrofits. The 150 replacements or retrofits consist of 100 warheads and 50 bombs. The capability of providing explosives for two weapons systems in any given year is maintained. The Stockpile Evaluation Program consists of 120 disassemblies and inspections, 110 rebuilds, and additional joint test assemblies, joint test assembly post mortems, and test beds consistent with current guidance and stockpile levels. Some existing programs in the enduring stockpile use main charges made from conventional HE. Insensitive HE machining and storage continue to be explosive hazard Class IV operations. All hexanitrostilbene-based explosives and micronized-triaminotrinitrobenzene materials required would be produced at the HE production plant. Spare equipment and facilities are not included in the minimum facility requirements. 

Facility and equipment maintenance would occur on the off-shift and the nonwork days when feasible. The Complex would be capable of producing materials and assembling replacement components and units for two weapon systems in any given year. This capability would be achieved by either simultaneous or sequential campaigns, as long as the sum of the product shipments for the year meets the annual production goals. The stockpile stewardship and management alternatives would not impact the ongoing plant missions, either during construction or during the life of the upgraded plant. Ongoing plant missions are defined as those functions performed today. 

Strategic reserve requirements for explosives would be stored at the HE production site. The selected site for the HE production mission would be operational within 2 years after the ROD for this PEIS. The baseline technology for HE production comprises the present techniques utilized at Pantex. If transferred, prebuilds at the donor site would fill any production capability gap between the donor and receiver site for the HE operations. If HE production missions are transferred, a 5-year period is required to accomplish the D&D activities at Pantex. 

Facility Description. As stated previously, there would be no product or process transfers; however, there would be substantial functional consolidation. For example, Pantex currently has seven functional test fire sites. All test activities identified as required to support the enduring stockpile can be consolidated into two sites: a fully contained indoor test chamber and an outdoor site to accommodate large charges. Explosives components fabrication would be reduced from four buildings to two. Chemical characterization, nondestructive evaluation, and mechanical testing would be consolidated from the current five facilities to two, as well. A comprehensive listing of the planned consolidations can be found in table A.3.5.1-2. Figures A.3.5.1-1, A.3.5.1-2, and A.3.5.1-3 show the locations of the zones and the facilities within these zones. 

Table A.3.5.1-2.-- Pantex Plant Functional Consolidation of Explosives Operations

Capabilities	Current Facilities	Consolidated Facilities (Projected)
Synthesis	11-36	11-55
Formulation	12-19E, 12-62	11-50, 12-62
Isostatic pressing	12-63	12-63
Explosives machining	11-50, 12-121	12-121
Explosives subassembly	12-31	12-121
Explosives components	11-20, 12-17, 12-62, 12-63	12-62, 12-63
Evaluation/characterization	11-5, 11-17, 11-51, 12-21, 12-59	11-51, 12-104A
Test fire	11-18, 11-38, FS-10, FS-11, FS-21, FS-22, FS-24	FS-11, FS-22, FS-24
Explosives storage	11-42, 12-65, 12-83, Zone 4  (8 magazines)	12-65, Zone 4  (4 magazines)
Explosives disposal	Burning Ground	Burning Ground

Source: PX DOE 1995e.

Pantex consists of 425 buildings containing approximately 232,300 m 2 (2.5 million ft 2 ) of floor space of which explosives operations occupy 37,200 m 2 (400,000 ft 2 ). Within 4,119 ha (10,177 acres), approximately 809 ha (2,000 acres) are dedicated to active facility operations. Approximately 3,270 ha (8,080 acres) are devoted to storage, disposal, and miscellaneous activities in support of plant operations. 

Pantex structures containing explosives operations comply with the DOE Explosives Safety Manual, DOE/EV/06194 and are generally constructed with steel-reinforced concrete and designed to mitigate the effects of an accidental explosion. Although insensitive HE materials can generally be processed in conventional steel structures, concrete construction is typically used to maintain the flexibility to process conventional explosives. The resulting facility design typically consists of a number of separate operating bays with remote and/or contact operating capability that are fully contained or could vent to an unoccupied area should a detonation occur. Most facilities include support areas for offices, break rooms, rest rooms, electrical equipment, heating, ventilation, and air conditioning equipment, maintenance, and in-process staging of materials, components, tooling, and supplies. Many production and laboratory facilities also include vacuum systems. Utilities required include steam, compressed air, and electricity. 

The HE facilities are primarily within the Applied Technology Division. These facilities would support main charge manufacturing, small component manufacturing, formulation and synthesis, and explosives testing and characterization, as well as HE storage and disposition. 

Design Safety. The following sections identify important safety considerations incorporated in the design of explosives facilities. Performance goals commensurate with the associated hazard are selected for all structures, systems, and components. The term "hazard" is defined as a source of danger, whether external or internal. Natural phenomena such as earthquakes, extreme winds, tornadoes, and floods are external hazards to structures, systems, and components; whereas toxic, reactive, explosive, or radioactive materials contained within the facilities are internal hazards. Usage category is established by DOE management. Guidelines for usage category (performance category) and the corresponding performance goals are given in Design and Evaluation Guidelines for DOE Facilities Subjected to Natural Phenomena Hazards (UCRL-15910). 

Earthquakes. All existing facilities meet the standards as cited below. Structures, systems, and components are designed for earthquake-generated ground accelerations in accordance with University of California Research Laboratory (UCRL)-15910. The applicable seismic hazard exceedance probability is 2x10 -3 for general use (performance category 1), 1x10 -3 for low and moderate hazard (performance categories 2 and 3), and 2x10 -4 for high hazard (performance category 4) for structures, systems, and components. 

Seismic design considerations for performance category 3 and 4 structures, systems, and components include provisions for such structures, systems, and components to function as hazardous materials confinement barriers and for adequate anchorage of building contents to prevent loss of critical function during an earthquake. In essence, design considerations are to avoid premature, unexpected loss of function, and to maintain ductile behavior during earthquakes. 

The fire protection system, emergency power, water supplies, and controls for the safety class equipment are some of the necessary emergency items that must be available following an earthquake. As stated in UCRL-15910, earthquake-resistant design considerations extend beyond the dynamic response of structures and equipment to include survival of systems that prevent facility damage or destruction due to fires or explosions. 

Wind . All existing plant structures, systems, and components at Pantex meet the wind or tornado load criteria and the corresponding facility usage and performance goals. Wind design criteria are based on annual probability of exceedance, importance factor, missile criteria, and atmospheric pressure changes as applicable to each performance (usage) category as specified in UCRL-15910. Wind loads are based on the annual probability of exceedance of 2x10 -2 for the general and low hazard (performance categories 1 and 2), 1x10 -3 for the moderate hazard (performance category 3), and 1x10 -4 for the high hazard (performance category 4) structures, systems, and components. Since tornadoes are the viable wind hazards, structures are designed for the annual probability of exceedance of 2x10 -5 as defined in UCRL-15910. 

Floods . All facilities required for the HE operations at Pantex are located above the critical flood evaluation. The extent of the flood hazard is determined using the appropriate usage (performance) category for determining the "Annual Hazard Probability of Exceedance": 2x10 -3 for the general use (performance category 1), 5x10 -4 for the important or low hazard (performance category 2), 1x10 -4 for the moderate hazard (performance category 3), and 1x10 -5 for the high hazard (performance category 4) facility as defined in UCRL-15910. 

Whenever possible, all facilities in performance categories above the general use category (performance category 1) are constructed with the lowest floor of the structure, including subsurface floors, above the level of the 500-year flood. This requirement can be met by siting and/or flood protection. Whenever possible, all facilities, including their basements, in all performance categories are sited above the 100-year floodplain. 

Fire Protection . The fire protection features for the plant and its associated support buildings are in accordance with DOE orders and the National Fire Prevention Association Fire Codes and Standards. Redundant firewater supplies and pumping capabilities are installed to supply the automatic and manual fire protection systems located throughout the site. Appropriate types of fire protection systems are installed to provide life safety, prevent large-loss fires, prevent production delay, ensure that fire does not cause an unacceptable onsite or offsite release of hazardous material that will threaten the public health and safety of the environment, and minimize the potential for the occurrence of a fire and related perils. Specific production areas and/or equipment are provided with the appropriate fire detection and suppression features, as required, with respect to the unique hazard characteristics of the product process. 

Safety Class Instrumentation and Contro l. The safety classification of instrumentation and controls are derived from the safety functions which they perform. The safety classification is based on appropriate DOE orders. Existing facilities at Pantex meet all safety class requirements. Safety instrumentation is designed to monitor identified safety-related variables in safety class systems and equipment over expected ranges for normal operation, accident conditions, and safe shutdown. Safety class controls are provided when required to control these variables. Safety class instrumentation is designed to fail in a safe mode following a component or channel failure. Safety class Uninterruptable Power Supply power is provided when appropriate. 

Ventilation . The heating, ventilation, and air conditioning system design of existing facilities meets all general design requirements in accordance with DOE orders, and American Society of Heating, Refrigerating, and Air Conditioning Engineers guides. The design includes engineered safety features to prevent or mitigate the potential consequences of postulated design basis accident events. 

Internal Explosion . Buildings containing HE are designed to mitigate the effects of accidental explosion within a bay or cell. The design is in accordance with the DOE Explosive Safety Manual , DOE/EV/06194, including the quantity-distance and the level-of-protection criteria for each class of explosives activities. 

Overall Facility Layouts and Design Description. Pantex facilities proposed for the HE fabrication mission are listed in table A.3.5.1-3 and described in this section. The table summarizes key facility data for existing buildings and support areas. Data for the facilities include building number, description, construction type (concrete or steel), gross square meters, number of levels in the structure, and explosives present. 

Structures containing explosives operations are generally constructed with steel-reinforced concrete and are designed to mitigate the effects of an accidental explosion. Although insensitive HE materials can generally be processed in conventional steel structures, concrete construction is typically used to maintain the flexibility to process conventional explosives. 

Table A.3.5.1-3.-- Pantex Plant High Explosives Fabrication Facility Data

Facility Function	Building  Number	Construction Type	Gross  Area (m 2 )	Number of Levels	Special Materials
Bulk explosives storage	04-101 - 04-104	Concrete	441	1	HE
Synthesis	11-55	Concrete	279	1	HE
HE formulation	11-50	Concrete	2,062	2	HE
Chemical testing/evaluation	11-51	Concrete	1,078	1	None
HE main charge pressing	12-63	Concrete	223	1	HE
Explosives staging/packaging/shipping	12-65	Concrete	753	1	HE
Fabrication/assembly	12-62, 12-63	Concrete	548	1	HE
Explosives machining/gaging/subassembly/ safety testing/physical testing/ nondestructive evaluation	12-121	Concrete	4,562	1	HE
Test fire assembly	FS-11	Steel	190	1	HE
Outdoor firing site	FS-22	Concrete	167	1	HE
Contained firing site	FS-24	Concrete	701	1	HE
HE disposal	Burning Ground	Concrete	56	1	HE

Source: PX DOE 1995e.

The resulting facility design typically consists of a number of separate operating bays that could vent to an unoccupied area should a detonation occur. Structures that do not require concrete construction due to the presence of HE are generally constructed of steel, although portions of these buildings may be concrete. Most facilities include support areas for offices, break rooms, rest rooms, electrical equipment, heating, ventilation, and air conditioning equipment, maintenance, and in-process staging of materials, components, tooling, and supplies. Many production and laboratory facilities also include vacuum systems. Utilities required include water, steam, compressed air, and electricity. 

High Explosives Main-Charge Manufacturing. These facilities manufacture explosive subassemblies, main charge mock explosive hemispheres, and explosive test specimens. An area is also provided for conducting physical property testing on explosive components and materials. Each functional area is described below. 

Isostatic Pressing (Building 12-63). Rough pressings for HE main charge subassemblies and material test billets are manufactured in Building 12-63. 

Explosives Machining (Building 12-121). The rough pressings are machined in Building 12-121. 

Main Charge Subassembly (Building 12-121). The explosives hemispheres are assembled in Building 12-121. 

Mechanical Properties Testing (Building 12-121). The physical properties of explosive components and materials are tested in a portion of Building 12-121. 

Small High Explosives Component Manufacturing (Buildings 12-63, 12-121) . Various small components are manufactured from HE powders and binders, metal or plastic components, electrical components, hardware, and assembly materials. The manufacturing process requires equipment for explosive powder heating, pellet processing, laser welding, ultrasonic cleaning, extrusion loading, density testing, inspection, and mechanical and electrical assembly. 

Test Firing (Buildings FS-11, FS-22, FS-24). Explosives test configurations are assembled and tested at Buildings FS-11, FS-22, and FS-24. The test data characterize the explosives performance and are required for the qualification of raw materials and production lots. Testing requires explosives containment chambers and an array of special instrumentation including streak cameras, rotating mirror framing cameras, digitizers, flash x-ray systems, and velocity interferometers. Outdoor firing sites are used to conduct explosives tests (e.g., skid and hydrodynamic tests greater than 1 kg [2.2 lb]) that cannot be performed in a test chamber. These facilities are remotely located from production operations. 

Nondestructive Evaluation (Building 12-121). Explosive components are inspected using neutron radiography, x-ray, magnetic particle, and eddy current equipment to detect flaws, cracks, and voids in explosives and inert components. Nondestructive evaluation also supports the A/D mission. 

High Explosives Formulation (Buildings 11-50 and 12-62) and Synthesis (Building 11-55). These facilities have the capability to produce a variety of explosives materials from chemical reactants and commercially produced explosives. Material lots up to about 91 kg (200 lbs) are produced through a series of batch operations. Some products are used to make small HE weapon components, while other products support the development of new explosives or explosives manufacturing processes. 

The HE formulation and synthesis facilities include several flexible processing bays that contain a variety of vessels, filters, and transfer pumps used to synthesize, recrystallize, blend, and wash explosive powders. The facilities also include bays for mixing/milling, reducing particle size, drying/weighing/packaging, storing solvent, and refrigerated storing of explosives and chemicals. Building 11-55 replaces the existing synthesis facility (Building 11-36), which is in deteriorating condition. Building 11-50 replaces an existing formulation capability in Building 12-19E. 

Production Support. The production support facilities house an analytical laboratory and material compatibility testing. 

Analytical Laboratory (Building 11-51). Chemical analyses are performed on explosive and nonexplosive materials in Building 11-51 to determine or verify their characteristics. The data obtained yield valuable information about the condition and composition of the material. This information is used to ensure components' reliability and to statistically evaluate performance with material characteristics. The methods used include gas chromatography, liquid chromatography, size exclusion chromatography, infrared spectroscopy, thermal analysis, particle characterization, atomic spectroscopy, and emission spectroscopy. Surface chemistry, metallography, optical and scanning electron microscopy, and wet chemistry are also performed. 

Material Compatibility Testing (Building 11-51). Test coupons are assembled such that the subject materials are in direct contact with each other. These coupons are then placed in environmental ovens to accelerate the aging process. Gas samples are periodically taken from the coupon containers and analyzed by the gas laboratory. Compatibility testing is accomplished in Building 11-51 and is required to certify new materials for weapon use. 

Bulk Explosives Storage (Buildings 4-101 through 4-104). These facilities are designed to store collectively 31,800 kg (70,000 lb) of conventional HE powders while awaiting transfer to or from the HE staging facility and offsite explosives vendors. These materials are typically received in 4,500 to 9,000 kg (10,000 to 20,000 lb) lots. These facilities also are used for storing 182,000 kg (400,000 lb) of HE awaiting transfer to or from the explosives staging facilities. The bulk explosives facilities would be designed to provide separation between incompatible explosives types and would be located remotely from the production operations. 

Explosive Staging/Packaging/Shipping (Building 12-65). These facilities are designed to stage a variety of explosives powders, components, and assemblies for supporting HE operations. These explosives materials include plastic bonded explosives for main charge manufacturing, completed main charges, small HE components, energetic feeds and products for HE formulation and synthesis, and explosives residues for disposal or recycling. These facilities are designed to provide separation between incompatible explosives types. 

Resource Requirements During Construction/Modification. Requirements during construction and modification to implement the downsized configuration for HE fabrication at Pantex are described below. 

Land Area Requirements During Modification. Downsizing in place of the explosives production operations at Pantex requires approximately 0.12 ha (0.3 acres) of land for construction laydown and warehousing and an additional 0.04 ha (0.1 acres) to accommodate construction parking. These activities would occur in previously developed land areas. 

Materials and Resources Consumed During Modification. The materials and resources consumed during downsizing of the explosives production operation at Pantex are shown in table A.3.5.1-4. These resources include utilities, construction materials, liquid fuels, and industrial gases. 

Table A.3.5.1-4.-- Pantex Plant High Explosives Downsizing Materials/Resources
Requirements

Material/Resource	Total Consumption	Peak Demand 1
Electricity	257 MWh	2 MWe
Water (L)	644,000
Concrete (m3)	356
Steel (t)	6
Liquid fuel (L)	12,200
Industrial gases 2 (m3 )	258

Emissions During Modification. Air pollutants are emitted during modification activities required for the downsizing of the explosives production operations. The principal sources of such emissions are fugitive dust from site preparation for material laydown areas, other construction activities, and exhaust from construction equipment and vehicles. The estimated annual emissions generated during a 1-year period with peak construction activity are shown in table A.3.5.1-5. 

Employment During Modification. The number of workers required during each year of construction at Pantex for the HE downsizing alternative is presented in table A.3.5.1-6. 

Table A.3.5.1-5.-- Pantex Plant High Explosives Downsizing Construction Emissions

Pollutant	Quantity (t)
Carbon monoxide	0.54
Nitrogen oxides	0.19
Particulate matter	0.08
Sulfur dioxide	0.02
Total suspended particles	0.19
Volatile organic oxides	0.09

PX DOE 1995e.

Table A.3.5.1-6.-- Pantex Plant High Explosives Downsizing Construction Workers

Employees	Year 1	Year 2	Year 3	Total
Craftworkers
Carpenter	1	3	1	5
Construction management and support staff	0	3	1	4
Concrete mason	1	2	1	4
Electrician	0	3	2	5
Iron worker	1	3	1	5
Laborer	1	3	1	5
Millwright	0	1	1	2
Operator	0	1	0	1
Other craftworkers	0	2	1	3
Pipe fitter	0	2	1	3
Sheet metal worker	0	3	1	4
Sprinkler fitter	0	2	1	3
Teamsters	0	1	1	2
Total Employment	4	29	13	46

Source: PX DOE 1995e.

Resource Requirements During Operations--High Explosives Fabrication Mission. No additional land is required to operate the HE downsizing alternative at Pantex. 

The utilities consumed during operation include electric power, liquid fuels, natural gas, and water. Annual utility consumption rates and peak electric power rates for surge operation are shown in table A.3.5.1-7 and are incremental to the A/D mission at Pantex. 

All activities would be accomplished on a single, 40 hours-a-week shift. Any surge production would be achieved by increasing personnel and adding shifts (1-year lead time). The facilities would be operated under existing site labor agreements. Surge operation of the HE Fabrication Facility would require 37 direct workers (PX 1996e:1). Support workers for the A/D mission would provide sufficient support for the HE fabrication mission. 

Table A.3.5.1-7.-- Pantex Plant High Explosives Downsizing Surge Operation Annual Utility Requirements

Utility	Consumption	Peak Demand 3
Electricity	3,250 MWh	1 MWe
Liquid fuel (L)	55,600
Natural gas 4 (m3 )	500,000
Water (L)	12,500,000

Chemicals Consumed During Operation. The chemicals and materials consumed during operations primarily include water treating chemicals, reactants and solvents for explosives formulation and synthesis, explosive powders, materials for facility equipment and vehicle maintenance, and bottled gases. No radioactive materials are required for explosives production. Materials with annual consumption in excess of 227 kg (500 lb) during surge operations are listed in table A.3.5.1-8. 

Table A.3.5.1-8.-- Pantex Plant High Explosives Downsizing Surge Operation Annual Chemical Requirements

Chemical	Quantity (kg)
Calcium chloride	4,080
Ethyl acetate	1,360
HE powders, insensitive	31,600
HE powders, conventional	15,800
Hydraulic/lubricating oil	4,310
Nitrogen	1,810
Paint	2,380
Source: PX 1995a:6; PX DOE 1995e.

Emissions During Operation. Gaseous environmental releases would result from operation of the thermal treatment units for bulk HE waste and nonradioactive HE-contaminated waste generated by Pantex for the explosives production operations. Emissions would also result from plant boiler operation, cleaning operations using solvents, and formulation and synthesis operations. The thermal treatment units would be designed and operated to attain and maintain temperatures which result in the destruction of hazardous constituents. Hazardous particulates would be trapped in filters. The releases would be limited to what is possible, using the best available control technology. The annual chemical emissions for the explosives production surge operations are shown in table A.3.5.1-9. 

Table A.3.5.1-9.-- Pantex Plant High Explosives Downsizing Surge Operation Annual Emissions

	Quantity (kg)
Pollutant	Incremental with Assembly/ Disassembly
Criteria Pollutant
Carbon monoxide	413
Nitrogen oxides	1,560
Particulate matter	68
Sulfur dioxide	0.01
Volatile organic compounds	122
Hazardous and Other Toxic Compounds
Acetonitrile	0.45
Aldehydes	2.04
Ammonia	0.02
Benzene	3.00
Cresylic acid	0.0014
Cyclohexane	1.70
1,2-Dichloroethane	0.03
Dimethyl formamide	0.01
Dioxane	0.04
Hexane	0.09
Hydrogen chloride	3.20
Hydrogen fluoride	4.50
Mercury	2x10 -8
Methanol	2.7
Methyl ethyl ketone	349
Toluene	9.5
1,1,1-Trichloroethane	0.54
Trichloroethylene	0.45
Xylene	8
PX DOE 1995e.

Waste Management 

Wastes Generated During Construction. The liquid and solid wastes generated during construction would include concrete and steel waste construction materials, hazardous wastes, and sanitary wastewater. The steel construction waste material would be recycled as scrap metal. No radioactive or mixed wastes would be generated during construction. 

The liquid and solid wastes generated during HE downsized fabrication functions are discussed in the subsections below. The annual quantity of solid and liquid waste generated by the explosives production operations at Pantex during surge operation is shown in table A.3.5.1-10. 

Hazardous toxic wastes would consist of solid residue (ash) from thermal treatment units, solvents from operations, wash water and residual reactants from explosives formulation and synthesis, and residue from painting and bonding operations. This waste would be stabilized and sent to an approved permitted RCRA disposal site. 

Solid nonhazardous, nonradioactive wastes generated by the explosives production operations would consist primarily of solid sanitary waste, residue from facility and vehicle maintenance, spent desiccants, and sanitized and demilitarized paper and parts. Nonrecyclable portions of this waste would be sent to an offsite landfill. Liquid sanitary wastewater and process wastewater would be treated and discharged to a permitted drainage channel. 

Transportation. The major type of hazardous material that would be transported to Pantex would be HE materials. Bulk explosives powders would be delivered to the site by DOT-approved bulk commercial carriers. The powder would be unloaded at the bulk explosives storage facilities, isolated from other facilities on the site. Subsequent movements of HE and explosives components would be performed by trucks and battery powered vehicles specifically designed for this purpose. The quantity of HE (conventional and insensitive) transported onsite by these trucks would be strictly limited. 

Explosives main charges and components would be transferred to staging areas for transfer to the A/D plant. In a similar manner, explosives components from the A/D plant would be transferred to the explosives production plant for demilitarization, sanitization, and disposition. Small quantities of hazardous waste generated during operations would be collected, packaged, and transported by electric car to local accumulation sites and then by truck to a staging area. The waste would be transferred by truck for offsite disposal. 

Table A.3.5.1-10.-- Pantex Plant High Explosives Fabrication Facility Waste Volumes

Category	Annual Average  Volume Generated  from Construction (m3)	Annual Volume Generated from  Surge Operations (m3)	Annual Volume  Effluent from  Surge Operations (m3)
Low-Level
Liquid	None	None	None
Solid	None	Minimal	Minimal
Mixed Low-Level
Liquid	None	None	None
Solid	None	None	None
Hazardous
Liquid	None	0.23	0.23
Solid	0.06	30	30
Nonhazardous   (Sanitary)
Liquid	146	7,120	7,120
Solid	None	17	8 5
Nonhazardous   (Other)
Liquid	Included in sanitary	None	None
Solid	2 6	Included in sanitary	Included in sanitary

A.3.5.2 Relocate to Los Alamos National Laboratory

Table A.3.5.2-1.-- Los Alamos National Laboratory High Explosives Fabrication Products
and Capabilities

Products	Capabilities
High Explosives	Manufacturing Process Development
	Stockpile stewardship support
	Formulation
	Surveillance
	Synthesis
Binders	Main Charge Manufacturing
	Pressing
	Machining
	Subassembly
	Receiving/storage
	Quality assurance-mechanical/chemical/test fire
	Disposition
Main Charge Formulations	Energetic Component Manufacturing
	Pressing
	Machining
	Subassembly
	Receiving/storage
	Quality assurance-mechanical/chemical/test fire
	Disposition
Initiation High Explosives	Detonators
Mock High Explosives Formulations	Testing
LANL 1995d.

Assumptions. The general and facility assumptions on which the data in this section are based follow. 

General Assumptions 

• LANL currently has adequate infrastructure in place to meet all ES&H safeguards and security and waste management requirements for the HE fabrication mission. 
• Additional staff would be required to support new HE production. 
• Transition from Pantex and qualification and process prove-in will take approximately 2 years, beginning in fiscal year 1997 after the ROD. 
• Steady state operations begin at LANL in fiscal year 1999. 
• Steady state operations include manufacturing, testing, and quality assurance evaluation of parts and returned stockpile surveillance components (approximately 10 percent of the production rate). 

• The capacity is defined as 150 sets of explosives components for new builds and 110 sets of explosives components for rebuilds. 
• All products and capabilities defined by the HE manufacturing block flow diagrams will be supported. 
• Some existing programs in the enduring stockpile use main charges made from conventional HE. All new weapon programs will use main charges made from insensitive HE. Insensitive HE machining and storage continue to be explosive hazard Class IV operations. 
• Appropriate portions of the existing storage facilities will be upgraded and reserved to provide adequate storage for the HE fabrication mission, estimated as 182,000 kg (400,000 lb) of insensitive HE and 31,750 kg (70,000 lb) of conventional HE. 
• Existing S-Site facilities will be operated according to the current shift system (four 10-hour days per week) to meet normal production requirements. The facilities will be operated under existing labor agreements. 
• No new facility construction will be needed. 

Table A.3.5.2-2.-- Los Alamos National Laboratory High Explosives Fabrication Facility Data

Functional Area	Existing Facilities
High Explosives Technology	Gross Area  (m 2 )	Building Number
Main Charge Fabrication
HE pressing	740	TA-16-430
HE machining, inspection	930	TA-16-260
HE subassembly	370	TA-16-410
Physical property testing	185	TA-11, All
High Explosives Staging, Insensitive High Explosives, and Conventional High Explosives	280	TA-16-261 TYPICAL
Main Charge Test Fire	93	TA-15, TA-40
Energetic Components
Small component fabrication	700	TA-16-340
Test fire	93	TA-15, TA-40
Component nondestructive evaluation	560	TA-8-22, -23
Formulation and Synthesis
HE synthesis	460	TA-9-45, -46
HE formulation	700	TA-16-340
Chemical storage	47	TA-16-344
HE staging	47	TA-16-341, -343, -345
Production Support
Analytic/environmental lab	460	TA-9-21 and -32
Metrology	185	TA-16-260, -410
Materials compatibility testing	280	TA-9-21, -40, -42
Machine shop	185	TA-16-370
High Explosives Shipping/Receiving	230	TA-16-280
Outdoor Test Fire	93	TA-15, TA-11
High Speed Test Machining	18	TA-16-340, -476
High Explosives Storage, Insensitive High Explosives, and Conventional High Explosives	930	TA-37-1 through -37
High Explosives Tech Ramps	2,790	TA-16-413, -332
Component Warehouse	280
Total	10,655
LANL 1995d.

Small High Explosives Component Manufacturing. This facility manufactures small HE weapon components and test assemblies and conducts qualification and development testing for explosives components and materials. Various small components are manufactured in TAs-16-340, -430, -260, and -410 from HE powders and binders, metal or plastic components, electrical components, hardware, and assembly materials. The manufacturing process requires equipment for explosives powder heating, pellet pressing, laser welding, ultrasonic cleaning, extrusion loading, density testing, and mechanical assembly. 

Inert Machining. Small components are manufactured in TA-16-370 and TA-3-39. Additional facilities at the central shop (TA-13-39) include full service, high precision metal manufacturing capability. 

Synthesis (Technical Areas 9-45, -46) and Formulation (Technical Area 16-340). These facilities have the capability to produce a variety of explosives materials from chemical reactants or to formulate HE composites from commercially produced explosives. Material lots up to about 91 kg (200 lb) are produced through a series of batch operations. Some products are used to make small HE weapons components, while other products support the development of new explosives or explosives manufacturing processes. Blending capabilities for producing uniform blends up to 454 kg (1,000 lb) to minimize batch-to-batch variations are available at the TA-16-340 complex. The HE formulation and synthesis facility includes several flexible processing bays that contain a variety of vessels, filters, and transfer pumps which are used to synthesize, recrystallize, blend, and wash explosive powders. The facility also includes six bays for mixing/milling, particle size reduction (micronization), drying/weighing/packaging, solvent storage, and refrigerated storage for explosives and chemicals. 

High Explosives Shipping and Storage. The HE shipping/receiving facility in TA-16-280 and TA-37-1 through TA-37-26 is designed to ship and receive bulk HE materials to and from the HE Fabrication Facility. These materials are typically received in 4,500 to 9,000 kg (10,000 to 20,000 lb) lots. Parts would be shipped out as needed in small lots to the A/D Facility. 

High Explosives Disposal (Technical Area 16-389). LANL disposal facilities is in place and permitted by the State of New Mexico for disposal of HE waste and HE-contaminated materials. There is a large flash pad that thermally decontaminates items subject to trace HE contamination prior to burial. Two aboveground burning trays are used to destroy HE scrap and residue, and two sand filters are used to remove HE-contaminated water from sump sludge for drying and burning. One aboveground tray burns contaminated oil. An incinerator burns room trash from the HE area (potential contamination due to association only). All water is filtered to remove HE; treated with activated carbon for solvent removal; and measured for chemical oxygen demand, suspended solids, and acidity prior to release to the environment. 

Explosives Testing and Characterization. HE testing and characterization cover a wide range of activities and processes and provide quality assurance data that can be used to certify a HE lot for production use or to provide test firing information to qualify small HE component lots for use in production assemblies. LANL has facilities, instrumentation, and test equipment to support the certification of HEs and HE components that would be used for production. These facilities can be used for analytical chemistry evaluation, physical testing, nondestructive evaluation, materials compatibility testing, and firing sites for performance and safety evaluations of HEs and HE assemblies. The full complement of testing and characterization activities is used for surveillance evaluation of returned stockpile HEs. 

Analytical Laboratory. Chemical analyses are performed in TA-9-21 on explosives and on explosives materials to determine or verify their characteristics. Analysis methods include gas chromatography, liquid chromatography, ion chromatography, size exclusion chromatography, infrared spectroscopy, thermal analysis, particle characterization, mass spectroscopy, atomic spectroscopy, and emission spectroscopy. Small-scale safety tests required for evaluation of HEs are conducted in this facility. Tests include drop weight impact, friction, electrostatic discharge, and thermal tests. 

Material Compatibility Testing. Test coupons are assembled in TA-9-40, TA-9-21, and TA-9-42 so that the subject materials are in direct contact with each other. These coupons are then placed in environmental chambers to accelerate the aging process. Temperatures can be cycled between -55 °C (-67 °F) and +75 °C (+167 °F) in the chambers. Gas samples are periodically taken from the coupon containers and analyzed. Compatibility testing is required to certify new materials for weapon use and HE compatibility. Two large environmental chambers that can be used for cycling full scale weapons systems are located in TA-9-42. 

Physical Properties Testing. The physical properties of explosives components and materials are tested in TA-16-340 and TA-9-37 to support lot certification for materials and components and to support production development. The test configurations are assembled, and tensile, torsion, and compression tests are conducted. 

Nondestructive Evaluation. Explosives and nonexplosives components are inspected in TAs-8-22, -23, -70 and TA-16-260 with neutron, x-ray, magnetic particle, and eddy current equipment to detect flaws, cracks, voids, and foreign materials. 

Test Firing. LANL assembles and detonates explosive test configurations in TA-15, TA-40, and TA-11-25. Tests require explosive containment chambers and an array of special instrumentation including streak cameras, rotating mirror framing cameras, an air image converter system, digital oscilloscopes, flash x-ray systems, and velocity interferometers. LANL conducts large-scale safety tests such as skid tests and spigots at the TA-11 drop tower facility. Vibration test capabilities are also located in this area and can be used for full scale weapons tests as well as components tests. 

High Explosives Staging Areas and Corridors. In-process storage in TA-16 is required for a variety of HE powders, components, and assemblies for supporting the HE fabrication operations. These explosives materials include PBXs for main charge manufacturing, completed main charges, small HE components, energetic feed materials and products for HE formulation and synthesis, and explosives residues for disposal or recycle. Staging magazines exist in conjunction with each operational building. The staging magazines are connected with the operational buildings with enclosed corridors. These corridors are used for equipment and material transfers only. Major process buildings are not interconnected. 

Resource Requirements During Construction/Modification/Transition. Since only minimal new equipment is needed at LANL, there are no facility construction or modification requirements to conduct the HE fabrication mission at LANL. LANL already has all the technologies needed to provide HE materials, component fabrication, characterization, surveillance, and quality assurance for the future nuclear weapons requirement. The capacity of LANL HE fabrication facilities exceeds R&D mission requirements and can easily accommodate the required production load. 

LANL has a full spectrum of HE research, development, fabrication, and test capabilities managed by the Dynamic Experimentation and Engineering Sciences and Applications Divisions. The existing facilities, equipment, and infrastructure would be used to satisfy future production requirements for the HE fabrication mission. The existing capabilities are used to manufacture prototype weapon components for full scale testing that provide the basis for production specifications. Additionally, LANL has demonstrated the capability to manufacture limited production quantities of HE components. Typically, LANL produces 1,200 to 1,500 HE parts per year for use in the weapons research development and testing programs, which include requirements for small production lots (~500) of HE components. These components are manufactured to strict quality assurance requirements and are used in complex hydrodynamic and NTS program requirements. 

The equipment and processes used in the HE fabrication processes are very similar and in some cases identical to those used at Pantex for production. By using the same equipment and processing technologies, both LANL and Pantex manufacture parts by the same methods. The processes used by Pantex for HE component production would be used by LANL, except in rare cases where process and/or product improvements can be demonstrated to be cost effective and still meet production requirements. Transition of the HE fabrication processes from Pantex to LANL would require very little press development since equipment and processes are almost identical. 

The transition period for transferring the HE fabrication mission to LANL is estimated to take 2 years after the ROD of this PEIS. HE main-charge components may exhibit dimensional instabilities (material creep) when stored for periods of time in excess of 6 to 8 months. Production scheduling plans for "just-in-time" manufacturing of HE components to be used in weapon assemblies. Additionally, extrudable HE used in weapons application, must be stored at -30 °C (-22 °F), and have a 24-hour room temperature working life before the materials cure and setup. The shelf life of the extrudables, when stored at -30 °C (-22 °F), is typically on the order of 6 to 8 months. Because of these concerns, it is not feasible to prebuild HE components during the transition period. It will be necessary for Pantex to remain operational for producing HE components until the receiver site becomes operational. For LANL, this transition period would require 2 years, with steady state operations beginning in fiscal year 1999. 

Resource Requirements During Operations-High Explosives Fabrication Mission. HE operations are conducted within the existing LANL boundaries and occupy approximately 5,180 ha (12,800 acres). Table A.3.5.2-2 lists all the required facilities for HE fabrication operations at LANL and the footprint or area on the ground required for each facility. 

General utilities and resource requirements including electric power, steam, natural gas, liquid fuels, and water would be supplied by existing LANL infrastructure. Capacity of the general utilities support is sufficient to meet the current requirements of the HE Fabrication Facility for R&D operations and an increase in capacity to meet production requirements is not needed. The utilities and resources consumed during operations include electric power, liquid fuels, natural gas, and water. Annual utility resource consumption rates and peak electric power rates for surge operation are estimated in table A.3.5.2-3. 

Table A.3.5.2-3.-- Los Alamos National Laboratory High Explosives Fabrication Surge Operation Annual Utility Requirements

Utility	Consumption	Peak Demand 7
Electricity	5,600 MWh	1.0 MWe
Liquid fuel (L)	94,600
Natural gas 8 (m3 )	3,650,000
Coal (t)	0
Water (L)	13,000,000

LANL's HE fabrication processing facilities currently operate on a 4-day week, 10 hours per day, for 50 weeks per year. Maintenance personnel that support the HE processing equipment work a 5-day week, 8 hours per day. Routine and preventive maintenance is conducted on Fridays, as scheduling permits. Actual operational schedules will be dependent on workload and scheduling requirements. 

Table A.3.5.2-4 provides the estimated number of additional direct operating and direct support personnel required at LANL to meet the HE fabrication requirements under base case surge (three shifts per day) operation. The DOE production control documents for the enduring stockpile systems would be used for planning and scheduling of the HE components needed to meet the production requirements. In addition, manpower estimates for manufacturing quality assurance parts and preparing surveillance samples for testing and evaluation have been included. 

Table A.3.5.2-4.-- Los Alamos National Laboratory High Explosives Fabrication 
Surge Operation Workers

Labor Category	Number of Workers
Direct workers	35
Direct support workers	30
Operations support workers	40
Indirect support workers	95
Total	200 9

Chemicals Consumed During Operation. The chemicals consumed during all HE fabrication operations are shown in table A.3.5.2-5. 

Emissions During Operations. The HE fabrication operations at LANL do not require radiological materials. Under normal operations, no workers could be exposed to radiation. Emissions during operation are listed in table A.3.5.2-6. Gaseous environmental releases would result from operation of the thermal treatment units (incinerator baseline) for bulk HE waste and nonradioactive HE-contaminated waste. Emissions would also result from plant boiler operation, cleaning operations using solvents, and small scale synthesis operations, although the incremental amount of emissions over current operations would be very small. The thermal treatment units would be designed and operated to attain and maintain temperatures which would result in the destruction of hazardous constituents. Hazardous particulates would be trapped in filters. The releases would be limited to as low as achievable using the best available control technology. 

Waste Management. Liquid and solid waste streams generated by the HE fabrication operations are processed to meet state, Federal, and DOE requirements for the various types of nonhazardous, hazardous, radioactive, and mixed wastes. LANL waste management facilities would be used to receive, track, characterize, treat, package, store, and ship wastes generated by HE plant operations. These facilities include a waste management operation, waste storage facility, sanitary wastewater treatment unit, and a sanitary and industrial landfill. 

Table A.3.5.2-5.-- Los Alamos National Laboratory High Explosives Fabrication
Surge Operation Annual Chemical Requirements

Chemical	Quantity (kg)	Chemical	Quantity (kg)
Acetone	2,722	Ethylene glycol	227
Acetonitrile	1,814	X-Ray film developer, fixer, and toners	227
Acid neutralizers/spill kits	272	HE powders	45,360
Adiprene polyurethane composition	45	Hydrochloric acid	45
Activated carbon	454	Hydraulic lube oils	2,268
Aluminum metal	454	Mild steel	454
Argon	907	Nitrogen	227
Carbon dioxide	227	Silicone elastomer	91
Cyanuric acid	454	Sodium hydroxide	227
Degreaser	45	Stainless steel	454
Desiccants/molecular sieves	136	Talc	454
Elastomer binders	227	Tetrahydrofuran	113
Ethanol	272	Toluene	680
Ethyl acetate	454	Water chemicals	91
LANL 1995b:4; LANL 1995d.

Table A.3.5.2-6.-- Los Alamos National Laboratory High Explosives Fabrication Surge Operation Annual Emissions

Pollutant	Quantity (kg)
Criteria Pollutants
Carbon monoxide	4,540
Nitrogen oxides	22,700
Particulate matter	227
Volatile organics	4,540
Hazardous and Other Toxic Compounds
Ammonia	454
Acetonitrile	4.5
Cyclohexane	2.3
Dioxane	2.3
Hydrogen chloride	113
Hydrogen fluoride	45.4
Methyl ethyl ketone	22.7
Toluene	22.7
LANL 1995d.

Nonhazardous wastes generated at the HE Fabrication Facility would primarily consist of solid sanitary waste, sludge from sanitary wastewater treatment, maintenance residues, and scrap parts. Materials unsuitable for recycle would be appropriately disposed of in an approved landfill. Liquid sanitary wastewater will be discharged to the environment after treatment, subject to the NPDES requirements. 

Hazardous wastes generated by the HE Fabrication Facility would consist of solid residue from thermal treatment of scrap explosives and explosive-contaminated combustible materials, spent carbon from HE- and solvent-contaminated water treatment, and waste oils and paint residues from routine maintenance operations. LANL would stabilize all hazardous materials for disposal/treatment at an approved RCRA disposal site. 

Low-level radioactive waste would only be generated from A/D operations involving depleted uranium parts, or from processing of surveillance materials or other HE charges returned from stockpile with slight contamination. There would be no radioactive wastes associated with HE fabrication. In all cases, compliance with all appropriate regulations and standards concerning all wastes, including mixed waste, would be met. 

HE residual materials, such as bulk HE machining scrap, off-specification HE components, HE-contaminated materials (including gloves, wipes, and rags) and process water generated during HE fabrication operations are the source of most of the waste material that must be processed. LANL uses waste minimization and recycle processes to reduce the amounts of material that ultimately must be subjected to waste treatment processes. Recycled scrap HE and HE-contaminated process water are not considered waste and are handled as in-plant operations. 

Currently, thermal treatment of HE and HE-contaminated materials (open air burning and incinerators) are the preferred permitted techniques used to dispose of and decontaminate solid materials. LANL is looking at several alternative processes in the event state and Federal agencies do not approve permit applications. Some of these processes include base-hydrolysis decomposition of HE, followed by supercritical water oxidation, molten salt destruction, and bioremediation techniques. The open burning and incineration techniques at LANL are subject to environmental monitoring, and emissions must meet permit requirements. 

HE-contaminated process water generated by synthesis and formulation processes, vacuum pump seal water, and HE machining processes, would be collected in tanks and then treated with activated carbon filters to remove residual HEs and solvents. The water would then be recycled or discharged to the environment subject to NPDES permit requirements. LANL collects sanitary wastewater in a separate system and routes it to septic tanks or sanitary waste water treatment facilities. Stormwater is collected separately, and a stormwater pollution prevention plan is in place. 

The thermal treatment of HE scrap and HE-contaminated materials would result in emission of decomposition gases. Typical decomposition gases include carbon monoxide, oxide of nitrogen, volatile organics, hydrogen chloride, hydrogen fluoride, and ammonia. Small amounts of organic solvent vapors from materials such as toluene, acetone, methyl ethyl ketone, and ethyl acetate can also be generated during treatment processes as well as normal plant operations. 

All LANL operations involving HE, including waste disposal, must comply with DOE/EV/106194 and meet explosives safety requirements. Buildings meet blast-resistant building construction standards and quantity distance criteria. Remote operations capabilities exist for disposal processes. 

The HE fabrication process would generate the following waste and residual materials: 

• Bulk HE machining scrap 
• Off-specification HE components 
• HE-contaminated materials, such as gloves and wipes, from manual cleaning operations 
• Glycerin pressing fluid 
• Developing materials from x-ray and n-ray film processing 
• Hazardous contaminated materials from chemical bonding operations, packaging/repackaging, storing/staging, and shipping for ultimate disposal. 

Several facilities exist within LANL's waste management infrastructure that process the plant non-HE wastes. These facilities are used to receive, track, characterize, treat, package, store, and ship wastes generated by HE fabrication operations. Included are a waste storage facility, a sanitary wastewater treatment unit, a sanitary and industrial landfill, and stormwater ponds. Hazardous waste that has been HE decontaminated would be handled through the LANL waste management operations at TA-54. The increased loading on the LANL infrastructure which handles these types of wastes would be minimal, requiring no additional capacity or facilities. The radioactive wastes, mixed wastes, hazardous wastes, and nonhazardous wastes generated during the surge operations are quantified in table A.3.5.2-7. 

Transportation. All intrasite transportation required for manufacturing is done within existing site boundaries and does not require use of public roads. Appropriate HE shipping regulations as defined by DOE and DOT are followed. 

The HE shipping and receiving facility is designed to ship and receive bulk HE materials to and from the HE Fabrication Facility. These materials are typically received in 4,500 to 9,000 kg (10,000 to 20,000 lb) lots. All completed charges are shipped following appropriate HE shipping regulations. All hazardous chemicals are shipped using appropriate DOT requirements. 

Table A.3.5.2-7.-- Los Alamos National Laboratory High Explosives Fabrication 
Waste Volumes

Category	Annual Average Volume Generated from Construction (m3)	Annual Volume Generated from Surge Operations (m3)	Annual Volume Effluent from Surge Operations (m3)
Low-Level
Liquid	None	None	None
Solid	None	Minimal	Minimal
Mixed Low-Level
Liquid	None	None	None
Solid	None	None	None
Hazardous
Liquid	None	4 10	4
Solid	None	13	13
Nonhazardous (Sanitary)
Liquid	None	5,900	5,880 11
Solid	None	Included in liquid	17
Nonhazardous (Other)
Liquid	None	6,930 12	6,930
Solid	None	28	28

A.3.5.3 Relocate to Lawrence Livermore National Laboratory

LLNL maintains self-contained HE RD&T, and fabrication capabilities at the remote explosives testing area, Site 300, and at the HE Applications Facility at the Livermore Site. LLNL has the facilities, equipment, and infrastructure to satisfy the current production requirements for the HE fabrication mission for all weapon systems in the enduring stockpile. The health and safety, materials management, and materials characterization (nondestructive examination, test fire, and chemical analysis) infrastructures are already in place and available to support the production function as well as the R&D function. No significant HE Applications Facility or Site 300 upgrades are anticipated to receive the mission for HE fabrication in the Complex. No deviations from the current baseline technologies at Pantex are anticipated. 

Site 300 is dedicated to all aspects of HE RD&T and is remotely situated on 2,800 ha (7,000 acres) in California's Central Valley, 24 km (15 mi) east of the Livermore Site (figure A.3.5.3-1). Large-scale synthesis, formulation, and test firing is done at Site 300. The HE Applications Facility staff administers the technical work from the Livermore Site. Small-scale process development/prove-in would be done in the HE Applications Facility. The HE Applications Facility meets or exceeds all the applicable ES&H requirements for explosives R&D and production support. Synthesis and formulation would be performed in this building and would be locally supported by the theory and modeling efforts in the HE Applications Facility. A full spectrum of other HE activities take place at this facility, ranging from detonator development to experiments involving 10-kg (22-lb) detonations. 

Table A.3.5.3-1.-- Lawrence Livermore National Laboratory High Explosives Fabrication 
Products and Capabilities

Products	Capabilities
High Explosives	Manufacturing Process Development
	Support stockpile stewardship
	Formulation
	Synthesis
	Surveillance
	Main charge manufacturing
Binders	Pressing
	Machining
	Subassembly
	Receiving/storage
	Quality assurance-mechanical/chemical/test fire
	Disposition
Main Charge Formulations	Energetic Component Manufacturing
	Pressing
	Machining
	Subassembly
	Quality assurance-mechanical/chemical/test fire
Initiation High Explosives	Detonators
Mock High Explosives Formulations	Testing
LLNL 1995j.

No significant upgrades to the HE Applications Facility would be required. Larger-scale work at Site 300 is done in parallel with the HE Applications Facility's small-scale process development. Both sites are fully self-contained installations. Site 300's synthesis and formulation complex provides the capability to conduct both remote and contact HE operations in facilities that meet current DOE design levels of environment, safety, and health protection criteria, as well as the current regulatory requirements of applicable Government agencies. LLNL would assume responsibility for providing all HE feedstock, main charge and component procurement, and fabrication as required by the production mission. The products and capabilities for which LLNL would be responsible are shown in table A.3.5.3-1. 

Assumptions. The specific assumptions for the HE fabrication mission at LLNL are as follows: 

• All production operations can be housed within existing buildings with one exception: modifications would be undertaken only when necessary or where it could be shown to be cost-effective. Modifications include moving, adding or subtracting walls, relocating existing equipment, purchasing new equipment and all associated costs. 
• DOE R&D funding for present HE activities would continue at the current level in fiscal year 1995 dollars, adjusted for inflation. This includes mutually dependent R&D missions and interfacing activities. The Work for Others category of activities in energetic materials would remain at least at constant fiscal year 1995 levels and would likely increase. 
• Baseline technologies would be employed except where alternatives could be shown to meet requirements and be more cost effective (i.e., faster, better, and/or cheaper). Technical shortfalls identified in the current baseline technology would be addressed with alternative technology. 
• The LLNL health and safety structure is adequate to support production needs. Additional staff would be added, if required. 
• The LLNL materials management infrastructure could fulfill all material, control, and accountability plus shipping and receiving requirements for the production operation. Additional staff would be added, if required. 
• The LLNL waste management infrastructure is adequate to deal with any new or additional waste streams. Additional staff would be added, if required. 
• LLNL has adequate safeguards and security infrastructure to deal with the production mission. Additional staff would be added, if required. 
• LLNL would not store excessive quantities of conventional HE or insensitive HE. In certain cases, there would be room to expand existing storage capacities by moderate amounts, as necessary, to accommodate production throughput requirements. 
• A separate management structure, capable of implementing the production operation and fulfilling all quality assurance and certification requirements, would be put in place if LLNL is selected for the HE production mission. 
• A site-specific EIS would most likely not be needed to fulfill NEPA requirements for the overall production mission. The need for further NEPA documents would be assessed, as appropriate. 
• The first production unit for new HE production would be October 1, 1998. 
• A 27-month period, commencing July 1, 1996, would be an adequate transition time with the only exception being Pantex D&D overhead costs and safe shutdown costs. 
• Dismantlement schedules would not affect first production unit for HE production. 

Table A.3.5.3-2.-- Lawrence Livermore National Laboratory High Explosives Fabrication Facility Infrastructure

23 buildings (Site 300 and Livermore Site)
66 magazines (200,000 lb limit)
Working space (68,000 ft2)
Waste tanks for all buildings
Backup power for all buildings and equipment
Independent boilers for all buildings
Independent compressors for all buildings
Air exchange cycle rate of 4 per hour per laboratory
Facilities meet all DOE explosives safety requirements
Operations are fully permitted
Open burning for disposal of minimized HE waste permitted
LLNL 1995j.

In addition to the facilities listed in table A.3.5.3-3 that are to be used directly in support of HE fabrication, 11,000 m 2 (119,000 ft 2 ) of other support facilities at Site 300 and at the Livermore Site would be available for support of HE fabrication efforts. There are also 8,600 m 2 (92,935 ft 2 ) of support facilities at Site 300 and at the Livermore Site. The nondestructive evaluation, chemical analysis, or characterization areas that directly support the HE effort are critically important support facilities for other LLNL missions and would remain whether or not HE fabrication is carried out as a LLNL mission. 

Design Safety. The following sections identify important safety considerations incorporated in the design of DOE facilities. Performance goals commensurate with the associated hazard are selected for all structures, systems, and components. The term "hazard" is defined as a source of danger, whether external or internal. Natural phenomena such as earthquakes, extreme winds, tornadoes, and floods are external hazards to structures, systems, and components; whereas, toxic, reactive, explosive, or radioactive materials contained within the facilities are internal hazards. The usage category is established by DOE management. 

Earthquake. All existing HE plant structures at Site 300 meet all current applicable standards. New plant structures, systems, and components, when required, shall be designed for earthquake-generated ground accelerations in accordance with Design and Evaluation Guidelines for DOE Facilities Subjected to Natural Phenomena Hazards (UCRL-15910), with applicable seismic hazard exceedance probabilities of 2x10 -3 for general use (performance category 1), 1x10 -3 for low and moderate hazard (performance categories 2 and 3), and 2x10 -4 for high hazard (performance category 4) structures, systems, and components. 

Wind. All existing HE plant structures at Site 300 meet the wind criteria as discussed below. All new plant structures, systems, and components would be designed for wind or tornado load criteria when required in accordance with UCRL-15910 and the corresponding facility usage and performance goals. Wind loads shall be based on the annual probabilities of exceedance of 2x10 -2 for the general and low hazard (performance category 1 and 2), 1x10 -3 for the moderate hazard (performance category 3), and 1x10 -4 for the high hazard (performance category 4) structures, systems, and components. Wind design criteria is based on annual probability of exceedance, importance factor, missile criteria, and atmospheric pressure change as applicable to each performance (usage) category as specified in UCRL-15910. 

Floods. All HE facilities and buildings at Site 300 are located above the critical flood elevation from the potential flood source (river, dam, levee, and precipitation). The extent of the flood hazard is determined, using the appropriate usage (performance) category for determining the Annual Hazard Probability of Exceedance: 2x10 -3 for general use (performance category 1), 5x10 -4 for important or low hazard (performance category 2), 1x10 -4 for moderate hazard (performance category 3), and 1x10 -5 for high hazard (performance category 4) facilities as defined in UCRL-15910. 

The critical flood elevation is determined by obtaining the appropriate design basics flood level. The design basics flood level is the peak hazard level (flow rate and depth of water) corresponding to the mean Annual Hazard Probability of Exceedance or combinations of flood hazards (river flooding and wind-wave action), and corresponding loads associated with peak hazard level and applicable load combinations (hydrostatic and/or hydrodynamic forces and debris loads). LLNL site drainage conforms to the governing local agency regulations. The minimum design level for the stormwater management system is the 25-year 6-hour storm, but potential effects of larger storms up to the 100-year 6-hour storm are also considered. 

Fire Protection. The fire protection features for the existing plant and its associated support buildings are in accordance with DOE orders and the National Fire Protection Association Fire Codes and Standards. A fire hazards analysis would be performed to assess the risk from fire to the HE Fabrication Facility within the individual fire areas of the facility. All fire sprinkler water that has been discharged during and after a fire would be contained, monitored, sampled and, if required, retained until it could be disposed. 

Safety Class Instrumentation and Control. The safety classification of instrumentation and controls is derived from the safety functions each performs. This safety classification is based on appropriate DOE orders. HE facilities at Site 300 that utilize instrumentation for explosives operations currently meet safety class requirements. 

Ventilation. The heating ventilation and air conditioning system provides environmental conditions for the health and comfort of personnel and for equipment protection. 

Internal Explosion. New and existing buildings are designed for the effects of accidental explosions within a bay or cell. The design is in accordance with DOE/EV/06194, including the quantity-distance and the level-of-protection criteria for each class of explosives activities. Additional resource documents for the siting and design of explosives facilities listed in the above-referenced manual are utilized to provide a safe design where applicable. 

Safeguards and Security System Description. Site 300 is surrounded by multiple fences for security. Although not indicated on the plot plan, there are two security access areas within which various components of the HE Fabrication Facility are located: the limited area and the property protection area. The property protection area surrounds the limited area. Main-charge pressing, machining, and inspection; HE and conventional explosives shipping and receiving; and explosives storage would be performed within a limited area. Synthesis and formulation and test firing would also be performed within a limited area. Most other support facilities would be in a property protection area. All security access areas meet DOE safeguards and securities standards for the proscribed activities associated with HE main-charge fabrication and associated activities for nuclear weapons applications. 

Table A.3.5.3-3.-- Lawrence Livermore National Laboratory High Explosives Fabrication 
Facility Data

Facility Function	Building 13	Construction Type	Footprint (m2)	Number of Levels	Special Materials	Access  Area
Main Charge Fabrication						LA
Pressing		Concrete		1	HE
Machining	817		300
	806		600
	809		150
Subassembly
Physical prop	810		500
	HEAF		66
Small High Explosives Components	HEAF	Concrete	30	1	HE	LA
	826		160
Main Charge Test Fire	851	Concrete	1,000	1	HE	LA
High Explosives Formulation and Synthesis	826		160			LA
	827A		155
	827C		168
	827D		168
	827E		168
Conventional High Explosives Storage	New	Concrete	116	1	HE	LA
Explosives Storage	854J	Concrete	500	1	HE	LA
Explosives Shipping, Receiving, and Inspection	805	Concrete	636	1	HE	LA
High Explosives Test Firing and Characterization	HEAF	Concrete	28	2	HE	LA
	222		28	1	non-HE	LA
	235		28	2	non-HE	LA
	241		9	2	non-HE	PPA
Nondestructive Evaluation	823	Steel	255	1	HE	LA
Metrology	806  (room 105)	Concrete	90	1	HE	LA

Table A.3.5.3-4.-- Lawrence Livermore National Laboratory Support Facilities Description

Facility Name	Building	Construction Type	Footprint (m2)	Number of Levels	Special Materials	Access Area
Central shipping and receiving warehouse	875	Steel	1,380	2	None	PPA
Effluent monitoring/ meteorological tower						PPA
Facility maintenance shops	873	Steel	1,400	2	None	PPA
Vehicle maintenance facility	879	Steel	255	1	None	PPA
Fire station and security	870 and 882	Steel	557	1	None	PPA/LA
Medical center	877	Steel	310	1	None	PPA
Administration	871	Steel	930	1	None	PPA
Change house/laundry	813	Steel	262	1	None	PPA
Cafeteria	880	Steel	218	1	None	PPA
ES&H lab	222					LA
Helicopter pad						PPA
Storage yard			1,860			PPA
Parking						PPA
LA - limited area; PPA - property protection area. LLNL 1995j.

Table A.3.5.3-5.-- Lawrence Livermore National Laboratory Support Function
Facilities Description

Facility Name	Building	Construction Type	Footprint (m2)	Special Materials	Access  Area
Plant Utilities
Utility building	All located  in General Services  Area	Steel	670	None	PPA
Water storage tanks			76		PPA
Raw water supply			186		PPA
Plant water treatment			427		PPA
Tower cooling water facility			560		PPA
Firewater storage tank and pumphouse			370		PPA
Switchyard			186		PPA
Emergency generator		Steel	130	None	PPA
Diesel fuel storage			93		PPA
Nitrogen tanks			200		PPA
Waste Management		Concrete		HE
Explosives waste management, handling, storage, and treatment	816, M1 through M5		96		PPA
			129
			827
Sanitary wastewater treatment	845		4,645	non-HE	PPA
PPA - property protection area. LLNL 1995j.

Overall Facility Layouts and Design Descriptions. The HE fabrication facilities are described in tables A.3.5.3-3, A.3.5.3-4, and A.3.5.3-5, which summarize facility data for buildings and support areas including the structure footprint area, construction material, and the security area. Structures containing explosives are generally constructed from steel-reinforced concrete and are designed to mitigate the efforts of a potential accidental explosion. Although insensitive HE materials can generally be processed in conventional steel structures, concrete construction is typically used in current facilities to maintain the flexibility to process conventional explosives. The resulting facility design typically consists of a number of separate operating bays that could vent to an unoccupied area should a detonation occur. This is true for existing buildings which meet current and anticipated explosives safety requirements. Structures that do not require concrete construction due to the presence of HE are generally constructed of steel, although portions of these buildings may be concrete. One-half of Building 875 would be used for inert storage for this mission. 

High Explosives Main-Charge Manufacturing. These buildings compose the facility that fabricates main-charge hemispheres, mock main-charge hemispheres, and explosive test specimens. The various functional areas are described below: 

Isostatic Pressing. Rough pressings for HE main-charge hemispheres and material test billets would be fabricated in Buildings 817A, B, C, D, E, and F, which are moderate hazard (performance category 2) facilities. 

Explosives Machining. The rough pressings are machined into hemispherical shapes or test elements in Buildings 806 and 809. 

High Explosives Main-Charge Subassembly. The explosive hemisphere assembly would be done in Buildings 810A and 810B. 

High Explosives Shipping and Receiving. Building 805 is designed to ship, receive, and inspect HE bulk and parts (both conventional and insensitive HE). 

High Explosives Storage. Building 854J comprises 378 m 2 (4,068 ft 2 ) and has more than adequate space available for bulk and parts storage and staging. 

Conventional High Explosives Storage. A facility would be constructed at the HE storage area near M30 and M34. This 116-m 2 (1,250-ft 2 ) facility would have a 11,350-kg (25,000-lb) conventional HE bulk and parts storage and staging capacity. 

Small High Explosives Component Fabrication. This activity fabricates small HE weapon components and test assemblies. Various small components are fabricated from HE powders and binders, metal or plastic components, electrical components, hardware, and assembly materials. The fabrication process requires equipment for explosive powder heating, pellet pressing, laser welding, ultrasonic cleaning, extrusion loading, density testing, and mechanical assembly. Functions are described below. 

Pellet Pressing. Small pellets are pressed to density specifications for small energetic component assemblies in Building 191 (HE Applications Facility). 

Extrusion Loading. Extrudable (paste) explosive is loaded onto small fixtures for small component assemblies in Building 826. 

Small Component Assembly. Small HE pellets and/or fixtures containing extrudable paste explosive are assembled with inert parts to make small components in Building 810A. 

High Explosives Formulation and Synthesis. This activity has the capability to produce a variety of explosive materials from chemical reactants and commercially produced explosives. 

High Explosives Formulation. For purposes of this analysis, material lots up to about 90 kg (200 lb) are assumed to be produced through a series of batch operations in Buildings 826 and 827C, D, and E. Some products are used to make small HE weapon components while other products support the development of new explosives or explosives fabrication processes. 

High Explosives Synthesis. Buildings 827C, D, and E contain a variety of vessels, filters, and transfer pumps which are used to synthesize, recrystallize, blend, and wash explosive powders. The facility also includes bays for mixing/milling, particle-size reduction, drying/weighing/packaging, solvent storage, and refrigerated storage for explosives and chemicals. 

High Explosives Testing and Characterization. Explosives test configurations are assembled and detonated. The test data characterizes the explosives performance and are required for the qualification of raw materials and production lots. Testing requires explosives containment chambers and an array of special instrumentation, including streak cameras, rotating mirror framing cameras, an air image converter system, oscilloscopes and digitizers, flash x-ray systems, and velocity interferometers. 

High Explosives Test Firing. Energetic materials components are test fired at the HE Applications Facility, Building 191, at the Livermore Site. This facility has a considerable gas gun capability with 10-kg (22-lb) (trinitrotoluene [TNT]-equivalent) rated contained-firing tank. This facility has a total of six contained firing chambers which range in HE capacity from a few grams to 10 kg (22 lb) (TNT-equivalent). 

The remote firing facility, Building 851 at Site 300, is remotely located from HE fabrication operations and includes an outdoor firing capability to conduct large-scale explosives tests that cannot be performed in a test chamber, such as main charges for explosives lot certification. 

Nondestructive Evaluation. Building 823 is an area where explosive and inert components are inspected with radiography equipment to detect flaws, cracks, and voids. 

Mechanical Properties Testing. The mechanical properties of explosive components and materials are tested in Building 191 (Livermore Site) to support lot certification for materials and components and to support fabrication development. The test configurations are assembled, and tensile and compressive tests are conducted. 

Analytical and Materials Characterization Laboratories. Chemical analyses are performed on explosive and nonexplosive materials in Buildings 191, 222, 235, and 241 (Livermore Site) to determine or verify their characteristics. The data obtained yield valuable information about the condition and composition of the material. The methods used include gas chromatography, liquid chromatography, size exclusion chromatography, infrared spectroscopy (Building 222), particle characterization (Building 241), atomic spectroscopy, emission spectroscopy (Building 235), and thermal analysis (Building 191). 

Material Compatibility Testing. Test coupons are assembled such that the subject materials are in direct contact with each other in Building 810A. These coupons are then placed in environmental ovens to accelerate the aging process. Gas samples are periodically taken from the coupon containers and analyzed. Compatibility testing is required to certify new materials for weapon use. 

Process Support Systems. Process support for the HE fabrication operation includes a machine shop and ES&H laboratory, as well as other plant general services facilities. These facilities directly support the HE fabrication mission, as well as existing, ongoing missions such as RD&T and other activities at LLNL. 

Resource Requirements During Construction. All HE fabrication operations can be housed within existing buildings except for the conventional HE storage building. This building would have 11,350 kg (25,000 lb) conventional HE bulk and parts storage capacity and a 116 m2 (1,250 ft2) staging capacity. The total construction requirements for materials and utilities are shown in table A.3.5.3-6. Peak construction year emissions and construction worker requirements are shown in tables A.3.5.3-7 and A.3.5.3-8, respectively. 

Table A.3.5.3-6.-- Lawrence Livermore National Laboratory High Explosives Fabrication Construction Materials/Resources Requirements

Material/Resource	Total Consumption 14	Peak Demand
Electricity (MWe)	15MWh	0.2 MWe
Water (L)	1,230,000
Concrete (m3)	190
Steel (t)	15
Liquid fuel,  and lube oil (L)	9,500
Industrial gases 15 (m3)	3

Table A.3.5.3-7.-- Lawrence Livermore National Laboratory High Explosives Fabrication Construction Emissions

Pollutant	Quantity (kg)
Carbon monoxide	7.3
Oxides of nitrogen	2.7
Particulate matter	0.9
Sulfur dioxide	0.23
Volatile organic compounds	1.4
LLNL 1995i:3; LLNL 1995j.

Table A.3.5.3-8.-- Lawrence Livermore National Laboratory High Explosives Fabrication Construction Workers

Employees	Year 1
Craftworkers
Carpenter	3
Concrete mason	1
Electrician	1
Iron worker	1
Laborer	1
Millwright	1
Operator	1
Other craftworkers	1
Pipe fitter	1
Sheet metal worker	1
Sprinkler fitter	1
Teamster	1
Construction management and support staff	5
Total Employment	19
LLNL 1995i:3; LLNL 1995j.

Table A.3.5.3-9.-- Lawrence Livermore National Laboratory High Explosives Fabrication Surge Operation Annual 
Utility Requirements

Utility	Consumption	Peak Demand 16
Electricity	4,300 MWh	1 MWe
Liquid fuel (L)	53,100
Natural gas 17 (m3 )	None
Water (L)	58,200,000

Table A.3.5.3-10.-- Lawrence Livermore National Laboratory High Explosives Fabrication Surge Operation Workers

Labor Category	Number of Employees
Direct workers	52.5
Direct support workers	42
Operations support workers	17
Facilities support workers	8.9
Indirect support workers	112
Total	232 18

Resource Requirements During -High Explosive Fabrication Mission. Table A.3.5.3-3 lists all the required facilities for HE fabrication operations at LLNL and the footprint or area on the ground required for each facility. Requirements to operate the LLNL HE fabrication facilities are shown in tables A.3.5.3-9, A.3.5.3-10, and A.3.5.3-11. The HE Fabrication Facility is located on approximately 2,800 ha (7,000 acres) of land at Site 300. The additional utilities and fuel required for conducting the HE fabrication mission at LLNL are shown in table A.3.5.3-9. 

The facility operations required to meet the HE fabrication mission at LLNL are based on a single shift per day, 50 weeks per year, 40 hours per week, for 250 days of operational time annually. Maintenance time and scheduling for manufacturing operations would be based on equipment and facility-specific requirements and, as such, routine maintenance would be performed as needed and scheduled such that there is minimal impact to operation schedules by correlating equipment maintenance with maintenance schedules for plant activities. 

The number of workers required at LLNL to accomplish the HE fabrication mission at LLNL are shown in table A.3.5.3-10. 

Chemicals Consumed During Operations. The chemicals consumed during all HE fabrication operations at LLNL are shown in table A.3.5.3-11. The HE fabrication operations do not require radiological materials and no workers would be exposed to radiation under normal operations. 

Emissions During Operations. The additional emissions that would result from accomplishing the HE fabrication mission are shown in table A.3.5.3-12. 

Table A.3.5.3-11.-- Lawrence Livermore National Laboratory High Explosives Fabrication Surge Operation Annual Chemical Requirements

Chemical	Quantity  (kg)	Chemical	Quantity  (kg)
Acetone	227	Helium	45
Acetonitrile	91	Heptane	45
Activated charcoal	45	Hydraulic/lubricating oil	908
Adiprene polyurethane composition	45	Hydrochloric acid	68
Aluminum metal	454	Joint compound	45
Ammonia	454	Kimwipes	908
Aqueous film forming foam	91	Micro liquid lab cleaner	5
Circlene Fg 20	91	Mild steel metal	454
CLEPOX 143	91	Molecular sieve	45
Copper/CuO wire	9	Neutrasorb acid neutralizer	45
Copper metal	23	Nitrogen	227
Cyanuric acid	45	Paint	454
Degreaser	5	PLANISOL-M concentrate	23
Desiccants	91	Polyalkylene and ethylene glycol	14
Dispersant	23	Potassium hydroxide	45
Dry air	136	Silicone elastomer	91
DUST-OFF	23	Siliconized ammonium phosphate base	5
ECO-STAR	23	Sodium hydroxide	45
Electrode/probe solutions	23	Solksorb solvent absorbent	227
Ethyl alcohol	91	Sulfuric acid	23
Ethyl acetate	136	TALC	5
Fixer and replenisher	91	Tetrahydrofuran	227
Glass cleaner	45	TISAB with CDTA	14
Glass beads	145	Toluene	227
Glycerine	68	Toner	23
HE powders, insensitive	54,432	Trichlorotrinitobenzene	23
HE powders, conventional	18,144	Water treating chemicals	91
LLNL 1995i:3; LLNL 1995j.

Waste Management. The liquid and solid waste streams generated by the HE fabrication mission would be processed to meet Federal, state, and DOE requirements for the various types of nonhazardous, hazardous, and radioactive wastes. Waste management facilities and assets would be used to receive, track, characterize, treat, package, store, and ship wastes generated by HE fabrication. Facilities would include a waste management operation, waste storage facility, sanitary wastewater treatment unit, and a sanitary and industrial landfill. 

Nonhazardous waste generated at the HE Fabrication Facility would consist primarily of solid sanitary waste, sludge from sanitary wastewater treatment, maintenance residues, and scrap parts. Materials unsuitable for recycling would be disposed of appropriately. Liquid sanitary wastes would be collected by independent underground septic tanks at HE fabrication buildings and by sewer pipe systems from most of the support buildings in the General Services Administration area and routed to the domestic sewage lagoon for evaporation and percolation. Excess water would be discharged to a natural drainage channel. Sewage sludge would be disposed of in offsite sanitary and industrial landfills. Process wastewater would be sent to holding tanks for treatment and recycling, where appropriate. Stormwater from all areas of Site 300 would go into natural drainage channels. Nonhazardous rinsewater from HE formulation and machining operations is discharged to a surface impoundment for evaporation. 

Table A.3.5.3-12.-- Lawrence Livermore National Laboratory Incremental Annual Emissions During Operations

Pollutant	Quantity  (kg)
Criteria Pollutant
Carbon monoxide	1,315
Nitrogen oxides	349
Ozone (as VOC)	45
Particulate matter	27
Sulfur dioxide	24
Hazardous and Other  Toxic Compounds
Ammonia	4.5
Acetonitrile	14
Bisphenol alpha epichlorohydrin	0.5
Benzene	0.2
Chloroform	0.5
Cresylic acid	0
Cyclohexane	0.5
Dibutyl phthalate	0.05
1,2-Dichloroethane	0.9
Dimethyl formamide	0.5
Dioxane	0.5
Ferric ferrocyanide	0
Hexane	0.5
Hydrogen chloride	11.3
Hydrogen fluoride	22.7
Hydrogen sulfide	0.2
Mercury	0
Methanol	4.5
Methyl ethyl ketone	22.7
n-Butyl glycidyl ether	0.2
Propylglycol methyl ether	0.5
Toluene	2.3
Trichloroethylene	0.2
Triethylamine	0.2
2,2,4-Trimethyl-1, 3-pentane-diol isobutyrate	0.5
Xylene	2.3
LLNL 1995i:3; LLNL 1995j.

Hazardous wastes generated by the HE fabrication mission would consist of solid residue from thermal treatment (open burning) of scrap explosives and explosives-contaminated combustible materials. This residue and other hazardous wastes, such as waste oils and paint residues, would be properly packaged and managed for offsite treatment and disposal at RCRA-permitted facilities. 

HE residual materials such as bulk HE machining scrap and off-specification HE components and HE-contaminated materials, including gloves, wipes, rags, and process water generated during HE fabrication operations, would be the source of most of the waste material that would be processed. Waste minimization and recycle processes would be used to reduce the amounts of material that ultimately must be subjected to waste treatment processes. Scrap HE and HE-contaminated process water that are recycled are not considered waste and would be handled as in plant operations. 

Currently, thermal treatment of HE and HE-contaminated materials (open air burning) is the preferred permitted technique used to dispose of and decontaminate solid materials. Next generation, more environmentally benign destruction technologies are being developed and would be incorporated when available and appropriate. 

HE-contaminated process water generated by synthesis and formulation processes, and vacuum pump seal water would be collected in tanks and analyzed for appropriate waste classification and then disposed of as appropriate. Water from HE machine processes would be filtered through a weir and clarifier system and then discharged to holding ponds. Sanitary wastewater would be collected in a separate system and routed to septic tanks or sanitary wastewater treatment facilities. Stormwater would go into natural drainage channels at Site 300. 

The utilities required for operation of waste treatment functions associated with the HE fabrication processes would include water, electric power, liquid fuels, steam, compressed air, and propane gas. These utilities are also used in normal HE plant operations and would not pose any significant increase in consumption nor any unique requirements. 

The wastes and emissions generated during HE fabrication waste treatment operations would include gaseous decomposition products of combustible materials, hazardous solid waste, and nonhazardous solid and liquid wastes. Hazardous wastes consisting of solid residue (ash) from the thermal treatment process would be characterized, packaged, and sent to an approved RCRA-permitted disposal site. Nonhazardous wastes generated by HE fabrication would consist of solid sanitary waste, sludge from sanitary wastewater treatment, and other noncombustible parts. Materials that cannot be recycled would be sent to an approved landfill. 

All operations involving HE must comply with DOE/EV.106194 and meet explosives safety requirements. Buildings must meet blast-resistant building construction standards and quantity-distance criteria. A capability for remote operations would also be necessary for disposal processes. The design would incorporate spill-prevention control and countermeasure elements. 

The Livermore Site and Site 300 waste management facilities to support the HE fabrication mission include: 

• The waste management facility, which provides space and equipment for receiving, tracking, packaging/repackaging, and shipping of solid and liquid wastes. Areas are segregated by waste type. Operating areas are provided for waste staging and container storage. 
• The waste storage facility, which stores hazardous waste for up to 1 year of operation prior to offsite treatment/disposal. An explosive waste storage facility is currently being constructed and permitted to manage explosive wastes. Storage and staging areas are segregated by waste type. Equipment and design features are provided for handling drums, controlling spills, and monitoring. 
• The open burn facility, which treats scrap explosives and explosive-contaminated combustible material. Plans and permits are being pursued for a new open burn and open detonation facility to treat high explosives. 
• The Livermore Site, which has the ability to handle and store mixed and LLW wastes, and the HE Fabrication Facility would have the ability to handle these types of wastes if required. 
• The HE fabrication facilities, all of which have a septic tank system. Industrial wastewater would be placed in holding tanks for chemical analysis to determine proper disposal method. Nonhazardous HE rinsewater is disposed of onsite in a permitted surface impoundment. Other liquid industrial wastes are shipped offsite for disposal. 

Table A.3.5.3-13 lists the incremental quantities of the types of wastes that would be generated at LLNL to accomplish the HE fabrication mission. 

Transportation. Transportation requirements exist at both the Livermore Site and Site 300 (intrasite) and between the HE Fabrication Facility and the A/D site (intersite). 

Intrasite Transportation. Transportation of products within the HE Fabrication Facility would be performed by LLNL transportation, meeting all applicable DOT and DOE criteria for transportation of the energetic materials. Transportation of classified products within the HE Fabrication Facility would be performed by LLNL transportation which meets DOE safeguards and security criteria for transporting classified products. Subsequent movements of HE and explosive products would be performed by vehicles specifically designed for this purpose. The quantity of HE (conventional and insensitive) transported onsite by these trucks would be strictly limited. HE products would be transported by appropriate vehicle to an HE staging area for eventual recycle or disposal onsite. HE waste would be collected, transported, and disposed of, as appropriate, for explosives materials. 

Intersite Transportation. Transportation of the products from the HE Fabrication Facility would be performed by commercial vendors that meet all applicable DOT and DOE criteria for transportation of the specified materials. Transportation of classified products from the HE Fabrication Facility to the A/D plant would be performed by commercial vendors that meet DOE safeguards and security criteria for transporting these classified products, as well as DOT requirements for safe packaging and shipping of HE products. Other inert or ancillary materials that would require transportation would also be transported by qualified commercial vendors. 

Table A.3.5.3-13.-- Lawrence Livermore National Laboratory High Explosives Fabrication 
Waste Volumes

Category	Annual Average Volume Generated from Construction (m3)	Annual Volume Generated from  Surge Operations (m3)	Annual Volume  Effluent from Surge Operations (m3)
Low-Level
Liquid	None	None	None
Solid	None	Minimal	Minimal
Mixed Low-Level
Liquid	None	None	None
Solid	None	None	None
Hazardous
Liquid	1	3	3
Solid	2	54	54
Nonhazardous (Sanitary)
Liquid	454	7,270	7,250 19
Solid	11	69	55 20
Nonhazardous (Other)
Liquid	946	568	566
Solid	8 21	36	20

PX 1995a:6; PX DOE 1995e. 

PX 1995a:5; PX 1995a:6; PX DOE 1995e. 

PX 1995a:5; PX 1995a:6; PX DOE 1995e. 

LANL 1995b:4; LANL 1995d. 

LANL 1995b:3; LANL 1995b:4; LANL 1995d. 

LA - limited area; PPA - property protection area.

LLNL 1995j. 

LLNL 1995i:3; LLNL 1995j.