Base Camp
Challenges in
Afghanistan
Talking Trash to Implement Green Changes
while completing the mission
AND
saving lives, money, resources
LTC Robert Tucker, Ph.D.
8-Apr-15
1
Agenda
 Engineer Responsibilities in Theater
 Base Camp Challenges in Afghanistan







8-Apr-15
Components of typical Army trash
Systems approach to waste management
Possible solutions to complex problems
Foaming issues
Water cycles and use
Cultural Heritage and Protected Items
Land farming
2
Basic Axioms of Engineering
• As capable engineers you know that:
– water runs down hill
– engineering decisions are best left to engineers and
not combat arms officers
– the mission of combat engineers is to break things or
in a pinch, build latrines and combat trails
– construction engineers build things and fix up
what combat engineers broke
– mud is an engineer's most persistent foe; but, when
properly harnessed is your best ally in defense
• At some point in the near future you will be heading to a base camp
in a third world country and will be expected to know ALL things
engineering
• Environmental stewardship and mission completion are
not mutually exclusive
8-Apr-15
3
Landpower and the Engineer
• Landpower is the ability-by threat, force, or occupation to promptly gain, sustain, and exploit control over land,
resources, and people. FM 1
• … you may fly over a land forever, you may bomb it, atomize
it, pulverize it and wipe it clear of life - but if you desire to
defend it, protect it, and keep it for civilization, you must
do this on the ground, the way the Roman legions did,
by putting your young men into the mud. T.R. Fehrenbach FM 1 pg 1-1
• Getting the youth of America's Armed Forces out of the
mud is a priority mission for the engineer's. R.E. Tucker
• Getting land forces, air forces and naval forces across the
next obstacle and their capabilities into the close and deep
fight is an engineer's priority mission. R.E. Tucker
• Planning, constructing, and management of base camp
infrastructure is an engineer's priority mission. R.E. Tucker
8-Apr-15
4
Environmental Missions
• Four main functions
–
–
–
–
–
Solid waste management
Liquid waste management
Cultural Heritage Protection
Endangered Species Protection
(Energy systems)
• Relooking theater wide programs
– Assisting with master planning at all levels
– Assisting with energy proposals (waste to fuels,
methane production)
– Innovative solutions, reuse programs, trading waste
for products and/or services
Waste Management Systems
• No Waste Segregation
– Burning then burying - worst option
– Managed Landfill - not viable
• With Waste Segregation
– Composting of organics
– Recycle materials (e.g., metals, wood)
– Incineration of organics
– Hydrolyses of all waste
fluff $$
– Pyrolysis of plastics/tires
fuel
8-Apr-15
6
Graphical Representation of End of Mission
cost in dollars
Clean up cost spike due to
lawful compliance requirements
often resulting from poor and/or
uninformed operating practices
during mission execution.
It is sometimes unfortunate
when the clean up spike
is larger than the initial
cost of a cleaner system.
savings
high initial investment
with low recurring costs
break even
point
low upfront costs but
linear increase with
time
x = b2 - b1
m1 - m2
b is Y intercept
m is slope
time (in months)
8-Apr-15
7
Components of Solid Waste
From a study conducted in Bosnia in June 03
component
•
•
•
•
•
•
•
•
•
8-Apr-15
Plastic bottles
other plastics
cardboard
other paper
food waste
glass
cans (Al & steel)
textiles, PS, misc
wood
percentage
24%
11%
28%
14%
4%
3%
2%
3%
weight, kg/day
1100
533
1300
667
188
148
78
149
15,000
recycle
compostable
reduce or dump
recycle
reduce or dump
reuse or
compost
8
Pros and Cons - Burning
• Pros –
–
–
–
–
very easy to begin, cheep to operate
good volume reduction
generally done outside the wire
simple to operate burn pits and covering
• Cons –
– produces toxic smokes, many components are
carcinogens
– probable ground water and ground contamination
– requires a lot of land
– Force Protection issues with soldiers or TCNs going
outside the wire
– always causes conflict with local populace
– undoubtedly will have a very high remediation cost at
end of mission due to high concentrations of metals and
possible ground water contamination
8-Apr-15
9
A Typical Burning Operation
8-Apr-15
10
An Incinerator Operation
in Iraq - 2005
incinerator
metals and bottles
must be removed
from feed stock
8-Apr-15
sorting is done by
hand after a truck
dumps its load on a
concrete pad, with
no over head cover
11
Need for System Approach
ash pile
stock pile of cans
and glass
DAH lessons here?
8-Apr-15
12
This is not an incinerator
 Air Curtain Destructor
used in the Balkans and
other CONOPS
 Not designed for
anything but wood and
paper, NOT wet garbage
or plastics
8-Apr-15
13
Afghanistan Solid Waste Management
• Initiating new processes to reduce, reuse,
recycle, remove, rebuy
• MILCON projects added waste treatment
yards, water treatment facility
–
–
–
–
–
–
–
Composting
Land farming (savings of ~$4 mil this year)
Recycling theater wide (DTM, Balad)
Oil Cat to recycle oil in tactical vehicles
Used oil for gravel swap at BAF (>$4 mil savings)
Shredded paper into fuel donuts - new project
Plastics and aluminum into products
• Incinerators
• Switching from paper to dishes
Example of Costs at BAF 09
Product
Used oil
waste fuel
rags, filters
contam soil
lithium bat
drums
2736
1676
1984
156
203
cost
$ 2.05 m
$ 1.26 m
$ 1.49 m
$ 0.117 m
$ 0.152 m
In 2010, we saved >$4m by land farming
PCS and pooh pond sludge from KAF
Solid Waste Facility
solid waste in
aluminum cans &
water bottles
sort
facility
compacting
markets
incinerate
small amounts
of trash
ash
Components
composting
land farming
agriculture
land fill
Processes
composting
HAZMAT yard
with minimal effort,
nearly all solid waste
will find a “home” and
not have to be burned
wood, paper,
cardboard,
metals, batteries,
covered waste,
tires, textiles,
other plastics
markets
markets,
proper disposal
4/8/2015
16
Recycling Facility Resource Areas
•
•
•
•
•
•
•
•
HAZMAT Yard
Incineration Area or (burn pit)
Sort Area
Administration Area and Scales
Power Generation Area
Compacting Area
Storage Bins
Composting area
MINIMUM Recycling Facility Resource
Areas for Large Bases
•
HAZMAT Yard
– 200 ft x 300 ft =
•
60000 sq ft
Incineration Area or (burn pit)
– 300 ft x 300 ft =
•
90000 sq ft
Sort Area
– 150 ft x 150 ft =
•
22500 sq ft
Administration Area and Scales
– Minimum 70 ft x 70 ft =
•
4900 sq ft
Power Generation Area
– 100 ft x 100 ft =
•
10000 sq ft
Compacting Area
– 200 ft x 450 ft =
•
90000 sq ft
Storage Bins
– 100 ft x 200 ft =
•
20000 sq ft
Composting Area
– 300 ft x 300 ft =
90000 sq ft
Total
387400 sq ft = 8.9 acres
round up to 9 acres and/or 3.7 hectares
MINIMUM Recycling Facility for Bn level
(below 4000 Pax?), area collection and transit site
• HAZMAT Yard
– Bn 2000 Pax
100 x 100 =
10000 sq ft
• Incineration Area or (burn pit)
– 200 x 200 =
40000 sq ft
• Sort Area
– 150 ft x 150 ft =
22500 sq ft
• Administration Area
– 70 ft x 70 ft =
4900 sq ft
• Power Generation Area
– 100 ft x 100 ft =
10000 sq ft MAYBE
• Compacting Area
– 100 ft x 100 ft =
10000 sq ft MAYBE
• Storage Bins
–
100 ft x 100 ft =
Total
10000 sq ft
107400 sq ft = 2.5 acres
= 1.0 hectare
Liquid Waste Management
• Goal is to reduce the “pump and dump” or
pixie dust treatment syndrome with proper
waste treatment facilities
– Lagoons on partnered bases
– US bases, use package plants on small FOBs
and package/lagoons on larger bases
• Focus on using water as many times as possible
– Purple pipe systems
– Limit RO systems for general use due to cost
and waste generated
Integrated Water System
disinfection
source
potable water
water bottling
plant
end user
solid
waste
stream
non-potable
water
DFAC
laundry
gray water
cleaned
purple pipe
loop
showers &
sinks
cooking
washing dishes
sludge to:
composting
land farming
agriculture
waste
treatment
stools
lagoons
effluent,
agriculture
multiple reuse
options
4/8/2015
21
Washing vrs Paper ware
• BAF/KAF size base, ~25,000 PAX
– $21,000/day for paper and plastic products
or a cost of $7.6 million/yr
– generates ~7,300 lbs of solid waste/day or
2.7 mil/yr
– assume a fully burdened cost factor or 4 the
cost soars to $30 mil/yr
• Payback period for changing to washing
dishes (includes cost of buying all
materials for a kitchen) is 45 to 50 days!
8-Apr-15
22
Foaming Tents
Energy Conservation
Full Life Cycle Management
Requirements
Life Cycle Costs of Foaming a Tent
• Loss of mobility of tent to Army
• Loss of ~$10,000 for tent
– without considering fully burdened cost to get
tent into theater
•
•
•
•
Cost of foaming (~$7/sq ft), ~$10,500/tent
Cost of burial (~500 cu ft/tent) ~$10,000
Replacement cost of new tent ~$10,000
Replacement of ECU to smaller size ~$5,000
• Life cycle investment cost is over $45,000
4/8/2015
24
Potential Savings by Foaming
• Fuel savings by having ECU run less
–
–
–
–
30 Kw generator at 60% capacity use ~2.3 gal/hr
Same generator at 40% capacity uses about ~1.8 gal/hr
ASSUME 0.3 gal/hr fuel savings (due to excessive cycling)
0.3 gal/hr x 24 hr = 7.2 gal/day (use 8 gal/day)
• Assume retail value of fuel at $3/gal = $24/d
– $45,000/$24 = 1875 days (5.1 years) for payback
• Assume retail value of fuel at $5/gal = $40/d
– $45,000/$40 = 1125 days (3.1 years) for payback
• Assume a fully burdened cost factor of 10 or $30/gal
provides a savings of $240/d
• ~ 50% of the tents are showing significant cracking in
less than 360 days and may need to be replaced
4/8/2015
25
Distracters
• FOBs are reporting that foamed tents have mold
and/or fungus growing between the foam and tent
(due to high humidity and organic substrates in
tent because they no longer breathe)
• Foam will release significant toxic gases if there
is a fire (HF in most foams used in theater)
• Current ECUs are over sized for the tent space
and should be resized to about 2 ton (capital
investment required)
• Current environmental mono-fill burial policy in
place; but, most FOBs do not have the space for
burial – we end up hauling foam around theater
(could negate the fuel savings during operations)
4/8/2015
26
Analysis of one tent block
• One tent block near the XXXX Red Horse
team tent was examined for wear
• The foam on the tents is about a year old
• 21 of the 27 tents showed cracks, some
damage was significant with small chunks
of foam missing and or broken away from
the tent and two were evidently leaking
• Patched foam was not coated and during
the rain, acted like a sponge for water
• Inside of the tent was not checked for mold
4/8/2015
27
Foamed Tent Block
X
X
X
9 X
5
9
4
X
9
3
30 Kw generator
supports two ECUs
X
X
X
X
8
8
X
X8 X
3 X
X
X
X
X
X
X7
X8 X
X X
Foamed tent
no cracks
X
X
X
X
X
X
X7
X2
X6
X
X6
X
X
X6
X0
X
Foamed tent
78% have cracks
X
X
X
X
X
5
4
5 X foam repair
1
Each tent has an ECU
X indicates crack(s) in foam. Each tent has four segments, x indicates
approximate location of cracks
4/8/2015
28
Pictures of Cracking, Tent 83
4/8/2015
29
FOB Shank Tent 76
Picture a
Picture b
4/8/2015
30
FOB Shank close ups
Picture B, close up. Shows one
of the few spots where repair of a
crack was done with what
appears to be the water repellant
coating
Picture A, close up. Shows some of the most
extensive cracking of foam within one tent
section from the tents examined in this block.
4/8/2015
31
Soldier Repair Kit
4/8/2015
32
Tent Foaming Detractors
• Fuel saving – depends on following factors:
– need to reduce size of HVAC. Otherwise the same current load
capability is required, thus the generator will run at a lower
efficiency
– works best with centralized power grid
• Foam used must not degas toxic or harmful compounds
• Correct sealant(s) must be used
• Install thermostats to regulate temperature and moderate
expectations on temperature inside a tent (65-68 winter
and 80-85 in summer), use fans to move air
• Correct for energy used to dehumidify structure to
prevent mold and other health effects
• Determine Full Life Cycle cost in analysis
– examine full disposal cost of foam and tent
– cost of replacing the tent to inventory
Alternatives to Foaming
• Build wooden structures correctly with
insulation or retrofit with insulation
• Use PV sunshades over tents to provide
convenience electricity (e.g., computers,
iPods)
• Add winterization kits to tents
• Use fans and tent flaps to mediate
temperature
• Set reasonable temperature expectations
Greenish Energy Alternatives
•
•
•
•
Conservation
Solar potential – cost and expectations
Methane from sewage and DFAC waste
Add generators to exercise equipment to
add power to grid
• Wind potential (minimal)
• Limit transportation of “stuff” into theater
Cultural Heritage Projects
• Support to the National Museum
– Renovations to existing building
– Support for new wing addition
• Support to the Antiquities Institute
– Construction of prefab storage and sorting
facilities at Mes Aynak and other active digs
– Construction of restoration and storage
facilities in Kabul
Requirements For National Museum
• Need technical support from Corps to:
–
–
–
–
–
assist in design of proposed new wing
assist with renovation planning
design security system for museum artifacts
design system to utilize PV and solar panels
assist in training university students
• Interface with international community to
identify sites for Regional or Provincial
Museums
• Design and construct Provincial Museums
Requirements for the Archeological Institute
• Need technical support from Corps to:
– assist in design of proposed new storage facility
– assist in design of proposed new artifact
restoration facility, incorporating natural light, PV,
and solar panels, identify equipment needs
– design security system for artifacts
– assist in design of storage facility and artifact
preparation facility on Mes Aynak and other sites
– assist in training university students
– assist in field work as security permits
Cultural Sites are Everywhere
8-Apr-15
39
Mes Aynak on Top of Copper Ore
8-Apr-15
40
Stupa in Monastary
8-Apr-15
41
Archaeologist at work
8-Apr-15
42
Murals
8-Apr-15
43
Copper Mines and Stained Rock
8-Apr-15
44
Ancient Slag and Russian Trenches
8-Apr-15
45
Environmental Protection
Bear Coat
Stripes and spots
not good
Cultural Heritage Items
8-Apr-15
46
Personnel Requirements
• Mandatory Center of Expertise for the
Curation and Management of
Archaeological Collections
• Two to four personnel in country on 6-12
month tours to support National Museum,
Archaeological Institute, Site assessments
across theater, LNO with DoS
• Reach back capability
• Capability to JARB resources to support
continuing requirements
Landscape Analysis
• Need to review as much satellite data as
possible to determine the impact of natural
events on selected sites and develop any
remediation steps to curb disruption at the
site (in coordination with DAFA and sites our
military activities impacted)
• To curb illegal digging at sites, identify where
such activity could be occurring (more on this
later)
• Identify possible new sites for examination
near mineral deposits or ancient trade routes
or militarily significant sites
Conclusions
• Burning waste produces potentially toxic smokes that can
impact our mission execution and bring ill will of host nation
populace
• Sewage lagoons and burn dumps can contaminate the
ground water and surface area where our Soldiers and
support personnel live
• Sloppy waste management practices may breed disease
vectors and/or attract vermin that will make our Soldiers and
support personnel sick
• High cost of FOB clean up when the mission is complete is
paid by the US taxpayer (including your grandparents)
• Environmental Stewardship SAVES LIVES and
resources; brings good will with host nation
populace ergo increasing Force Protection support,
protects our Soldiers and staff so they may return
home safely
8-Apr-15
49
Questions and Answers
8-Apr-15
50