RMI Titanium Company Extrusion Plant

 Home
 BEMR Contents
 U.S. Map

RMI Titanium Company Extrusion Plant (formerly known as Reactive Metals, Inc.) is located in northern Ashtabula County, Ohio, about 5 kilometers (three miles) northeast of the center of the City of Ashtabula and approximately one mile south of Lake Erie. The plant is in a sparsely populated and highly industrialized area. Several chemical production and metal conversion plants are located nearby.

FACILITY MISSION

The RMI Titanium Company Extrusion Plant is a privately owned facility. From 1962 to 1988, the company received uranium billets and refined them into various shapes for fuel and target fabrication use by the Department of Energy and its predecessors. RMI also performed work for the Department of Defense and a number of commercial entities under a Nuclear Regulatory Commission License. Twenty-six years of handling, extruding, forging, and machining uranium at the facility have resulted in onsite and offsite contamination of buildings and environmental media. Contaminants consist of solvents and low-level radionuclides.

In 1990 all extrusion operations ceased and the project was transferred to the Environmental Management program for environmental restoration. Decommissioning and remediation activities at the site are projected to be complete in FY 2002. Environmental restoration activities include remediation of local ground water, surface soils, buildings, and associated processing equipment, as well as landlord activities attributable to the Department of Energy. Areas needing cleanup are being carefully monitored and, to date, pose no threat to the health and safety of workers, the public, or the environment.

Remediation of the soil and ground water will be conducted in compliance with the Resource Conservation and Recovery Act under the jurisdiction of the Environmental Protection Agency, while decommissioning and dismantlement of the facility will be conducted under the jurisdiction of the Nuclear Regulatory Commission.

All waste management activities at the facility are performed within the scope of the Environmental Restoration program. There are no current or planned nuclear material and facility stabilization activities.

FUTURE USE

The overall goal of the project is to decontaminate facility equipment buildings and release the facility and surrounding areas to the owner (RMI) for Industrial/Commercial use in FY 2002. At that time, Department of Energy liability at the site will end, and all future use decisions will rest with RMI. Buildings below the free release criteria for the radiological contaminants may be left onsite. Most will be disassembled and removed from the site.

ENVIRONMENTAL RESTORATION

Environmental restoration activities at the RMI site currently include three release sites: Corrective Action Management Unit ground-water and soils cleanup, building and equipment decontamination and removal, and removal or treatment of uranium-contaminated soils and restoration of the surrounding area to "green field" status. It is estimated that remedial action and decommissioning activities will generate approximately 38,781 cubic meters (50,803 cubic yards) of low-level waste and 55 cubic meters (72 cubic yards) of low-level mixed waste. See the Site Map for the location of Environmental Restoration program activities.

Since the regulatory driver at RMI is not the Comprehensive Environmental Response, Compensation, and Liability Act, there is no Record of Decision or Compliance Agreement with any regulatory agency. Decommissioning activities are being performed in accordance with the site decommissioning plan, which the Nuclear Regulatory Commission approved. The RMI site maintains Resource Conservation and Recovery Act permits for hazardous waste storage.

The Department of Energy has prepared a Site Treatment Plan under the Federal Facility Compliance Act for treatment of mixed waste generated during the environmental restoration of the RMI Facility. In October 1995, the Ohio Environmental Protection Agency issued direction to the Department regarding compliance with the Federal Facility Compliance Act.

Corrective Action Management Unit

RMI is undertaking a corrective action to remediate an area of soil and ground-water contamination associated with the operation of the former evaporation and seepage ponds. This area is a proposed Corrective Action Management Unit and is regulated by Region V of the Environmental Protection Agency.

ASSESSMENT

The RMI Plant Resource Conservation and Recovery Act permit required the plant to complete a Facility Investigation on the Corrective Action Management Unit. The issuance of the Resource Conservation and Recovery Act Facility Investigation Equivalency document and the Supplemental Hydrogeological Assessment in 1989, together with the Summary of Revised Estimates and Proposed Cleanup Levels in 1991, satisfied this requirement.

Based on existing characterization information for this area, the concentrations of radiological and hazardous contaminants in the Corrective Action Management Unit exceed the proposed soil cleanup criteria. Uranium, trichloroethylene, and technetium-99 are the contaminants of concern in the soils and ground water.

In October 1992 the plant submitted a Corrective Measures Study to the Environmental Protection Agency for the cleanup of the Corrective Action Management Unit. The Environmental Protection Agency commented on the Corrective Measures Study in FY 1994. RMI responded to these comments in FY 1995. The Environmental Protection Agency is currently reviewing RMI's responses to its comments.

REMEDIAL ACTION

The proposed remedial strategy for radiologically contaminated soils would consist of (1) excavating those soils containing radiological contaminants in excess of the proposed cleanup levels, (2) relocation of the material to the RMI plant material staging area, (3) packaging and shipment of radioactive soil (approximately 29,000 cubic meters [37,990 cubic yards]) to the Nevada Test Site, and (4) backfilling the excavated areas with clean soil.

Onsite treatment will be required to remove the trichloroethylene from soils and ground water in this area. Remediation will involve, (1) excavation of soils, (2) placement and containment of the soils in a temporary enclosure, and (3) removal of the trichloroethylene from the soil by active or passive volatilization. Using this approach, the soil cleanup level would be achieved in approximately two years. After the contaminated soils have been removed, the affected area will be returned to its original condition by, (1) backfilling the excavated areas with clean soil, (2) regrading the area to the approximate original contours, and finally (3) revegetating the area with wetland species via natural colonization or planting with commercial seed/root stocks. The disturbed area would be reconstructed to possess similar hydrologic and vegetative characteristics currently featured in this area. Remediation of the soils will be completed in FY 2002.

Remediation of the contaminated ground water in the Corrective Action Management Unit involves the collection of the ground water using a subsurface drain system, transfer to an air stripping unit, and removal of the trichloroethylene from the water to the gas phase by forcing atmospheric air countercurrent to the ground-water flow in the air stripping unit. The off-gas effluent would be treated, monitored, and discharged to the atmosphere. The treated liquid effluent would be transferred to the existing RMI plant wastewater treatment facility where the uranium isotopes would be removed to an acceptably low level.

LONG-TERM SURVEILLANCE AND MONITORING

Surveillance and monitoring activities required as a part of this remedial activity include an annual ground-water and surface-water monitoring campaign throughout the duration of the remedial action, an annual perimeter air monitoring campaign and an annual soil sampling campaign. Surveillance and monitoring of the soils will be performed during the three to five years of the remedial project. Surveillance and monitoring activities of ground water will continue until ground-water cleanup meets Environmental Protection Agency standards. The Department expects completion of this activity in FY 2015.

Noncorrective Action Management Unit Area Soils

Previous sampling and analysis efforts have confirmed the presence of radioactive contamination in onsite soils, as well as some offsite areas adjacent to the RMI plant site. Similar to the building contamination, the radioisotopes of concern in the soil include uranium-234, 235, 238 and technetium-99. A number of locations to the east and north of the site have been identified as containing total uranium concentrations above background.

The alternative treatment technologies for cleanup of radiologically contaminated soils in the Noncorrective Action Management Unit areas have been evaluated. This baseline report assumes that cleanup of the soils consists of excavating those soils containing radiological contaminants in excess of the proposed cleanup levels. This step will be followed by backfilling the area with clean fill materials and revegetation to prevent erosion. No long-term surveillance and maintenance activities will be necessary; all activity will be complete in FY 2002.

This report estimates that the soils in the Noncorrective Action Management Unit areas will be below free-release limits will be used as fill for the excavated areas. If characterization determines that the soils exceed free-release limits, the low-level waste will be packaged and shipped to Envirocare of Utah.

DECOMMISSIONING

Characterization of the 25 buildings and structures at the RMI site indicate that the most of the buildings, equipment, slabs and subslab soils are contaminated to some extent with uranium. Buildings below the free-release criteria for radiological contaminants may be left onsite. Most of the buildings will be disassembled and removed from the site. Contamination on the slab and subslab will also be removed. This report expects that activities will be completed by FY 2002.

The proposed decommissioning and remediation activities at the RMI plant will be in compliance with the requirements of the Nuclear Regulatory Commission regarding site cleanup. These activities will include: decontamination and decommissioning of site structures and buildings, materials, and equipment; remediation of contaminated soil beneath buildings; construction of temporary onsite decontamination and decommissioning support structures and treatment facilities; disposition of associated waste generated during the site decontamination and decommissioning (including any new structures); and soil and ground-water remediation.

Following completion of all onsite and offsite cleanup activities, the entire facility will be subject to a final radiological survey required for license termination. An independent survey commissioned by the Nuclear Regulatory Commission will validate the results of this survey. The validated final survey will confirm that the required cleanup levels and/or criteria for free release have been attained.

The current focus of surveillance and maintenance activities includes characterization, survey, and cleanup and removal of equipment in preparation for decommissioning work. Also included are handling and disposal of existing legacy waste stored at the RMI facility. Legacy waste will be removed prior to the startup of any decommissioning activities. Approximately 610 cubic meters (799 cubic yards) of low-level waste will be transported to the Nevada Test Site. Fourteen cubic meters (18 cubic yards) of asbestos and 266 cubic meters (350 cubic yards) of radioactive asbestos will be generated and disposed of at the Nevada Test Site.

Low-level mixed waste will be managed in compliance with the requirements of the Federal Facility Compliance Act Site Treatment Plan. Currently, the RMI site stores 35 cubic meters (46 cubic yards) of mixed waste. This report assumes an additional 20 cubic meters (26 cubic yards) will be generated. Therefore, a total of 55 cubic meters (72 cubic yards) will be disposed of at the Toxic Substances Control Act Incinerator at the K-25 Site at Oak Ridge National Laboratory.

The decommissioning of the onsite hazardous waste storage structure will proceed in accordance with the closure requirements of the Resource Conservation and Recovery Act permit, as well as the RMI Decommissioning Plan described above.

Environmental Restoration Activities Cost Estimate

(Five-Year Averages, Thousands of Constant 1996 Dollars)
	FY 1996-2000	2005	2010	2015	2020	2025	2030	Life Cycle*
Reactive Metals, Inc.
Assessment	2,432	793						16,121
Remedial Action	14,478	6,585	75	271				107,043
Direct Program Management/Support	1,168	457						8,125
Total	18,078	7,834	75	271				131,289
* Total Life Cycle is the sum of the annual costs in constant FY 1996 dollars.

Direct Program Management/Support

Program management at RMI is concerned with decontamination and remediation planning, project control and decommissioning management. RMI does not fund any grants or Agreements-in-Principle at this time. RMI is listed as a Principal Responsible Party for the remediation of the Fields Brook Superfund site and has, to date, paid a share of Fields Brook costs. The Department of Energy is not a Principal Responsible Party; however, the Department pays one-third of the cost because the RMI Titanium Company Extrusion Plant is one of three RMI sites with an outfall to Fields Brook.

Future activities will focus on procurement and management of architectural engineering and major remediation subcontracts.

LANDLORD ACTIVITIES

Landlord costs include security for buildings and grounds, maintenance and testing of site equipment, maintenance of site utilities, and equipment procurement. Landlord costs will end by FY 2005 when the remedial action activities are completed and long-term surveillance and monitoring are under way. This report assumes that after FY 2005, all landlord activities will be the responsibility of the RMI Titanium Company.

DESCRIPTION OF PERSONNEL

Current Composition

The current work force mix of federal contractor and subcontractor employees is presented in the table below. The federal work force is made up of managers, administrative support and engineers. The contractors and subcontractors are a mix of professional and labor personnel who conduct the day-to-day site operations and plan and conduct site remediation.

* The Projections for Full-Time Equivalent employees are based on FY 1996 planning baselines (see Reader's Guide).

Site Management Structure

The RMI site is privately owned and operated under a Decontamination and Decommissioning Contract through the Department of Energy Ohio Field Office. The site is unique in the Department's system because RMI is the landlord as well as the contractor. The RMI Titanium company provides surveillance and maintenance services for the privately owned facility. Architect-engineering services are subcontracted, and other site services are managed on fixed price subcontracts. The actual decontamination and decommissioning work will be subcontracted to a qualified contractor using a fixed fee incentive contracting strategy. Competing contracts support contract reform efforts to the greatest extent possible and provide incentives for those agreements as appropriate.

Future Full-Time Equivalent Needs

Decommissioning and remediation activities will begin in FY 1997. The personnel mix will remain relatively constant through FY 2001 because the project will be in the latter stages of completion. The number of Full-Time Equivalents will decrease by approximately 50 percent in FY 2002, the final year of restoration activities. This report expects this decrease to be evenly distributed across all categories.

FUNDING ESTIMATE

The following table presents estimated funding information for the RMI Titanium Company Extrusion Plant.

COMPARISON WITH PREVIOUS ESTIMATE

The 1995 RMI Baseline Environmental Management Report Base Case did not reflect the RMI Decommissioning Plan. The reported estimate was based on an independent third-party evaluation. The 1996 RMI Base Case is consistent with the estimate submitted with the RMI Nuclear Regulatory Commission Site Decommissioning Plan. Improved remediation strategies and completion of characterization has contributed to a more precise cost estimate. The Corrective Action Management Unit has employed the newer strategy of shipping low-level soils to Envirocare of Utah instead of shipping to the Nevada Test Site. Use of this strategy produces a savings of approximately $156,000.

The previous cost estimate included costs for dismantlement, size reduction, and packaging of the building materials into shipping containers. The packaged material would be shipped via truck to the Nevada Test Site. The previous RMI estimated costs for the building and equipment remediation were $57.7 million over 15 years. In the current cost estimate, based on the Decommissioning Plan, estimated costs are $56.7 million over seven years. This savings is based on improved waste disposal methods and an accelerated schedule.

Incomplete characterization data for the Noncorrective Action Management Unit soils led to the previous estimate of $47 million. Data, which was validated in the 1995 RMI Site Characterization report, provided the foundation of an amended estimate of $53.6 million. This estimate does not consider cost efficiencies that may be realized from implementing new technologies. It does include projected cost savings that will be realized by shipping the material by rail to Envirocare of Utah.

Project planning has been revised to reflect an expedited project funding scenario in line with the Department of Energy Small Sites Acceleration Initiative. This initiative will result in the completion of RMI decommissioning activities, with the exception of ground-water remediation, by FY 2002. The previous estimate for program management was $16.5 million, compared with the current estimate of $10.2 million, and the previous estimate for landlord activities was $18.5 million, versus the current estimate of $11 million.

The revised management strategy, which includes reduced program management and landlord costs, has resulted in an increase in surveillance and monitoring costs from the previous estimate of $16.5 million to a current estimate of $18 million.