Kansas City Plant

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The Kansas City Plant is part of the Bannister Federal Complex, a 120-hectare (300-acre) site 19.2 kilometers (12 miles) south of downtown Kansas City, Missouri. The Department of Energy occupies 56.4 hectares (141 acres) of this reservation. The complex is zoned by local government for heavy industry. The surrounding area consists of single- and multiple-family residences, commercial establishments, industrial districts, and public-use lands.

FACILITY MISSION

The Kansas City Plant was constructed in 1942 to build aircraft engines for the Navy. After World War II, it was used for storage, and in 1949 it was selected for its current mission, manufacturing nonnuclear components for nuclear weapons. Electrical, electromechanical, mechanical, and plastic components are manufactured or procured by this facility.

Various spills and leaks from production activities have resulted in soil and ground-water contamination. Ground-water contamination is mainly trichloroethylene and its degradation products 1,2-dichloroethylene, and vinyl chloride. Soil is contaminated with volatile organic compounds, polychlorinated biphenyls, and petroleum products. The approximate surface area of contamination is 310,000 square meters (76.6 acres) for ground water and 70,000 square meters (17.3 acres) for subsurface soil. An interceptor trench and wells are used to contain contaminated ground water. Although no immediate risk to employees or the public exists, the plant has been aggressively cleaning up its environmental problems. Cleanup activities are driven by a Consent Order Agreement with the Environmental Protection Agency.

The Environmental Management program began providing funding for environmental restoration and waste management activities in 1990. The Office of Defense Programs is the landlord for the site, and this report assumes it will continue in that capacity indefinitely. Environmental management activities contribute to landlord costs through an indirect burden rate captured in each of the activity estimates. There are no current or planned nuclear material and facility stabilization projects at this site.

The Waste Management program, which supports environmental restoration activities, as well as the Office of Defense Programs, includes primarily hazardous waste storage in preparation for offsite treatment or disposal. These activities include providing containers to waste generators, characterization, packaging, transportation, treatment, storage, and disposal, as applicable. Small quantities of low­level radioactive waste are also generated. There is no onsite waste disposal. Treatment operations are limited to industrial wastewater pre-treatment. The Office of Defense Programs, as landlord, disposes of sanitary waste consisting of normal garbage and sewage.

FUTURE USE

The Kansas City Plant has been selected as the nonnuclear manufacturing facility for the nuclear weapons complex. This report assumes that this mission will continue indefinitely.

Alternatives for the future use of the land occupied by the entire federal complex have been reviewed and a proposal has been developed. The proposal was presented to other occupants of the federal complex and a community involvement group for stakeholder input on April 11, 1995. The community involvement group consists of representatives of local government, community groups, business groups, and environmental organizations. The consensus opinion of all parties was that the entire federal complex will continue to be used for industrial purposes for the foreseeable future.

ENVIRONMENTAL RESTORATION

The purpose of the Environmental Restoration program is to evaluate potentially contaminated areas and to clean up areas found to be a threat to human health or the environment. Forty-one sites have been identified and investigated under a Consent Order Agreement between the Department of Energy and the Environmental Protection Agency. The agreement requires the Department of Energy to analyze the extent and type of contamination, evaluate cleanup alternatives, and implement the selected cleanup alternative at each site. Prior to selecting the cleanup alternative, the Environmental Protection Agency provides the public with the opportunity to comment on the recommended alternative. Although the Environmental Protection Agency is the only regulator for the Environmental Restoration program, all regulatory documents are provided to the State of Missouri for review and comment.

The main sources of contamination are accidental spills and leaks from manufacturing processes. Soil has been contaminated with volatile organic compounds, polychlorinated biphenyls, and petroleum hydrocarbons. Some of the contaminants, mainly the volatile organics, have migrated through the soil and have contaminated the ground water. To control the migration of contaminated ground water, a treatment system was installed and has been operating since 1988. Source contaminant migration is monitored by periodic sampling of an extensive array of wells.

The 41 sites were grouped into ten projects, primarily by geographic areas, and the Department has investigated all of them. Fifteen sites have either been cleaned up or found not to require cleanup. Typically, cleanup has involved excavating contaminated soil and disposing of it in a certified offsite landfill. The Department is currently evaluating cleanup alternatives for the remaining sites. The evaluation of the alternatives considers the future land use of the site, exposure risk, cost, and technological feasibility.

Existing down gradient ground-water monitoring wells will be sampled semiannually to ensure that the contamination does not migrate offsite. Monitoring costs are shown in the site-wide ground-water treatment and monitoring project. For estimating purposes, this report has assumed a monitoring duration of 30 years.

Although alternatives for the remaining sites have not been selected or agreed to by the regulators, selection assumptions have been made in developing costs for this report. Specifically, this report assumes that contaminated sites with minimal exposure risk will require No Further Action other than implementing procedural controls. If cleanup of these sites is required, the cost will increase significantly. This report assumes that no contamination will be found in addition to the material identified in the assessments subsections for the active environmental projects discussed below, and there are no decommissioning activities needed. The cost for characterizing, storing, treating, transporting and disposing of waste generated during remedial action is included within the Environmental Restoration program costs.

Department 26: Southeastern Quadrant Beneath Main Manufacturing Building

ASSESSMENT

Polychlorinated biphenyls contamination of subsurface soils was suspected because of the heat-transfer fluid (Therminol FR-1) previously used in the plastic molding operations. Polychlorinated biphenlys were released by piping system leaks. The heat-transfer fluid was replaced with a nonpolychlorinated biphenlys-bearing fluid in 1974. Investigation of this site is complete and soil sample analysis confirmed significant areas of polychlorinated biphenyls-contamination. The contamination is primarily under the main manufacturing building and extends approximately 40 feet down to bedrock. Approximately 7,325 cubic meters (9,600 cubic yards) of soil is contaminated. The Environmental Protection Agency has approved the Resource Conservation and Recovery Act Facilities Investigation report and the corrective measures study is being developed. The assessment phase for this project is approximately 92 percent complete, with a projected completion date of July 1996.

REMEDIAL ACTION

Remediation alternatives are being evaluated. The contamination is primarily under the main manufacturing building, and there is little exposure risk. However, removing the contamination could endanger workers and damage the structural integrity of the building. Technology to treat the contamination without removing the soil does not exist. Therefore, this report assumes that the remediation alternative selected will leave the contamination in place until the building is demolished or a technology is developed to treat the contamination without removing the soil. The final selection will not be made until the proposal is submitted to the regulators and the public has been given the opportunity to provide comments. Monitoring of down gradient ground-water wells will be conducted to ensure that contamination does not migrate. The estimate assumes remediation will be complete in FY 1998.

Department 27 (Inside): Northeastern Quadrant Beneath Main Manufacturing Building

ASSESSMENT

The presence of polychlorinated biphenyls was suspected in the soil beneath this quadrant because of the past use of Therminol FR-1 to control the temperature of molds used to form rubber and plastic components. Leaks in the heat transfer system were thought to have allowed the polychlorinated biphenyls to seep into the underlying soil through joints and cracks in equipment foundation pits. Therminol FR-1 was replaced with a nonpolychlorinated biphenyls-bearing fluid in 1974. Investigation of this site is complete, and soil sample analysis found approximately 100 cubic meters (130 cubic yards) of minor polychlorinated biphenyls contamination. However, the level of contamination found is not above cleanup levels. Ground-water volatile organic compound contamination was detected because of up gradient soil contamination. Low levels of petroleum hydrocarbon contamination were also detected. The Environmental Protection Agency has approved the Resource Conservation and Recovery Act Facilities Investigation report and the corrective measures study is being developed. The assessment phase for this project is approximately 91 percent complete with a projected completion date of July 1996.

REMEDIAL ACTION

The Department is evaluating remediation alternatives. The contamination is primarily under the main manufacturing building and there is little risk of exposure. However, removing the contamination could endanger workers and damage the structural integrity of the building. Technology to treat the contamination without removing the soil does not exist. Therefore, this report assumes that the remediation alternative selected will leave the contamination in place and use institutional controls to manage the risk. Institutional controls will ensure that any soil excavated from this area will be handled in a manner that protects employees and the public and will be disposed of in accordance with applicable regulations. The final remedial action alternative will not be selected until the proposal is submitted to the regulators and the public has been given the opportunity to provide comments. Monitoring of down gradient ground-water wells will be conducted to ensure contamination does not migrate. The estimate assumes remediation will be complete in FY 1997.

Miscellaneous Contaminated Soils

ASSESSMENT

Four potentially contaminated areas were investigated as a part of this project, the North Lot, Building 16, the abandoned fuel lines, and the fuel oil tank loading and unloading area. Old aerial photographs indicate the northwest corner of the north parking lot was used as a staging area for drums prior to being paved. The contents of the drums, the occurrence of any leaks, and their final disposition is unknown.

Building 16 houses an in-ground centrifuge used to test weapons components and a mold-flushing facility. The concrete centrifuge chamber has a sump where water and hydraulic fluid from equipment leaks have accumulated. The mold-flushing facility includes a below-grade storage area for spent flushing solvents. A 11,300-liter (3,000-gallon) steel tank is buried outside the building to capture fire-sprinkler water from mold flushing.

The abandoned fuel lines were installed when the plant was constructed to transfer fuels, kerosene, oils, rust inhibitors, and solvents from truck and railcar unloading stations to underground storage tanks and from tanks to the main manufacturing building.

The fuel oil tanks consist of two above-ground 1.5 million liter (400,000-gallon) steel tanks, a loading and unloading area, and associated piping. The tanks originally stored jet fuel and were later converted to store fuel oil. The tanks were initially surrounded by an earthen berm to contain spills. The berm has been replaced by concrete walls. The floor of the containment area consists of unlined earth. Petroleum products were occasionally spilled on the ground at the loading and unloading area. In-tank steam coils used to heat the fuel oil leaked in 1989, causing the tank to overflow onto the floor of the containment area.

Investigation of these sites is complete, and soil sample analysis found no contamination at the north lot and Building 16 locations. These two sites have received No Further Action designations from the Environmental Protection Agency. Petroleum products were found in the soil at the abandoned fuel lines and the fuel oil tanks. Additionally, volatile organics compounds were detected in the soil at the abandoned fuel lines. Approximately 6,880 cubic meters (9,000 cubic yards) of soil is contaminated. The Environmental Protection Agency has approved the Resource Conservation and Recovery Act Facilities Investigation report. The corrective measures study has been submitted to the regulators and no comments were received from the public during the public notice period. The assessment phase for this project is approximately 96 percent complete, with a projected completion date of May 1996.

REMEDIAL ACTION

The Department has evaluated remediation alternatives and recommended to the regulators that it address the contamination in place and use institutional controls to minimize the risk of exposure. Institutional controls will ensure any soil excavated from this area will be managed in a manner that protects employees and the public and will be disposed in accordance with applicable regulations. The public has been given the opportunity to comment on this recommendation, and no comments were received during the public notice period. Monitoring of down gradient ground-water wells will be conducted to ensure contamination does not migrate. The estimate assumes no further action after FY 1996 when the remediation should be completed.

Miscellaneous Polychlorinated Biphenyls Sites

ASSESSMENT

The Department believes that a lightning strike at an electrical substation may have caused the release of polychlorinated biphenyls. The substation is housed in a small containment structure attached to the north side of the Manufacturing Support Building. There was additional polychlorinated biphenyls contamination in an underground ductbank. The cable was insulated with polychlorinated biphenyls-impregnated paper. Investigation of this site is complete, and sample analysis confirmed the presence of polychlorinated biphenyls contamination. Approximately 11 cubic meters (14 cubic yards) of structures and equipment was contaminated. The Environmental Protection Agency approved the recommendation made in the Resource Conservation and Recovery Act Facilities Investigation report to clean up this site via the Interim Measures process. The assessment phase for this project is complete.

REMEDIAL ACTION

Decontamination, demolition, and disposal of the containment structure and electrical cables have been completed as outlined in the Interim Measures work plan approved by the Environmental Protection Agency. Approximately 33 tons (30,000 kilograms) of Toxic Substances Control Act-regulated waste were generated and disposed of at a certified commercial landfill. A portion of the wall shared with the Manufacturing Support Building and the concrete floor could not be decontaminated below the cleanup standards. A proposal to encapsulate the wall surface has been submitted to the Environmental Protection Agency. This estimate assumes that the regulators will approve the proposal, and the wall shared with the Manufacturing Support Building and floor will be encapsulated to stabilize the residual polychlorinated biphenyls contamination. The estimate assumes remediation will be complete in FY 1996.

Northeast Area and the Outfall 001 Raceway

ASSESSMENT

The Northeast Area encompasses the northeastern portion of the complex and includes land administered by the General Services Administration, the Internal Revenue Service, and the Union Pacific Railroad. The ground water in this area is contaminated with volatile organic compounds. The source of this contamination is unknown but is probably due to random dumping, leaking pipelines, and a wastewater lagoon.

The Outfall 001 Raceway is the discharge point for the 001 Storm Sewer System which drains the north-central and northeastern portions of the plant. It passes through an area of ground-water and soil contamination derived from past waste handling practices. The area has also been affected by past discharges through the 001 Storm Water Outfall.

Old aerial photographs show ponds in and just north and west of the former north lagoon. This area was originally low-lying and poorly drained. Photographs indicate that material was dumped in the area from makeshift haul roads.

Investigation of these sites is complete and soil sample analysis found volatile organic compound and petroleum product contamination in soils primarily at and below the water table in the area of the old ponds. The extent of the contaminated ground-water plume was also defined. Approximately 2,220 cubic meters (2,900 cubic yards) of soil is contaminated. The Environmental Protection Agency has approved the Resource Conservation and Recovery Act Facilities Investigation report. The corrective measures study has been submitted to the regulators and no comments were received from the public during the public notice period. The assessment phase for this project is approximately 95 percent complete, with a projected completion date of May 1996.

REMEDIAL ACTION

Remediation alternatives have been evaluated, and the recommendation has been made to the regulators to address the contamination in place and minimize exposure risk through institutional controls. Institutional controls will ensure any soil excavated from this area will be handled in a manner to protect employees and the public and will be disposed of in accordance with applicable regulations. Since the contamination exists on non-Department of Energy property, the procedures used for institutional controls will be developed with other occupants. The public was given the opportunity to comment on this recommendation, and no comments were received.

Contaminated ground water is being contained from migrating offsite by the existing ground-water treatment system. In addition, the recommended remediation alternative for ground-water contamination is to add another production well in the Northeast Area to ensure plume containment. The recommended alternative also provides for an increase in the interceptor trench pumping rate, requiring construction of an additional production well in the interceptor trench. The estimate assumes remediation will be complete in FY 1998.

The contaminated ground-water plume is near the property boundary of the federal complex. To keep the contamination from migrating into the nearby Blue River, an interceptor trench and production wells were installed in 1988. Ground water is pumped from these wells to an Ultraviolet/Hydrogen Peroxide treatment system. This system eliminates 99.7 percent of the contamination in the ground water. The resulting effluent is discharged into the city sanitary sewer. This project is part of the ground-water treatment and monitoring program.

Plating Building

ASSESSMENT

The plating building was constructed in 1957 to provide onsite metal plating. A new plating facility was constructed in 1987, and the old facility was removed from service. Portions of its structure, including concrete floors and walls, were found to contain heavy metals, polychlorinated biphenyls, cyanide, and petroleum products. This project includes Building 57, the Waste Oil Tank, Substation 18, and the Department 26 outside sites.

Building 57 was the original plating building, and demolition was completed 1990. Following demolition, the site was paved with asphalt.

An abandoned 98-cubic meter (26,000-gallon) waste oil tank is buried under the north foundation wall of Building 57. This tank was originally installed to recover spent anti-rust oil from operations in the main manufacturing building. The tank was abandoned and filled with sand in the early 1950s. Sampling indicated the tank contents are contaminated with polychlorinated biphenyls. The soil immediately around the tank is also saturated with petroleum.

Substation 18 was constructed to provide electrical power for the plating building. It included an oil-filled transformer containing a polychlorinated biphenyls-based cooling oil (Aroclor 1260). Multiple spills occurred and were cleaned up during the 30-year operation of the building. The polychlorinated biphenyls transformer was removed from the substation when the plating building was demolished. Polychlorinated biphenyls from this transformer have contaminated the soil in this area.

A portion of the piping system for heating and cooling the Department 26 plastic molding operations was located between the main manufacturing building and the plating building. A buried 37,800-liter (10,000-gallon) tank supplied a polychlorinated biphenyls heat transfer fluid (Therminol FR-1) for the system. Polychlorinated biphenyls from the tank and piping system have contaminated the soil down to bedrock. The tank and piping system were removed and replaced with a polychlorinated biphenyls-free system in 1983.

Investigation of these sites is complete. Approximately 2,935 cubic meters (3,800 cubic yards) of soil is contaminated. The Environmental Protection Agency has approved the Resource Conservation and Recovery Act Facilities Investigation report, and the corrective measures study is being developed. The assessment phase for this project is approximately 93 percent complete, with a projected completion date of July 1996.

REMEDIAL ACTION

Remediation alternatives are being evaluated. For estimating purposes, the assumed remediation strategy is to remove surface and shallow contamination sources that have the potential of contaminating storm water. This will include removing and disposing of the cyanide spill sump, the remains of the Building 57 foundation, Substation 18, the abandoned Waste Oil Tank, the Building 57 abandoned floor drain piping, the abandoned caustic/acid sump structure, and the pipe gallery containment basin and 0.6 to 1.2 meters (2 to 4 feet) of underlying soil. The estimates included in this report assume disposal of 2,060 cubic meters (2,700 cubic yards) of Toxic Substances Control Act-regulated soil and debris, 233 cubic meters (305 cubic yards) of soil as sanitary waste, and incineration of 2 cubic meters (2.6 cubic yards) of concrete, 6.5 cubic meters (8.5 cubic yards) of other solids, and 11 cubic meters (14 cubic yards) of waste oil regulated by the Toxic Substances Control Act.

An asphalt cap was placed over the soil after the old plating building was demolished. An accelerated interim measures project is in process to remove the underground Waste Oil Tank prior to conducting further remedial actions. Remediation activities are assumed to be completed in FY 2000.

South Lagoon

ASSESSMENT

The South Lagoon is in the northeast quadrant of the Department of Energy property. It was constructed in 1975 to assist the North Lagoon in receiving industrial wastewaters from production activities and was used until 1988. The wastewater consisted of rinse waters, drain input, and treated cooling water from various manufacturing processes including electroplating and degreasing. Sludge from the North and South Lagoons was removed in 1985 and 1988, respectively. A nonpermeable cap was installed over both lagoons in 1988. The Environmental Protection Agency has approved the Resource Conservation and Recovery Act Facilities Investigation report and has agreed to monitor this site in lieu of further ground-water remediation. The public has been given the opportunity to comment on the recommendation to designate this site for No Further Action. No comments have been received. Assessment activities are assumed to be completed in FY 1998.

Trichloroethylene Still Area

ASSESSMENT

The Trichloroethylene Still Area contains multiple release sites: the former trichloroethylene still, the classified waste burial trenches, the oil house, Department 95, the former aluminum chip handling facility, the former sales building, the waste transfer spill area, the abandoned sump, and the Department 20 sump.

Investigation of these sites is complete, and soil sample analysis found volatile organic compound contamination above the water table at the oil house, trichloroethylene still, classified waste burial trenches, Department 20 sump, abandoned sump, and waste transfer spill area. Soil contamination above the water table was also found at the abandoned sump/waste transfer spill area. Petroleum product contamination was found in soil above the water table at the abandoned sump and the waste transfer spill area. Soil contamination below the water table was found at the oil house, trichloroethylene still, Department 20 sump, classified waste burial trenches, aluminum chip handling facility, sales building, the abandoned sump, and waste transfer spill area. Approximately 884 cubic meters (1,160 cubic yards) of soil is contaminated. The Environmental Protection Agency has approved the Resource Conservation and Recovery Act Facilities Investigation report, and the corrective measures study is being developed. The assessment phase for this project is approximately 94 percent complete, with a projected completion date of July 1996.

REMEDIAL ACTION

The Department is evaluating remediation alternatives. For estimating purposes, the assumed remediation strategy is partial excavation of contaminated soil at the trichloroethylene still, oil house, abandoned sump, and Department 20 sump. The report assumes that most waste will be disposed of in a certified commercial landfill and some waste from the abandoned sump will have to be incinerated. Three ground-water production wells will be added to further control contaminated ground water. The Department will not select the final remedial action alternative until the proposal is submitted to the regulators and the public has been given the opportunity to provide comments. Monitoring of down gradient ground-water wells will be conducted to ensure that the contamination does not migrate. The estimates included in this report assume disposal of 621 cubic meters (812 cubic yards) of Resource Conservation and Recovery Act-regulated soil and remediation will be complete in FY 2000.

Maintenance Vehicle Repair Shop Sump

ASSESSMENT

Three areas of concern are associated with maintaining the vehicle repair shop sump: the sump pits, Building 54, and the test cell area.

The sump pits were built in 1970 to house a hydraulic vehicle lift. Plant vehicles were washed on the lift before repair. The lift has been decommissioned. Building 54 was constructed to test aircraft engines. The building's basement housed electric motors used to circulate water through cooling towers. The test cells were originally used to test aircraft engines. It is likely that fuel, oils, and degreasers were used in the cells during manufacturing.

Investigation of these sites is complete and although ground-water contamination exists, no soil source contamination was found at the maintenance vehicle repair shop sump, the sump pits, or Building 54. Significant areas of petroleum product contamination were found at the test cell area. Approximately 1,000 cubic meters (1,300 cubic yards) of soil is contaminated. The Environmental Protection Agency has approved the Resource Conservation and Recovery Act Facilities Investigation report, and the corrective measures study is being developed. The assessment phase for this project is approximately 92 percent complete, with a projected completion date of July 1996.

REMEDIAL ACTION

The Department is evaluating remediation alternatives. For estimating purposes, the assumed remediation strategy is excavation and disposal of shallow contamination sources that have the potential to contaminate storm water or pollute ground water. The Department will not select the final remedial action alternative until the proposal is submitted to the regulators and the public has been given the opportunity to provide comments. Monitoring of down gradient ground-water wells will be conducted to ensure contamination does not migrate. The estimates included in this report assume disposal of 1,000 cubic meters (1,300 cubic yards) of Resource Conservation and Recovery Act-regulated soil, and incineration of 24 cubic meters (31 cubic yards) of liquid waste regulated by the Toxic Substances Control Act. Remediation is assumed to be complete in FY 1998.

Ground-Water Treatment and Monitoring

This project includes ground-water monitoring for the entire plant. An extensive array of ground-water monitoring wells has been installed, and the wells are sampled twice a year. The extent of ground-water plume contamination was determined from assessment activities for other projects and from monitoring well data.

Contaminated ground water is being contained by the ground-water pump-and-treatment system. This system uses an ultraviolet/hydrogen peroxide treatment system to break down the chemical bonds of the contaminants. This project is also evaluating source remediation technologies, including deep soil mixing and in situ microwave remediation.

Deep soil mixing uses a large diameter mixing blade modified to allow the injection of reagents during the mixing process. The reagents will chemically react with the contamination during the mixing process, thus immobilizing it or reducing its toxicity. In situ microwave remediation uses down-hole antennae selectively tuned to heat targeted contamination. The contamination will vaporize, and it is extracted. Field studies to test the effectiveness of these technologies are scheduled for FY 1996.

An alternate concentration limit petition is being prepared for submittal to the Environmental Protection Agency. The petition proposes that ground-water treatment can be discontinued with no significant impact on the environment. If the Environmental Protection Agency agrees with the petition, ground-water treatment will no longer be required. For estimating purposes, ground-water treatment costs are included only through the year FY 2001.

Direct Program Management/Support

Program management and support functions cut across all environmental restoration activities. Costs are included for personnel to develop and validate cost estimates; manage project cost, schedule, and technical baselines; formulate and execute budget requirements; develop performance reports; ensure regulatory compliance; and support audits, reviews, and validations.

WASTE MANAGEMENT

The Waste Management program conducts a waste acceptance certification program to certify all waste generated at the Kansas City Plant. Waste is characterized in the generating process and then transferred to temporary storage and prepared for offsite shipment and disposal at permitted treatment, storage, and disposal facilities. No waste is either treated or disposed onsite. Sanitary waste disposal is the responsibility of the Office of Defense Programs in its role as site landlord. In the future, waste generation from existing production operations is expected to decrease as a result of downsizing. Costs for transportation of waste appear in disposal costs for each waste type.

Waste Management provides technical guidance to other onsite programs for proper management of waste generated from construction/remediation projects, as well as for waste received from field return activities. Processes transferred to the Kansas City Plant as the result of nonnuclear consolidation will increase the volume of activities that generate sanitary, hazardous, low­level, and low-level mixed waste. The most significant generation at Kansas City is the hazardous waste resulting from the Office of Defense Programs machining, plating, and etching processes. The Department will ultimately manage any low-level mixed waste generated from these activities as low-level waste after elementary neutralization.

The Environmental Protection Agency Region VII and Missouri Department of Natural Resources are the federal and state agencies regulating the Kansas City Plant. The plant has prepared and submitted a Resource Conservation and Recovery Act Part B permit application and is currently operating under interim status. The plant continues to operate in compliance with federal, state, and local regulations.

Since FY 1994, the plant has aggressively pursued a plan to eliminate all mixed waste in storage. To this end, the plant has used a chemical process to segregate the radioactive and hazardous components from electronic assemblies. This eliminated two mixed waste streams. In 1994, the plant established a vendor return program for smoke detectors, thereby preventing the generation of mixed waste containing transuranic radionuclides. These approaches will continue to be applied in an effort to reduce the potential for creating mixed waste.

The Department does not anticipate future generation of mixed waste. Therefore, a Site Treatment Plan will not be required. However, mixed waste will be generated from operations that will be integrated at this site from nonnuclear reconfiguration activities beginning in FY 1998. Waste from these activities will ultimately be managed as low-level waste after elementary neutralization. In lieu of a Site Treatment Plan, the Mixed Waste Contingency Plan has been submitted to and approved by the State of Missouri.

Technical support costs for development of the Mixed Waste Contingency Plan and compliance with storage requirements are identified in low-level waste storage. Costs for the chemical segregation process and offsite transportation and disposal are identified in low-level waste disposal. No low-level radioactive waste is treated onsite.

Low-Level Waste

GENERATION AND HANDLING

Small quantities of low-level radioactive waste are generated from the disassembly and testing of irradiated components, the scheduled replacements of exit signs containing small amounts of tritium for illumination, the replacement or excess of X-ray sources. These sources are all from Defense Programs activities.

STORAGE

The Kansas City Plant low-level waste storage area is located in the Waste and Excess Property Management Department. The 23-square meter (250-square foot) area is protected from inclement weather, unauthorized entry, and has secondary containment. The maximum storage capacity is 96 0.2-cubic meter (55-gallon) drums.

DISPOSAL

Low-level waste is shipped to the Nevada Test Site for disposal. Shipments are made infrequently and only when a sizable quantity of waste accumulates. Shipments were made in 1985 and 1995. At present, approximately 0.5 cubic meters (0.65 cubic yards) of low-level waste is in storage. This report assumes that approximately 30 cubic meters (39 cubic yards) will be transported to the Nevada Test Site between now and FY 2070.

Hazardous Waste

GENERATION AND HANDLING

Principal hazardous substances include acids, alkalines, ignitable waste, miscellaneous toxic waste, nonfriable asbestos, oil, polychlorinated biphenyls, solvents, wastewater treatment sludge, and infectious waste from the employee medical department. Waste from manufacturing processes is certified by process prior to acceptance into the Waste Management program.

Numerous laboratories and small departments within the plant also generate miscellaneous hazardous waste in small amounts. These items are combined, when practical, for controlled disposal. Waste contaminated with polychlorinated biphenyls and asbestos is also routinely generated in the decommissioning of inactive facilities. Polychlorinated biphenyl waste is shipped offsite for disposal within 30 days.

Several initiatives are currently being developed to reduce hazardous waste volumes. A carbon dioxide separation system is being developed that will treat oil- and solvent-contaminated waste. The Department plans to use fuel-blending to recycle oils and solvents. Coolant recycling equipment has also been procured to reuse and recycle coolants. The Department is also implementing a process to treat acid/chromate and alkaline/cyanide solid debris streams generated during plating operations. The Department expects this process to reduce the amount of hazardous waste by 2.25 metric tons (2.5 tons).

In 1994, the hazardous waste generated at the plant totaled 850 cubic meters (1,100 cubic yards), most of which, 510 cubic meters (670 cubic yards), was waste regulated by the Toxic Substances Control Act, and 256 cubic meters (335 cubic yards) was waste regulated by the Resource Conservation and Recovery Act. The remaining waste was state-regulated waste. Hazardous waste generation is expected to decline approximately five percent per year. Waste generated from construction and environmental restoration activities is approximately 450 metric tons (500 tons) and is not expected to increase. The Kansas City Plant expects to generate approximately 475 cubic meters (620 cubic yards) of hazardous waste from production operations in FY 1995 and FY 1996. Legacy- classified waste was sanitized onsite and shipped for disposal in FY 1995, eliminating the inventory of classified waste.

TREATMENT

The Kansas City Plant does not treat any hazardous waste regulated by the Resource Conservation and Recovery Act. The only treatment that is performed at the site is the pre-treatment of wastewater from manufacturing under a City of Kansas City, Missouri Clean Water Act pre-treatment permit. The pre-treatment is performed at the industrial wastewater pre-treatment facility, which destroys or removes hazardous chemicals like cyanide and chromium. The pre-treatment facility also de-waters sludge, reducing its volume. Resource recovery and recycling are performed at locations throughout the plant, with the wastewater piped to the pre-treatment facility.

Future waste volumes, pre-treated by the Industrial Wastewater Pre-Treatment Facility and generated from production operations, are anticipated to decrease then remain constant as the result of downsizing, even though the mission at the Kansas City Plant is assumed to continue indefinitely.

STORAGE

The Department stores hazardous waste at a tank farm and at various locations in the plant. The tank farm consists of five bulk storage tanks: 23 cubic meters (6,000 gallons) of acids, 23 cubic meters (6,000 gallons) of alkalines, 60 cubic meters (two 8,000-gallon tanks) of solvents, and 30 cubic meters (8,000 gallons) of oil. Because of recent Department of Energy initiatives to downsize the nuclear weapons complex, projects are being identified at the Kansas City Plant to consolidate waste storage into vacated buildings.

The Kansas City Plant is currently under interim status as a treatment, storage, and disposal facility. According to the permit, waste can be stored for up to one year on specified waste management storage lots.

DISPOSAL

No hazardous waste is disposed of onsite. Disposal preparations include packaging, repackaging, consolidating, and manifesting hazardous waste in compliance with the Resource Conservation and Recovery Act and Department of Transportation regulations. Hazardous waste is transported for offsite treatment and disposal to approved commercial treatment and disposal facilities. Shipments are made when a sizable quantity of waste accumulates. This report assumes that 46,675 cubic meters (61,144 cubic yards) will be disposed of at offsite commercial facilities between now and FY 2070.

Direct Program Management/Support

Program management and support functions cut across all waste management activities. Costs are included for personnel to develop and validate cost estimates; manage project cost, schedule, and technical baselines; formulate and execute budget requirements; develop performance reports; ensure regulatory compliance; and support audits, reviews, and validations. Each cost table shows the program management cost associated with that program.

An Agreement-in-Principle has been reached with the Missouri Department of Natural Resources for independent oversight of environmental and emergency management programs. In FY 1996, this oversight will include state reviews of the air, surface water, emergency management, and waste management programs. Annual costs to support this agreement are approximately $200,000.

This report anticipates cost savings in program support activities through the integration of the individual Environmental Restoration and Waste Management programs into a single Environmental Management program Support Team. The result should be reduced duplication of effort and will require fewer employees.

DESCRIPTION OF PERSONNEL

Current Composition

There are federal and management and operating contractor employees funded by the Environmental Management program at the Kansas City Plant. Approximately 68 of the management and operating contractor employees are directly funded by the Environmental Management program. The remaining employees are funded indirectly through a burden rate applied to environmental management activities. The directly funded employees consist of managers, administrative personnel, engineers, scientists, administrators and other professionals, technicians, and laborers. The table below presents the federal and contractor work force by labor category.

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

Site Management Structure

The Department of Energy owns the Kansas City Plant. Allied Signal operates the facility through a cost-plus-award-fee management and operating contract which expires in March 2000. The management and operating contract is structured to provide financial incentives for waste volume reduction and productivity savings. Some work is subcontracted to private companies or other federal contractors through Integrated Contractor Orders. These contracts are usually annual contracts or contracts for a specific portion of a project that may span several years. Commercial contracts are competitively bid. Two of the primary subcontracts for Environmental Management are for support of environmental restoration assessment and ground water-related activities and for support of the Industrial Wastewater Pre-treatment Facility.

Future Full-Time Equivalent Needs

The number of Environmental Management Full-Time Equivalents at the Kansas City Plant has peaked. The size of the Environmental Restoration staff will steadily decline until work is complete in FY 2000.

FUNDING ESTIMATE

The following tables present estimated funding information for the Kansas City Plant.

COMPARISON WITH PREVIOUS ESTIMATE

Significant changes have been incorporated into the cost estimates from the FY 1995 Baseline Environmental Management Report. Environmental Restoration costs have decreased by 71 percent, and Waste Management costs have increased by 90 percent. The overall result for the site is an increase in estimated life-cycle cost of approximately 4 percent. Also, note that program management costs have been integrated into relevant activity costs and are not a separate category. See the Comparison Table on the following page for additional life-cycle cost information.

Comparison Table

Activity	FY 1995 Life Cycle	FY 1995 Only 1	FY 1996 Life Cycle	Change in Dollars	Change in Percent
	Thousands of Dollars
Nuclear Mat. & Fac. Stab.	-	-	-	-	-
Environmental Restoration	99,822	3,478	28,081	­68,263	­71
Waste Management	226,898	6,116	418,710	197,928	90
Landlord	-	-	-	-	-
Program Management 2	113,377	2,225	-	-	-
Site Total	440,097	11,818	446,791	18,512	4
1 The FY 1995 life-cycle and annual costs are provided to determine the corrected FY 1995 cost. 2 Program Management was reported in an independent cost table last year, but is reported as a line item in the relevant program (Nuclear Material and Facility Stabilization, Environmental Restoration, and Waste Management) activity cost estimate tables for the FY 1996 Baseline Report.

Last year's report assumed all contamination would be excavated and disposed of in certified offsite landfills, regardless of risk. The FY 1996 report contains risk-based assumptions. Cleanup activities, like other construction projects, have inherent safety risks. In evaluating cleanup alternatives for this report, the risk of exposure at each site was also considered. At minimal risk sites, the assumption was made that remedial action will not be required and exposure risks could be minimized through procedural controls. As a result, the waste volume projections and the costs associated with remedial action have been significantly reduced.

Also, assumptions concerning the duration of the Waste Management program have changed. Last year's Baseline Report assumed activities to cease in FY 2030; this year they are assumed to end in FY 2070. Waste Management program cost estimates also include a line item to replace industrial waste piping that was not in last year's report. In FY 1998, low­level waste generation rates increased significantly from previous estimates because nonnuclear consolidation by the Department has increased the number of activities at the Kansas City Plant that have the potential to generate low-level waste.