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P-9 Project

The P-9 Project was the codename assigned during to the Project's initiative for producing (deuterium oxide), a key moderator substance intended for nuclear reactors to facilitate production as a backup to graphite-moderated systems at Hanford. Launched in October 1942 under the Office of Scientific Research and Development and led by chemist Hugh Taylor of , the project combined research into heavy water's properties with large-scale manufacturing to support the Allied atomic bomb effort. The program's origins stemmed from early recognition of 's potential in , building on Canadian electrolytic expertise and U.S. distillation methods, with initial emphasis on secrecy due to its ties to the broader . By , production ramped up across multiple sites, yielding a total of approximately 81,470 pounds of by the end of 1945, though U.S. facilities often fell short of targets while the Canadian plant performed reliably. Ultimately, the was not used in the uranium-based bombs dropped on , serving instead as a vital reserve for postwar reactors like (critical in 1944) and Canada's (critical in 1945). Key production occurred at four primary facilities: the Consolidated Mining and Smelting Company's plant in , Canada, which utilized a hydrogen-water exchange process and began operations in summer 1943, producing about 0.5 tons per month until 1956; and three U.S. sites built in 1943—the Morgantown Ordnance Works in (electrolytic finishing, 0.4 tons/month capacity), Ordnance Works in (1.2 tons/month), and Childersburg Auxiliary Plant in Childersburg, (0.8 tons/month). These efforts, costing over $17 million in construction and $11 million in operations by 1946, were discontinued in the U.S. by summer 1945 following the war's end, highlighting the project's role in accelerating amid intense wartime pressures.

Background

Manhattan Project Context

The was established in 1942 as a top-secret program under the U.S. Army Corps of Engineers to develop atomic weapons during . The project was directed by Brigadier General , who oversaw its military and engineering aspects, while physicist provided scientific leadership, particularly in directing the Laboratory for bomb design. The primary goals of the Manhattan Project centered on producing fissile materials for atomic bombs through two parallel paths: enriching for one type of weapon and producing for another via nuclear reactors fueled by uranium. Plutonium production required constructing reactors to irradiate , transforming it into plutonium through and subsequent , with facilities like dedicated to large-scale operations. Heavy water, or deuterium oxide (D₂O), played a as a in certain designs, slowing neutrons to sustain reactions while having a lower probability of absorbing them compared to ordinary water. It was recognized as superior to in moderating efficiency, particularly for enabling reactions using due to deuterium's low neutron absorption cross-section. In October , the heavy water production effort was assigned the codename P-9 as a covert sub-program within the to maintain secrecy and prevent alerting to Allied advancements.

Scientific Need for Heavy Water

In nuclear fission, neutrons released from the splitting of fissile isotopes like uranium-235 or plutonium-239 are produced at high energies and must be slowed to thermal speeds for efficient capture by additional fissile nuclei, enabling a self-sustaining chain reaction. Moderators facilitate this neutron slowdown through elastic scattering collisions, but an effective moderator must also exhibit low neutron absorption to avoid terminating the chain prematurely. Heavy water, chemically deuterium oxide (D₂O), features oxygen bound to —a hydrogen isotope with one proton and one —rather than (ordinary ). This isotopic substitution imparts with a neutron absorption cross-section over 600 times lower than that of light water (H₂O), primarily because scatters neutrons more effectively via elastic collisions without capturing them as readily as protium does. As a result, serves as a superior moderator, preserving a higher fraction of neutrons for while also providing cooling capabilities in reactor designs. Compared to , the moderator employed in the (CP-1) reactor that achieved the first controlled in , offers enhanced performance by allowing reactors to operate with fuel, obviating the costly and complex need for isotopic enrichment. Early 1942 experiments at the demonstrated 's potential superiority over for sustaining s in unenriched , despite 's greater availability after purification to remove impurities like . The P-9 Project's focus on production addressed this scientific imperative by scaling up output to several dozen tons, sufficient to fuel experimental -moderated reactors like (CP-3) at , which went critical on May 15, 1944, and supported broader efforts in research.

Origins and Development

Initial Proposals

The initial proposals for what would become the P-9 Project emerged in the summer of 1942, as part of the broader efforts to explore alternative pathways for nuclear chain reactions. Harold C. Urey, based at , and Eugene P. Wigner played pivotal roles in advocating for the use of as a moderator in reactors designed for production. Their work built on earlier theoretical insights into deuterium's neutron-absorbing properties, proposing that could facilitate controlled fission in reactors fueled by , thus avoiding the complex and resource-intensive enrichment processes being pursued under other project branches. These ideas gained traction through discussions at the in , where researchers under evaluated reactor designs. The laboratory's teams recognized heavy water's potential to serve as both moderator and coolant, offering a more efficient route to plutonium separation without relying on graphite moderation or supplies, which were facing significant production bottlenecks. This conceptual shift emphasized heavy water's role in scaling up output for military applications, prompting preliminary specifications for production requirements, such as achieving at least 99.7% deuterium oxide concentration. In late 1942, the Manhattan Project's Military Policy Committee formally approved the initiative, marking a key decision to pursue production as a parallel track to (P-5) and (P-10) efforts. The committee allocated an initial budget of $10 million via a supplement to Letter Contract No. W-7412 eng-4, dated 31 December 1942, to fund research, development, and procurement. The project was designated with the codename "P-9" to specifically denote heavy water activities, distinguishing it from other classified components of the program.

Site Selection Process

The site selection process for the P-9 Project's heavy water production facilities prioritized several key criteria to ensure efficient, secure, and rapid implementation amid wartime constraints. Access to abundant hydroelectric power was essential for the energy-intensive process, while isolation in remote areas enhanced security by minimizing risks and public exposure. Proximity to established chemical industries facilitated resource availability and technical expertise, and all sites were chosen to avoid densely populated urban regions, thereby reducing potential disruptions and maintaining operational secrecy. Evaluations encompassed both U.S. and Canadian options, with a strong preference for leveraging existing industrial facilities to accelerate startup times and control costs, rather than constructing new sites from scratch. East Coast locations were explicitly rejected due to heightened vulnerabilities associated with sympathizers and urban density. In the U.S., the Ordnance Department conducted comprehensive surveys of government-owned reservations to identify suitable venues, ultimately selecting three ordnance works under construction that met the criteria for power, isolation, and chemical infrastructure. For Canada, the focus narrowed to facilities with proven capabilities, building on initial U.S. proposals from 1941 that highlighted the need for as a . The Cominco facility in , was selected in , following proposals from 1941, for its established electrolytic hydrogen production since the 1930s using hydroelectric power, providing immediate expertise in large-scale . This remote, mountainous location offered inherent security advantages, far from potential intelligence threats. In parallel, U.S. sites were finalized through Department assessments: the Works in for its central location and power access; the Works near Childersburg for southern industrial synergies; and the Morgantown Works in for its isolation and river-based resources. Contracts were awarded under strict Army oversight to expedite construction while preserving secrecy, with the plants disguised as conventional ordnance facilities. received contracts for all three U.S. sites in late 1942, leveraging its chemical engineering prowess: the Ordnance Works targeting 1.2 tons of per month, the Alabama Ordnance Works (Childersburg Auxiliary Plant) at 0.8 tons per month, and the Morgantown Ordnance Works at 0.4 tons per month. These selections ensured a combined U.S. output capacity of about 2.4 tons per month, complementing Trail's 0.5 tons to meet demands.

Canadian Operations

Trail Facility Construction

The Trail heavy water facility was established through the expansion of the Consolidated Mining and Smelting Company of Canada (Cominco)'s existing electrolytic plant located in , a site selected for its proximity to abundant, low-cost hydroelectric power from the and its established infrastructure for large-scale since 1930. This expansion was initiated under the Manhattan Project's P-9 program, with the U.S. government providing full funding for the modifications, estimated at approximately $2.6 million, while Cominco handled operations at cost. Key infrastructure additions included secondary electrolysis cells to enrich deuterium from an initial concentration of about 2.3% to 99.8%, integrated into the existing setup of 3,215 primary cells that consumed 75 MW of hydroelectric power. A dedicated dual-temperature tower, known as the P-9 Tower, was also constructed to perform the initial deuterium-hydrogen , raising concentration from natural levels of 0.015% to 2.3% before further . These enhancements transformed the site into a dedicated facility without disrupting Cominco's operations. Security was paramount given the project's classified nature; the initiative was codenamed "Project No. 9" starting in October 1942, with information restricted to a small, vetted group of personnel and no direct U.S. scientific involvement in daily operations to minimize risks. Strict compartmentalization ensured no security breaches were reported throughout the wartime effort. The facility achieved operational status in January 1944, meeting the urgent wartime timeline, and targeted an initial production goal of approximately 1,000 pounds (0.5 tons) of per month to support nuclear research needs. This capacity leveraged the site's hydroelectric resources efficiently, enabling rapid scaling for the Allied effort.

Cominco's Production Methods

Cominco's production at the facility utilized a combined catalytic and process, leveraging the company's existing infrastructure for efficient enrichment. The initial stage involved a countercurrent -water catalytic in tall towers packed with catalysts, including on carbon for the first three stages and nickel-chromia for the fourth. gas, generated by of ordinary in Cominco's synthesis plant, was introduced at the bottom of the towers, where it preferentially absorbed protium (light ) over due to isotopic differences in reaction rates, enriching the descending stream to approximately 2.3% oxide concentration. This was facilitated by steam at to enhance the equilibrium shift toward transfer into the water phase. The enriched water from the exchange towers was then directed to secondary electrolysis cells for further concentration. In these batch electrolysis units, water was decomposed into hydrogen and oxygen gases, with protium evolving preferentially at the cathode, leaving the residual water progressively richer in deuterium. This dual-stage electrolysis cascade raised the concentration from 2.3% to 99.8% deuterium oxide purity, suitable for use as a nuclear moderator. The process was based on a patented method developed by Fritz Hansgirg, adapted by Cominco engineers for large-scale operation. Cominco adapted elements of its fertilizer production facilities for heavy water synthesis, notably repurposing the electrolytic hydrogen plant—originally comprising 3,215 cells powered by 75 MW for ammonia production—to supply the exchange towers and support the secondary electrolysis. Key innovations included the countercurrent cascade design of the exchange towers for optimal isotope separation efficiency and the integration of steam-assisted catalysis to reduce energy demands compared to purely electrolytic methods. Isotope ratios were monitored throughout production using mass spectrometry to verify deuterium concentrations and maintain process control.

American Facilities

Morgantown Ordnance Works

The Morgantown Ordnance Works, situated near Morgantown in , on the west bank of the , represented the inaugural U.S. facility dedicated to production within the Manhattan Project's P-9 initiative. Spanning an area integrated into the broader 800-acre ordnance complex, the site was selected for its pre-existing infrastructure, including access to utilities, steam generation, and hydroelectric power resources in the region, which expedited development amid wartime urgency. Construction of the plant commenced on January 7, 1943, under contract with E. I. du Pont de Nemours & Company, and reached substantial completion by September 1943, with full operational readiness by December 31, 1943, at a total cost of $3,476,205. The facility comprised seven specialized buildings, including a critical electrolytic finishing plant, process pump and control structure, product storage unit, , and supporting boiler house and spaces, all constructed with temporary wood-frame designs to accelerate deployment. Approximately workers, predominantly drawn from local communities, staffed the operations, contributing to the site's role in bolstering the nation's nascent nuclear efforts. Designed with a production capacity of 0.4 tons of per month, the Morgantown plant marked a pivotal advancement in domestic synthesis, enabling its use as a in experimental reactors. A distinctive feature was the seamless incorporation of activities into the guise of conventional ordnance manufacturing, providing essential operational secrecy and camouflage against potential intelligence threats. The facility achieved its inaugural U.S. output on May 28, 1943, shortly after startup of the first electrolytic unit, thereby initiating American contributions to the allied nuclear program.

Wabash River Ordnance Works

The Wabash River Ordnance Works heavy water facility was located near and in , along the . This site was selected as part of the broader American site selection for its reliable access to large volumes of essential for the and its rural isolation, which facilitated security and secrecy for operations. Construction of the heavy water plant was managed by E.I. du Pont de Nemours & Company under a Manhattan Engineer District contract, beginning in early 1943 and reaching substantial completion by December 1943, with full operational readiness by September 1943. The facility was integrated into the existing 6,990-acre ordnance reservation, encompassing specialized structures such as a process pump and control building, product storage building, power house addition, , and warehouse, totaling around 40 buildings across the heavy water area. The project cost approximately $7.5 million, reflecting the rapid wartime buildout to meet urgent demands. As the largest of the three U.S. heavy water production sites, the Wabash facility targeted an output of 1.2 tons per month through methods, contributing significantly to the combined goal of three tons monthly across all American plants. Peak operations involved about 1,200 personnel, including women serving as equipment operators, highlighting DuPont's emphasis on workforce expansion during the . Initial production commenced in June 1943, with the plant running until 1946 before entering standby. The site's riverside position presented flooding hazards from the , which were countered by ongoing construction and flood protection measures to safeguard operations.

Childersburg Auxiliary Plant

The Childersburg Auxiliary Plant was located in Childersburg, , within the existing Alabama Army Ammunition Plant (also known as the Alabama Ordnance Works) in Talladega County, approximately 45 miles southeast of at the junction of Talladega Creek and the . The site was selected as part of the broader U.S. production efforts due to its access to abundant water supplies from local rivers and proximity to power resources in the region, leveraging chemical manufacturing expertise already present in the ordnance facility. Construction of the auxiliary heavy water facility began on February 11, 1943, under the management of E.I. du Pont de Nemours & Company, which integrated the production units into the existing ammunition plant with minimal new construction, utilizing temporary wooden frames and corrugated siding for buildings such as process pumps, control rooms, and towers. The project was completed by November 15, 1943, at a total cost of approximately $5 million, with the first production unit becoming operational on May 28, 1943, and full operations achieved by September 4, 1943. This retrofitting approach allowed for rapid deployment while maintaining the site's primary cover as an explosives manufacturing operation. The plant's capacity was designed for 0.8 tons (1,600 pounds) of semi-finished per month using a process in eight stages to concentrate deuterium oxide to about 90%, though actual average output from January 1944 to July 1945 was around 588 pounds monthly, with a total of 11,160 pounds produced before shutdown in June 1946. Employing roughly 300 workers, the facility operated under strict secrecy, with the production disguised as part of the powder and munitions activities to avoid detection; most personnel were unaware of the purpose, and output was shipped in sealed containers via Railway Express as intermediate product to the Trail facility in for further processing before distribution to sites. Security measures included fenced perimeters, guarded access points, and restricted technical oversight by District engineers to preserve compartmentalization.

Production and Operations

Heavy Water Synthesis Techniques

The primary method for heavy water synthesis in the P-9 Project relied on electrolytic enrichment, a process that exploits the preferential evolution of protium (light , ^1H) over (^2H) during the . In this technique, ordinary water is subjected to , where light gas is released more readily at the due to its lower compared to , thereby concentrating the heavier oxide (D_2O) in the residual liquid. The fundamental reaction is: $2\text{H}_2\text{O} \rightarrow 2\text{H}_2 + \text{O}_2 with isotopic favoring the separation, achieving a separation factor of approximately 5 to 8 per electrolytic stage depending on conditions such as composition and temperature. Multiple cascaded stages were employed to progressively enrich the content from the natural abundance of about 0.015 atomic percent to over 99%. Following initial enrichment, fractional distillation under vacuum refined the product to high purity. This step capitalized on the slight difference in boiling points between H_2O (100°C at standard pressure) and D_2O (101.4°C), allowing separation in multi-stage distillation towers operated at reduced pressure to lower boiling temperatures and prevent decomposition. At the American facilities, an eight-stage vacuum distillation train concentrated water to approximately 90% D_2O, after which it was fed into finishing electrolysis cells for final purification to ≥99.7% deuterium oxide. The process used steam-heated calandrias and bubble-cap plates in towers of varying sizes, with vacuum maintained by steam jet ejectors. Site-specific variations adapted the core techniques to local . At facility operated by Cominco, electrolytic enrichment was supplemented by a catalytic hydrogen- exchange process involving , where was preferentially exchanged from synthesis gas into liquid over a catalyst before reconversion to enriched ; this leveraged the existing plant's supply for initial concentration to about 2.3% D_2O prior to . In contrast, the American plants emphasized as the primary enrichment step, with reserved for the final finishing at Morgantown. Energy demands were substantial, with electrolytic processes requiring approximately 30-50 kWh per gram of produced, derived from operational costs and hydroelectric or integration at the sites. Safety protocols addressed the inherent risks of flammability and high-voltage operations. Facilities incorporated traps, liquid-gas separators, and duplicate pumping systems to mitigate gas buildup and ensure continuous flow without interruptions that could lead to pressure hazards. Electrolytic cells used non-corrosive electrolytes like (7.5% by weight) to prevent acidic degradation, and all shipments of enriched product employed sealed containers with numbered for secure transport. Purity was verified through measurements, as D_2O exhibits a density of 1.105 g/cm³ compared to 1.000 g/cm³ for H_2O, allowing precise assessment via pycnometry or hydrometry.

Output Quantities and Challenges

The P-9 Project achieved significant production milestones during , culminating in approximately 81,470 pounds (40.7 short tons) of by the end of 1945. The facility in accounted for approximately 34,800 pounds (17.4 short tons), while the combined output from the three U.S. sites—Morgantown Ordnance Works, Wabash River Ordnance Works, and Childersburg Auxiliary Plant—reached 46,667 pounds (23.3 short tons) by September 1945. Production ramped up progressively from mid-1943 across all sites, with the Trail plant attaining its design capacity of around 1,000 pounds per month by December 1944 and the U.S. facilities entering full operation by September 1943. Peak monthly output across the project reached approximately 3,600 pounds (1.8 short tons) in late 1945, exemplified by the U.S. plants' combined high of 2,592 pounds in August 1945. This was distributed to essential components, including shipments to the for the CP-3 reactor, which achieved criticality in May 1944 using as a moderator, and to the Hanford site's B-Reactor for experimental purposes. Despite these accomplishments, the project encountered notable operational challenges. Equipment posed a persistent issue at the U.S. facilities, particularly in the calandrias caused by tube failures in the electrolytic cells, which required ongoing maintenance and adjustments to sustain output. At , power shortages stemming from an abnormally between and April 1944 curtailed hydroelectric supply, limiting production to 67% of maximum capacity during that period. The overall construction costs totaled $17.8 million, representing a savings compared to initial estimates of nearly $28 million, though operational complexities contributed to delays in reaching full efficiency. These efforts proved vital to the , enabling the successful operation of heavy water-moderated research reactors like CP-3 (critical in May 1944) and providing a strategic reserve of for potential backup production systems at sites like Hanford, though it was not utilized in the wartime atomic bombs.

Legacy

Post-War Applications

Following the end of , the remaining stocks of produced under the P-9 Project were transferred to the newly established (AEC) in 1946 for allocation to research reactors and nuclear development programs. This transfer marked the shift from wartime military control under the Manhattan Engineer District to civilian oversight, enabling the repurposing of the material for peacetime scientific and energy applications. By the end of 1945, cumulative P-9 production across all facilities had reached approximately 81,470 pounds (about 37 metric tons), with significant portions retained for post-war use after wartime consumption in experimental setups. Key applications included fueling the Chicago Pile-3 (CP-3) reactor at , which utilized around 6.5 tons of as both moderator and to study behavior and production techniques into the late 1940s. In the 1950s and early 1960s, P-9-derived supported operations at the Savannah River Site's Heavy Water Components Test Reactor, testing fuel elements and components for advanced heavy-water-moderated designs. These efforts provided critical data on reactor efficiency and safety, laying groundwork for scalable systems. Additionally, the material contributed to early Canadian nuclear initiatives, supporting prototype heavy-water reactors that informed the development of CANDU (CANada Deuterium Uranium) designs, which relied on and moderation for commercial power generation. The facility in , a of P-9 production, continued operations post-war at a rate of over 1,100 pounds per month until 1956, with dedicated production for the project ceasing in 1949 to meet ongoing demands from allied programs. During this period, heavy water from Trail was exported to support U.S. research reactors and the United Kingdom's emerging nuclear efforts, fostering international collaboration. The P-9 Project's electrolytic enrichment process advanced knowledge of hydrogen isotope separation, providing foundational techniques for deuterium extraction that later influenced the production of fusion fuels in hydrogen bomb development during the early Cold War era. This legacy extended beyond reactors, enabling precise isotopic manipulation essential for thermonuclear weapons and broader isotope research.

Decommissioning and Environmental Effects

The U.S. P-9 facilities at Morgantown Ordnance Works, Ordnance Works, and Childersburg Auxiliary Plant were idled between 1945 and 1947 following the conclusion of , with full decommissioning completed by 1950 as heavy water production needs diminished after the Project's primary goals were met. The Cominco plant at , ceased dedicated production for the project in 1949 and was repurposed for fertilizer manufacturing, though some operations continued in a limited capacity until 1956. Following idling in 1945, the Morgantown site was leased to chemical companies until the early 1950s and later converted to an in 1962, with structures razed over time. The facility was converted for storage and later repurposed as the for ammunition handling. The Childersburg plant was decommissioned after the war and later became part of efforts. Environmental concerns from P-9 operations primarily stemmed from tritium contamination generated as a byproduct during deuterium enrichment via , alongside and from chemical electrolytes and process wastes, prompting Department of Energy () monitoring programs that extended into the at affected sites. Sites like Morgantown were designated under the program due to disposal, with remediation addressing contaminants in and to mitigate long-term ecological risks; the site was deleted from the in 2018. At the Alabama Army Ammunition Plant (former Childersburg site), ongoing DOE oversight focused on chlorinated solvents and metals leaching into aquifers, with restrictions on use implemented to protect . Worker health and safety records from the P-9 Project indicate no major accidents or radiation incidents, but documented exposures to hazardous chemicals such as and caustic solutions prompted retrospective epidemiological studies in the late to assess long-term effects on personnel. These investigations, part of broader evaluations of sites, revealed potential risks for respiratory and dermatological issues among operators, leading to compensation considerations under veteran health programs. Environmental remediation efforts across the U.S. sites, including soil excavation and water treatment, were estimated to approximately $10 million by 2000, reflecting the of legacy .

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