19Q0163_SOW.docx

STATEMENT OF WORK

Pilot-Scale Continuous Flow Reactor 13 February 2019

1.0 BACKGROUND

The Energetic Materials Research Branch of the Naval Air Warfare Center Weapons Division (NAWCWD) requires an update to the current chemical pilot plant in order to improve process safety and increase the scope of NAWCWD capabilities to produce fine chemicals and explosives. The laboratory update will provide NAWCWD with the capability to safely support the warfighter by making energetic chemicals as needed. This includes the ability to transition research discoveries from material readiness level 1 through material readiness level 8/9.

1.1 Scope

This requirement is for continuous flow reactors which improve process safety and improve product throughput. The continuous process is safer because small amounts of dangerous chemicals are continuously processed and pushed through the system, rather than one large batch. The proposed solution will provide the capability to produce specialty chemicals and energetics, via continuous flow reactors at the pilot scale.

2.0 APPLICABLE DOCUMENTS

System Engineering Plan: Chemical Pilot Plant Modernization CIP FY2019, Revision A, 12 September 2018.

3.0 REQUIREMENTS

The contractor shall provide a continuous flow chemical reactor system, meeting all the requirements and specifications detailed in the following sections. The chemical reactor system shall be comprised of, at minimum, a continuous flow reactor, a dosing pump system, heater-chiller unit, and a control system.

3.1 Continuous Flow Reactor

The contractor shall provide, as part of the continuous flow chemical reactor system, a continuous flow reactor. This reactor shall be of a design and configuration to react liquid reagents, and provide heat transfer to process fluid.

3.1.1 Capacity and Volume

The continuous flow reactor shall be capable of a volumetric flowrate of no less than 10 L per hour and not more than 50 L per hour, standardized to water. The total process fluid volume of the reactor system shall be no less than 40 mL and no more than 100 mL. The total process fluid volume shall be adjustable; this might be accomplished by having multiple modules of smaller volumes, which are used in series to create the total desired volume.

3.1.2 Materials of Construction

The materials of construction for process-wetted surfaces shall be compatible with reagents and solvents common to the direct nitration of polyols; including concentrated sulfuric acid, concentrated nitric acid, white fuming nitric acid, oleum, and common organic and inorganic solvents.

The materials of construction for heat-exchange-wetted surfaces shall be compatible with heat transfer fluid, a propylene glycol / water mixture of nominal 50 vol%.

3.1.3 Operating Conditions and Boundaries

The process side of the reactor system shall be capable of full and unhindered operation within a process fluid temperature range of -5°C to 120°C, and a pressure range of ambient to 10 barg.

The heat exchange side of the reactor system shall be capable of full and unhindered operation within a heat exchange fluid temperature range of -25°C to 150°C and a pressure range of ambient to 2 barg.

The design shall include appropriate temperature sensors to support the safe operation of the reactor while conducting chemical reactions capable of thermal-runaway.

3.1.4 Process Channel Geometry

The geometry of the process fluid channel in the reactor shall be of a design that is directly scaled from a smaller, bench-scale reactor. The specific geometry shall not be circular, but shall be designed to increase heat and mass transfer characteristics, beyond that of circular flow-channels.

3.2 Liquid Dosing Pumps

The contractor shall provide a dosing pump system designed to support the utilization of continuous flow reactor for the purpose described in previous sections.

3.2.1 Number and Type of Pumps

The contractor shall provide a total of four (4) pumps: three (3) of these pumps shall configured for general chemical resistance, the remaining pump shall be configured for the pumping of white fuming nitric acid (WFNA).

3.2.2 Materials of Construction

The materials of construction for the wetted surfaces of pumps configured for general chemical resistance shall have good corrosion resistance characteristics for common organic solvents, common inorganic solvents, common halogenated solvents, weak acids, weak bases, and common organic reagents (specifically alcohols). The contractor shall use any one or combination of stainless steel (either 316 or 316L), chemically resistant glass, and fluorinated elastomers.

The materials of construction for the wetted surfaces of pumps configured for WFNA resistance shall have good corrosion resistance to WFNA specifically and exclusively.

3.2.3 Performance and Operation Specifications

All pumps shall have a design pressure consistent and compatible with the design of the reactor system. Individual pumps shall be capable of a volumetric output of no less than 5 L per hour and no more than 10 L per hour, standardized to water.

The dosing pump system shall have a pressure relief mechanism, appropriate to prevent damage to the pumps and connected equipment. The pumps shall also be equipped with pressure transducers, as well as flowrate sensors. The dosing pump system shall be controllable from the control system detailed in later sections.

3.3 Heater-Chiller Unit

The contractor shall provide a heat exchange fluid heater-chiller unit, designed to support the use of the continuous flow reactor for the intended purpose, described in previous sections.

3.4 Control System

The contractor shall provide a control system, designed to support the use of the continuous flow reactor for the intended purpose, described in previous sections.

3.4.1 Automation

The control system shall be capable of controlling the dosing pump system, described in previous section; to include the ability to power on and off, start and stop pumping, and adjust the rate of pumping of each pump independently.

3.4.2 Data Acquisition

The control system shall be capable of collecting, displaying, and storing measurements from the pressure, temperature, and flowrate sensors described in the preceding sections. The memory capacity shall be no less than 8GB.

3.4.3 Remote Operation

The control system must be capable of being physically separated from the rest of the system, i.e. housed in a control room. The control room will be no more than 100 linear feet from the operational room wherein the rest of the system resides. The control system must integrate with the rest of the system via a physical connection, e.g. fiber optical cable or wire, not through radio communication.

3.5 System Integration

The contract shall provide all appropriate fittings, connectors, adapters, cables, hoses, lines, and anything else necessary for the assembly and integration of the system components.

3.6 Installation and Training

3.6.1 Installation and Start-Up

The contractor shall provide installation of the equipment at NAWCWD, to include an initial start-up of the system. The contractor shall allow NAWCWD personnel to observe the installation. The contractor shall execute an acceptance test procedure, demonstrating and verifying the ability of the installed system to meet all of the aforementioned requirements. Upon delivery and installation, the contractor shall provide a printed copy of the self-generated test report to NAWCWD personnel (A00X).

3.6.2 Training

The contractor shall provide on-site training to NAWCWD personnel, in the operation of the system.

3.6.3 Documentation

The contractor shall provide an operating manual for all hardware and software provided (CDRL A00X).

3.6.4 Travel

The contractor shall travel to NAWCWD China Lake for no less than 3 days to conduct installation, start-up, and on-site training.