Statement_of_Work.docx

STATEMENT OF WORK

Large Scale Synthesis Laboratory Design Package 01 February 2019

1.0 BACKGROUND

Chemical obsolescence is a current and evolving challenge to the U.S. energetics research and production community. Several materials critical to fielded weapon systems are no longer produced by an approved CONUS source, and a great number more are in danger of such. Additionally, research and development of energetic materials relies heavily on commercial sources of materials, however the quantities needed are often so small as to be disincentivizing to the manufacturer. Mitigation strategies and measures are currently being implemented at a high level within the DOD and industry, but those solutions will be long term and will likely fail to address the specific and immediate needs of on-going research.

An additional dimension to the overall challenge is the shelf-life and storability of certain materials. Some energetic materials are less amenable to long term storage than others. Storing these materials long term, as is common in the R&D community, incurs significant cost and risk. These materials are often of limited availability from commercial sources for all the aforementioned reasons.

In order to bridge the gap between the current shortage of materials and a long term solution in the greater community, it is proposed that the Naval Air Warfare Center at NAWCWD modernize its capability to make small quantities of specialty chemicals to support energetic material research at NAWCWD and partner DOD facilities. This capability would include the ability to make a wide range of energetic and specialty materials, on-demand, and to-quantity. The proposed funding source for this effort is an FY2019/FY2020 Capital Improvement Project (CIP).

When this CIP is complete, NAWC-WD will have 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. Activities like this are required if the US Navy is to regain dominance. Updating our current laboratory will greatly improve process safety, and it will increase the scope of NAWC-WD capabilities to produce fine chemicals and explosives.

2.0 SCOPE

The current chemical pilot plant at NAWC-WD is obsolete. The current batch reactor, while operational and sufficient for the proposed usage in-and-of itself, is not attached to any other unit operations that would make it usable. Additionally, it is located in a space that makes it impossible to establish such connections The proposed solution will create a design which utilizes the existing equipment in a new usable configuration integrated with several other unit operations. This will provide the initial design for follow-on projects to establish the capability to produce specialty chemicals and energetics, via batch reactions at the pilot scale.

3.0 REQUIREMENTS

The contractor shall provide a process engineering package consisting of specifications and drawings of the equipment, controls, and processes for a design of a Large Scale Synthesis Laboratory that meets the requirements defined in section 3.1. Deliverables for the process engineering package are defined in section 3.2.

Please note that the numbering system for the design requirements matches that in the Systems Engineering Plan wherein they were first documented. For that reason, the numbering of the requirements begins with R.2 (Large Scale Synthesis) and is decomposed into a hierarchy, see Figure 1, below.

Figure 1 Design Requirements Hierarchy

3.1 LARGE SCALE SYNTHESIS DESIGN REQUIREMENTS

Large Scale Synthesis Subsystem Level Requirements Generally, the production of chemicals in accomplished in either batch or continuous modes. The particular mode chosen will depend on both the particular chemical being produced and the amount required. Generally, the batch mode of production is most useful for small quantities of either solid or liquid material, whereas the continuous mode is useful for liquids in intermediate and large quantities. The chemical pilot plant system must be capable of producing materials in the batch mode. Rarely are chemicals, energetic or otherwise, produced in a useable form in a single step. In the majority of cases, the material must be recovered from the reaction mixture and purified in a process called recovery.

Table 1 Large Scale Synthesis Subsystem Level Requirements

Figure 2 Large Scale Synthesis Requirements

Batch Production Requirements Batch production will use existing equipment E.1., a 50 gallon, glass-lined, jacketed, stirred-tank reactor. Several subsystems will comprise the batch production. A secondary vessel capable of supporting E.1 during nitration chemistries and work-up steps (e.g. a quench vessel) must be installed.

Table 2 Batch Production Requirements

Figure 3 Batch Production Requirements

Utilize E.1 The existing equipment E.1 is suited to the purpose of energetic material synthesis generally. In order to integrate E.1 into the Pilot Plant system, several requirements must be met, see Table 3. Currently, E.1 is installed in BLDG A and must be moved to the proposed location, BLDG B. The reactor will also need to be integrated with the existing gantry, such that the top of the body of the reactor is level with the gantry platform. This will allow better access to both the bottom drain and ports on the lid. It will also be necessary to ensure secondary containment of the reactor system. Installation of E.1 will necessitate a regulatory compliance review and survey for the specified facility and room.

Table 3 Batch Production Requirements

Figure 4 Utilize E.1 Requirements

Temperature Control E.1 is a jacketed reactor vessel, giving it the ability to heat or cool reaction mixtures via a liquid heat transfer medium, typically a propylene glycol-water solution. The heat transfer medium must be conditioned by heating and cooling equipment external to the reactor. E.1 is also equipped with a thermowell with three RTDs at staggered depths.

Table 4 Temperature Control Requirements

Figure 5 Temperature Control Requirements

Agitation Control E.1 is equipped with an integrated agitator with an electric drive.

Table 5 Agitation Control Requirement

Material Control Requirements It will be necessary to control the mass flow into and out of the reactor. Solid, liquid, and gas streams will be required to accomplish the wide range of syntheses desired. Additionally, the reactor is equipped with a mechanical agitator, which must be electronically controlled.

Table 6 Material Control Requirements

R.2.1.4.5

Figure 6 Material Control Requirements

Recovery Requirements In a typical recovery of a solid product, the material is physically filtered from the reaction mixture and then washed with solvent to remove impurities. Liquid products are often either extracted; mixed with a non-miscible solvent that traps contaminants or distilled, wherein the solvent or product is driven off the reaction mixture as a vapor using heat. The material can then be treated with additives to protect it, such as antioxidants, or mixed with diluting or inerting agents for shipment.

Table 7 Recovery Processes

Figure 7 Recovery Requirements Constraints Beyond the capability requirements of the Chemical Pilot Plant, there will be several constraints that will directly impact the contracting, design, and installation efforts. These constraints will be developed in an iterative manner, as project matures. The relevant stakeholders in each area will direct the development of these constraints.

Explosive Safety NAVSEA OP 5 Ammunition and Explosives Safety Ashore Provides explosives safety information and regulations regarding conventional ammunition, ammunition components, explosives, and related hazardous material operations at all DON facilities. Compliance with explicit safety rules and regulations specified in this publication are mandatory.

OPNAV Instruction 5530.13C Physical Security Instruction for Conventional Arms, Ammunition, and Explosives (AA&E) Provides DON policy and guidance for the protection of conventional AA&E against loss or theft.

Occupational Safety and Health OSHA 29 CFR 1910 Occupational Safety and Health Standards Federal regulator guidance including, but not limited to sections:

38 - Emergency action plans.

39 - Fire prevention plans.3. 1910.94 - Ventilation.

95 - Occupational noise exposure.

101 - Compressed gases (general requirements) 106 - Flammable liquids.

119 - Process safety management of highly hazardous chemicals.

120 - Hazardous waste operations and emergency response.

132 - General requirements.

133 - Eye and face protection.

134 - Respiratory Protection 138 - Hand Protection.

141 - Sanitation.

151 - Medical services and first aid.

157 - Portable fire extinguishers 176 - Handling materials - general.

212 - General requirements for all machines.

307 - Hazardous (classified) locations. (Electrical) 1003 - 13 Carcinogens (4-Nitrobiphenyl, etc.).

1200 - Hazard Communication.

1450 - Occupational exposure to hazardous chemicals in laboratories.

Chemical Hygiene NAWCWD Instruction 5100.7 Chemical Hygiene Plan Chemical hygiene policy and practices at the Naval Air Warfare Center, Weapons Division.

Environmental Protection Regulatory information withheld by stakeholder. Per NAWCWD Environmental Protection Specialists, environmental concerns will only be addressed after the system is fully designed and/or specified in contracts; i.e. during a Site Design Review.

Information Technology Regulatory information withheld by stakeholder. Per the NAWCWD Energetics ISSO, IT concerns will only be addressed after the system is fully designed and/or specified in contracts; i.e. during a Site Design Review.

3.2 Process Engineering Package Deliverables

The contractor shall provide a Process Engineering Package, consisting of the deliverables described in Table 7.

Table 7 Process Engineering Package Deliverables

4.0 Contractor Requirement

5.0 Schedule Requirement

Contractor must be able to provide completed Process Engineering Package within 18 weeks of contract award.

6.0 Conclusion

This Statement of Work describes the Navy’s need for a Process Engineering Package supporting a Capital Improvement Project to modernize the NAWCWD Chemical Pilot Plant. The Process Engineering package is defined as a set of deliverables, which in turn are based on a set of design requirements, both described herein.

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