A -- Topical BAA for - Analysis and Technical Assessment of High Energy Aluminum/Seawater Combustion Systems for Undersea Propulsion (PART 1 of 2)

This synopsis constitutes a Broad Agency Announcement (BAA) per FAR 6.102; there will be no formal request for proposals (RFP) or other solicitation in regard to this announcement. Competition is Unrestricted. Anticipated award date: November, 2005.A. INTRODUCTION The Naval Undersea Warfare Center Division Newport, Rhode Island (NUWCDIVNPT), in support of the Defense Advanced Research Projects Agency (DARPA) is interested in soliciting participation by both industry and academia in the development of Aluminum Seawater Combustion systems for air-independent underwater applications, including submarines, torpedoes, and Unmanned Undersea Vehicle (UUVs) of various sizes. DARPA is presently involved in Phase II of the development of an advanced Hybrid Aluminum Combustor (HAC). It is investigating both fundamental science and technology at the component level for a variety of related energy and power conversion systems and subsystems. DARPA is also looking at the larger multi-component, full-up propulsion system level optimization and technologies required to integrate these novel Hybrid Aluminum Combustors (HAC) into efficient overall underwater propulsion systems. These efforts are focused on maximizing the specific energy and energy density of both the Hybrid Aluminum Combustor (HAC) and the energy density and overall performance of the propulsion system. Candidate underwater propulsion systems that may benefit from the use of Hybrid Aluminum Combustors include UUVs with concepts of operations as discussed in the Navy's master plan; a copy of the current UUV Master Plan can be found online at the following URL: http://www.chinfo.navy.mil/navpalib/technology/uuvmp.pdf. The HAC system technology is a unique compilation of multi-disciplinary advanced technologies; for example, the effective operation of a HAC system will require extensive analysis and understanding of advanced thermodynamics and thermodynamic cycles, multi-phase fluid mechanics, metal/seawater combustion dynamics, radiation/convection/conduction heat-transfer, turbo machinery, gas/liquid/solid separation and handling, materials synthesis and dynamic control systems theory all within the context of system integration and vehicle operations and handling. Proposals may be for studies or investigations that can be completed within a year of award, or may be for multiyear efforts as long as each subsequent phase can be funded as individual options with clearly defined milestones and deliverables. B. GOALS The objective of this solicitation is to develop the full potential of this HAC technology; this can only be accomplished if these disciplines are fully understood and synergistically developed at both the fundamental and system levels. It will require bringing together multiple experts within the applicable technology disciplines to pursue a tightly integrated research and development program that will ultimately produce an unprecedented major performance breakthrough in energy storage and power conversion for underwater vehicles and weapons, including UUVs. NUWCDIVNPT/DARPA are seeking participation from two areas of the community: 1. Entities with established and demonstrated expertise with High Performance combustion and power conversion and expertise with air-independent undersea vehicles (submarines, weapons, UUVs, and devices) capable of accurately assessing the feasibility of and issues associated with the development and manufacture of Hybrid Aluminum Combustors and potential underwater propulsion systems that could benefit from the use of a Hybrid Aluminum Combustor (HAC) 2. Entities to conduct independent technical assessments of specific HAC related technologies in an effort to fully understand the specific technical issues in a manner that will enable the best technical system solutions and yield the highest possible technical capabilities of the HAC components and subsystems 1. Scope of Requirement Area 1: For the first category, companies must demonstrate their ability to fully understand the issues involved in bringing an advanced energy storage and power conversion technology from early concept development and demonstration through advanced development, manufacture, integration, operation and maintenance. The specific energy of the HAC system is targeted to approach 1000 to 1500 Wh/l on a full systems basis for an undersea vehicle with a nominal diameter of 60 inches; such an aggressive number will mandate the use of very advanced manufacturing processes and controls together with the understanding of the use and processing of high strength to weight materials, high temperature materials as well as employing state of the art design for manufacture methodologies and technologies. The HAC system employs an Aluminum metal/seawater combustor as a heat source for a Rankine cycle air-independent 75 HP power conversion system in a UUV. Companies must have demonstrated the ability to understand the critical component technologies of the HAC system sufficiently well enough to optimize the HAC on a systems basis; this can only be accomplished by the efficient and synergistic integration of subsystem components including metal/sweater combustion chambers, metal fuel storage and feed systems, Rankine cycle turbomachionery, compressors, condensers, gas/solids separators, gas/liquid separators, water management, vehicle weight and trim management, component control and integration, and optimizing energy density against the issues of manufacturability, reliability, safety, maintenance and affordability. Area 2: For the second category, NUWCDIVNPT is interested in funding consultants/companies with expertise in specific technological areas of which the HAC system is comprised; expertise is being sought in one or more of the following areas: - Aluminum/metallic alloy powder synthesis and processes to produce specific powder grain sizes ranging from 3 to 15 microns; expertise to determine methodologies/processes to synthesize powders with consistent particle geometries/sizes with tight tolerances and low variances; controlling particle size synthesis of 3 microns, 5 microns, 7 microns, 10 microns and 15 microns. Expertise in metal powder storage and handling and dispensing/injecting; Aluminum metal powders ranging in size from 3 micron to 15 micron; agglomeration characteristics and fluidization for dispensing of metal powders at ambient conditions as well as elevated pressures up to 400 psia; Delivery of Aluminum powders at 0.035 lbm/sec; storing, dispensing and handling of a nominal 150 lb of aluminum powder. - Expertise to quantify the sensitivity of metal powder combustion dynamics as a function of particle compositions as well as particle size. Ignition and control of Aluminum powder combustion; Aluminum, Aluminum alloys of Magnesium, oxidizer-coated aluminum powders; optimize combustor designs for efficient, stable and slag free combustion, aluminum/water combustion dynamics, stoichiometry and efficiency based on combustor geometry, pressure, temperature, flow rate, etc. - Expertise in gas/liquid (H2/H2O(g)/ H2O(l))separators, cyclonic gas/solid separators, separation of alumina particles (0.8 to 30 microns in diameter) from steam/H2; optimizing cyclonic separators by minimizing pressure drop while maintaining highest possible separator efficiency; design variables and particle size and their sensitivity to efficiency; separating aluminum oxides at an average mass flow rate of 28 lbm/hr from high temperature and pressure steam. - Rankine cycle system and component expertise; Steam turbine design, 75 HP, +70,000 rpm nominal, maintaining high efficiency with consideration for ingesting abrasive aluminum oxides entrained in the steam feed; blade erosion and abrasive-resistant materials; maintaining efficiency over a broad turndown ratio of 10:1. - Component integration and system level analysis of HAC system; optimization of system based on individual component performance with consideration towards vehicle integration. The Government is not interested in funding enhancements to proprietary products that may already exist in the commercial domain. C. SUBMITTAL INSTRUCTIONS 1. Potential vendors must submit their technical/management proposal (3 hard copies) and cost proposal (1 hard copy) with one CD-ROM containing both no later than 1400 hours on 12 OCT 2005 to the following address: Commercial Acquisition Department- Bldg. 11, Naval Undersea Warfare Center Division, Newport, Code 5911- Attn: Nancy Teasdale, Simonpietri Drive, Newport RI 02841-1708. 2. Proposals must be valid for 60 days from submission. Any classified information up to the SECRET level must be separated and forwarded to the Naval Undersea Warfare Center Division, Newport, Attn: Pamela Raposa, Code 10C, Bldg. 990/1, 1176 Howell St., Newport, RI 02841-1708. The label should refer to BAA 055428, and reference to the existence of such material should be in the unclassified proposal. The Government anticipates the use of Firm Fixed Price orders/contracts. However, offerors may propose a different contract type. 3. Multiple awards are expected in both topic areas. Approximately $400,000 in total awards are anticipated: approx. $150,000 for area 1 and approx. $250,000 for area 2. However, offerors should be aware that there is no certainty in the funding. The Government reserves the right to select for award all, some, or none of the proposals received. 4. All routine communication concerning this acquisition should be directed to Nancy A. Teasdale, (401) 832-1898, e-mail: teasdalena@npt.nuwc.navy.mil. All technical related issues should be directed to Eric G. Dow, e-mail: doweg@npt.nuwc.navy.mil; Naval Undersea Warfare Center, Newport Division, 1176 Howell Street, Bldg 1302, 2nd Floor, Newport, RI 02841. 5. Proposal length, exclusive of cost and pricing data, is limited to twenty (2) 8-1/2 x 11 inch typewritten pages, and should specify the technical area of concern addressed. The proposal submitted by an offeror is the only vehicle available to the offeror for receiving consideration for award. If an offeror is interested in both technical areas 1 and 2, it should submit two separate proposals. The proposal(s) must stand on their own merit- no supplemental information provided by the offeror will be considered. 6. Offerors should identify proposed costs with a breakdown of cost elements such as direct labor, overhead, G&A, fee or profit, travel, ODs. Pricing should be based upon the assumption that work will begin no sooner than November 2005. The proposal should also contain offer's contractual point of contact information. 7. Proposals containing data that is not to be disclosed to the public for any purpose or used by the government except for evaluation purposes shall include the following statement on their title pages:The proposal includes data that shall not be disclosed outside the government and shall not be duplicated, used, or disclosed, in whole or in part, for any purpose other than to evaluate this proposal. If however, a contract is awarded to this offeror as a result of, or in connection with, the submission of these data, the government shall have the right to duplicate, use, or disclose these data to the extent provided in the resulting contract. This restriction does not limit the government's right to use the information contained in these data if they are obtained from another source without restriction. The data subject to this restriction are contained on sheets (insert page numbers or otherwise identify the sheets). Each restricted data sheet should be marked as follows. "Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this proposal." This statement may be in a small font and should be at the bottom only of each applicable page. 8. All material submitted to NUWCDIVNPT under this announcement shall be considered Government property. The Government requires unlimited data rights with regard to any procurement, with the possible exceptions of (1) a negotiated position for data rights to existing concepts that may be further developed under a procurement, and (2) for efforts conducted under a procurement with leveraged funds. 9. For purposes of this solicitation, offerors should anticipate that contract awards will require a Contract Data Requirements List (CDRL) exampled in Exhibit A that will vary depending on the nature of the contract award. For planning purposes, all awards will require the following data items as a minimum: DI-MISC-80508A- Technical Report, Studies/Services; DI-MISC-80368- Status Report. Depending on what the contractual end items and deliverables are to be, the following may also be required as applicable: DI-MCCR-80700- Computer Software Product End Items; DI-MCCA-80590A- Computer Software Product End Items Documentation. 10. Contractor's format and report consolidation are highly encouraged. Although not required, the government would prefer that offerors use electronic/digital media for report draft and publishable submittals. Microsoft Word 2000 or above will be acceptable for submittal of draft documents, and the use of a CD-ROM is acceptable for the submittal of the final copy. The offeror should consider proposing the use of electronic/digital media for any report. Submittals on CD-ROM should be in a format that is compatible for any PC. Financial and status reporting requirements will be identified per DD Form 1423 as applicable. 11. To be eligible for award an offeror must be registered in the Central Contractor Registration (CCR) database pursuant to Defense Federal Acquisition Regulation Supplement (DFARS) Subpart 204.73. Any offeror, who is not registered, may register at http://www.ccr.gov/index.cfm. 12. Foreign Participation & Disclosure Restrictions. This acquisition involves technology that has a military or space application. It is anticipated that foreign firms will be excluded from participating on this topic.