SOURCES SOUGHT
A -- Commercial Product Trials and Demonstrations with Cast CF8C-Plus Austenitic Stainless Steel
- Notice Date
- 9/8/2009
- Notice Type
- Sources Sought
- NAICS
- 331221
— Rolled Steel Shape Manufacturing
- Contracting Office
- Department of Energy, Oak Ridge National Laboratory - UT Battelle LLC (DOE Contractor), Oak Ridge National Laboratory, Bethel Valley Road, P.O. Box 2008, Oak Ridge, Tennessee, 37831-6192
- ZIP Code
- 37831-6192
- Solicitation Number
- 3400121834
- Archive Date
- 10/30/2009
- Point of Contact
- Shannon E. Bridges, Phone: 8655761426, Christine M Sullivan, Phone: 865-574-7507
- E-Mail Address
-
bridgesse@ornl.gov, sullivancm@ornl.gov
(bridgesse@ornl.gov, sullivancm@ornl.gov)
- Small Business Set-Aside
- N/A
- Description
- Request for Expression of Interest, C ommercial Product Trials and Demonstrations with Cast CF8C-Plus Austenitic Stainless Steel Introduction UT-Battelle, LLC, acting under its Prime Contract No. DE-AC05-00OR22725 with the United States Department of Energy (DOE) for management and operation of Oak Ridge National Laboratory (ORNL), conducts technology research and development (R&D) in support of the U.S. Department of Energy's (DOE) Office of Industrial Technologies Program (ITP). Its mission is to lead the national drive to reduce energy intensity and carbon emissions by changing the way industry uses energy. ORNL is requesting an Expression of Interest (EOI) from prospective vendors to select applications which promote and enhance the objectives of the American Recovery and Reinvestment Act (ARRA) of 2009, P.L. 111-5, especially economic recovery in an expeditious manner. This includes the selection of projects that promote economic recovery, assist those impacted by the recession or provide general economic benefit. As part of this effort, new projects are being developed involving ORNL advanced materials R&D in support of the DOE/ITP mission. Advanced materials with enhanced high-temperature capability, performance, and reliability are essential to enable more energy efficient and cleaner power production, both for transportation and electric power generation applications. New materials that are cost competitive enhance the economic opportunities for improvements in energy efficiency. ORNL has developed a unique new alloy, CF8C-Plus cast austenitic stainless steel, which can out-perform many conventional heat-resistant stainless steels and alloys and match the creep performance of more costly Ni-based superalloys. However, as a new material, this alloy needs trial demonstrations in potential commercial applications. It is, therefore, the purpose of this Expression of Interest request to encourage interested or beneficial teams of stainless steel foundries and component end-users to engage in commercial scale trials of this new steel. Background CF8C-Plus is a new cast austenitic stainless steel based on deliberate additions of Mn and N to an alloy that is otherwise similar to conventional type 347 stainless steel (i.e. standard CF8C steel). It was developed by ORNL and Caterpillar, Inc. for diesel-engine exhaust component applications. The Mn and N additions to this Nb-stabilized steel create stable dispersions of nano-carbides and -nitrides, which then give this stainless steel creep-resistance at 700-900 o C that compares well with much more expensive Ni-based superalloys like alloys 625, 617, Hastelloy® X or 230. CF8C-Plus steel won a 2003 R&D 100 Award, and was patented in 2006. CF8C-Plus can be air-cast, and requires no additional heat-treatments for optimum performance. CF8C-Plus steel has excellent castability and metal-fluidity, which has led to first-part success for a wide range of large and small cast components. CF8C-Plus steel has outstanding resistance to creep and creep-rupture, to fatigue and thermal-fatigue, and to aging-embrittlement at 600-900 o C. CF8C-Plus was recognized as a new heat-resistant cast alloy grade by ASTM (HG10MNN), which included meeting the weldability and weldment properties requirements. In 2006, CF8C-Plus was successfully commercialized for the Caterpillar Regeneration System (CRS) burner housings, required for the ceramic diesel particular filters (DPF) needed for all on-highway diesel engines. The CRS units must withstand severe thermal shock and cycling, and over 450 tons of CF8C-Plus have been cast for this single application; there have been no CRS unit failures, with many component lifetimes exceeding 2.5 years. It is anticipated that such commercial success to-date for the CRS application has merit and can be translated to an expanded range of commercial component applications. Examples of such potential applications are listed below. The expected economic benefit of cast CF8C-Plus steel depends on the application, as well as the materials that it replaces or displaces for such applications. For diesel exhaust systems, the current 400 tons of CF8C-Plus steel used to make the regeneration system burner housing for diesel particular filters has a direct materials value of over $5 million, but prevents the use of nickel-based superalloys that would cost $28 million for the same application and requires no heat treatment saving another $5 million, so the benefit is a savings of ~$28 million compared to alloys requiring heat treatment. Energy benefits for automotive and diesel exhaust component applications accrue from diesel engines being 10-15% more fuel efficient and cleaner (and 15-20% lower emissions) at higher engine temperatures, while turbo-gasoline benefits can be 20% more fuel efficient. Substituting CF8C-Plus for conventional exhaust materials can use 4-5 times less material, which is another energy and cost savings. If CF8C-Plus can be used for fossil energy steam boiler/reheater and turbine applications, energy would be saved by higher efficiency. The economic impact of widespread use of CF8C-Plus for chemical/petrochemical, electric power production and transportation exhaust systems could easily be $2-3 billion. Most data and commercial trials and applications have focused on CF8C-Plus steel, but another version, modified with further additions of Cu and W to further enhance creep-resistance at 750-850 o C, is also available. While only a few thousand pounds of this CF8C-Plus Cu/W steel have been melted, and data are limited, critical foundry trials indicate this steel also has the same castability and weldability benefits found in the CF8C-Plus steel. Opportunities for commercial trials and demonstrations for the CF8C-Plus Cu/W steel are also sought. Requirements The intent of this EOI is to identify prospective Vendors who can propose a plan to demonstrate the use of CF8C-Plus cast austenitic stainless steel in new commercial applications. To support these plans, ORNL plans to award several cost sharing no fee subcontracts, with a maximum cost reimbursement of $450,000 per proposal (anticipated awards totaling $900,000). Prospective Vendors are envisioned to propose a team consisting of a critical component end-user and qualified stainless steel foundry. It is expected that foundries will either have or be willing to obtain the appropriate license to produce CF8C-Plus for commercial sales. To maximize the impact and effect of these special DOE/ITP ARRA funds, the minimum Vendor cost share contribution requirement is 50%. It is strongly encouraged that the teams be willing to produce components for additional property evaluations at ORNL and, if applicable, be willing to endorse or support with data, an ASME Pressure Vessel Code case for cast CF8C-Plus steel. ORNL is encouraging end-users in these areas (but other applications will be considered): 1) Passenger vehicle engine (diesel and/or gasoline) exhaust components (i.e. manifold, turbocharger): Proposals can also include components for larger on-highway, off-highway, marine, stationary and locomotive diesel engines, or other reciprocating engines (i.e. natural gas), but it is our desire to push beyond current diesel engine applications. 2) Equipment for electric power generation, including coal-fired steam plants, gas-fired integrated combined cycle (combustion-turbine/steam-turbine), fuel cell power systems or distributed power generation (e.g., microturbines, combined heat and power, fuel-cell/turbine hybrid systems). 3) Gas-turbine outer structural or support components, or internal hot-gas path components. 4) Tubing or piping for chemical, petrochemical or other materials processing. 5) Pumps, valves and other ancillary components for any of the above. 6) Applications with high (>800°C) temperature or aggressive environments where the need for a corrosion-resistant coating may be demonstrated. This proposed work is expected to begin in early 2010 and conclude by September 2011. ORNL desires the interest of Vendors with a team that can manufacture and test real components, thereby expanding the license and commercialization of CF8C-Plus cast stainless steel. A formal ORNL Solicitation will be issued for the scope to be subcontracted and will include specific requirements, such as a willingness to cost share 50%. Please email the EOI, specifying project team members and proposed components, by 4:00 PM, October 15, 2009. Mr. Shannon E. Bridges, Subcontract Administrator, UT Battelle, LLC, c/o Oak Ridge National Laboratory, PO Box 2008, Bldg. 1060 COM, Room 259-12, Oak Ridge, TN 37831-6337, Phone 865-576-1426, Fax 865-241-1034, bridgesse@ornl.gov ; http://www.ornl.gov/adm/contracts/
- Web Link
-
FBO.gov Permalink
(https://www.fbo.gov/spg/DOE/ORNL/ORNL/3400121834/listing.html)
- Place of Performance
- Address: (To be determined), United States
- Record
- SN01946160-W 20090910/090909090244-55d8eb3d195c9a9e398b58cede411f36 (fbodaily.com)
- Source
-
FedBizOpps Link to This Notice
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