This is interesting...
https://sam.gov/opp/8f7fc94a12fd459186366c09d9bea565/viewThis RFI is being used to gather market research for ICAM office to make decisions regarding the Titanium Production. ICAM office will use the results of this RFI to determine current capabilities in Titanium Production. Additionally, this information will be used to develop preliminary cost estimates and an acquisition strategy.
Highlights:
- Domestic / North American Production
- 100 to 200 tons per month
- Collaboration / Partnerships encouraged
- Anticipate an FY24 award
Background:
The Department of Defense seeks practical alternatives to the current import-dominated supply chain for high-purity titanium sponge and titanium alloy metals suitable for use in a broad range of defense manufacturing efforts. The United States imports more than 95 percent of the titanium sponge needed domestically, 80 percent from Japan in 2022, with lesser quantities from Kazakhstan and Ukraine.[1] The ideal solution will domestically mine, process, and refine ore, and recycle scrap titanium to produce titanium powder, metal stock (ingot, bar, plate, etc.), and relevant alloys for use in a wide variety of applications and sizes. The ideal solution will also: provide clear benefits regarding material quality and cost; reduce or eliminate adverse by-products, effluents, and environmental impacts; and improve process energy efficiency when compared to current methods (i.e., the Kroll or Hunter processes).
Titanium and titanium alloys are prized for their light weight, high strength-to-weight ratio, and resistance to high temperatures and corrosion It is also compatible for use with materials like carbon fiber reinforced plastics. Titanium is a critical material for many defense systems, including military fighter aircraft and engines, munition and weapon components, and military ground vehicles. It is also extensively used in naval applications due to is excellent anti-corrosion characteristics.
Current primary titanium metal production processes rely mainly on the Kroll process,[2] “in which titanium dioxide minerals are reacted with chlorine to form titanium tetrachloride, which is then reacted with magnesium to strip away the chlorine and leave behind the pure metal.” The resulting metal is called titanium "sponge” because it has multitudes of pores. The sponge can be melted in under vacuum or inert gas into ingots which solidify in vacuum to prevent oxygenation. The older Hunter process[3] uses sodium as a reductant, and produces powder “sponge fines,” which are useful in powder metallurgy. Both processes present challenges in the areas of energy consumption, high cost, the use and control of harmful chemicals, and pollution through production of by-products.
- Impact Analysis of Proposed Process: The Contractor will provide the following:
- Technical description of the proposed production process for production from ore and or recycling of scrap titanium metal and alloys into powder and metal stock, including the separation and recovery of constituent alloying elements and safe disposition of other substances, including potential toxic chemicals.
- A listing of the products (e.g. sponge, powder, ingot), including alloys, and associated specifications. Please indicate the time needed to bring production up to capacity by product type. Note: Demand may be on the order of 100 to over 200 tons per month.
- If a contractor intends to provide interim products, indicate what products and in what quantities (e.g. Sponge, powder etc.)
- If a contractor intends to process interim product s into other products, indicate what the interim products and finished products and quantities.
- Review of the impacts on capacity, quality, and throughput per ton of input material resulting from the process, including a comparative of the efficiency of the proposed process. Assessment of improvements to resulting titanium cost per ton of final material, along with an assessment of potential return on investment to the U.S. Government for investing in the new process. Separate assessments may be submitted for production of powder vs. metals, if the Offeror determines there is sufficient difference in the economic impacts. Prospective assessments of potential further process improvements are also desirable.
- Development, documentation, and operation of a self-sustaining production-scale operation with sufficient capability to meet domestic demand, where total DoD demand will average 30-40% of total production per year.
- Develop, implement, maintain, and continuously improve processes that ensure titanium products consistently meet required quality specifications (e.g. ASTM specifications) to provide material properties in use.
- The facility must comply with all relevant local, state, and federal laws, ordinances, and policies related to occupational health and safety, as well as environmental requirements.
- Owing to the limited availability of natural rutile, efforts should try and make use of ilmenite or titanium slag as feedstocks. In the 3rd quarter of 2022, U.S. imports of titanium mineral concentrates included ilmenite (139,000 t), slag (136,000 t), and rutile (87,900 t).[4]
