Potential for Lower Cost Gas Analysis Using Miniaturized Industrial Raman Spectroscopy IFPAC 2004 Presentation January 13, 2004

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Potential for Lower Cost Gas Analysis Using
Miniaturized Industrial Raman Spectroscopy
IFPAC 2004 PresentationJanuary 13, 2004

• Ronald R. Rich, President
• Atmosphere Recovery, Inc.
• 15800 32nd Avenue North, Suite 110
• Plymouth, MN 55447
• Ph [phone] Fax [phone]
• Web www.atmrcv.com E-mail rrr_at_atmrcv.com

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Company Background

• Founded 1994 - Dana Corporation DOE RD
• Heat Treating Furnace Processes
• Grant Contract Funding
• 1995-1998 - Process Gas Recycling System
  Development
• 1997-2000 - Laser Raman Gas Analyzer
  Gas Processing Development
• 2000-2001 Analyzer/Controller Field Trials
• 2002- Furnace Analyzer Offerings
• 2003- Bio-Pharma Analyzer Offerings

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Significant Process Industries - Gas Based

• Metal Processing Initial Success
• Automotive Aerospace Heat Treating
• Metal Refining Powdered Metal
• Many Others Ready for Trials
• Bio-Pharma
• Petrochemical
• Semiconductor
• Energy Utilities
• Glass Ceramic
• Continuous Emission Monitoring

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Manufacturing Process Goals General

• Lower Production Costs
• Higher Productivity and Yields
• Improved Quality
• Capital Avoidance
• Reduced Feedstock Energy Use
• Other Factors
• New Processes Materials
• Lower Analyzer Cost of Operation
• Reduced Process Air Emissions
• 12 Month Payback (Max.)

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Process Gas Conceptual Needs Better Control,
Less Use
Waste Gas Amounts H M L
Natural Gas and Liquid Fuels
Fixed Flow or Single Gas High Use (H)
Std. Multi-Gas Adds Control Med. Use (M)
Gas-Based Process Reactor
Process Gases and Liquids (Vapors)
Complete Gas Control/Reuse Low Use (L)
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Typical Process Gas Control - Measures Only One
Gas Species

• Example Types
• Zirconia Oxygen Probe Measures Oxygen
• Dew Point Meters Measures Water Vapor
• Electrochemical Cells Low Range Single Gases
• Thin Film Technologies Too Many Interferences
• Benefits
• Proven Technology (Typically)
• Lower Capital Cost
• Low Complexity
• Disadvantages
• Other Gas Constituents Assumed (Guessed)
• Assumptions Often Wrong
• Least Accurate Process Control Option
• Limits Process Control Options Improvements

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Improved Process Gas Control Absorption-Based
Optical (IR)

• Measures Multiple Gas Species
• Carbon Monoxide
• Carbon Dioxide
• Methane
• Benefits
• Proven Technology and Vendors
• Can be Used to Reduce Process Gas Use Somewhat
• Disadvantages
• Cannot Measure Most Diatomics (H2, N2, F2, O2,
  Etc.)
• Expensive to Measure Many Corrosive Gases
• Detectors Have Limited Measurement Range
• Requires Frequent Calibration
• Species Measurement Has Significant Overlap
• Limits Use of Higher Efficiency Gas Mixtures

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Other Gas Analysis Technologies Higher Cost of
Ownership

• Gas Chromatography (GC)
• High Installed Capital Cost (25,000 - 60,000)
• Slow (2 Minutes)
• Complex Use Requires Training
• Carrier Gas and Frequent Calibration
• Laboratory and Petrochemical Processes
  Predominate
• Mass Spectroscopy (MS)
• Higher Capital Cost (50,000 - 120,000)
• Requires Vacuum Pump
• Ionizer Susceptible to Water Damage
• Expensive to Maintain
• Gas Mixtures Often Require Second Analysis Method

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Ultimate Process Control Goal Practical
Complete Gas Analyzer

• Measure All Reactive Gas Species
• Detector Range - Low PPM to 100
• Work with Elevated Sample Temperatures
• Fast Response
• Compact and Operator Friendly
• Rugged, Reliable, Easy to Service
• Minimal Calibration
• Low Cost of Ownership
• Potential for Miniaturization

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Laser Raman Gas Spectroscopy - Features

• Unique Frequency Shift for Each Chemical Bond
• Little Interference Between Most Gases
• Measures Gases of All Types (Except Inerts)
• Rapid Real Time Response Rates Possible
• Signal Directly Proportional to Number of Gas
  Atoms
• PPM-100 Gas Concentrations with One Detector
• Resolution and Accuracy Depends On
• Laser Power and Optics Variation
• Gas Concentration and Pressure
• Molecular Bond Type
• Background and Scattered Radiation
• Optical and Electronic Detector Circuitry

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Core of Laser Gas Control Unique 8 Gas
Detector Module
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Detector Module Features

• Internal Cavity-Based Raman
• Low Power Laser (Helium-Neon Plasma)
• Sample Gas Flows Through Instrument
• Higher Inherent Accuracy
• Discrete Optical Filtering and Quantifying
• Any 8 Gases Detected Per Module
• Process Specific Configurations Module s
• Simultaneous Detection of All Gas Species
• Fast Detector Updates (50 milliseconds)
• Only High Nitrogen Dioxide Levels Interfere
• Array Based Interference Computations
• 10 Minute Module Exchange

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Typical Gas Constituents Monitored and Detection
Limits
Customer Selectable Selecting Lower Value
Limits The Upper Range to 30 Other Gas
Species Substitutable as Options
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Gas Analyzer Current Subsystem
Integrated Computer Control System
Detector Assembly
Sample Pump, Valves and Pressure Control
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Subsystem Features

• Integrated Sampling and Calibration System
• Internal Pump and Valves
• Low Volume Sample Gas Flows (200 ml/minute)
• Multiple Sample Port Options
• Automated Zero and Span Calibration
• Automated Sample Line Monitoring (Flow
  Pressure)
• Integrated Electronics Software
• Pentium III Computer w/ HMI and Data Trending
• Customizable Process Deviation Analysis
• Local and Remote Displays and Interfaces
• OPC Server and Client for Connectivity
• Available Analog and Digital I/O Options
• Multiple Configurable Process and PLC Interfaces
• NeSSI Integration Now
• NeSSI Generation II Potential

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Example Main Control Screen
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RD Analyzer 4 Sample Locations
Model 4EN Furnace Gas Analyzer
Inside View
Outside View
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Mobile Furnace Audit Analyzer 4 Samples, 8
Pressures, 8 Temperatures

• Furnace Tuning Commissioning
• Furnace Performance Problem Resolution
• Advanced Atmosphere Demonstration and Testing
• ARI/APCI Consulting
• Service

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RC Analyzer/Controller 2 Batch Furnaces
Inside View
Outside View
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Analyzer/Controller 16 Zone Continuous Furnace
Inside View
Outside View
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Current Product Integrates Sampling System
Added Features

• Fully Integrated Sample System (1-16 Ports)
• Real Time On-Line Monitoring and Control
• (1 to 15 Second to Update Each Sample Location)
• Operates with Existing PLCs and Sensors
• Low Volume Sample Gas Flows (200 ml/minute)
• Electronic Flow and Pressure Monitoring
• Optics Protection and Enclosure Inerting
• Sample Line Pre-Purge and Back-flush Options
• Automatic Condensate Removal
• Precision Temp. Controlled NEMA Enclosures
• Self-Monitoring of Critical Functions
• Many Wired and Wireless Communication Options

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Phase I Analyzer Subsystem Summary

• Dimensions 45 x 30 x 25 cm. (18 x 12 x 10)
• Weight 20 kg. (45 lbs.)
• Laser HeNe Gas Intracavity
• Detector Module Discrete Optics Detectors
• Electronics Discrete Components on Multiple
  Boards
• Power 150 Watts (with Detector Heaters)
• Sample System Control PC-Based - Fully
  Integrated
• Process Control Function PLC PC-Based -
  Integrated
• Subsystem Price 15,000 (100 Units)

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Phase II Analyzer Size Reduction
Phase II Raman Multi-gas Analyzer Relative
Size (2004-2005)

• Dimensions 20 x 15 x 10 cm. (8 x 6 x 4)
• Weight 7 kg. (15 lbs.)
• Laser Solid State Intracavity
• Detector Module Integrated Optics Detectors
• Electronics Discrete Components on Single Board
  
• Power 30 Watts (with Detector Heaters)
• Sample System Control External Controller
  (CANBus ?)
• Process Control Function Reliant on External
  Controllers
• Subsystem Price 5-7,000 (1,000 Units)

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Phase III Analyzer Size Reduction
Phase III NeSSI Gen II Raman Multi-gas Analyzer Re
lative Size (2006)
Phase II Raman Multi-gas Analyzer Relative
Size (2004-2005)

• Dimensions 3.8 x 3.8 x 10 cm. (1.5 x 1.5 x 4)
  
• Weight 2 kg. (4 lbs.)
• Laser Solid State Intracavity, Chip Integrated
• Detector Module Chip Integrated Optics
  Detectors
• Electronics Chip Integrated as Possible
• Power 3 Watts or less (with Detector Heaters)
• Sample System Control NeSSI on CANbus (or None)
• Process Control Function External Controllers
• Subsystem Price 1-3,000 (10,000 Units)

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Markets Applications

• Phase I Current Fully Customizable Product
• 24/7 Manufacturing Multi-gas Analysis Control
• High Temperature or Severe Environments
• Phase II Next Product
• Industrial, Portable and IAQ/Security Analysis
• General Purpose Industrial, Commercial Military
  
• Phase III Fully Compliant NeSSI Product
• Replacement of Single Purpose Gas Detectors
• Higher-End Direct Consumer and OEM Markets
• Allows Close Proximity or In-Situ Installation

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Thank You For Listening

• Looking for Demonstration Sites
• Looking for Technology, Marketing Financial
  Partners
• Brochures if Interested
• Questions?