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Removing the Guesswork from Furnace Atmosphere Control with

Laser Gas Analysis

Removing the Guesswork from Furnace Atmosphere Control with

Laser Gas Analysis

Atmosphere Recovery, Inc.Atmosphere Recovery, Inc.15800 32nd Avenue North, Suite 11015800 32nd Avenue North, Suite 110

Plymouth, MN 55447Plymouth, MN 55447Ph: (763) 557-8675 Fax: (763) 557-8668Ph: (763) 557-8675 Fax: (763) 557-8668

Web: www.atmrcv.com E-mail: rrr@atmrcv.comWeb: www.atmrcv.com E-mail: rrr@atmrcv.com

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Presentation Outline

Application IntroductionExisting Technology LimitationsLaser Gas Analyzer Technology Economic Benefits of LGAExample Process Applications

Standard Carburizing Rapid Carburizing Exothermic Annealing

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Industrial Furnace Atmospheres – Similar Constituents

Industrial Furnace Atmospheres – Similar Constituents

Carburizing, Carbonitriding, FNC & NitridingCarburizing, Carbonitriding, FNC & Nitriding NN22, CO, H, CO, H22, CO, CO22, H, H22O, CHO, CH44, O, O22, NH, NH33, CH, CH33OHOH

Atmosphere Tempering and Annealing Atmosphere Tempering and Annealing NN22, H, H22, CO, CO, CO, CO22, H, H22O, CHO, CH44, O, O22, NH, NH33, Ar , Ar

Steel, Copper and Aluminum BrazingSteel, Copper and Aluminum Brazing NN22, H, H22, CO, CO, CO, CO22, H, H22O, CHO, CH44, O, O22, NH, NH33, Ar , Ar

Powdered Metal Sintering and AnnealingPowdered Metal Sintering and Annealing HH22, N, N22, CO, CO, CO, CO22, H, H22O, CHO, CH44, O, O22,, NHNH33, H, H22SS

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Atmosphere Conceptual Needs –Atmosphere Conceptual Needs –Better Control, Less UseBetter Control, Less UseAtmosphere Conceptual Needs –Atmosphere Conceptual Needs –Better Control, Less UseBetter Control, Less Use

Fixed Flow or Single Gas

High Gas Use (H)

Std. Multi-Gas Adds Control Med. Gas Use (M)

Complete Gas Control/Reuse

Low Gas Use (L)

Industrial Process

Gas Furnace

Natural Gas and

Other Fuels

Process Gases

and Liquid

(Vapors)

Waste Gas Amounts H M L

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Typical Atmosphere Control - Measures Only One Gas Species

Typical Atmosphere Control - Measures Only One Gas Species

TypesTypes Zirconia Oxygen Probe – Measures OxygenZirconia Oxygen Probe – Measures Oxygen Dew Point Meters – Measures Water VaporDew Point Meters – Measures Water Vapor Electrochemical Cells – Low Range Single GasesElectrochemical Cells – Low Range Single Gases

BenefitsBenefits Proven TechnologyProven Technology Lower Capital Cost Lower Capital Cost Low ComplexityLow Complexity

DisadvantagesDisadvantages Other Gas Constituents Assumed (Guessed)Other Gas Constituents Assumed (Guessed) Assumptions Often WrongAssumptions Often Wrong Limits Process Control & Improvement OptionsLimits Process Control & Improvement Options Requires High Process Atmosphere FlowsRequires High Process Atmosphere Flows

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Improved Atmosphere Control –Single Gas Plus Infra-Red

Improved Atmosphere Control –Single Gas Plus Infra-Red

Economically Measures Three More GasesEconomically Measures Three More Gases Carbon MonoxideCarbon Monoxide Carbon DioxideCarbon Dioxide MethaneMethane

BenefitsBenefits Proven Technology and VendorsProven Technology and Vendors Can be Used to Reduce Atmosphere UseCan be Used to Reduce Atmosphere Use

DisadvantagesDisadvantages Cannot Measure Hydrogen, Nitrogen and InertsCannot Measure Hydrogen, Nitrogen and Inerts Expensive to Measure Other Significant GasesExpensive to Measure Other Significant Gases Limited Measurement RangeLimited Measurement Range Requires Frequent CalibrationRequires Frequent Calibration Limits High Efficiency Atmosphere Gas MixturesLimits High Efficiency Atmosphere Gas Mixtures Can’t Significantly Reduce Atmosphere UseCan’t Significantly Reduce Atmosphere Use

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Other Gas Analysis Technologies –Not Very Applicable to AtmospheresOther Gas Analysis Technologies –

Not Very Applicable to Atmospheres

Gas Chromatography (GC)Gas Chromatography (GC) High Capital Cost ($15,000 - $60,000)High Capital Cost ($15,000 - $60,000) Slow (2 Minutes+)Slow (2 Minutes+) Complex – Use Requires TrainingComplex – Use Requires Training Carrier Gas and Frequent CalibrationCarrier Gas and Frequent Calibration Few Used for Atmosphere ControlFew Used for Atmosphere Control

Mass Spectroscopy (MS) Mass Spectroscopy (MS) Higher Capital Cost ($50,000 - $120,000)Higher Capital Cost ($50,000 - $120,000) Best Applied on Vacuum ProcessesBest Applied on Vacuum Processes Expensive to MaintainExpensive to Maintain Many Gases Cannot be Determined (Equal Mass)Many Gases Cannot be Determined (Equal Mass)

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Ultimate Atmosphere Control Goal –Practical Complete Gas Analyzer

Ultimate Atmosphere Control Goal –Practical Complete Gas Analyzer

Measure All GasesMeasure All Gases Except Inert Gases (Can be Inferred) Except Inert Gases (Can be Inferred) Low Levels of Oxygen (Work with Existing Controls)Low Levels of Oxygen (Work with Existing Controls) Dew Point Range of –40 Deg. C (or F) and UpDew Point Range of –40 Deg. C (or F) and Up

Monitoring of Any Industrial AtmosphereMonitoring of Any Industrial Atmosphere Fast Analyzer ResponseFast Analyzer Response Compact and Operator FriendlyCompact and Operator Friendly Rugged, Reliable, Easy to ServiceRugged, Reliable, Easy to Service Minimal CalibrationMinimal Calibration Cost-EffectiveCost-Effective

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Unique Frequency “Shift” for Each Chemical BondUnique Frequency “Shift” for Each Chemical Bond Little Interference Between Most GasesLittle Interference Between Most Gases Measures Gases of All Types (Except Inerts)Measures Gases of All Types (Except Inerts) Rapid “Real Time” Response Rates PossibleRapid “Real Time” Response Rates Possible Signal Directly Proportional to Number of Gas Atoms Signal Directly Proportional to Number of Gas Atoms 0-100% Gas Concentrations with One Detector0-100% Gas Concentrations with One Detector Resolution and Accuracy Depends On:Resolution and Accuracy Depends On:

Laser Power and Optics Variation Laser Power and Optics Variation Gas Concentration and PressureGas Concentration and Pressure Molecular Bond TypeMolecular Bond Type Background and Scattered RadiationBackground and Scattered Radiation Optical and Electronic Detector CircuitryOptical and Electronic Detector Circuitry

GOALS MET! GOALS MET!

Laser Raman Spectroscopy - Why Selected?

Laser Raman Spectroscopy - Why Selected?

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Core of Laser Gas Control – Unique 8 Gas Detector

Core of Laser Gas Control – Unique 8 Gas Detector

Mirror Polarizer Prism & Mirror

Laser BeamGas Sample Tube

Gas Out

8 Optical Filters/Sensors (1 for Each Gas Measured)

Detector AssemblyDetector Assembly

Gas Out

Special Particle Filter

Plasma Cell

Gas to be Analyzed In

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LGA Detector Features LGA Detector Features

Internal Cavity-Based RamanInternal Cavity-Based Raman Low Power Laser (Helium-Neon Plasma)Low Power Laser (Helium-Neon Plasma) Sample Gas Flows Through InstrumentSample Gas Flows Through Instrument Higher Inherent AccuracyHigher Inherent Accuracy

Discrete Optical Filtering and QuantifyingDiscrete Optical Filtering and Quantifying 8 Gases Detected – Can be Process Specific8 Gases Detected – Can be Process Specific Simultaneous Detection of Each Gas SpeciesSimultaneous Detection of Each Gas Species Fast Detector Response (50 milliseconds)Fast Detector Response (50 milliseconds) Only High Nitrogen Dioxide Levels InterfereOnly High Nitrogen Dioxide Levels Interfere Array Based Interference Computations Array Based Interference Computations

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Standard Furnace Constituents Monitored and Detection LimitsStandard Furnace Constituents Monitored and Detection Limits

Gas Species Lower Limit

Hydrogen - H2 100 ppm

Nitrogen - N2 50 ppm

Oxygen - O2 50 ppm

Water Vapor - H2O 10-50 ppm*

Carbon Monoxide - CO 50 ppm

Carbon Dioxide - CO2 25 ppm

Organics - CxHy 10-50 ppm*

Ammonia - NH3 10-50 ppm*

*Customer Selectable – Selecting Lower Value Limits The Upper Range to 30%; Other Gas Species Substitutable as Options

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Gas Analyzer – Basic System ViewGas Analyzer – Basic System View

Detector AssemblyDetector Assembly

Integrated ComputerIntegrated Computer& Control System& Control System

Sample Pump, ValvesSample Pump, Valvesand Pressure Controland Pressure Control

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Analyzer System FeaturesAnalyzer System Features

Integrated Sampling and Calibration SystemIntegrated Sampling and Calibration System Internal Pump and ValvesInternal Pump and Valves Low Volume Sample Gas Flows (200 ml/minute) Low Volume Sample Gas Flows (200 ml/minute) Multiple Sample Port OptionsMultiple Sample Port Options Automated Zero and Span CalibrationAutomated Zero and Span Calibration

Integrated Electronics & SoftwareIntegrated Electronics & Software Pentium/Pentium III Computer and Monitor Pentium/Pentium III Computer and Monitor Customizable Windows Based OSCustomizable Windows Based OS Local and Remote Displays and Data StorageLocal and Remote Displays and Data Storage Available Analog and Digital I/OAvailable Analog and Digital I/O Multiple Configurable Process and PLC Interfaces Multiple Configurable Process and PLC Interfaces

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Example Main Control ScreenExample Main Control Screen

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Analyzer – Industrial ProductAnalyzer – Industrial Product

Model 4EN Furnace Gas Analyzer

Inside ViewInside ViewOutside ViewOutside View

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Industrial Product FeaturesIndustrial Product Features “Real Time” Process Monitoring and Control

(1 to 15 Seconds - Depends on Number of Ports and Options)

Operates with Existing PLCs and Sensors Low Volume Sample Gas Flows (200 ml/minute) Electronic Flow and Pressure Monitoring Optics and Enclosure Inerting (Standard for Heat Treating Atmosphere Analysis)

Multiple Sample Ports (16 + Optional) Sample Line Purge and Back-flush (Optional) High Dew Point Atmosphere Operation (Optional) Standard NEMA Enclosures

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Economic Benefits of Laser GasAtmosphere Analysis and ControlEconomic Benefits of Laser Gas

Atmosphere Analysis and Control Multiple Gas Analysis Capability

= System Versatility

Economic Paybacks in Many Ways Reduce Energy Costs Increase Production Capacity Improve Component Quality Improve Component Consistency Reduce Destructive Analysis Costs Reduce Re-Work Costs Better Process Documentation Maintenance Early Warnings Enhanced Furnace Safety

DependsDependson Systemon SystemFunctionsFunctions

UsedUsed

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Benefits of Laser Gas Analysis -Surface Hardening Quality

with Standard Atmospheres

Benefits of Laser Gas Analysis -Surface Hardening Quality

with Standard Atmospheres Surface Carbon (or Nitrogen) Properties

Improved Surface Hardness

Controlled Surface Retained Austenite

Consistent Compressive Residual Stress

Reduced Intergranular Oxidation

Improved Same Batch Consistency Improved Batch-to-Batch Consistency Faster Cycle Times

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Benefits of Laser Gas Analysis - Heat Treating Energy Savings

Benefits of Laser Gas Analysis - Heat Treating Energy Savings

Atmosphere Gas Consumption ReducedEndothermic Example – 90%+

Exothermic Example – 50%+

Extra Gas Generators Turned Off Shorter Cycle Times Inherent

Carburizing Example – 20%

Total Process Savings Significant Carburizing Example – 25% of Total Furnace

Exothermic Example – 15% of Total Furnace

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Example 96% Endo SavingsExample 96% Endo Savings

Surface Combustion All-Case Furnace Surface Combustion All-Case Furnace (Shown Under Standard Operation)(Shown Under Standard Operation)

Stack and FlareShut OffDoor and Burner

Leaks Reduced

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Benefits of Laser Gas Analysis –In-Situ Rapid Carburizing

Benefits of Laser Gas Analysis –In-Situ Rapid Carburizing

Greatly Increased Production CapacityExample: Cycle time for ~1mm case reduced 50%

Up to 40% Energy Savings

Elimination of Endo Generators

Further Improved Product Quality

Reduced Sooting and Furnace Maintenance

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0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

-2.5 -2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0Program Time, hours (0.0 = time at initial 1750 deg F)

0

7

14

21

28

35

42

49

56

63

70

Step (0-20) Deg F (0-2000) Carbon Pot (0-2%) % CO (0-70) % N2 (0-70) % CO2 (0-70) % H2 (0-70) % CH4 (0-70) Dew Point (0-70)

Example Use for Rapid CarburizingExample Use for Rapid Carburizing

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System Paybacks in Less Than 12 MonthsSystem Paybacks in Less Than 12 Months

* Includes Furnaces, Atmosphere Generators, and Ancillary Equipment if Plant New or Near Capacity

Benefit Standard Carburizing

Rapid Carburizing

Exothermic Annealing

Productivity Improvement

• Reduced Processing

• Times  Improved Quality

Up to 20% Up to 50% Up to 50%

Reduced Energy Consumption 25% 40% Up to 30%

Reduced Process Gas Use Up to 90% Up to 98% Up to 90%

Reduced Regulated Emissions Over 90% Over 98% Over 90%

System Price (Typical) $40-100K $70-150K $40-90K

Example CustomerGear

ManufacturerAxle

ManufacturerNon-Ferrous

Annealer

Cost Benefits• Capital Savings (Avoiding Conventional Equipment)*• Operation & Maintenance Cost Reduction

$150K

$100K/year

$250K

$200K/year

$90K

$100K/year