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Eight Gas Analysis for Complete Furnace Atmosphere Control

October 9, 2002

Eight Gas Analysis for Complete Furnace Atmosphere Control

October 9, 2002

Ronald R. Rich, PresidentRonald R. Rich, PresidentAtmosphere Recovery, Inc.Atmosphere Recovery, Inc.

15800 32nd Avenue North, Suite 11015800 32nd Avenue North, Suite 110Plymouth, MN 55447Plymouth, MN 55447

Ph: (763) 557-8675 Fax: (763) 557-8668Ph: (763) 557-8675 Fax: (763) 557-8668Web: www.atmrcv.com E-mail: rrr@atmrcv.comWeb: www.atmrcv.com E-mail: rrr@atmrcv.com

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Presentation Outline

Atmosphere Control Issues Laser Gas Analyzer Technology Standard Process Applications

Endothermic Carburizing Annealing/Brazing

New Process Example Rapid Carburizing

Economic Benefits of Eight Gas Control Questions

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Heat Furnace Atmospheres –Similar Constituents & Control Needs

Heat Furnace Atmospheres –Similar Constituents & Control Needs

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 Control Needs (1) –Atmosphere Control Needs (1) –Better Control = Less UseBetter Control = Less UseAtmosphere Control Needs (1) –Atmosphere Control Needs (1) –Better Control = Less UseBetter Control = Less Use

Fixed Flow or Single Gas High Use (H)

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

Complete Gas Control/Reuse

Low 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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Atmosphere Control Needs (2) –Part/Product Quality

Atmosphere Control Needs (2) –Part/Product Quality

Improved Real Time “Potential” ControlImproved Real Time “Potential” Control Carbon (Carburizing & Neutral Hardening) Carbon (Carburizing & Neutral Hardening) Nitrogen (Nitriding)Nitrogen (Nitriding) Oxidation/Reduction (All Gas Processes)Oxidation/Reduction (All Gas Processes) Impurity Diffusion (Most Gas Processes)Impurity Diffusion (Most Gas Processes)

Surface FactorsSurface Factors Retained Austenite Retained Austenite Intergranular OxidationIntergranular Oxidation HardnessHardness Scaling/Coating for Process FunctionScaling/Coating for Process Function

Atmosphere Constituent Uniformity Atmosphere Constituent Uniformity

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Atmosphere Control Needs (3) –Operation & Maintenance

Atmosphere Control Needs (3) –Operation & Maintenance

Equipment Deterioration CompensationEquipment Deterioration Compensation Process Gas/Liquid Supply VariationProcess Gas/Liquid Supply Variation Burner TubesBurner Tubes Soot BuildupSoot Buildup Door and Seam LeaksDoor and Seam Leaks Control System PerformanceControl System Performance

Reduction of Downtime Reduction of Downtime Scheduled and PeriodicScheduled and Periodic UnscheduledUnscheduled

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Atmosphere Control Needs (4) –Other Significant Issues

Atmosphere Control Needs (4) –Other Significant Issues

Energy Costs

Destructive Analysis Requirements

Parts Re-Work

Process Documentation

Furnace Safety

Increase Furnace Throughput

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ARI Products Measure, ControlARI Products Measure, Control& Recycle Process Gases& Recycle Process Gases

ARI Products Measure, ControlARI Products Measure, Control& Recycle Process Gases& Recycle Process Gases

Laser Gas Analyzer

Process Gas Controller

Process Gas Recycling

Furnace

Gas

Mixtures

Natural Gas and

Other Process

Fuels

Process

Gas

Supply

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Core of ARI Control – Unique Process Gas Detector

Core of ARI Control – Unique Process 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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Unique Signature for Each Chemical Bond Type(Molecular Scattering of Laser Light: “Raman Effect”)

All Pertinent Gaseous Species Measurable (Principle of Measurement Requires a Chemical Bond)

Simultaneous Measurement of 8 Different Species “Real Time” Detector Response (50 milliseconds) Linear Proportionality to Number of Gas Atoms 0-100% Gas Concentrations with One Detector Accuracy Better Than NIST Calibration Gases Stable Zero and Single-Span Gas Calibration

Laser Gas Analysis PrincipalsLaser Gas Analysis Principals

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Analyzer – Industrial ProductAnalyzer – Industrial Product

Model 4EN Furnace Gas Analyzer

Inside ViewInside ViewOutside ViewOutside View

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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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Example Software Control Screens

Main Control ScreenMain Control Screen Atmosphere Analysis ValuesAtmosphere Analysis Values

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LGA Analysis AdvantagesLGA Analysis AdvantagesARI Approach Features

Raman Gas Analyzer

• Multi-Gas Detection (Eight)

• Fast – Response in Seconds

• All Key Gas Processes Controlled

• Rugged and Reliable

Other Approaches Limitations

Manual Flow Control• Inefficient & Quality Control Issues

• High Energy Use & Emissions

Single Gas Analyzers• Inefficient & Quality Control Issues

• Still High Energy Use & Emissions

Infrared Analyzers• Can’t Detect Key Gases

• Low Range & Frequent Calibration

Gas Chromatographs• Slow – Response in Minutes

• Carrier Gas & Frequent Calibration

Mass Spectrometers (Future)

• Can’t Discriminate Key Gases

• Complex & Expensive

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Benefits of Laser Gas Analysis -Surface Hardening Quality Using

Standard Atmospheres

Benefits of Laser Gas Analysis -Surface Hardening Quality Using

Standard Atmospheres Surface Carbon and Nitrogen Properties

Improved Surface Hardness

Controlled Surface Retained Austenite

White Layer Control

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 Control -Brazing and Annealing with Standard

Exothermic & Hydrogen/Nitrogen

Benefits of Laser Gas Control -Brazing and Annealing with Standard

Exothermic & Hydrogen/Nitrogen Reduced Atmosphere Consumption

Reduced Energy Use

Lower Air Emissions (Exo)

Generator Air/Fuel Ratio Control (Exo)

Burner/Chiller Malfunction Warning (Exo) Gas Supply Quality Warnings Purge and Leak Safety Improvements Improved Part/Product Consistency

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Annealing Furnace Analysis

0.01

0.10

1.00

10.00

100.00

0 20 40 60 80 100 120 140 160 180 200Distance From Furnace Inlet (feet)

Con

cent

ratio

n (%

) or

Dew

Poi

nt T

emp.

(deg

. F.)

CO H2O NH3 O2 N2 CO2 H2 CxHy Dew Pt

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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%+

Hydrogen/Nitrogen Example – 80%+ Ammonia Reduction – 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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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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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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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%

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

Example Customer Gear Manufacturer

Axle Manufacturer

Copper TubeAnnealer

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

$150K

$100K/year

$250K

$200K/year

$90K

$100K/year