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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: [email protected]: www.atmrcv.com E-mail: [email protected]
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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