Post on 11-Jan-2016
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Rapid Carburizing and Atmosphere Recovery
Rapid Carburizing and Atmosphere Recovery
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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Company HistoryCompany History
Founded 1994Founded 1994 - Dana & USDOE R&D - Dana & USDOE R&D Heat Treating Furnace ProcessesHeat Treating Furnace Processes Grant & Contract FundingGrant & Contract Funding
1995-19981995-1998 - Process Gas Recycling System - Process Gas Recycling System Development Development
1997-20001997-2000 - Laser Gas Analyzer & Process - Laser Gas Analyzer & Process Gas Controller Developments Gas Controller Developments
2000-20012000-2001 - Initial Sales: $300K - Initial Sales: $300K
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Industrial Heat Treating of MetalsIndustrial Heat Treating of Metals
Typical PartsTypical Parts GearsGears SpringsSprings BearingsBearings TubesTubes FastenersFasteners ToolTool
Typical ProcessesTypical Processes HardeningHardening SofteningSoftening BrazingBrazing SinteringSintering CleaningCleaning CoatingsCoatings
Typical WasteTypical Waste Process Gas: 50-95%Process Gas: 50-95% Energy: 20-40% Energy: 20-40%
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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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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)
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 Allows Advanced Atmosphere ControlAllows Advanced Atmosphere Control
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ARI Products Measure, Control & ARI Products Measure, Control & Recycle Furnace Process GasesRecycle Furnace Process GasesARI Products Measure, Control & ARI Products Measure, Control & Recycle Furnace Process GasesRecycle Furnace Process Gases
ARI Laser Gas Analyzer
(System 1)
ARI Process Gas
Controller (System 2)
ARI Process Gas
Recycle System (System 3)
Industrial Process
Gas Furnace
Natural Gas and Other Process
Fuels
Process Gases and
Vapors
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Unique & Protected Product FamilyUnique & Protected Product Family
System 1 ($30K-60K): Furnace Gas Analyzer System 1 ($30K-60K): Furnace Gas Analyzer Laser Gas Detector ($20M Spent to Develop)Laser Gas Detector ($20M Spent to Develop)
Sole Instrument Based on Raman SpectroscopySole Instrument Based on Raman Spectroscopy 11 US Patents Awarded11 US Patents Awarded Exclusive ARI License for Non-MedicalExclusive ARI License for Non-Medical
Gas Flow and Control Software ($300K Spent)Gas Flow and Control Software ($300K Spent) ARI Proprietary AlgorithmsARI Proprietary Algorithms Software Developed and OperatingSoftware Developed and Operating
System 2 ($75K-150K): Process Gas Control System 2 ($75K-150K): Process Gas Control ARI Proprietary Processes ($500K Spent)ARI Proprietary Processes ($500K Spent) Software Mostly DevelopedSoftware Mostly Developed
System 3 ($250K-1M): Gas Recovery & ReuseSystem 3 ($250K-1M): Gas Recovery & Reuse Initial Focus on Metals ($700K Spent)Initial Focus on Metals ($700K Spent) Many Future ApplicationsMany Future Applications
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Core of ARI Technologies – Unique Process Gas DetectorCore of ARI Technologies –
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
Gas to be AnalyzedIn
Plasma Cell
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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
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Gas Measurement Options for ARI AnalyzersChemical Name Formula Chemical Name FormulaAcetone C3H5OH Hydrochloric Acid HCL
Acetylene C2H2 Hydrofluoric Acid HF
Ammonia NH3 Hydrogen * H2
Benzene C6H6 Hydrogen Sulfide (Average) H2S
Butane C4H10 Hydrogen Sulfide (High) H2S
Butene C4H8 Hydrogen Sulfide (Low) H2S
Carbon Dioxide CO2 ISOFLURANE
Carbon Disulfide CS2 Methane CH4
Carbon Monoxide CO Methanol CH3OH
Carbon Tetrachloride CCL4 Napthalene C8H10
Chlorine * CL2 Nitric Oxide NO
Chloroform CHCL3 Nitrogen * N2
DESFLURANE Nitrogen Dioxide NO2
ENFLURANE Nitrous Oxide N2O
Ethane C2H6 Oxygen * O2
Ethanol C2H5OH Pentane C5H12
Ethene C2H4 PENTHRANE (Canada)
Formaldehyde HCHO Propane C3H8
Formamide CH3NO Propene C3H6
HALOTHANE Propionaldehyde
Hexane C6H14 SEVOFLURANE
Hydrocarbon (10NM Ctr) CXHY Styrene Monomer C8H8
Hydrocarbon (6NM Ctr) CXHY Sulfur Dioxide SO2
Hydrocarbon Stretch (10-high) CXHY Toluene C6H5CH3
Hydrocarbon Stretch (10-low) CXHY Water H20
Hydrocarbon Stretch (6-high) CXHY Zylene-M C6H4CH3
Hydrocarbon Stretch (6-low) CXHY Zylene-O C6H4CH4
Hydrocarbon Stretch (Gen Ctr) CXHY Zylene-P C6H4CH4
* Cannot be done with Infrared Analyzers Currently measured gases in red
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Analyzer – Industrial ProductAnalyzer – Industrial Product
Model 4EN Furnace Gas Analyzer
Inside ViewInside ViewOutside ViewOutside View
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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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Example Main Control ScreenExample Main Control Screen
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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)
Continuous Data RecordingContinuous Data Recording
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Benefits of Laser GasAnalysis and ControlBenefits of Laser GasAnalysis and Control
Multiple Gas Analysis Capability
= System Versatility 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
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Economic Benefits of Laser Gas Analysis
Economic Benefits of Laser Gas Analysis
Atmosphere Gas Consumption ReducedEndothermic Example – 90%+
Exothermic Example – 50%+
Extra Gas Generators Turned Off Shorter Cycle Times Inherent
Carburizing Example – Up to 20%
Process Energy Savings Significant Carburizing Example – 25% of Total Furnace Use
Exothermic Example – 15% of Total Furnace Use
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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
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Product Quality Benefits of Laser Gas Analysis
Product Quality Benefits of Laser Gas Analysis
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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Case Depth and Profile of PartsCase Depth and Profile of Parts
RCRC5050 Value Case Depths Always Obtained Faster Value Case Depths Always Obtained Faster
Improvement Percentages Depends Primarily on Improvement Percentages Depends Primarily on Desired Final Case Depth (Shallower is Faster)Desired Final Case Depth (Shallower is Faster)
Less Case Depth Variation in LoadLess Case Depth Variation in Load Hardness and Carbon Profile ConsistentHardness and Carbon Profile Consistent Profiles Consistent with Higher Surface Carbon Profiles Consistent with Higher Surface Carbon
PotentialsPotentials Surface Hardness AcceptableSurface Hardness Acceptable Surface Cleanliness not Significant (8620/8625/8630)Surface Cleanliness not Significant (8620/8625/8630)
Higher Quality PartsHigher Quality Parts
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Retained Austenite/Carbides in PartsRetained Austenite/Carbides in Parts
““ARI Process Better (Lower Levels)”ARI Process Better (Lower Levels)” Levels Can Be Adjusted to Suit Desired ResultLevels Can Be Adjusted to Suit Desired Result Controllable with Wide Atmosphere FluctuationsControllable with Wide Atmosphere Fluctuations
BaselineBaseline ARI AcceleratedARI Accelerated
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Grain Boundary Oxidation in PartsGrain Boundary Oxidation in Parts
““ARI Process Better (Lower Levels)”ARI Process Better (Lower Levels)” Levels Can Be Adjusted to Suit Desired ResultLevels Can Be Adjusted to Suit Desired Result Controllable with Wide Atmosphere FluctuationsControllable with Wide Atmosphere Fluctuations
BaselineBaseline ARI AcceleratedARI Accelerated
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Rapid Carburizing – Metallurgical Findings Summary
Rapid Carburizing – Metallurgical Findings Summary
Batch Cycle Times Faster (Load to Unload)Batch Cycle Times Faster (Load to Unload) Same Process Temperature (Typically 1750 Deg. F.)Same Process Temperature (Typically 1750 Deg. F.) Case Depth of .040” – 35% to 50% FasterCase Depth of .040” – 35% to 50% Faster Case Depth of .065 – 20-30% FasterCase Depth of .065 – 20-30% Faster
Less Case Depth Variation Though the Load Less Case Depth Variation Though the Load Controllable Carbon Content/Hardness ProfileControllable Carbon Content/Hardness Profile Controllable Retained Austenite LevelsControllable Retained Austenite Levels Controllable Iron Carbide LevelsControllable Iron Carbide Levels Wide Variation in Atmosphere Constituents ToleratedWide Variation in Atmosphere Constituents Tolerated Soot Control Algorithms Do Not Affect PartsSoot Control Algorithms Do Not Affect Parts
All Parts Released for ProductionAll Parts Released for Production
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Improvements May Be Initiated Because of Air Emission Concerns
Improvements May Be Initiated Because of Air Emission Concerns
Previously Recognized Air EmissionsPreviously Recognized Air Emissions Smoke from QuenchingSmoke from Quenching Burner Combustion GasesBurner Combustion Gases
Unrecognized Air Emissions IssuesUnrecognized Air Emissions Issues Carbon Monoxide (CO) from Atmosphere UseCarbon Monoxide (CO) from Atmosphere Use Comes from Atmosphere Generation, LeakageComes from Atmosphere Generation, Leakage
and Flaringand Flaring
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ARI Products’ARI Products’Sustainable Competitive AdvantagesSustainable Competitive Advantages
* Includes Furnaces, Atmosphere Generators, and Ancillary Equipment if Plant New or Near Capacity
ARI Approach Features
ARI Systems
• 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
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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ARI’s Heat Treating Market is HugeARI’s Heat Treating Market is Huge
Current ARI Installations
Industries Near Term Customers Market Size
ManufacturersAutomotiveAerospaceMachinery
Dana, Timken, ZF/Ford
John Deere
$650M US
$1.5B WW
Job Shops Bodycote, Hi-Tech Metals $300M WW
Metal ProcessRefiningPowderTube/Sheet
Amax Steel Hoeganaes Cerro Copper Tube
$150M US
$500M WW
OEM Vendors Praxair, Air Products, Drever $80M WW
Other IIT Research Institute $20M WW
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FurnaceInstallation& Startup
FurnaceManufacturer
FurnaceDesign
FurnaceSupplier
FurnaceConsultant
GasSupplier
Controls/AnalyzerManufacturer
FurnaceMaintenance
FurnaceOperation
FurnaceUpdate or
Replacement
GasContractor
ControlsContractor
FurnaceContractor
ServiceContractors
FurnaceMarketing & Sales
Thermal Processing Value ChainThermal Processing Value Chain
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Capturing Customer ValueCapturing Customer Value
Profit Margin on Analyzers SalesProfit Margin on Analyzers Sales Analyzer Services: Leasing & Contract FeesAnalyzer Services: Leasing & Contract Fees Analyzer Leasing to Service Contractors Analyzer Leasing to Service Contractors and/or Gas Suppliersand/or Gas Suppliers Control System Sales as Control Contractor Control System Sales as Control Contractor
for System 2 Upgradesfor System 2 Upgrades Licensing Fees for Control Software UsageLicensing Fees for Control Software Usage Consulting, Licensing & Service Fees from Consulting, Licensing & Service Fees from
Recycling Systems (System 3)Recycling Systems (System 3) Shared Energy/Operational SavingsShared Energy/Operational Savings
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Publications Featuring ARI Technology
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Why ARI Will Be SuccessfulWhy ARI Will Be Successful Unique, Fully-Developed ProductUnique, Fully-Developed Product
Exclusive License for Patented DetectorExclusive License for Patented Detector $20M Spent to Develop (by Licensor)$20M Spent to Develop (by Licensor) $1.1M Spent on Proprietary Software and $1.1M Spent on Proprietary Software and
New Gas Control Methods (by ARI)New Gas Control Methods (by ARI) Compelling Customer BenefitsCompelling Customer Benefits
Reduced Costs & Improved QualityReduced Costs & Improved Quality Payback in less than 12 monthsPayback in less than 12 months
Large Existing Customer OpportunityLarge Existing Customer Opportunity 80,000 Furnaces installed in U.S.80,000 Furnaces installed in U.S. 200,000 Furnaces Worldwide200,000 Furnaces Worldwide