Transcript ARI - Atmosphere Control - Atmosphere Recovery Inc.

Advanced Gas Measurement of
Bio-Pharma Processes
IFPAC 2004 Presentation
January 15, 2004
Ronald R. Rich, President
Atmosphere Recovery, Inc.
15800 32nd Avenue North, Suite 110
Plymouth, MN 55447
Ph: (763) 557-8675 Fax: (763) 557-8668
Web: www.atmrcv.com E-mail: [email protected]
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Company Background
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Founded 1994 - Dana Corporation & DOE R&D
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Heat Treating Furnace Processes
Grant & Contract Funding
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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
Bio-Pharma Process Goals –
General
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Lower Production Costs
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Other Factors
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Higher Productivity and Product Yields
Reduced Feedstock Use
Improved Consistency & Quality
Capital Avoidance (Lower Vessel Numbers)
New Processes & Materials
Lower Analyzer Cost of Operation
Reduced Process Air Emissions & Energy
12 Month Payback (Max.)
Process Gas Conceptual Needs –
Better Control, Less Use
Feedstock
Liquids &
Solids
Process
Gases
(O2) and
Liquids
(Vapors)
Analysis & Control
Off Gases
& Vapors
Off-Line
Analysis
High Use (H)
Std. Infrared
Adds Control
Med. Use (M)
Complete Gas
Control/Reuse
Low Use (L)
Biological
Process
Reactor
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Metal Processing Gases –
Similar Constituents
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Carburizing, Carbonitriding, FNC & Nitriding
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Atmosphere Tempering and Annealing
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N2, H2, CO, CO2, H2O, CH4, O2, NH3, Ar
Steel, Copper and Aluminum Brazing
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N2, CO, H2, CO2, H2O, CH4, O2, NH3, CH3OH
N2, H2, CO, CO2, H2O, CH4, O2, NH3, Ar
Powdered Metal Sintering and Annealing
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H2, N2, CO, CO2, H2O, CH4, O2, NH3, H2S
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Bio-Pharma Off-Gas Applications –
Similar Needs
 CO2,
O2, - Routinely Sampled
 N2, H2, NH3 – Sometimes Desired Now
 Organic Vapors – Very Important
 Alcohols,
 Other
 S,
Ketones, Aldehydes, Etc.
Inorganics – Determine Rates
N, P and Other Compounds
 Water
Vapor – Determines Balance
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Typical Process Gas Control Measures Only One or Two Species
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Example Types
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Benefits
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Paramagnetic Oxygen Probe – Measures Oxygen
Infrared – Measures Carbon Dioxide
Electrochemical Cells – Low Range Single Gases
Thin Film Technologies – Too Many Interferences
Proven Technology (Typically)
Lower Capital Cost
Low Complexity? (Two Analyzers Needed)
Disadvantages
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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)
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Can Measure Multiple Gas Species
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Benefits
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Carbon Dioxide
Methane
Alcohols (Some)
Ketones (Maybe)
Aldehydes (?)
Proven Technology and Vendors
Can be Used to Reduce Feedstock Use Somewhat
Disadvantages
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Cannot Measure Diatomics (O2, H2, N2, Etc.)
Detectors Have Limited Measurement Range
Requires Frequent Calibration
Species Measurement Has Significant Overlap
Restricts Optimal Control
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Other Gas Analysis Technologies –
Higher Cost of Ownership
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Gas Chromatography (GC)
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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)
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Higher Capital Cost ($50,000 - $120,000)
Requires Vacuum Pump
Gas Mixtures Often Require Second Analysis Method
Ionizer Susceptible to Water Damage
Expensive Sampling System
Expensive to Maintain
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Ultimate Process Control Goal –
Practical Complete Gas Analyzer
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Measure All Reactive Gas Species
 Detector Range - Low PPM to 100%
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Work with Elevated Sample Temperatures
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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:
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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
Gas to be Analyzed In
Special Particle Filter
8 Optical Filters/Sensors (1 for Each Gas Measured)
Detector Assembly
Plasma
Cell
Mirror Polarizer
Gas Sample Tube
Laser Beam
Prism & Mirror
Gas Out
Gas Out
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Detector Module Features
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Internal Cavity-Based Raman
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Discrete Optical Filtering and Quantifying
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Low Power Laser (Helium-Neon Plasma)
Sample Gas Flows Through Instrument
Higher Inherent Accuracy
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
Gas Species
Hydrogen - H2
Nitrogen - N2
Oxygen - O2
Water Vapor - H2O
Carbon Monoxide - CO
Carbon Dioxide - CO2
Organics - CxHy
Ammonia - NH3
Lower Limit
10-50 ppm*
50 ppm
50 ppm
10-50 ppm*
50 ppm
25 ppm
10-50 ppm*
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 – Current Subsystem
Integrated Computer
& Control System
Detector Assembly
Sample Pump, Valves
and Pressure Control
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Subsystem Features
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Integrated Sampling and Calibration System
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Integrated Electronics & Software
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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)
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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Remote Analyzer/Controller –
4 Port Bio-Pharma Product
Model 4FM
Fermentation
Off-Gas Analyzer
Outside View
Inside View
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Mobile Process Audit Analyzer –
4 Samples, 8 Pressures, 8 Temperatures
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Bio-Pharma
Commissioning
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Performance
Problem
Resolution
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Advanced Control
Demonstration
and Testing
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ARI Consulting
Service
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Analyzer/Controller –
Eight Gases, Four Process Tanks
Outside View
Inside View
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Analyzer/Controller –
16 Gases, 16 Process Tanks
Outside View
Inside View
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Products Integrate Sampling System
& Fully Automated Operation
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Fully Integrated Sample System (1-16 Ports)
 “Real Time” On-Line Monitoring and Control
(1 to 15 Second to Update Each Sample Location)
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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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Economic Benefits of High-Speed
Gas Process Analysis and Control
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Multiple Gas Analysis Capability
= System Versatility
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Economic Paybacks in Many Ways
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Increase Production Capacity
Depends
Improve Product Quality
Improve Product Consistency
on System
Reduce Analysis Costs
Functions
Reduce Instrumentation and Control
Used
Complexity
Reduce Lost Batch Costs
Better Process Documentation
Maintenance Early Warnings
Enhanced Process Safety
Reduce Energy Costs
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Thank You For Listening
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Looking for Demonstration Sites
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Looking for Technology,
Marketing & Financial Partners
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Brochures if Interested
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Questions?
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