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Advanced Gas Measurement of Bio-Pharma Processes
IFPAC 2004 Presentation
January 15, 2004
Advanced Gas Measurement of Bio-Pharma Processes
IFPAC 2004 Presentation
January 15, 2004
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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Company BackgroundCompany Background
Founded 1994Founded 1994 - Dana Corporation & DOE R&D - Dana Corporation & DOE 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 Raman Gas Analyzer & - Laser Raman Gas Analyzer & Gas Processing Development Gas Processing Development
2000-20012000-2001 – Analyzer/Controller Field Trials – Analyzer/Controller Field Trials 2002- 2002- – Furnace Analyzer Offerings – Furnace Analyzer Offerings 2003- 2003- – Bio-Pharma Analyzer Offerings – Bio-Pharma Analyzer Offerings
Significant Process Industries - Gas Based
Significant Process Industries - Gas Based
Metal Processing – Initial SuccessMetal Processing – Initial Success Automotive & Aerospace Heat TreatingAutomotive & Aerospace Heat Treating Metal Refining & Powdered MetalMetal Refining & Powdered Metal
Many Others – Ready for TrialsMany Others – Ready for Trials Bio-PharmaBio-Pharma PetrochemicalPetrochemical SemiconductorSemiconductor Energy UtilitiesEnergy Utilities Glass & CeramicGlass & Ceramic Continuous Emission MonitoringContinuous Emission Monitoring
Bio-Pharma Process Goals – General
Bio-Pharma Process Goals – General
Lower Production CostsLower Production Costs Higher Productivity and Product YieldsHigher Productivity and Product Yields Reduced Feedstock UseReduced Feedstock Use Improved Consistency & QualityImproved Consistency & Quality Capital Avoidance (Lower Vessel Numbers)Capital Avoidance (Lower Vessel Numbers)
Other FactorsOther Factors New Processes & MaterialsNew Processes & Materials Lower Analyzer Cost of OperationLower Analyzer Cost of Operation Reduced Process Air Emissions & EnergyReduced Process Air Emissions & Energy
12 Month Payback (Max.)12 Month Payback (Max.)
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Process Gas Conceptual Needs –Process Gas Conceptual Needs –Better Control, Less UseBetter Control, Less UseProcess Gas Conceptual Needs –Process Gas Conceptual Needs –Better Control, Less UseBetter Control, Less Use
Off-Line Analysis
High Use (H)
Std. Infrared Adds Control Med. Use (M)
Complete Gas Control/Reuse
Low Use (L)
Biological Process Reactor
Feedstock Liquids &
Solids
Process Gases
(O2) and Liquids (Vapors)
Off Gases & VaporsAnalysis & ControlAnalysis & Control
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Metal Processing Gases – Similar Constituents
Metal Processing Gases – 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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Bio-Pharma Off-Gas Applications –Similar Needs
Bio-Pharma Off-Gas Applications –Similar Needs
COCO22, O, O22, - Routinely Sampled, - Routinely Sampled
NN22, H, H22, NH, NH33 – Sometimes Desired Now – Sometimes Desired Now
Organic Vapors – Very ImportantOrganic Vapors – Very Important Alcohols, Ketones, Aldehydes, Etc. Alcohols, Ketones, Aldehydes, Etc.
Other Inorganics – Determine Rates Other Inorganics – Determine Rates S, N, P and Other CompoundsS, N, P and Other Compounds
Water Vapor – Determines BalanceWater Vapor – Determines Balance
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Typical Process Gas Control - Measures Only One or Two Species
Typical Process Gas Control - Measures Only One or Two Species
Example TypesExample Types Paramagnetic Oxygen Probe – Measures OxygenParamagnetic Oxygen Probe – Measures Oxygen Infrared – Measures Carbon DioxideInfrared – Measures Carbon Dioxide Electrochemical Cells – Low Range Single GasesElectrochemical Cells – Low Range Single Gases Thin Film Technologies – Too Many InterferencesThin Film Technologies – Too Many Interferences
BenefitsBenefits Proven Technology (Typically)Proven Technology (Typically) Lower Capital Cost Lower Capital Cost Low Complexity? (Two Analyzers Needed)Low Complexity? (Two Analyzers Needed)
DisadvantagesDisadvantages Other Gas Constituents Assumed (Guessed)Other Gas Constituents Assumed (Guessed) Assumptions Often WrongAssumptions Often Wrong Least Accurate Process Control OptionLeast Accurate Process Control Option Limits Process Control Options & ImprovementsLimits Process Control Options & Improvements
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Improved Process Gas Control –Absorption-Based Optical (IR)
Improved Process Gas Control –Absorption-Based Optical (IR)
Can Measure Multiple Gas SpeciesCan Measure Multiple Gas Species Carbon DioxideCarbon Dioxide MethaneMethane Alcohols (Some)Alcohols (Some) Ketones (Maybe)Ketones (Maybe) Aldehydes (?)Aldehydes (?)
BenefitsBenefits Proven Technology and VendorsProven Technology and Vendors Can be Used to Reduce Feedstock Use SomewhatCan be Used to Reduce Feedstock Use Somewhat
DisadvantagesDisadvantages Cannot Measure Diatomics (OCannot Measure Diatomics (O22, H, H22, N, N22, Etc.), Etc.) Detectors Have Limited Measurement RangeDetectors Have Limited Measurement Range Requires Frequent CalibrationRequires Frequent Calibration Species Measurement Has Significant OverlapSpecies Measurement Has Significant Overlap Restricts Optimal ControlRestricts Optimal Control
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Other Gas Analysis Technologies –Higher Cost of Ownership
Other Gas Analysis Technologies –Higher Cost of Ownership
Gas Chromatography (GC)Gas Chromatography (GC) High Installed Capital Cost ($25,000 - $60,000+)High Installed Capital Cost ($25,000 - $60,000+) Slow (2 Minutes+)Slow (2 Minutes+) Complex – Use Requires TrainingComplex – Use Requires Training Carrier Gas and Frequent CalibrationCarrier Gas and Frequent Calibration Laboratory and Petrochemical Processes PredominateLaboratory and Petrochemical Processes Predominate
Mass Spectroscopy (MS)Mass Spectroscopy (MS) Higher Capital Cost ($50,000 - $120,000)Higher Capital Cost ($50,000 - $120,000) Requires Vacuum PumpRequires Vacuum Pump Gas Mixtures Often Require Second Analysis MethodGas Mixtures Often Require Second Analysis Method Ionizer Susceptible to Water DamageIonizer Susceptible to Water Damage Expensive Sampling SystemExpensive Sampling System Expensive to MaintainExpensive to Maintain
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Ultimate Process Control Goal –Practical Complete Gas AnalyzerUltimate Process Control Goal –Practical Complete Gas Analyzer Measure All Reactive Gas SpeciesMeasure All Reactive Gas Species Detector Range - Low PPM to 100%Detector Range - Low PPM to 100% Work with Elevated Sample TemperaturesWork with Elevated Sample Temperatures Fast ResponseFast Response Compact and Operator FriendlyCompact and Operator Friendly Rugged, Reliable, Easy to ServiceRugged, Reliable, Easy to Service Minimal CalibrationMinimal Calibration Low Cost of OwnershipLow Cost of Ownership Potential for MiniaturizationPotential for Miniaturization
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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 PPM-100% Gas Concentrations with One DetectorPPM-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
Laser Raman Gas Spectroscopy - Features
Laser Raman Gas Spectroscopy - Features
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Core of Laser Gas Control – Unique 8 Gas Detector Module
Core of Laser Gas Control – Unique 8 Gas Detector Module
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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Detector Module Features Detector Module 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 Any 8 Gases Detected Per ModuleAny 8 Gases Detected Per Module Process Specific Configurations & Module #s Process Specific Configurations & Module #s Simultaneous Detection of All Gas SpeciesSimultaneous Detection of All Gas Species Fast Detector Updates (50 milliseconds)Fast Detector Updates (50 milliseconds) Only High Nitrogen Dioxide Levels InterfereOnly High Nitrogen Dioxide Levels Interfere Array Based Interference Computations Array Based Interference Computations
10 Minute Module Exchange10 Minute Module Exchange
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Typical Gas Constituents Monitored and Detection Limits
Typical Gas Constituents Monitored and Detection Limits
Gas Species Lower Limit
Hydrogen - H2 10-50 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 – Current SubsystemGas Analyzer – Current Subsystem
Detector AssemblyDetector Assembly
Integrated ComputerIntegrated Computer& Control System& Control System
Sample Pump, ValvesSample Pump, Valvesand Pressure Controland Pressure Control
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Subsystem FeaturesSubsystem 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 Automated Sample Line Monitoring (Flow & Pressure)Automated Sample Line Monitoring (Flow & Pressure)
Integrated Electronics & SoftwareIntegrated Electronics & Software Pentium III Computer w/ HMI and Data TrendingPentium III Computer w/ HMI and Data Trending Customizable Process Deviation AnalysisCustomizable Process Deviation Analysis Local and Remote Displays and InterfacesLocal and Remote Displays and Interfaces OPC Server and Client for ConnectivityOPC Server and Client for Connectivity Available Analog and Digital I/O OptionsAvailable Analog and Digital I/O Options Multiple Configurable Process and PLC InterfacesMultiple Configurable Process and PLC Interfaces
NeSSI Integration NowNeSSI Integration Now NeSSI Generation II Potential NeSSI Generation II Potential
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Example Main Control ScreenExample Main Control Screen
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Remote Analyzer/Controller – 4 Port Bio-Pharma Product
Remote Analyzer/Controller – 4 Port Bio-Pharma Product
Model 4FM Fermentation
Off-Gas Analyzer
Inside ViewInside ViewOutside ViewOutside View
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Mobile Process Audit Analyzer – 4 Samples, 8 Pressures, 8 Temperatures
Mobile Process Audit Analyzer – 4 Samples, 8 Pressures, 8 Temperatures
Bio-Pharma Commissioning
Performance Problem Resolution
Advanced Control Demonstration and Testing
ARI ConsultingService
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Analyzer/Controller – Eight Gases, Four Process Tanks
Analyzer/Controller – Eight Gases, Four Process Tanks
Inside ViewInside ViewOutside ViewOutside View
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Analyzer/Controller – 16 Gases, 16 Process Tanks
Analyzer/Controller – 16 Gases, 16 Process Tanks
Inside ViewInside ViewOutside ViewOutside View
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Products Integrate Sampling System & Fully Automated Operation
Products Integrate Sampling System & Fully Automated Operation
Fully Integrated Sample System (1-16 Ports) “Real Time” On-Line Monitoring and Control
(1 to 15 Second to Update Each Sample Location)
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-SpeedGas Process Analysis and ControlEconomic Benefits of High-SpeedGas Process Analysis and Control Multiple Gas Analysis Capability
= System Versatility
Economic Paybacks in Many Ways Increase Production Capacity Improve Product Quality Improve Product Consistency Reduce Analysis Costs Reduce Instrumentation and Control Reduce Instrumentation and Control
ComplexityComplexity Reduce Lost Batch Costs Better Process Documentation Maintenance Early Warnings Enhanced Process Safety Reduce Energy Costs
DependsDependson Systemon SystemFunctionsFunctions
UsedUsed
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Thank You For ListeningThank You For Listening
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