Atmospheric Plasma Alternative for Metal Degreasing

1. Atmospheric PlasmaAlternative for Metal Degreasing

3. What is Plasma? • Fourth state of matter • Gas-like • Consists of neutral atoms/molecules, ions, and electrons • High energy, highly reactive substance • Electrons have 10,000 K worth of energy • Activates surfaces Image: http://discovery.nasa.gov/genesis.html

4. Plasma for Metal Treatment • High Temperature Arc Plasma (up to 16000ºC) Ceramic Deposition • Radio Frequency Induction Coupled Plasmas (5000ºC) Surface treatments for semiconductors • Electrodeless Atmospheric Microwave Plasmas EAMP

5. ≠ The Sun AtmosphericPlasma • Non-equilibrium plasma • Electrons at 10-20,000 ºC • Ions, molecules at 60-80 ºC • Relatively uniform energy distribution • Does not require special vacuum chambers like low pressure plasma Image: http://www.seas.ucla.edu/prosurf/plasmapro.htm

6. Atmospheric Plasma • Use microwave energy to create gas plasma streams at atmospheric pressure and moderate temperature (70-200ºC) • 10-20% conversion to active ion and radical species • Flow gas through an orifice to create a plasma jet or through into an application chamber

7. A microwave plasma torch and itsapplicationsH S Uhm, Y C Hong and D H ShinDepartment of Molecular Science and Technology, Ajou University, San 5 Wonchon-Dong,Youngtong-Gu, Suwon 443-749, Korea

8. Plasma Jet

9. APNEP ResearchAtmospheric Pressure Non-Equilibrium Plasmas • ELIMINATION OF ORGANIC SOLVENTS FOR DEGREASING OF METAL COMPONENTS BY USE OF A NOVEL MICROWAVE PLASMA • P. Aguirre, B. San Pedro, N. Wright, W. Hopkins, Global Symposium On Recycling, Waste Treatment and Clean Technology ’04. Madrid. • Jointly sponsored by INASMET, C-Tech Innovation, Phoenix Scientific Industries

10. APNEP Research • Examined the effects of Atmospheric Non Equilibrium Plasmas of Oxygen, Nitrogen, Argon, and Mixtures. • Treated standard industrial components contaminated with commercial oils and lubricants at loadings of 1-5 g/m2

11. APNEP Research • Varied plasma flow rate, microwave output power, and exposure duration. Plasma jet temperatures averaged 200ºC. • Achieved cleanliness equivalent to TCE vapor degreasing with an emission profile that met EU Industrial limits. • Claimed 98-100% removal of oils. • Paper left out key detail to determine exact operation costs. • Nitrogen plasmas produce NOX, leading the focus to oxygen

12. APNEP Results • Elevated gas temperatures -10% evaporation captured with coalescing filters. • Emission profile for Oxygen Plasma (10% radicalization) on components at 5g/m2 contamination level

13. For immediate release - 10 November 2004 C-Tech Lands DTI Grant for APNEP Plasma Development C-Tech Innovation Limited has successfully obtained funding from the DTI to further develop its unique, Atmospheric Pressure, Non-Equilibrium Plasma (APNEP), which has enormous potential in a wide variety of industrial and environmental applications. C-Tech has been awarded a Research and Development grant (formerly SMART award) for the ongoing development of the APNEP plasma. The DTI grants are provided to help small and medium-sized businesses research and develop technologically innovative products and processes, to generate new scientific or technical knowledge that will be…

14. Commercialization 06/07 • Several commercial lab systems • One (?) industrial system supplier in US

15. Plasma-Preen Cleaner/Etcher (Patent Pending) • Water-Cooled*8" x 6" x 2"100-550W 9505-03-220 $ 5,700.00 • 9" x 7" x 3"100-700W 9505-20-220 $ 6,290.00

18. Diener Electronics • German concern with sales office in Reading, PA • Offers standard and custom systems for RF and Microwave plasma treatment systems • Utilize 40KHz generators to minimize emissions. • Established marketing, several industrial placements in US at present.

19. Diener Economic Example • 22 liter chamber turn-key system- $27,250 • 40KHz/300W generator • One hour treatment with oxygen plasma • Operation cost on “small industrial parts” of “3-5 cents per piece”.

20. Technical and Economic Hurdles • Technology acceptance • System capital cost • Equipment compatibility with current processing lines • Throughput limitations; chamber volume, exposure duration. • QC and MIL-SPEC requirements • Batch consistency

21. OPPORTUNITIES for IMPLEMENTATION • Combination cleaning/degreasing and sterilization; medical devices. • Displacing infrequently used vapor degreasers. Relieve regulatory burdens. • Low throughput/high finish parts; aviation. • Energy conservation • Solvent use reduction

22. What Can It Do for Textiles and Adhesives ? • Surface modification and functionality • Hydrophobicity  Stain resistance • Oleophobicity  Hydrophilicity • Flame retardants  Antimicrobials • Printability of polypropylene/polyester • Pollution prevention • Uses significantly lower quantities of chemicals • Plasma treatments can enable conversion from solvents to aqueous coatings http://enerconind.com/treating/eLibrary/multimedia/plasmaOnly.swf

23. Can Plasma Be Used to Make a Light Saber ?

24. At this point maybe a Light Dagger

25. Gerry Podlisny Process Engineer/Environmental Analyst Mass OTA Gerald.Podlisny@state.ma.us