1. Atmospheric Plasma Alternative for Metal Degreasing

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

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

5. Atmospheric Plasma  Non-equilibrium plasma Electrons at 10-20,000 ºC Electrons at 10-20,000 ºC Ions, molecules at 60-80 ºC Ions, molecules at 60-80 ºC  Relatively uniform energy distribution  Does not require special vacuum chambers like low pressure plasma ≠ The Sun 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 its applications H S Uhm, Y C Hong and D H Shin Department of Molecular Science and Technology, Ajou University, San 5 Wonchon-Dong, Youngtong-Gu, Suwon 443-749, Korea

8. Plasma Jet

9. APNEP Research Atmospheric 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 NO X, 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 TOC (mg/m3) C1-C5 CO (ppm) NOX (ppm) SO2 (ppm) TEMPERING OIL 2353323 BENDING OIL 3041283 STAMPING LUBE 2138422 CUTTING OIL 21452313 ENVIRONMENTAL LIMITS ED 1999/3 50-150170-250370175

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

16. Sold for: US $189.50 US $189.50 Auction ended early with Buy It Now. Ended: Nov-02-06 06:40:11 PST Shipping costs: US $19.70 UPS Ground Service to 02067, United States (more services)Calcul ate 02067, United States (more services)Calcul ate02067, United States (more services)Calcul ate Ships to: Worldwide Item location: Niagara Falls, USA or Canada, United States History: 1 bid 1 bid Buyer: bcnu2bcnu2 ( 293 ) 293 bcnu2293

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 Technology acceptance System capital cost System capital cost Equipment compatibility with current processing lines Equipment compatibility with current processing lines Throughput limitations; chamber volume, exposure duration. Throughput limitations; chamber volume, exposure duration. QC and MIL-SPEC requirements QC and MIL-SPEC requirements Batch consistency 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 Hydrophobicity  Stain resistance Oleophobicity  Hydrophilicity Oleophobicity  Hydrophilicity Flame retardants  Antimicrobials Flame retardants  Antimicrobials Printability of polypropylene/polyester Printability of polypropylene/polyester  Pollution prevention Uses significantly lower quantities of chemicals Uses significantly lower quantities of chemicals Plasma treatments can enable conversion from solvents to aqueous coatings 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