Research Project Summary Information
BatchMatch Real-Time Analyzer & Control Product for Chemical Industry(ST10300-1)
August Ninth Analyses , Inc.
August Ninth Analysis, Inc. (ANA) is committed to creating and producing a real-time analyzer and control production for the chemical processing industry. ANA is already active in this business. ANA makes the “Pod,” an integrated analyzer programmer logic controller (PLC) station that automates batch manufacturing. With NYSERDA funding, ANA has developed methods to connect optical analyzers, both near infrared and visible light, to mixing vats using fiber optic cables. This technology is currently running at Kolmar, a cosmetics manufacturer that purchased a system after the NYSERDA demonstration. The main drawback of the Pod is that cost and implementation are well beyond the means of small manufacturers; a substantial market has been almost completely overlooked. The proposed program will produce and implement an analyzer, with most of the functions of the Pod, that is inexpensive and easy to use. The proposed product is the BatchMatch.
ANA will produce and implement the BatchMatch, an analyzer that is inexpensive and simple to operate. It will allow small manufacturers to enter into the automation game. This real-time analyzer and control system inexpensively replicates most of the functions of the Pod. It operates off one control computer using a Windows platform, and can be reconfigured by inexperienced factory personnel to handle a wide variety of production needs. With this unique product, ANA is responding with a product that provides a clear and demonstrable benefit that can be readily appreciated by this underserved market.
There will be numerous energy, environmental, and economical benefits to this project. The BatchMatch will result in significant energy and environmental benefits to New York State in the form of load reduction, peak load shifting, and waste reduction. Waste reduction potential, due to the BatchMatch’s improved control, will result in reduced off-spec batches. This waste reduction will also contribute to monetary savings from increased product sales, energy saved by avoiding waste production, and waste disposal cost reduction. Furthermore, large quantities of liquid/sludge waste from extra cleaning of tanks would be avoided by better process control.
BatchMatch was installed at two project site locations: Kolmar Laboratories, in Port Jervis, New York, and Joseph H. Lowenstein, in Brooklyn, New York. Kolmar realized the following benefits: it reduced batch process times by 20%, saving 642,970kWh/yr; shifted up to 624 kW of peak load; and saved up to 320,000 lbs of bulk waste per year. Overall, Kolmar sees an annual savings of approximately $160,000. Lowenstein realized the following savings: it reduced batch process times by 21%, saving 70,560 kWh/yr; shifted up to 88kW of peak load; and saved up to 62.5 tons of bulk waste per year. Overall, Lowenstein sees an annual savings exceeding $50,000, a simple payback of less than one year.
August Ninth Analyses , Inc.
63 Franklin Rd
Scarsdale, NY 10583
NYSERDA Contact Information
R&D - Mfg Tech & On-Site Pwr