Small Business Innovation Research
$/i Success Stories
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The 22 million small businesses in the United States employ about 50
percent of the private work force and develop most of the country's
new technologies. Recognizing the tremendous potential of small
businesses to help meet federal research and development goals,
Congress passed the law creating the Small Business Innovation
Research (SBIR) Program in the early 1980s.
Since its inception, EPA's SBIR Program
\V* ^^|> has provided over $88 million
through more than 980 awards to
small businesses to translate
their innovative ideas into
commercial products that
address environmental prob-
lems. These innovations are
the primary source of new
technologies that can provide
improved environmental pro-
tection at lower cost with better
performance and effectiveness.
*QfM ^1*^ SBIR has helped spawn successful
commercial ventures that not only
improve our environment, but also create jobs,
increase productivity and economic growth, and enhance the inter-
national competitiveness of the U.S. technology industry.
The highlights of many successful SBIR projects are included in this
folder--many of them have been commercialized and are generating
more revenue than the funding provided by EPA. As more projects
reach milestones or commercialization, their success stories will be
added or updated to this collection, expanding the Nation's knowl-
edge base of innovative environmental technologies.
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Advanced Technology Materials, Inc.
7 Commerce Drive, Danbury, CT 06810
(?ni) 704-1100 http://www.atmi.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, ATM I, Inc., developed an innovative solid scrub-
bing material designed especially to reduce toxic air emis-
sions from the semiconductor industry. With 30 times the
capacity of activated carbon, the new material became
the core of the Novapure Dry Scrubber System that was
introduced into the market in 1991. The Novapure Sys-
tem has broad application in the electronics industry and
in research and development institutions where small
amounts of hazardous materials are routinely employed
in chemical vapor deposition (CVD) processes.
Since the award of this SBIR contract, ATMI has de-
veloped a family of novel vent gas scrubbers that are
cost effective in reducing toxic air emissions from small
quantity CVD processes as well as toxic air emissions
released by semiconductor manufacturers. ATMI pro-
cess scrubbers are smaller than traditional air pollu-
tion control equipment. Instead of a single large in-
stallation outside a Fabrication plant, ATMI's abatement
products are small enough to be located at each indi-
vidual pollution source.
SIGNIFICANCE OF THE TECHNOLOGY
The rapid growth of the American microelectronics in-
dustry has spawned new environmental challenges asso-
ciated with the processes used to prepare semiconductor
chips that are key components of sophisticated electronic
devices. Silane, phosphine, and arsine are used in CVD
steps in semiconductor fabrication. Although large com-
panies have built expensive facilities for handling small
amounts of these materials, small manufacturers have
vented the gases to the atmosphere or used similar unac-
ceptable techniques. As production increased, however,
venting of these gases to the atmosphere was no longer
an option.
The Emergency Planning and Community Right-to-Know
Act designates silane, phosphine, and arsine as extremely
hazardous chemicals used by the semiconductor industry;
these chemicals are also regulated as toxic chemicals un-
der the Clean Air Act. ATMI's scrubber system transforms
these toxic gases into nonvolatile, benign solids through
chemical absorption. By neutralizing, solidifying, and con-
centrating hazardous effluent up to 20,000 times, this
technology helps to eliminate toxic air emissions and
minimize solid toxic wastes from small semiconductor
manufacturers.
COMMERCIALIZATION SUCCESS
ATMI was granted four U.S. patents on its dry scrubber
technology, and in just 3 years, the company's annual
sales grew to nearly $6 million. To expand its environ-
mental control equipment market, in 1994 arid 1995
ATMI acquired the rights to alternative technologies,
including wet scrubbing and combustion scrubbing.
These acquisitions increased ATMI's annual revenues
to nearly $30 million at that time.
+ ATMI's dry scrubber system reduces toxic air emissions from the semiconductor industry.
> The innovative solid scrubbing material, the core of ATMI's Novapure dry scrubber, has 30 times the
capacity of activated carbon.
•f This SBIR contract led to the development of a family of novel vent gas scrubbers that are cost effective
in reducing toxic air emissions from chemical vapor deposition processes as well as several new safety-
related products that eliminate the use of toxic gases in the semiconductor industry.
+ ATMI has received the Tibbetts Award in recognition of the company's excellence in the area of high
technology, as well as several other awards.
+ ATMI has grown from four employees in 1987 to nearly 1,100 employees; revenues for 2001 were
$213 million.
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ATMI's Novapure Dry Scrubber
System, designed to reduce toxic
air emissions from the semicon-
ductor industry, was introduced
into the market in 1991.
ATMI's patented SDS® adsorbent tech-
nology stores toxic gases below at-
mospheric pressure, removing the
concerns of catastrophic releases of
high-pressure hazardous gases.
ATMI is the largest supplier of point-of-use emission con-
trol equipment for the semiconductor industry in the world.
This SBIR project led to the development of several
new safety-related products for the semiconductor in-
dustry. One product, called the Safe Delivery Source®,
or SDS®, that uses absorbent materials similar to those
of the dry scrubber system, eliminates the use of high-
pressure toxic gases in the semiconductor industry.
ATMI's SDS® Sub-Atmospheric Gas Delivery Systems
represent the company's largest source of revenue.
AWARDS AND COMPANY HISTORY
In recognition of its outstanding achieve-
ments in technology innovation, ATMI re-
ceived the Tibbetts Award in 1996. This
award is presented by the U.S. Small Busi-
ness Administration to companies associated
with the SBIR Program that are models of excel-
lence in the area of high technology. In 1997, ATMI
was recognized as an Outstanding Small Business En-
terprise by EPA. ATMI also was identified as one of
America's 100 Fastest Growing Companies by Individual
investor Magazine in 2000, and ranked 63rd on For-
tune's list of 100 Fastest Growing Companies. In 2002,
ATMI was included in Business 2.0's list of Fastest
Growing Companies, and made the Connecticut Tech-
nology Fast 50 list for the sixth time. Since 1987, when
ATMI was awarded the EPA SBIR Phase I contract,
the company has grown from four employees work-
ing in a small garage in New Milford, CT, to nearly
1,100 employees in numerous locations around the
world. Revenues in 2001 were $213 million. Originally
called Advanced Technology Materials, Inc., the com-
pany changed its name to ATMI, Inc., in 1997.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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Atmospheric Glow Technologies
924 Corridor Park Boulevard, Knoxvllle, TN 37922
(865) 573-7808 http://www.atmospherlcglow.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Program,
Atmospheric Glow Technologies (ACT) has developed and
commercialized a breakthrough air filtration system that
destroys all microorganisms—including biological warfare
agents such as anthrax and smallpox. In seconds, this sys-
tem captures microorganisms on standard filter media from
indoor air streams, preventing their circulation throughout
a building. The Enhanced Plasma Sterilized (EPS™) Fil-
tration System is the first heating, ventilation, and air con-
ditioning (HVAC) filtration system to combine a high-cap-
ture capability with an effective sterilization technology. The
EPS™ System safely captures, neutralizes, and/or destroys
all airborne microorganisms with greater efficacy and at a
lower cost than previously possible.
To develop a more practical, economical filtration system
that significantly improves indoor air quality, ACT com-
bined the effects of electrically enhanced filtration with
the rapid, nonthermal sterilization capabilities of its pat-
ented One Atmosphere Uniform Glow Discharge Plasma
(OAUGDP™) technology. Unlike other plasma technolo-
gies, OAUGDP"' generates plasma in air, under standard
pressure and at ambient temperature, without the need
for either a vacuum or a non-atmospheric gas, such as
compressed helium or argon. EPS™ Systems using
OAUGDP™ produce no harmful byproducts and have no
deleterious effects on sensitive materials.
The EPS™ System, which works with installed commer-
cial and residential HVAC systems, can be retrofitted to al-
most any HVAC unit. It is placed in the return air stream, and
an electrostatic field is used to continuously apply charge
across the filter to increase capture of microorganisms. The
electrostatic field positively charges the filter and there-
fore attracts (and traps) negatively charged microorgan-
isms, while consuming less power than the standard night
light. The increased capture abilities achieved with the
electrostatic field allows a porous, non-high-efficiency par-
ticulate, low-pressure drop air filter to provide high effi-
ciency service. This results in less energy consumption for
the HVAC unit. Periodically, the electrodes are energized
with the power source, creating plasma on the filter sur-
face that kills and desut>ys all of the captured microorganisms.
SIGNIFICANCE OF THE TECHNOLOGY
In addition to providing an efficient, cost-effective, envi-
ronmentally friendly, and safe means of eliminating bio-
logical warfare agents, the EPS "' System also provides a
healthier environment for commercial buildings and in-
stitutions, such as schools and hospitals. Therefore, the
EPS™ System offers tremendous economic and social ben-
efits by helping to reduce absenteeism, improve produc-
tivity, and provide for the better health of building occu-
pants. With only 30 seconds ofexposure to AGT's atmospheric
plasma, bacterial cells are desU'oyed.
Extensive testing by ACT confirmed that:
•*• The application of an electrostatic charge to the fil-
ter face results in enhanced capture for bacteria (450%
increase in capture for Staphylococcus aureus") and
representative viral particles (900% increase in cap-
ture for bacteriophage OX 174).
This novel system captures, neutralizes, and/or destroys microorganisms—including biological warfare agents
such as anthrax and smallpox—with greater efficacy and at a lower cost than previously possible.
It is the first heating, ventilation, and air conditioning filtration system to combine a high-capture capa-
bility with an effective sterilization technology. Bacterial cells are destroyed in only 30 seconds.
The EPS™ System provides a healthier environment for commercial buildings and institutions, such as
schools and hospitals.
AGT's technology combines the effects of electrically enhanced filtration with the rapid, nonthermal
sterilization capabilities of the OAUGDP™ technology.
In recognition of its technical innovation, AGT received one of R&D Magazine's prestigious R&D 100
Awards in 2002.
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EPS™ filtration system
in capture mode (presterilization).
EPS™ filtration system
in sterilization mode.
-f Filters loaded with 1 million bacterial cells and viral
particles are sterilized with only 15 seconds of
OAUGDP™ exposure.
•f The intermittent OAUGDP1" exposure does not re-
sult in a decrease in filter capture efficiency or in
electrode damage.
COMMERCIALIZATION SUCCESS
Since the initial product offering in November 2001, ACT
has been negotiating with federal agencies for incorpora-
tion of the EPS™ into highly visible federal buildings and
mass transit facilities. The EPS ™ System is commercially
available in three categories. Category 1 provides maximum
protection to sensitive buildings and includes additional fea-
tures such as ionizers, ports for sensors, and enhanced elec-
trodes for chemical and biological warfare attacks. Category
2 is designed with specialty applications, such as airplanes,
schools, and office buildings ki mind. The Category 3 EPS ™
System is marketed for the protection of high-value equip-
ment and is a simplified version of Category 2.
ACT is initially targeting high-value, indoor air- quality sen-
sitive customers, such as government and hospital facili-
ties and the military. These EPS ™ Systems will be equipped
with highly distinctive features, such as automated con-
trols and superior killing ability. Over time, ACT will
broaden its efforts to include more cost-sensitive markets,
such as office buildings, schools, and lastly, residential ap-
plications, with the more economical models having fewer
features. To execute this plan, ACT is focusing on identify-
ing and recruiting manufacturing, distribution, sales, and
product development partners.
The EPS™ System in a fully instrumented version is be-
ing monitored in a local area building, and ACT is develop-
ing relationships with a utility company for a field test as
well as with distributors for hospitals and other medical fa-
cilities. In addition, ACT has had discussions with the Ten-
nessee Office of Homeland Security to place an EPS™ unit
in a Tennessee Slate government building. Several EPS™
inquiries have been made by various parties experienc-
ing indoor air problems,
AWARDS AND COMPANY HISTORY
In recognition of its technical innovation, ACT
received one of ft&D Magazine's R&D 100
Awards in 2002. ACT also was awarded the U.S.
Small Business Administration's 2001 Tibbett's
Award for success in the SBIR Program. Based
in Rockford, TN, ACT was founded in 2000, to
develop and market an innovative method of
generating atmospheric plasma. With 12 employees, ACT
has become a leader in developing atmospheric plasma
technology for products to solve pertinent environmental
and health issues.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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Compact Membrane Systems, Inc.
325 Water Street, Wilmington, DE19804
(302) 999-7996 http://www.compactmembrane,com
Ex,
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram and collaboration with major industrial gas compa-
nies and major diesel engine manufacturers, Compact
Membrane Systems, Inc. (CMS), has developed high gas
flux and chemically resistant membranes. Membrane
module flux is sufficiently high that modules can be
placed under the hood of diesel engines to produce nitro-
gen-enriched all- (NEA) to reduce nitrogen oxide (NOx)
emissions by 50 percent. Environmental regulations are
requiring major diesel engine NOx reductions in the 2006-
2007 time frame. CMS' membrane modules offer a timely
alternative to existing hot and corrosive exhaust gas re-
circulation technologies.
CMS membranes are ideally suited in that they can sim-
ply be placed between the diesel turbo charger/after cooler
and the engine. A small amount of oxygen-enriched air
permeates the membrane, leaving highpressure NEA be-
hind to be fed directly to the engine.
Using SBIR funds and, subsequently, collaborations with
an industrial gas partner and major diesel manufacturer,
CMS successfully has improved membrane performance
towards meeting flux, size, ruggedness, and power-con-
sumption needs. Multi-point operation on commercial
large-size engines verified NO reduction levels. Mem-
brane performance was not affected during lengthy truck
tests. Simultaneous with 50 percent NOx reduction, mini-
mal changes in soot, particulate, hydrocarbons, or CO
emissions were observed.
SIGNIFICANCE OF THE TECHNOLOGY
This NEA membrane technology is a broad new mem-
brane platform. The CMS NEA membrane technology
allows, for the first time, sufficient productivity for mo-
bile applications and an ability to supply low-cost nitro-
gen up to 93 percent NEA in small- and large-volume
applications. Costs are projected to be significantly less
than for other conventional forms of nitrogen enrichment
techniques (e.g., cryogenics, pressure swing absorption)
for both large and small facilities.
Diesel engines, which run with excess oxygen (run lean),
produce high levels of nitric oxide or NOx and particu-
late matter (PM). This excess NOx is a major limitation
to broad utilization of diesel engines and the associated
enhanced fuel economy of U.S. vehicles. The EPA has
mandated that NOs and PM emissions from diesel trucks
be reduced by approximately 90 percent. Exhaust emis-
sions consisting of nitrogen oxide(NO) and small amounts
of nitrogen dioxide (N02) from internal combustion en-
gines present a serious environmental problem, Although
the problem exists for both gasoline and diesel engines,
CMS' membrane system provides a clean, cool, high-productivity, low-cost system to supply NEA to reduce
NO emissions by 50 percent.
* Compared to the existing NOx reduction technology, exhaust gas recycle, CMS membranes are much
cleaner, which should improve engine life, and they do not require cooling.
+ In addition to diesel engines, the CMS system is ideally suited for retrofitting diesel generators for NO,
reduction.
4- The NO, reduction capability of CMS' membranes has been shown to be of value for engines (discussed
above) and furnaces as well. This is timely with EPA regulations corning into force on electrical power
plants and other large furnaces.
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This 1.9 L Lister Direct Injection engine, which operates
at 8 psi turbo boost and has an output of 35 Hp at 1,800
rpm (55 Hp at 3,000 rpm), uses one 6" x 20" cylindrical
membrane module to reduce NOX emissions by 50 percent
with no significant change in soot, participate, hydrocarbon,
or CO emissions.
one-third of all NOx emissions in the Northeast United
States come from heavy-duty diesel truck engines.
Consumption of diesel fuel and gasoline have led to sig-
nificant dependence on foreign fuel and increased car-
bon dioxide emissions as well as the associated concern
for global warming. Diesel engines are much more fuel
efficient than spark/gasoline engines, but diesel engines
produce high N0x emissions. Exhaust gas recycle, while
lowering NOx emissions by 50 percent, reduces engine
life and puts significant stress on the cooling system.
COMMERCIALIZATION SUCCESS
CMS, working with EPA SBIR funds and subsequently
with a large industrial gas partner, is focusing its activity
on two commercial areas. The first is on-road large-scale
diesel engines that require large NOs reductions as part
of the 2007 Tier III specifications (several systems have
been installed on commercial diesel trucks over an ex-
tended time frame and performance has been verified).
The second area is retrofitting diesel generators to re-
duce NOs emissions.
AWARDS AND COMPANY HISTORY
CMS received the Tibbetts Award for Out-
standing Small Business in the State of Dela-
ware in 1998 and 2000. The award is given
by the Small Business Administration to firms
judged to exemplify the best in small busi-
ness innovation and research. Founded in
1993, CMS has a growing patent portfolio due
to its successful track record of obtaining research grants.
CMS is a membrane technology company engaged in re-
search and development of fluoropolymer membranes and
thin films with exceptional gas transport properties and
chemical resistance.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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EnerTech Environmental, Inc.
739 TrabertAvenue, NW,Atlanta, GA 30318
(404) 355-3390 http-J/www.enertech.com
'<• ^ <
'''''ON »**
I
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, EnerTech Environmental, Inc., successfully devel-
oped the SlurryCarb™ Process, an innovative process that
chemically converts municipal sewage sludge (MSS),
municipal solid waste (MSW), and other organic wastes
into a high-energy liquid fuel (or slurry) that is cleaner to
combust than most coals. Because the SlurryCarb™ Pro-
cess eliminates the need to land apply, landfill, or incin-
erate organic wastes such as MSS and MSW, its use can
help address current disposal problems (e.g., volatile or-
ganic compounds, disease vectors, dust, odor, hazardous
air pollutants, methane and other greenhouse gases, land-
fill space, leachate, and heavy metals). In addition, this
technology supports EPA's strategic goals of decreasing the
quantity of waste requiring disposal, reusing waste ben-
eficially, and utilizing renewable fuels.
SlurryCarb™ is a highly adaptive system that can stand
alone or be used in combination with existing or planned
waste disposal strategies. Simplicity of operation is key to
the SlurryCarb™ Process. MSS or MSW is brought to a cen-
tral manufacturing facility where it is converted into a uni-
form, pumpable slurry. The slurry can be created from a
single waste stream such as MSS or a combination of
wastes. The product fuel, known as "E-Fuel™," is a re-
newable fuel that can be utilized as a pellet or as a slurry
by industrial or utility users. E-Fuel™ is consumed as a
supplement or substitute for conventional fossil fuels such
as coal or oil. E-Fuel™ can produce up to 10,000 Btu/lb
(as a dry pellet), and easily fired into coal boilers via
conventional feed systems. In addition, the Slurry-
Garb7" Process removes more than 99 percent of the
feed chlorine, greatly reducing HC1 emissions and boiler
corrosion. Without extensive air pollution control sys-
tems, the CO, NOX, trace metal, and dioxin emissions
from the combustion of E-Fuel™ are well below EPA's
New Source Performance Standards (NSPS) for munici-
pal waste combustion, and the SO2 emissions are com-
parable to the NSPS for extensive air pollution control
systems.
SIGNIFICANCE OF THE TECHNOLOGY
With the SlurryCarb"1 Process, collected waste is pro-
cessed as a fluid in continuous equipment, which pro-
vides savings in capital and operating costs. The feed waste
is chemically altered so that it becomes a uniform, en-
ergy-dense fuel that can be used onsite or exported to a
customer. In addition, waste stream components, which
typically must be cleaned from the flue gas after combus-
tion (i.e., chlorine, ash, sulfur, etc.), instead are removed
during the front end of the process at a lower cost per ton
of pollutant removed. The technical advantages of the
SlurryCarb™ Process contribute to its excellent econom-
ics. A 100 ton per day sludge facility can operate profit-
ably at a tipping fee of $40 per as received ton (assuming
the sludge enters the SlurryCarb™ system at 20 percent
EnerTech's SlurryCarb™ Process eliminates solid waste by converting municipal sewage sludge, mu-
nicipal solid waste, and other organic wastes into a high-energy fuel that burns cleaner than most coals.
Because the SlurryCarb™ Process eliminates the need to burn or landfill organic wastes, its use can
help address landfill overcrowding and reduce air emissions from municipal incinerators and landfills.
The economic and operational viability of the SlurryCarb™ Process has been successfully demonstrated
at the 20 ton/day level using municipal solid waste as a feedstock.
EnerTech negotiated with a consortium of companies to construct a 100 ton/day facility in the United
States, which will springboard this technology into the U.S. commercial market.
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This 20 ton/day unit, which began operating
in Japan in early March 1997, was designed
as a fully integrated commercial-scale system
for local MSW. The product fuel from the fa-
cility is co-fired in a pressurized gasifier for
hydrogen production or co-fired in a cement
kiln for heat production.
Waste Pum pa ble Slurry E-Fuel™ Utilization
wof E-Fuel™
The SlurryCarb™ Process can generate a qual-
ity fuel from many low-grade fuels and wastes,
including municipal sewage sludge and munici-
pal solid waste.
solids). Reduced-capacity units (i.e., 25-50 tons/day) have
similarly strong economics.
In the United States alone, 8 million dry tons of MSS
and 210 tons of MSW are produced every year. EnerTech's
cost of disposal is below the average cost of conventional
thermal disposal options for these wastes. Smaller com-
munities now have available to them a clean and afford-
able method of MSS disposal that reduces landfill de-
mands and eliminates the need for a combustion facility
to burn wastes. Instead, the waste is converted to a valu-
able fuel and then exported to the marketplace.
COMMERCIALIZATION SUCCESS
Through an agreement with Mitsubishi Corporation, con-
struction of a 20 ton/day (as received MSW) unit in Ja-
pan was completed in early 1997. EnerTech has signed
an agreement with a large water and waste water com-
pany to build the first commercial plant for MSS. Having
successfully piloted this technology in the United States,
EnerTech is negotiating with a consortium of companies
to construct a 100 ton/day facility in the United States,
which will springboard the technology into the U.S. com-
mercial market.
COMPANY HISTORY
EnerTech Environmental currently holds 12 U.S. patents
for a number of combustion and high-pressure technolo-
gies, including the SlurryCarb"1 process. In addition, it
maintains international patent protection in 18 other
countries, encompassing a population of 3.3 billion people.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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eSp/n Technologies
WO Cherokee Boulevard, Suite 325, Chattanooga, TN 37405
(423) 267-NANO (6266) http://www.nanospin.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, eSpin Technologies has developed and commer-
cialized custom-made non-woven membranes, whiskers,
and three-dimensional structures of nanofibers. These
fibers can be made from a variety of organic (nylon, poly-
ester, polyaramid, acrylic) or biological (protein, collagen)
polymers. Using a proprietary process, eSpin is able to
produce minute fibers that are 10-100 times smaller in
diameter than fibers produced using conventional textile
technologies. eSpin's nanofibers are 20-200 nm in diam-
eter (about 1,000 times smaller than a human hair), have
a very high surface area-to-mass ratio, and can be formed
into sheet structures with very high porosity.
As filters, nanofiber-based membranes are capable of fil-
tering and separating blood, water, air, beverages, gases,
chemicals, oils, paints, etc., while at the same time
adsorbing harmful volatile organic compounds and toxic
gases. The nanofibers are spun from a solution of poly-
acrylonitrile in dimethylformamide in the form of a wo-
ven mat, which is further processed for conversion into
an activated nano-carbon fiber media. The web architec-
ture is tailored to achieve the desired filter performance
and gas adsorption by varying fiber diameter, fiber orien-
tation, fiber-packing fraction within the nanoweb, activa-
tion level, and nanoweb thickness.
eSpin has successfully developed nanofiber-based high
surface area NanoFilters made from activated carbon for
the removal of gaseous pollutants. Nanofiberous mem-
branes are ultra-thin products made up of randomly laid
nanofibers. Some of the important membrane character-
istics are: high porosity, large pore volume, high mois-
ture vapor transport, high surface area, high absorbency,
and the ability to perform specific tasks via large numbers of
chemically functional groups. Potential applications include
the use of nanofibers in filtration products, high-performance
structures, barrier fabrics, and biomedical devices.
SIGNIFICANCE OF THE TECHNOLOGY
As a platform technology, eSpin's nanofibers have an in-
credibly broad range of market opportunities in traditional
areas such as filtration and cosmetics, and in emerging
segments of industries such as aerospace, structural com-
posites, health care, and energy storage. Nanofibers' un-
usual characteristics can provide orders of magnitude of
improvement in critical product properties when com-
bined with existing technologies by innovatively overcom-
ing many technical hurdles faced by incumbent prod-
ucts.
Fine paniculate matter, aerosols, and air toxins are be-
ing emitted daily from a variety of sources such as auto-
mobiles, factories, and power plants. These toxic com-
pounds are complex mixtures of panicles, 90 percent of
which are smaller than 1 micrometer in diameter. In
addition, these particles have hundreds of chemicals
adsorbed onto their surfaces, including many known or
suspected mutagens and carcinogens. Also, gaseous pol-
lutants contain many irritants, toxic chemicals, and
+ eSpin produces minute fibers that are 20-200 nm in diameter (about 1,000 times smaller than a human
hair), have very high surface area-to-mass ratios, and can be formed into sheet membranes having very
high porosity with small pore size.
+ Nanofiber-based membranes are capable of filtering and separating blood, water, air, beverages, gases, chemi-
cals, oils, paints, etc., while at the same time adsorbing harmful volatile organic compounds and toxic gases.
•f Potential applications include filtration products, high-performance structures, barrier fabrics, and bio-
medical devices.
+ eSpin currently is supplying nanofibers for clean room products, nanocomposites, filtration, surgical
gowns, biomedical devices, and specialty fabrics, among others.
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eSpin's nanofibers (background) compared
to a single human hair (foreground).
Nanofibers compared to a single blood cell.
oxides of nitrogen, which are o/one precursors. The minute
ske and the abundance of these toxins gives them a greater
opportunity to enter our bodies via air and water, with the
potential of adverse heald: effects.
COMMERCIALIZATION SUCCESS
eSpin currently is supplying nanofibers for clean room
products, nanocomposites, filtration, surgical gowns, bio-
medical devices, and specialty fabrics, among others.
eSpin's global partners include Fortune 500 corporations,
government and military laboratories, research institu-
tions, and select high-tech companies around the world.
eSpin's carbon nanofibers are being used for end uses
such as thermal insulation, energy storage devices, envi-
ronmental applications, and lightweight structural com-
posites. The strategic applications targeted are those that
require the use of high surface area material and/or high
porosity combined with small pore size. These applica-
tions are well suited to address the problems of adsorbing
gaseous pollutants or filtering particles smaller than 3
microns from effluent gases or liquids economically
(where superior efficiency of nanowebs in capturing sub-
micron particles is very attractive). Alternatively, such fil-
ters will increase the particle-loading capacity of the filters, or
reduce the pressure drop for a variety of filtration end uses.
AWARDS AND COMPANY HISTORY
Founded in 1999, eSpin Technologies, Inc.,
is a high-tech start-up company based in Chat-
tanooga, TN, and is one of the first commer-
Acial producers of nanofibers. In addition to
receiving funding through EPA's SBIR Pro-
gram, eSpin also recently won grants from the
National Science Foundation and the Depart-
ment of Energy for the continued development of
nanofiber technology. In October 2002, eSpin received
a $2 million award from the Department of Commerce's
Advanced Technology Program to fund engineering ef-
forts related to eSpin's nanofiber technology platform
for developing a high-throughput process to enable large-
scale and economical production of nanofibers. This
prestigious award recognizes eSpin's potential to create
opportunities for new, world-class products, services, and
industrial processes that will benefit not only eSpin, but
also other companies, industries, and ultimately, con-
sumers and taxpayers. As one of 40 finalists from 473
companies across the country, eSpin was the first com-
pany from the State of Tennessee to win the award.
eSpin has been featured in global industry publications
such as Non-woven World, Chemical Engineering News,
and Nature.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA atso offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
-------
Faraday Technology, Inc.
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, Faraday Technology, Inc., has developed a cost-com-
petitive functional trivalent chromium (Cr+3) plating pro-
cess to replace hexavalent chromium (Cr+6). The
pilot-scale technology is validating Faraday's electrically
mediated Cr+3 plating process (the Faradaic"' Process) as
a "drop-in" replacement for the use of Cr+6 plating. This
manufacturing process validation is being executed with
Moyno Industrial Products, a large manufacturer of in-
dustrial pumps, and the Naval Air Depot (NADEP) at
Cherry Point, NC.
The process uses modulated reverse-current electrolysis
in conjunction with aCr"1"3 plating chemistry and results in
a performance-based, functional Cr*3 plating process to
replace conventional Cr+s chromium plating. The process
incorporates Faraday's E-CHANGE™ In-Process Recycling
System (also developed under EPA SBIR Program fund-
ing) for effluent waste management. A controlled Alpha
test of the Faradaic"1 Process was completed in a pilot-scale
manufacturing cell designed and built by Faraday. This test
was conducted using strut rods provided by a Tier 1 automo-
tive supplier.
Faraday's functional Cr+3 plating process demonstrates
equivalent or superior plating rate, hardness, and current
efficiency; replaces the conventional Cr+6 plating process;
and results in a more environmentally friendly and worker-
safe plating process. The Faradaic ™ Process demonstrates
a thickness of 10 mils (250 m) and a plating rate of 1.44-
2.25 um/min; whereas, conventional Cr+e plating processes
demonstrate a thickness of 6-10 mils (150-250 m) and a
plating rate of 0.76-1.27 jam/min.
SIGNIRCANCE OF THE TECHNOLOGY
EPA has identified Cr+e as 1 of 17 "high-priority" toxic
chemicals. These chemicals were selected based on their
known health and environmental effects, production vol-
ume, and potential for exposure. Hexavalent plating baths
operate at elevated temperatures and produce a mist of
chromic acid. The Clean Air Act, as well as local constraints,
regulate the emission of chromium to the air and water.
Because Cr+s plating produces hazardous air emissions,
all of the Cr+B platers must control and monitor the bath
surface tension and report the results to EPA. In contrast,
Cr+3 platers are not required to monitor bath surface ten-
sion. Use of Cr+3 in industrial and commercial processes is
preferred over Cr+s on the basis of the comparison of the
toxicities. EPA has classified Cr+6 as a group A, known
human carcinogen, and considers Cr+3 as being much less
toxic and an essential element in the human diet. Cr*3 is
classified by EPA as a Group D carcinogen, not classifiable
as to carcinogenicity in humans.
•f Faraday Technology, Inc., developed a cost-competitive Cr3 plating process to replace Cr6 plating.
-f The process uses a modulated reverse-current electrolysis in conjunction with a reduced-cost Cr3
plating chemistry.
•f Faraday's functional Cr3 plating process demonstrates equivalent or superior plating rate, hardness,
and current efficiency.
+ To date, $219,723 in commercial revenue has been secured to support Faraday's pilot-scale activity.
-------
A pilot-scale plating Cr+3 line (left) is being operated at the Faraday facility in Clayton, OH.
This plating line is a small-scale version of a shop-floor full-scale line. This line is being
used to validate the Faradaic™ Process on shock rods and pump rotors (right).
The Faradaic™ Process is being widely implemented for:
•f Faradaic™ Industrial Coatings, such as functional
chromium from a trivalent chromium bath.
+ Faradaic™ Edge and Surface finishing of advanced
engineering alloys, such as stainless steel, aluminum,
nickel, titanium, and the like without toxic, exotic
electrolytes.
+ Faradaic™ Leveling—metalization without leveler-
brightener additives for advanced electronics appli-
cations.
•+• Faradaic™ Environmental Countermeasures—elec-
trically mediated systems for in-process recycling of
rinse waters and plating bath chemistry.
The functional Cr+3 plating process supports the Fara-
daic"' Process technologies listed above, by providing
environmentally conscientious reclamation and reuse of
process solutions.
COMMERCIALIZATION SUCCESS
To date, Faraday has secured $219,723 in commercial rev-
enue to support this pilot-scale activity. Additionally, Fara-
day is preparing samples for external evaluation by Con-
current Technologies Corporation and NADEP Cherry
Point. Faraday has a successful track record of technology
commercialization, with six strategic technology alliances
currently under contract and 60 percent of its annual sales
coming from commercial sources. Faraday has filed patent
application #08/871,599 titled, "Electroplating of Metals
Using Pulse Reverse Current for Control of Hydrogen Evo-
lution" based on this SBIR-funded project.
!
AWARDS AND COMPANY HISTORY
Faraday Technology, Inc., is an electrochemi-
cal process technology development company
focused on enhancing and commercializing the
k Faradaic™ Process, its platform electrochemi-
•B cal manufacturing technology. Founded in
^ 1991, Faraday has established itself as a
noteworthy applied research and development company
with approximately 80 publications and more than 30
patents/patents pending. The company has been recog-
nized with a number of awards, including: the U.S. Small
Business Administration-sponsored Small Business/En-
terprise Spirit Awards, the State of Ohio Governor's Tho-
mas Edison Emerging Technology Award, the Affiliate's
Society Council of Dayton Outstanding Technology Lead-
ership Award, the Abner Brenner Silver Medal Award
for a paper published in Plating & Surface Finishing,
and the Ernst & Young Entrepreneur of the Year Award
(High Technology Finalist for 2001).
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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5
.*
ft
ionEdge Corporation
513 B North Link Lane, Fan Collins, CO 80524
(970) 491-9942 http://www,ionedge.com
UJ
x
o
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, ionEdge Corporation has developed and commer-
cialized an innovative metal-plating technology that re-
sults in "zero-waste." It eliminates most of the air
emissions, wastewater, and solid and hazardous wastes
associated with zinc and cadmium plating. One EPA study
noted that electroplating effluents are the single largest
source of natural water contamination in the United States
(Electroplating Wastewater Sludge Characterization, EPA-
600/52-81-064). Much of the waste from conventional elec-
troplating operations is associated with contaminated rinse
waters, which require treatment and subsequent disposal
of a hazardous sludge in an approved landfill.
To address environmental and occupational issues related
to electroplating, ionEdge achieved zero-waste plating by
using the novel concept of a vapor bath inside a vacuum
in lieu of the conventional liquid bath in air. Further-
more, special technological features of the ionEdge pro-
cess allow for material recycling. Only the parts exiting
the chamber are plated, leaving the chamber and racks
free of deposits. The seated chamber operation also mini-
mizes operator exposure to hazardous particle emissions.
The dry-plating line consists of only four process steps as
opposed to the dozen bath operations in conventional elec-
troplating, and a waste treatment facility is unnecessaiy.
SIGNIFICANCE OF THE TECHNOLOGY
ionEdge's zero-waste dry plating process eliminates the
costs and liabilities related to the transport and disposal
of hazardous sludges; waste treatment savings are esti-
mated to exceed $1,000 per day for the average elec-
troplater. Because ionEdge's plating process lakes place
in a sealed chamber, it also minimizes operator exposure
to hazardous particle emissions and eliminates solid waste
by facilitating in situ recycling of the metals used in the
plating process. In addition, the dry-plating process de-
veloped by ionEdge uses (ess chemicals, requires 75 per-
cent less energy, and reduces water consumption by an
order of magnitude in comparison to conventional elec-
troplating processes.
Zinc and cadmium coatings are electroplated on steel
hardware components used in the defense, aerospace,
automotive, and construction industries to protect them
from corrosion in natural environments. The electroplat-
ing process is occupationally and environmentally haz-
ardous because it requires the use of toxic liquids and
generates large quantities of contaminated wastewater
and solid and hazardous wastes.
A rack plating apparatus using ionEdge's process has been
in production for more than 4 years. For a batch of parts,
the start-to-finish process time for the degrease-to-
chrornate operation is about 30 minutes. The quality of
ionEdge has developed a zero-waste dry plating process that eliminates most of the air emissions,
wastewater, and solid and hazardous wastes associated with zinc and cadmium plating.
ionEdge's dry plating process eliminates the need for conventional toxic plating bath liquid chemicals
and minimizes the liabilities related to the transport and disposal of hazardous sludges.
The zero-waste dry plating process is economical—it requires 75 percent less energy, reduces water
usage by an order of magnitude, and results in waste treatment cost savings of approximately S1,000 per
day, for an average electroplater.
ionEdge's in-house dry-plating line has been certified for use by an aerospace company. ionEdge is
seeking strategic partnerships for implementation of a plan to expand the dry plating line to increase
throughput by an order of magnitude, along with installation of a full commercial production line for
high-volume processing (10,000 parts/hour).
-------
ionEdge achieved zero-waste plating by using the novel concept of a vapor
bath inside a vacuum in lieu of the conventional liquid bath in air. This technol-
ogy eliminates most waste associated with plating; reduces chemical, water,
and energy consumption; and significantly reduces waste treatment costs.
ionEdge's cadmium coatings has been acceptable accord-
ing to standard federal and U.S. military specifications,
and the coatings have performed well in more than 7,000
hours in salt-fog tests. The apparatus and process devel-
oped during the EPA SBIR project were upgraded and im-
proved to meet customers' requirements in pilot produc-
tion. In-process improvements and adjustments were made
to maintain product quality and to achieve process repeat-
ability. Test samples from three prospective customers were
coated on the pilot line. The quality of these coatings was
evaluated and approved by all three customers.
COMMERCIALIZATION SUCCESS
This success led to the first commercial sale of the dry-
plating process to an aerospace customer who requested
ionEdge to set up three additional processes to complete
the customer's plating fine. The expanded plating fine
and processes have been certified for coating aerospace
parts, and ionEdge continues to provide coating services
to the aerospace industry. During 1998 alone, more than
50,000 steel components were cadmium dry plated on
this plating line. These components are now in service in
commercial airplanes, jel fighters, helicopters, and mis-
siles. ionEdge is preparing a business plan for expanding
the dry-plating line to increase the throughput by an or-
der of magnitude (in the range of 2,000 parts of 1-inch
size/hour). Simultaneously, a full commercial production
plating line will be installed for high-volume parts pro-
cessing (10,000 parts/hour), which will allow customers
to evaluate the full economic benefits of the dry-plating
process. ionEdge is seeking strategic partnerships for
implementation of this expansion plan.
AWARDS AND COMPANY HISTORY
I
Due to its outstanding technological contribu-
tions over the years, ionEdge Corporation was
awarded the prestigious 1998Tibbetts National
^ Award by theU.S. Small Business Administration.
•• The company was founded in 1988, with the spe-
^ cific goal of developing environmentally safe coat-
ing and surface nnishingmethods. ionEdge's cad-
mium-plated parts are in service in various fighter and
commercial airplanes, helicopters, and missiles. The tech-
nology has been extended to plating other metals such as
aluminum, copper, chromium, and nickel on ceramics and
other non-conductive materials.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
-------
KSE, Inc.
P.O. Box 368, Amherst, MA 01002
(413) 549-5506 http://www.kse-online.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, KSE, Inc., has developed a novel technology that
economically destroys airborne contaminants. The Ad-
sorplion-Integrated-Reaction (AIR) Process employs a pro-
prietary photocatalytic adsorbent that traps airborne toxic
contaminants on its surface. When illuminated by ultra-
violet (UV) light bulbs, the photocatalyst converts vola-
tile organic compounds (VOCs) and microorganisms to
environmentally safe products at ambient temperature.
The AIR Process is a selective, energy-efficient, and eco-
nomic technique for indoor air quality control.
The use of UV light bulbs to photocatalytically destroy
pollutants provides simple controls. The unit can be
turned on or off with the flip of a light switch. The ambi-
ent operating temperatures result in low energy consump-
tion and low-cost operation. Ambient temperature AIR
units can be constructed of fiberglass-reinforced plastic,
rather than the expensive exotic alloys used in alterna-
tive high-temperature technologies.
Contaminated groundwater can be cleansed by air strip-
ping, and contaminated solids may be remediated by soil
vapor extraction. However, these methods lead to emis-
sions of toxic air pollutants. Industrial facilities also pro-
duce emissions of hazardous air pollutants. KSE's AIR
Process destroys these emissions, at low cost and at ambi-
ent temperature. Contaminated ground -water first must
be stripped with air, and contaminated soil must be ther-
mally desorbed or vacuum extracted, alt of which are cost
effective in combination with the AIR Process.
SIGNIFICANCE OF THE TECHNOLOGY
The AIR Process has advantages over alternative air emis-
sions control options. The process has been dem-onstrated
to achieve 99,99 percent destruction efficiency of air emis-
sions in commercial applications and produces benign
products and completely destroys the contaminants, avoid-
ing the production of seconary wastes, as is frequently
found in activated carbon treatment.
The cost of the new emissions technology dependson gas
flow rate, contaminant type, and destruction efficiency.
Operations and maintenance costs at one operating site
are estimated at $6,000, compared with $355,000 for dis-
posable carbon. It also can destroy contaminants that are
not economically treated by conventional technology, such
as vinyl chloride. No secondary wastes are produced, other
than spent caustic for high-concentration chlorinated hy-
drocarbons. The project-life cost of the AIR unit can be
less than one-tenth the cost of activated carbon, depend-
ing on inlet concentrations. The innovative air purifica-
tion technology offers orders of magnitude reduction in
costs compared to conventional control methods.
The photocatalysts developed for this technology are sig-
nificantly improved compared to the conventional titania
photocatalyst that historically has been employed for
T KSE's AIR Process uses a photocatalytic adsorbent to trap airborne toxic contaminants on its surface. When
illuminated by UV light, the photocatalyst converts VOCs and microorganisms to environmentally safe prod-
ucts at ambient temperature.
+ The AIR Process achieves 99.99 percent destruction efficiency of air emissions in commercial applica-
tions and offers orders of magnitude reduction in costs compared to conventional airborne contaminant
control methods.
4 The AIR technology can effectively destroy anthrax spores in heating, air conditioning, and ventilation
systems.
> AIR units have been used at the Stamina Mills Superfund Site in Rhode Island, and in the International
Space Station.
-------
Photograph of the first commercial photo-
catalytic unit for the destruction of chlorinated
hydrocarbons at the Stamina Mills Superfund
Site. The AIR Unit reactors are in the foreground;
the groundwater strippers and the soil extrac-
tion vacuum pumps are in the background.
photocatalytic applications. When destroying formalde-
hyde and cai'bon monoxide, back-to-back comparison tests
found that these catalysts were orders of magnitude more
active than titania. For formaldehyde, for example, the
Phase I photo-catalyst was shown to be 48 times more
active than titania. For cai'bon monoxide, the same photo-
catalyst was shown to be 257 times more active than tita-
nia, at the same operating conditions. The technology
also is effective for the destruction of anthrax spores in
heating, air conditioning, and ventilation systems.
COMMERCIALIZATION SUCCESS
A 700 ftVmin at standard conditions commercial unit has
been demonstrated at the Stamina Mills Superfund Site
in Rhode Island, and destroyed 99.99 percent of entering
contaminants. Another AIR unit has been used in the
International Space Station to destroy ethylene (KSE
partnered with Orbital Technology Corp., in Madison, WI,
to develop an AIR Process unit capable of withstanding
travel to and from space). Currently, AIR Process units
are commercially available for the elimination of chlori-
nated and mixed non-chlorinated materials. A unit for
removal of benzene, toluene, and xylene will be avail-
able soon.
AWARDS AND COMPANY HISTORY
The AIR Process has been recognized by
the 1997 SBIR Technology of the Year
Award for Environment, Energy, and Re-
source Management, as an innovative, new
technology that results in the improvement
of everyday life and the betterment of man-
kind. The technology also has been recog-
nized by the 1998 U.S. EPA Environmental Innovator
Award and the 1997 R&.D Award as one of the 100 most
technologically significant new products of the year.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
-------
LSR Technologies, Inc.
898 Main Street, Acton, MA 01720
(978) 635-0123 http://www.lsnech.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, LSR Technologies, Inc., has developed the Core
Separator, a mechanical dust-collecting device that re-
moves micron- and submicron-sized particles from gas
streams. Historically, mechanical collectors have been
ineffective in removing particles with diameters of less
than 10 microns.
The Core Separator System includes two conventional
components, a cyclone collector for extracting solids and
a fan for flow recirculadon. A complete system is actu-
ally a multitude of cylindrical units, each with a single
inlet for the stream to be treated and two outlets. One
outlet is for the clean gas stream and the other contains
a highly concentrated recirculation stream. The dust-
laden recirculadon stream is fed to a cyclone and re-
turned again by means of the fan. The Core Separator
component cleans the inlet stream and detains dust par-
ticles in the system. Because its efficiency is very high,
most particles do not leave the system. They recirculate
until collected by the cyclone. Two factors govern the
performance of Core Separators: (1) high separation ef-
ficiency of the separator component, and (2) the inter-
action between individual components. To achieve high
separation efficiency, a proper bleed-flow ratio (i.e., ra-
tio of the recirculation flow to the total flow) is required.
By controlling bleed flow, the tangential and radial ve-
locities are controlled independently to maintain them
in the desirable range.
High efficiency in the Core Separator results from low
particle reentrainmenl. The system is designed to avoid
formation of toroidal vortices. Because the Core Separa-
tor component functions as a separator and not a collec-
tor, a flow U-turn within the device can be avoided. It is
entirely cylindrical, and surfaces promoting the forma-
tion of vortices are moved away from the clean outlet.
This theory has been verified by actual testing and
through computer modeling using computational fluid
dynamics to study flow fields. It should be noted that each
of these factors individually cannot prevent vorticity; how-
ever, working together they achieve what each cannot
independently. The conflicting processes of separation
and solids collection are accomplished separately and in
different components. The interaction between compo-
nents is the principal means of attaining high system ef-
ficiency.
SIGNIFICANCE OF THE TECHNOLOGY
Paniculate matter is being regulated as a criteria air pol-
lutant (i.e., pollutants causing human health impacts due
to their release from numerous sources) under the Clean
Air Act. EPA has proposed tightening the National Ambi-
ent Air Quality Standards for the allowable levels of par -
ticulate matter, decreasing the size of the particles that
must be removed from gas streams from 10 microns to 2.5
microns. Unlike other mechanical collectors, the Core
Separator is capable of removing dust particles with di-
ameters of less than 10 microns; it even can remove a
high percentage of particles in the micron range. This is
equivalent to the performance of a medium-efficiency
LSR Technologies' Core Separator can remove micron- and submicron-sized particles from gas streams.
By removing micron-sized particles from gas streams, the Core Separator reduces particulate matter
emissions and the human health and environmental effects associated with this criteria air pollutant.
More than 65 Core Separators have been sold in the United States and abroad. These units are attributed
with a major reduction of particulate air emissions. For example, stack compliance testing has shown
particulate emissions to be below 100 mg/nnV when used on coal-fueled boilers.
A Core Separator installation used for recovery of chemical catalysts by a Fortune 500 company has
produced a payback in less than 6 months.
-------
Clean Flow
Core Separators
Cyclones
.Process
Flew
Solids
Recirculatton Lines
LSR Technologies' Core Separator System con-
sists of a series of cylindrical units, each with a
single inlet for the stream to be treated and two
outlets. One outlet is for the clean gas stream
and the other is for the highly concentrated re-
circulation stream. The dust-laden recirculation
stream is fed to a cyclone where solids are ex-
tracted and returned again by means of the fan,
which facilitates flow recirculation.
More than 65 Core Separators, such as
the one at the asphalt plant above, have
been installed in the United States and
other countries to remove dust particles
from gas streams.
electrostatic precipitate' and better than the performance
of a high-energy Venturi scrubber. Yet, the Core Separa-
tor still has the traditional advantages of mechanical col-
lectors such as simplicity, reliability, compactness, and low
maintenance.
COMMERCIALIZATION SUCCESS
There is strong demand for the Core Separator both as
an air pollution control device and as a means to recover
valuable product material. More than 65 Core Separa-
tors have been sold in the United States and abroad, and
at least one company using the technology for recovery of
chemical catalysts lias experienced a payback period of
less than 6 months. This product is quite significant in
light of the fact that very few advances have occurred in
particulate control technology in recent years.
Another emerging industrial application for the Core
Separator is as a control device for collecting particulate
matter upstream of regenerative thermal oxidizers, which
are used in the production of wood products for the build-
ing industry (e.g., medium-density flberboard, particle-
board, and oriented strandboard). The Core Separator
currently is being demonstrated for wood dryer applica-
tions, and could emerge as the "Best Available Control
Technology" for these processes.
AWARDS AND COMPANY HISTORY
In 1996, the Core Separator was selected for the
prestigious R&D 100 Award, signifying it as one
of the world's best new technology-based prod-
ucts of the year. LSR Technologies, Inc., is a Mas-
sachusetts-based engineering firm that offers
emission control and process equipment to in-
dustrial clients. The company has supplied in-
novative equipment and novel solutions for difficult in-
dustrial separations since 1989. LSR equipment is in
operation in numerous plants around the world for prod-
uct recovery and for emissions control. LSR equipment
applications include minerals and metals processing, re-
covery of chemicals and catalysts, coal-fired power plants,
furnaces, dryers, acid gas removal, and wood-fired boilers.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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Nanomaterlals Research Corporation
2021 Miller Drive, Suite B, Langmont, CO 80507
(720) 494-840 J hnp://www.nanoproducts,com
. A i i
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SB1R) Pro-
gram, Nanomaterials Research Corporation (NRC) has
developed and commercialized an innovative manufac-
turing technology for performance ceramics. NRC's pro-
cess improves device quality while preventing pollution
by reducing the amounts of raw materials, solvents, and
binders required for production of these ceramics in com-
parison to conventional manufacturing techniques.
NRC's manufacturing method for performance ceramics
offers the following advantages over conventional tech-
niques in that it: (1) eliminates the formation of second-
ary gaseous, liquid, or solid wastes; (2) reduces the pro-
cessing, containment, and treatment of solvents and
resulting vapors by more than 10-fold; (3) reduces energy
requirements by recovering mass and heat through pro-
cess integration; and (4) produces performance ceramics
of significantly improved quality (i.e., monodisperse,
nanosize particles with extraordinary properties).
SIGNIFICANCE OF THE TECHNOLOGY
The performance ceramics industry produces and sells
more than $18 billion of ceramic products annually and
is one of the fastest growing segments of all industries
listed by the North American Industry Classification Sys-
tem. The performance ceramics industry is enabling growth
within the electronics, utilities, medical devices, optics,
and telecommunications industries, and the market for
such ceramics is expanding in conjunction with this
growth. More than 1 billion ceramic devices (e.g., capa-
citors, thermostats, varistors, inductors, resistors, and 1C
substrates) are produced and sold each week. Anticipated
growth in the market for ceramic devices will further ex-
tend the role of performance ceramics.
Performance ceramics typically are produced by solvent-
based techniques that inadvertently lead to processing,
containment, and treatment of hazardous solvents and
byproducts. Given the commercial importance of the
electroceramic industry, it is imperative that environmen-
tally benign manufacturing techniques are developed to
prevent pollution at its source while providing perfor-
mance improvements to customers.
COMMERCIALIZATION SUCCESS
NRC has demonstrated that devices produced from
nanosized electroceramics are nanostructured and meet
the needs of high-performance components that will be
NRC has developed and commercialized a manufacturing technology for performance ceramics that
improves device quality while preventing pollution at its source by reducing the amounts of raw materi-
als, solvents, and binders required for processing.
This technology enables the manufacture of nanoscale electronic grade powders needed in next gen-
eration miniature electronics. The market for nanostructured components is expected to exceed $100
million/year in less than 5 years.
NRC is scaling up the manufacturing process to produce 100,000 nanostructured components per week
from electroceramic nanoscale powders.
-------
Nanopowders of performance
ceramics produced by NRC.
Nanotechnology electronic devices from
nanopowders of performance ceramics manu-
factured using NRC's innovative manufactur-
ing technology.
essential for the anticipated era of nanodevices and mo-
lecular electronic components. Manufacturing of these
devices is being scaled up by NRC to serve surface-mount
electronics, cellular telecommunications, power compo-
nents for utilities, laptop computers, and biomedical prod-
ucts. The market for nanostructured components should
exceed $100 million/year in less than 5 years.
COMPANY HISTORY
Since the company was founded in 1994, NRC has ex-
perienced an average annual growth of more than 100
percent. NRC currently has more than 60 employees.
In 2000, the company began a scale up of its manu-
facturing process, which was successfully completed in
2001. In March of that year, NRC was reorganized into
two companies: (1) Nanomaterials Research LLC, which
focuses on nano-engineered device development and
manufacture; and (2) NanoProducts Corporation, which
focuses on the development and manufacture of
narioscale powders and emerging powder-based energy
technology products. In February 2002, NanoProducts
Corporation and Hosokawa Micron Corporation an-
nounced a strategic partnership and signed a letter of
intent for a joint venture in Japan to develop, manu-
facture, and market nanoscale powders and related
nanotechnology.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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National Recovery Technologies, Inc.
566 Mainstream Drive, Suite 300, Nashville, TN 37228-1202
(615) 734-6400 http://www.nrt-inc.com
%>N ***
&
i
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, National Recovery Technologies, Inc. (NRT) has
developed and commercialized an innovative process for
sorting poslconsumer plastic containers. NRT's process is
capable of sorting plastics by polymer with high accuracy
and at the high-speed throughputs required for cost-ef-
fective recycling. Plastics constitute about 9 percent by
weight of municipal solid waste, and they occupy approxi-
mately one-fourth of the volume of the waste stream. The
cost of transporting and disposing of plastics in landfills is
very expensive due to their light weight and large vol-
ume. In addition, plastics in landfills are highly resistant
to degradation. Therefore, EPA has recommended recy-
cling as the preferred management method for plastics
over alternative landfill or incineration methods.
For plastics recycling to be economically viable, the re-
cycled resins must be of high quality and priced competi-
tively with virgin resins. To produce high-quality recycled
resins that can replace virgin resins, it is necessary that
the recycled resins be cost-effectively sorted to high-pu-
rity specifications. In particular, it is necessary that the
plastics be sorted by individual polymer while minimiz-
ing processing costs. NRT's sorting process satisfies these
requirements by coupling high-speed spectroscopy for posi-
tive polymer identification, concurrent parallel process-
ing for rapid identification, quick real-time sorting re-
sponse, and precision air jet selection of materials. Be-
cause NRT's sorting process facilitates plastics recycling,
it supports EPA's goal to reduce the quantity of waste re-
quiring disposal.
Previously, some postconsumer packaging container res-
ins were sorted automatically according to their visual
color characteristics and visual light transmission proper-
ties, resulting in a pseudo-polymer sort. However, this is
only an approximation and until the introduction of NRT's
technology, it only was possible to sort plastics into a few
major constituents and only at relatively low accuracy,
requiring significant manual sorting for quality control.
Another system using expensive x-ray technology currently
is used to sort polyvinyl chloride (PVC) plastics from
polyethylene terephthalate (PET) plastics; however, its
accuracy is somewhat limited and is not applicable to
other polymers.
SIGNIFICANCE OF THE TECHNOLOGY
NRT's new technology overcomes the inaccuracies and
limited applicability inherent in existing technologies by
providing rapid positive identification of plastics by poly-
mer type according to its infrared (IR) spectral finger-
print. Each polymer has a unique IR fingerprint and,
. NRT has developed a highly accurate, high-speed process for sorting postconsumer plastics resins by
polymer type.
•»• The new technology enables low-cost automated sorting of postconsumer plastics for recycling, which
significantly improves the economics for plastics recycling.
+ NRT's new technology is cost effective for low- and high-volume applications, making automated sort-
ing of plastics affordable for community materials recovery facilities.
Numerous commercial systems have been installed at recycling facilities in North America and Europe.
+ Negotiations are in process for installation of additional units in the United States, Europe, and Japan.
-------
NRT's technology facilitates accurate, high-speed sorting of postconsumer
resins by polymer type. It couples high-speed spectroscopy for accurate poly-
mer identification with concurrent parallel processing for rapid identification
to enable cost-effective sorting to high-purity specification.
therefore, can be readily distinguished and sorted from
other polymers.
Current automated systems are complicated and require
a high level of technical sophistication to reconfigure sys-
tem sorting characteristics. Consequently, it has been dif-
ficult for operators to control these systems to the level
and precision necessary to optimize performance. NRT's
technology eliminates this problem by introducing a user
friendly man-machine interface that incorporates a touch
screen graphical interface so operators can easily set
system- sorting parameters and control system operation.
COMMERCIALIZATION SUCCESS
Numerous commercial systems have been installed in
North American and European recycling facilities. NRT
expects that this innovative sorting system will be applied
in the recycling industry worldwide, both in new applica-
tions and in replacement of older generation automated
sorting systems currently in use. In 1991, NRT introduced
the award-winning VinylCycle8 Separator, the world's
first system for sorting PVC bottles from PET bottles at
industrial feed rates. Developed in cooperation with EPA
and the Vinyl Institute, the VinylCycle® has become
the industry standard for this critical sorting task and
the "workhorse" system for most major PET plastics
recyclers. NRT's VinylCycle* Separator is in commercial
operation at various Fortune 500 companies, plastic pro-
cessors, and waste companies in the United States and
throughout the world.
COMPANY HISTORY
NRT based in Nashville, TN, is a leader in the recycling
equipment industry, providing equipment arid systems ten-
sorting municipal solid waste, curbside collected materi-
als, and plastics waste streams. NRT proprietary technolo-
gies are on the cutting edge of automated sorting systems.
NRT assists in the recovery of materials for alternate uses
while preserving valuable landfill space. NRT systems re-
cover aluminum, steel, glass, newspaper, corrugated box-
board, mixed waste paper, plastics, and batteries.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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NITON LLC
900 Middlesex Turnpike, Building 8, Billerica, MA Q1B21
(978) 670-7460 http://www.niton.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, NITON LLC, has developed and commercialized a
unique instrument to detect lead in paint that solves the
problems encountered with x-ray fluorescent analyzers.
The NITON XL-309 Dual Detector is compact, lightweight,
and batteiy operated. It produces rapid, accurate mea-
surements of lead and can be equipped with the capabil-
ity to be used for the following applications:
•f Lead in paint, independent of the composition, thick-
ness, and substrate of the paint.
•*• Lead in soil for site characterization, clearance screen-
ing, and remediation quality control.
•*• Lead in dust wipes for lead inspection, risk assessment,
and site clearance.
•f Lead on filters for tracking workers' exposure to harm-
ful ail-borne lead.
The NITON analyzer uses a 109Cd source to measure the
concentration of lead in paint, even when covered by 15
or more layers of non-lead paint of unknown thickness
and composition. This results in no substrate correction
and simple, point-and-shoot operation on any surface.
Positive/negative classifications are displayed automati-
cally when 95 percent confidence is achieved, and the
results are continuously displayed and updated. In some
cases, results are obtained in as little as 1 second with no
inconclusive ranges. Equipped with a fully automated
data entry and onsite report generation capability, the
XL-3Q9 is a powerful onsite package capable of solving
the most challenging lead-hazard problems.
SIGNIFICANCE OF THE TECHNOLOGY
Lead in paint has been associated with a number of envi-
ronmental and health risks. Exposure of pregnant women
to lead can result in premature birth, low birth weight, or
spontaneous abortion. Lead exposure in infants and young
children may lead to decreased intelligence scores, de-
celerated growth, and hearing problems. Also, exposure
of adults and children to high levels of lead may cause
brain and kidney damage. NITON's device helps detect
and subsequently eliminate the health risks associated
with lead-based paint (LBP).
Lead in soil contamination, at residential and industrial
sites, poses numerous environmental, safety, and reme-
diation problems. Depending on the source (s) of lead, the
contamination may be highly localized or distributed ex-
tensively about a property. For example, if the main source
of lead is due to external house paint, then the lead in soil
is expected to be highest near the dripline of the house
and decrease rapidly away from the structure. Conversely,
if the lead source is from a nearby industry or large lead
abatement project, the soil contamination may be perva-
sive throughout the property. Only a thorough site assess-
ment involving a detailed sampling pattern will produce
an accurate contamination profile of such sites.
The NITON 300 series analyzer, as part of a soil-testing
strategy, can reduce the cost and disruption of soil reme-
diation. The NITON analyzer is in full compliance with
U.S. EPA Method 6200, "Field Portable XRF Spectrometry
NITON has developed and commercialized the NITON XL-309 Dual Detector, which produces accurate
measurements of lead in paint independent of the composition, thickness, and substrate of the paint.
The analyzer uses a 109Cd source to measure the concentration of lead in paint, even when covered by
15 or more layers of non-lead paint of unknown thickness and composition.
The device also can be used for detecting lead in soil, dust wipes, and on filters.
Since receiving SBIR funding 6 years ago, the NITON XL-309 dual detector has become the industry
standard for lead in paint analyses and has evolved into a complete lead analyzer.
-------
The NITON XL-309 dual detector has become the industry standard for lead in paint
analyses and has evolved into a complete lead analyzer, capable of detecting lead in
soil, dust wipes, and on filters.
for the Determination of Elemental Concentrations in
Soils and Sediments" for lead analysis. When used as
part of a remediation project, it is expected to reduce off-
site analytical costs, reduce the amount of soil to be pro-
cessed, reduce the time required for remediation, and
reduce or perhaps eliminate the need to remove con-
taminated soil for storage at hazardous waste landfills.
It is expected that these benefits would greatly increase
the overall amount of soil remediation because costs
would be substantially lower for many sites.
Dust wipe analysis with the NITON 300 series analyzer is a
non-destructive method that provides real-time analytical
data that are invaluable when conducting a risk assessment
after abatement of a lead hazard. It conclusively determines
whether clearance criteria have been met while abatement
workers are still onsite, eliminating the rernobilization and
re-cleaning associated with failed clearance tests while al-
lowing for re-occupancy of the dwelling in less time, at a
lower cost, and with less inconvenience to the occupants.
Filter analysis provides onsite screening of workers' exposure
for industrial hygiene and safety testing. Filter cassettes may
be tested immediately following collections, or at midpoints
throughout the sampling process, to rapidly determine if
the working environment is safe, or if workers are being
appropriately protected. Environmental and industrial fil-
ters also may be checked during sampling, offering close-to-
real-time analysis and the ability to immediately correct
possibly erroneous procedures and environmental protec-
tion. NITON analyzers offer unprecedented speed-to-results
to ensure the safety of workers and are listed in National
Institute for Occupational Safety and Health Method 7702
for airborne lead monitoring.
COMMERCIALIZATION SUCCESS
Since receiving SBIR funding 6 years ago, the NITON XL-
309 dual detector has become the industry standard for
lead in paint analysis and has evolved into a complete
lead analyzer. From LBP to soil to dust wipes, it is an in-
valuable tool to ensure the safety of children and adults,
and the environment in which they live.
With thousands in use worldwide, NITON's award-win-
ning 300 series lead analyzer has become the instru-
ment of choice for the lead analysis industry. In No-
vember 2001, NITON participated with the 300 series
analyzer in the "Evaluation of Field Portable Mea-
surement Technologies for Lead in Dust Wipes" con-
ducted by EPA's Environmental Technology Verifica-
tion (ETV) Program to evaluate the performance of
commercially available field analytical technologies
for analyzing dust wipes for lead. Data from the XL-
300 series showed excellent agreement with the esti-
mated lead value for the range of samples analyzed, with
very few false negative results.
AWARDS AND COMPANY HISTORY
In recognition of its technological innova-
tion, NITON was a finalist for the 1994 Dis-
covery Award and received the prestigious
R&D 100 Award in 1995. NITON also received
the Lead Tech Product of the Year Award in
1995. NITON's headquarters are located in
Billerica, MA, and the company has facilities in North
Kingstown, RI; Bend, OR; and Garchingbei Miinchen,
Germany. NITON also has satellite sales and service of-
fices in countries throughout the world.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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Physical Sciences, Inc.
20 New England Business Center, Andover, MA 01810
(978) 689-0003 http://www.pslcorp.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, Physical Sciences Inc. (PSI), has developed a pro-
totype monitor for the onsite characterization of soil us-
ing spark-induced breakdown spectroscopy (SIBS). This
device determines the elemental composition of soil by
emission spectroscopy, including dangerous heavy metal
pollutants, using an electrically generated pulsed plasma
as an excitation source.
The PSI prototype metals monitor is based on the excita-
tion of a sample with a large, robust electric spark. Fol-
lowing the excitation, the elements in the sample emit
light. These emissions provide the basis for the detection:
the energy of the radiated light identifies the element
and the intensity of the light indicates the concentration
of the element in the matrix. The use of a small spec-
trometer enables simultaneous multi-metal determi-
nations. Analytical methodology is based on the use of
standard additions to the sample and normalization to
persistent iron lines. Detection limits for lead (Pb), chro-
mium (Cr), cadmium (Cd), mercury (Hg), and barium
(Ba) have been determined to be near 25 mg metal/kg
soil, and determination times of a few minutes are pos-
sible.
SIGNIFICANCE OFTHETECHNOLOGY
Metals are a ubiquitous waste material present in soils
and sediments at sites across the United States. Contami-
nation levels range from individual species present at low
concentrations to multiple class mixtures present in parts
per thousand quantities. These sites are the result of years
of disposal of chemicals into the environment. Prior to
the 1970s, disposal of hazardous material into unlined
shallow pits was a common practice. This method mini-
mized costs associated with waste disposal, and the gen-
eral public was mostly ignorant of the dangers caused by
the disposed chemicals. Moreover, it was generally as-
sumed, even more recently, that metals buried in soils
remained in the top few centimeters of soil. This is now
known not to be the case. Hazardous wastes spilled or
disposed on land migrate through the surface and sub-
surface soils under certain conditions, and can access
ground water and aquifers.
When hazardous waste sites are under remediation,
samples of soil are continuously collected and analyzed.
+ SIBS determines the elemental composition of soil by emission spectroscopy using electrically generated
pulsed plasma as an excitation source.
-f Using the technology, detection limits for Pb, Cr, Cd, Hg, and Ba have been determined to be near 25 mg
metal/kg soil, and determination times of a few minutes are possible.
+ SIBS offers greater potential sensitivity and more representative sampling than other technologies,
such as laser-induced breakdown spectroscopy.
+ By operating in situ, the technology avoids the high capital and operating costs of inductively coupled
plasma atomic emission spectroscopy and microwave methods.
-------
PSI's SIBS monitor determines the elemental
composition of soil, including dangerous heavy
metal pollutants.
These samples determine the type and extent of the con-
tamination, and ongoing sampling is necessary as the
remediation proceeds. These samples are usually ana-
lyzed offsite in a laboratory setting. This approach is reli-
able, but the time required for the continuing sample/
analysis iteration is lengthy and adds substantially to the
labor budget of site clean up. A portable or onsite multi-
metals field-screening instrument will be a valuable ad-
dition to the onsite arsenal of the hazardous waste re-
mediation team.
SIBS offers greater potential sensitivity and more repre-
sentative sampling than other technologies, such as la-
ser-induced breakdown spectroscopy, and uses an inex-
pensive spark power supply in place of a laser. By operating
in situ, the technology avoids the high capital and oper-
ating costs of inductively coupled plasma atomic emis-
sion spectroscopy and microwave methods and uses simple
and inexpensive radiometric optical detection.
SIBS was evaluated at a joint EPA/U.S. Department of
Energy test at the Rotary Kiln Incinerator Facility at Re-
search Triangle Park, NC, The instrument was config-
ured for real-time, in situ measurement of Pb and Cr in
gas-borne particulate at target levels of 15 and 75 /ig/
dscm in simulated combustion Hue gas. Both Pb and Cr
were detected at the low- and high-level concentrations.
The hardware performed without failure for more than
100 hours of operation and acquired data for all of the
reference tests (data were acquired using EPA Reference
Method 29).
COMMERCIALIZATION SUCCESS
Although not yet fully commercialized, this monitor has
attracted a good deal of attention from potential com-
mercial partners. Using internal funding, PSI has de-
signed a manufacturable model of the monitor that will
be the size of a briefcase and be saleable on the open
market for less than $10,000.
COMPANY HISTORY
PSI was founded in 1973 by employees of Avco-Everett,
a large and well-known defense contractor. Since then,
PSI has focused on providing contract research and
development services in a variety of technical areas to
both government and commercial customers. PSI has a
staff of more than 120, approximately one-half of whom
are at the doctoral level. The company's core technolo-
gies have been developed with more than $250 million
of federal and industrial funding over 3 decades of op-
erations, a period in which PSI has acquired an interna-
tional reputation for technical excellence and innova-
tion. The SBIR Program has played a pivotal role in PSI's
technical and commercial success, and has been respon-
sible for a family of intelligent instrumentation products
based on proprietary electro-optical and electromechani-
cal technologies.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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Precision Combustion, Inc.
41 OSackett Point Road, North Haven, CT 06473
(203) 287-3700 http://www.pfecision-combustion.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, Precision Combustion, Inc. (PCI) has developed
the Microlith® Fast lightoff Catalytic Converter that of-
fers an economical approach to significantly reduce auto-
motive combustion emissions and has found numerous
additional applications where its unique operational char-
acteristics offer reactor design advantage. PCI's Microlith®
catalytic converter includes novel substrate geometry,
which offers high mass and heat transfer, together with a
complementary coating system. The resulting reactor is
small and lightweight, and exhibits rapid thermal re-
sponse. The improved mass transfer provides high con-
version efficiency, allowing substantial reduction in con-
verter volume, weight, and the amount of precious metal
required. The high heat transfer and lower weight of the
substrate provide very rapid thermal response, reaching
inlet gas temperatures within 1 second. These attributes
make the Microlith*' substrate ideal for high-performance
catalytic converter applications as well as for various
burner and fuel reforming reactors used to create hydro-
gen and/or syngas from hydrocarbon fuels.
SIGNIFICANCE OF THE TECHNOLOGY
Regulations governing automotive emissions in the United
States are increasing in number and stringency, and there
is a constant need for technological innovation to reduce
emissions levels as more vehicles are produced with longer
useful lifetime requirements. Current technology for auto
emissions control consists primarily of ceramic-based cata-
lytic converters in the exhaust system. Although these
catalytic converters are 95 percent effective once they
reach operating temperature (after "lightoff"), they are
ineffective during the first 1 to 2 minutes following en-
gine startup. As a result, approximately 80 percent of au-
tomotive hydrocarbon and carbon monoxide emissions
are released during the initial period of a typical drive.
Because PCI's Microlilh" preconverter helps control these
startup emissions when combined with a three-way main
converter, it is capable of achieving an 80 percent reduc-
tion in emissions of hydrocarbons and carbon monoxide,
and a 50 percent reduction of nitrogen oxide emissions
compared to a conventional catalytic converter alone.
As a lightoff converter, or preconverter, used in conjunc-
tion with a conventional main converter, Microlith® sub-
strate technology offers the potential for achieving Ultra
Low Emission Vehicle (ULEV) performance using a de-
vice one-fourth the volume of conventional advanced
technology lightoff converters with much less catalyst used.
PCI also has developed a smaller, less expensive lightoff
converter that achieves Low Emission Vehicle perfor-
mance as a stand-alone unit. The effectiveness and du-
rability of the Microlith® catalytic converter have been
demonstrated in prototype tests conducted at the Ford
Motor Company (successfully demonstrated ULEV emis-
sions from an Escort), other major auto manufacturers,
and automotive suppliers. Comparative laboratory tests
4- The Microlith® Fast Lightoff Catalytic Converter, when used in conjunction with a conventional automo-
tive main converter, is capable of achieving a greater than 80 percent reduction in emissions of hydro-
carbons and carbon monoxide, and a 50 percent reduction of nitrogen oxide emissions.
+ The Microlith® is substantially smaller in volume and weight than conventional converters and requires
considerably less precious metal.
+ The rapid thermal response characteristics as well as the small size and low weight of Microlith sub-
strate versus competing technologies are an important attribute to enable the development of on-board
fuel reforming for automotive fuel cells.
+• Microlith-based decomposition rectors enable the development and use of lower polluting aerospace
propulsion.
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PCI's automotive Microlith® converter and
main converter assembled in an integrated
can (left). A model of a stand-alone Microlith®
automotive preconverter (right).
between conventional ceramic monolith and Microlith®
substrates have shown that with a 20-fold reduction in
converter volume, the Microlith* substrate delivers
equivalent mass transfer-limited conversion. The Micro-
lith* catalytic converter also reaches 350°C lightoff
temperatures in less than l/20th the time required for
a conventional automotive ceramic monolith.
PCI has found multiple uses for the Microlith® substrate.
Catayltic converter applications include marine four-
stroke engine, natural gas internal combustion engine,
and small two-stroke utility engine emissions reduction.
Department of Defense applications include use as in-
frared signal generators for aerial target drones and
for hydrogen peroxide decomposition for various mili-
tary and propulsion applications. Participating in the
genesis of the hydrogen economy, PCI has found increas-
ing interest in Microlith®-based catalytic reactors for use
in the various aspects of fuel reforming for fuel cells such
as for catalytic partial oxidation, water gas shift, and pref-
erential oxidation reactions, as well as for reformer start
burners and fuel cell anode gas burners.
COMMERCIALIZATION SUCCESS
Award of the EPA SBIR contract helped PCI attract sub-
stantial industrial investment that has advanced the Mi-
crolith® technology along the path of large-scale pro-
duction. Because of the value that Microlith® substrates
PCI's Microlith® automotive preconverter
undergoing a hot vibration test (100 Hz, 28 g,
at 950°C for 150 hours).
have demonstrated as a platform technology, PCI has
focused its commercialization efforts on tailoring the tech-
nology for specific product application, manufacturing
process development, and provision of prototype samples
for testing to potential customers and partners. PCI has
13 issued patents on this technology and others pending.
PCI already has received investment for spin-off applica-
tions (e.g., industrial fume abatement, clean burners, fuel
reformers, etc.) from private industry as well as the Na-
tional Aeronautics and Space Administration, the U.S.
Air Force, the U.S. Army, and the National Science Foun-
dation.
AWARDS AND COMPANY HISTORY
In recognition of its significant achievement
in developing the Microlith® Fast Lightoff
Catalytic Converter and other innovative en-
vironmental technologies, PCI received EPA's
prestigious Environmental Technology Inno-
vator Award in March 1998. Later that year,
PCI also was selected as a recipient of the Tibbetts Award
from the Office of Technology, U.S. Small Business Ad-
ministration, in recognition of its unique contributions
as a "Small Business Innovation Research Model of
Excellence." PCI also was selected by Deloitte & Toche
as a member of the Connecticut "Fast Fifty," in recogni-
tion of its status as one of the fastest growing technology
companies in that state during the years 1998-2001.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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Sea Sweep, Inc.
2305 S. Syracuse Way #5, Denver, CO 8023 7
(303) 337-9890 http://www.seasweep,com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, Sea Sweep, Inc., developed and commercialized
an innovative absorbent called Sea Sweep* that func-
tions both on land and water to absorb spilled oil and
chemicals. The absorbent is made using a patented pro-
cess that involves heating sawdusl to a temperature at
which the oil-like pyrolysis products render it very attrac-
tive to oil (oleophylic), but so repellent to water (hydro-
phobic) that it floats for many days. It absorbs the oil or
chemicals immediately upon contact, and will float in-
definitely in water, preventing environmental damage to
marine life and bird species.
Sea Sweep® can absorb up to four times its weight in oils
and chemicals immediately on contact, and it will not leach.
Typically, 1 Ib of Sea Sweep® absorbs 3.5 Ibs of oil (the prod-
uct absorbs oils on both fresh and salt water). Nonsaturated
Sea Sweep®is nontoxic, biodegradable, and harmless to mi-
croorganisms and wildlife (the product does not adhere to
the feathers of birds or to any type of marine life). Sea
Sweep® can be applied by using a variety of methods to
drop it onto a spill (e.g., using a blower or auger system
from a barge or tugboat, or releasing drop bags from a heli-
copter, crane, or boat boom). It can be recovered in place
with a screen scoop or boom system, or it can be pushed
to a designated area for retrieval by mechanical or suc-
tion methods.
SIGNIFICANCE OF THE TECHNOLOGY
There are many absorbents on the market that attract oil
and chemicals to their surface, but these products re-
lease them easily (leach), like a mop. Sea Sweep's absor-
bent is unique in that oils or chemicals are taken into
the interior of the particles (an absorbent), similar to a
sponge, where the oil and chemicals are held and do not
leach. Sea Sweep* absorbs spilled oils and chemicals,
and it is easily retrieved from spill sites, which helps pre-
vent damage to shorelines and beaches. In addition, Sea
Sweep* helps bacteria attack the spilled oil or chemical.
SBIR funding enabled Sea Sweep to evaluate the perfor-
mance of this absorbent using various types of sawdust to
determine which is most effective for absorbing oils and
chemicals. Sea Sweep found that softwood sawdust is
optimal in performance, availability, and cost. The tests
also demonstrated that Sea Sweep® absorbs almost all
chemicals, including antifreeze and some strong acids.
Saturated Sea Sweep® can be burned as fuel for power
plants or industrial furnaces.
Oil spills from vessels and facilities (both onshore and off-
shore) are regulated by the Clean Water Act. Sea Sweep®
has been recognized by EPA in the National Contingency
Sea Sweep, Inc., has developed an innovative absorbent that functions both on land and water to
absorb spilled oils and chemicals.
Nonsaturated Sea Sweep® is nontoxic, biodegradable, and harmless to microorganisms and wildlife. It
is capable of absorbing up to four times its weight of oils and chemicals immediately on contact and it
will not leach. Sea Sweep"9 also floats indefinitely making it easy to collect with screens or skimmers.
In 1993, Sea Sweep® was selected by R&D Magazine as one of the 100 most technologically significant
new products of the year.
Sea Sweep is licensed by the State of California and has been recognized by EPA as an oil spill
cleanup agent. It also is a listed product on the U.S. Coast Guard National Strike Force Response Re-
sources Inventory.
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Sea Sweep® is used around the world to clean up oil spills of all
sizes and can be recycled as a petroleum product. Here, Sea Sweep's
President, William Mobek, prepares a demonstration in Indonesia.
Plan for use in recovering oil spills in U.S. navigable wa-
ters. Sea Sweep® also is a listed product on the U.S. Coast
Guard National Strike Force Response Resources Inven-
tory In addition, Sea Sweep's absorbent is licensed by the
California State Water Control Board as an oil spill cleanup
agent for use in California marine waters.
Immediately on contact, Sea Sweep® absorbs crude oils,
refined hydrocarbons, and many chemicals on land or
sea, even after extensive loss due to volatilization. Crude
oils, 17° API and 37° API are absorbed at ratios of 1,000
and 1,500 gallons per ton of Sea Sweep®, respectively.
Refined hydrocarbon absorption capacity varies from 720
to 1,960 gallons per ton of Sea Sweep®.
COMMERCIALIZATION SUCCESS
Sea Sweep® is marketed in the United States, Europe,
South America, Australia, New Zealand, Japan, Indone-
sia, and the Persian Gulf. Internationally, Sea Sweep's
absorbent has received approval for use by the United
Kingdom River Authority, Thames Region; the Greek
Ministry of Merchant Navy, Directorate of Marine Envi-
ronment Protection and Ministry of Industry, Energy, and
Technology; the Chilean Oceanograpbic Institute and the
Chilean Navy; the Ministry of the Environment in Malta;
and the Argentinian Coast Guard. Sea Sweep® also has
received an LR-type approval from Lloyds Register of Ship-
ping in London; it is the only spill absorbent to hold this
distinction. The company's customer list includes oil com-
panies, fire departments, and shipping companies across
the United States and internationally.
AWARDS AND COMPANY HISTORY
In 1993, the Sea Sweep product was selected
by ft&D Magazine as one of the 100 most tech-
nologically significant new products of the year.
At the Clean Seas '93 International Confer-
ence, Sea Sweep was the only commercial com-
pany to be awarded a gold medal "for its praise-
worthy efforts in conjunction with the preservation of a
Clean Marine Environment." In 1997, Sea Sweep, Inc.,
received a Gold Medal from the United States Defense
Supply Center, identifying Sea Sweep® as one of the
Center's "Best Value" products. Sea Sweep was founded
in 1990, in the wake of the Exxon Valdez oil spill on the
Alaskan coast in March 1989.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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Sigma Technologies International, Inc.
W960 N, Stallard Place, Tucson, AZ85737
(520) 575-8013 bttp-J/www.sigmalabs.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, Sigma Technologies International, Inc., developed
inexpensive, high-speed, inline technology and equipment
for the treatment (i.e., functionalization) of film surfaces
to promote adhesion of'solventlessand aqueous-based inks.
Surface functionalization is achieved by an appropri-
ate combination of plasma treatment and thin (submi-
cron) acrylate coating within a vacuum environment.
Functionalization is performed inline at high speed us-
ing Sigma Technologies' proprietary equipment. The
process begins with plasma treatment of one surface of
the plastic film using a moderate energy flux with a
suitable gas mixture. As the plastic film continues
through the web-processing machinery, it can be met-
alized and coated or coated directly with a very thin
layer of an acrylate-based monomer that is 100 per-
cent active (i.e., no solvents). The monomer is depos-
ited on the surface of the plastic film, then passed in
front of an electron beam where the monomer is rapidly
and completely polymerized. The functionalized film
then is ready for printing, labeling, or other processing.
Sigma Technologies also has developed radiation-curable,
acrylate monomers that either repel or attract water.
Monomer biends can be tailored to meet the specific sur-
face energy requirements of the client.
SIGNIFICANCE OF THE TECHNOLOGY
This technology offers the environmental benefit of re-
ducing the dependence of the packaging film printing
industry on solvent-based inks. Use of solvent-based inks
results in the release of volatile organic compounds
(VOCs)—particularly toluene—to the atmosphere. Tolu-
ene has been near the top of the Toxic Release Inven-
tory List in recent years, with tens of millions of pounds
released annually. Solvent-based inks are responsible for
approximately 50 percent (by weight) of the VOCs emit-
ted from a typical printer, and VOCs are regulated as
criteria air pollutants under the Clean Air Act. Sigma
Technologies' surface functionalization technology pro-
vides packaging film industiy printers and converters with
a pollution prevention alternative to the use of solvent-
based inks. Use of this technology will eliminate the re-
lease of VOCs associated with the use of solvent-based
inks. It also eliminates the need to dispose of waste sol-
vent-based inks as hazardous wastes.
Sigma Technologies has developed inexpensive, high-speed, inline technology and equipment for sur-
face functionalization of plastic film that promotes adhesion of aqueous-based and solventless inks.
The technology eliminates the use of solvent-based inks by packaging film printers, preventing the
release of VOCs to the atmosphere as well as the need to dispose of waste solvent-based inks as hazard-
ous wastes.
Functionalization of packaging films increases the metal "sticking coefficient" for metallized plastic
packaging film, reducing the amount of metal wasted and the resulting disposal costs.
The acrylate coating technology can be tailored to provide almost any surface energy desired on a
plastic film substrate.
SBIR funding helped Sigma Technologies obtain R&D commitments from major players in the packag-
ing film industry to accelerate commercialization of this technology.
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Polymer Film Web
From Unwind Roll
Coaled Polymer Film
Web To Wind Roll
Curing Device
Plasma
Treater
Nozzle
Metallizaliort
VAC
Degas Vessel With
Liquid Monomer
Schematic of vaccum deposition of a polymer coat-
ing. First, the film is plasma treated to promote adhe-
sion of the vaccum deposited coating. A reactive liq-
uid monomer (one or more double bonds) then is
degassed, atomized into a flash evaporator, converted
to vapor, delivered to the film surface through a nozzle,
condensed back into a liquid on the moving film sur-
face, and finally cross-linked to polymer with an e-
beam gun or UV lamp. A polymer layer can be depos-
ited by itself, or before and/or after a metallized or
sputtered layer.
In addition to eliminating the use of solvent-based inks,
Sigma Technologies' surface functionalization process is
more efficient for clients who metallize plastic packaging
film following plasma treatment. Functionalization of
packaging films increases the "sticking coefficient" for
the metal in comparison to untreated film. That is, the
percentage of the evaporated metal that condenses and
adheres to the surface of the film is slightly higher for
films that have been plasma treated. More efficient metal
deposition means less metal is wasted, and waste disposal
costs are reduced.
COMMERCIALIZATION SUCCESS
EPA SBIR funding significantly contributed to the suc-
cess of Sigma Technologies' commercialization efforts. The
Phase I project helped compile credible data and im-
portant findings, which resulted in R&D commitments
from clients who are major players in the packaging
film industry to run concurrently with the Phase II EPA
SBIR effort. The SBIR funding, combined with the pri-
vate sector efforts, helped Sigma Technologies to overcome
technical and financial obstacles during Phase II and
achieve successful commercialization of its equipment de-
sign and technology concept.
COMPANY HISTORY
Sigma Technologies International, Inc., is a technology
company that provides a broad range of products and
services, Sigma manufactures innovative turnkey coat-
ing and surface treatment systems for functionalizing
material surfaces, and for producing multilayer thin-film
coatings. The company also designs and manufactures
instrumentation for customers in the optics, packaging,
and energy storage markets. These include state-of-the-
art optical densitometers for measuring optical density,
coating thickness, and electrical resistivity of thin films;
specialty power supplies; and partial-discharge data ac-
quisition and analysis systems.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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SpectraCode, Inc.
1291 Cumberland Avenue, Suite B, West Lafayette, IN 47906-1385
(765) 463-7427 http://www.spectracode.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, SpectraCode, Inc., developed the RP-1 Polymer Iden-
tification System, a laser-based device that enables recy-
clers to easily identify and sort a wide range of plastics.
The current technology for identifying dismantled plastic
materials is slow and dependent on operator accuracy.
SpectraCode's RP-1 is a new spectroscopic device that is
capable of identifying the chemical composition of plas-
tic parts at rates that could ultimately exceed 100 pieces
per second (500 tons per day).
The RP-1 system is an industry-ready device for the manual,
point-and-shoot identification of plastic components, feed-
stocks, and plastic scrap. The RP-1 device consists of a hand-
held probe, which looks like a hair dryer, connected to a
mobile console. The probe illuminates a solid object with
a laser and collects the light scattered from the sample,
much like a bar-code scanner. The device uses the prin-
ciple of Raman speetroscopy to read the information en-
coded in the molecular structure of the plastic itself and
thereby identify its chemical composition.
When a part is illuminated with the laser output of the
probe, it causes the sample's molecules to vibrate. The
vibrations in turn cause the light to scatter in a pattern
that is specific for each type of plastic. The scattered light
is recorded and analyzed by a computer, which displays
the result on a color monitor located on the console. The
entire identification cycle requires less than I second. By
eliminating the need to locate and read resin identifica-
tion codes, a single RP-1 system could increase a worker's
rate of manual sorting by more than a factor of four. The
instrument is simple to use because it has no moving parts
and does not require precleaning, processing, or precise
positioning of the plastic waste material. The RP-1 uses
SuperFocal imaging of the scattered light from the plastic
waste to provide an unsurpassed depth of field (5 mm)
that eliminates the need for precise sample alignment.
SIGNIFICANCE OF THE TECHNOLOGY
A number of industries are making advances to bring plas-
tic products with high recycle content to market. To suc-
ceed, these initiatives need a reliable stream of recov-
ered plastic feedstock. Polymers of different composition
are incompatible when melted together. Therefore, cost-
effective methods to sort plastics by individual polymer
are needed. Because the RP-1 reduces the cost of plastics
recycling and improves the purity of recovered product
streams, it will help facilitate the recycling of billions of
pounds of plastics that are landfilled or incinerated
SpectraCode has successfully developed and commercialized the RP-1, a laser-based device that is
capable of identifying the chemical composition of plastic parts at rates that could exceed 100 pieces
per second (500 tons per day).
The RP-1 device will help facilitate the recycling of billions of pounds of plastics that are being landfilled or
incinerated every year.
The RP-1 system has added value to plastic recycling processes by reducing manpower costs and im-
proving the purity of recovered product streams.
SpectraCode's RP-1 currently is used for automotive component recycling and is slated for introduction as a
new-parts process-control diagnostic by a major manufacturer of injection-molded plastic components.
In 1998, R&D Magazine selected SpectraCode's device as one of the year's 100 most technologically
significant products.
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Spectra Code's RP-1 system is being used to identify the plastic backing on an automobile
headlight. This technology can identify plastics so they can be sorted for recycling, including
plastics that currently are impossible or difficult to sort.
every year due to the lack of accurate separation that is
needed to avoid cross contamination during collection.
This technology supports EPA's goal to reduce the quan-
tity of waste requiring disposal.
Applications for which the RP-1 was designed include
the screening of production and packaging waste and
the identification and sorting of commercial and post-
consumer plastic waste in community recycling cen-
ters and transfer stations. The RP-1 device can be used
to sort a wide range of plastics. For example, it can be
used to sort plastic components in cars, synthetic fi-
ber resins in carpets, and a number of plastics used in
the building and construction industry. It also can be
used to sort plastic films such as those found in dry
cleaning bags, shrink wrap, and packaging material.
With simple user modification, SpectraCode's device
can be used for manual process control as a probe for
feedstock identity and purity.
COMMERCIALIZATION SUCCESS
SpectraCode installed RP-1 systems at two large-scale
recycle facilities and in the Detroit Vehicle Recycling
Development Center, a joint research facility of Gen-
eral Motors, Ford, and Chrysler. Ford Motor Company's
automotive component operations, now known as
Visteon, has supported development of the RP-1 and is
using the product in its recycling efforts. About 75 per-
cent of the typical Ford vehicle is recyclable at the end
of its working life, and the company believes that the
RP-1 device will help increase that percentage in the
future. SpectraCode is marketing the RP-1 to other au-
tomobile manufacturers and large-scale recyclers as well
as plastic molders and resin formulators that can use the
diagnostic capabilities of the RP-1 for process control.
AWARDS AND COMPANY HISTORY
In recognition of SpectraCode's technological
achievement, the RP-1 device was named one
of the 100 most technologically significant prod-
Is ucls and processes of 1998 by R&D Magazine.
The RP-1 device was recognized as one of the
Top 25 Technologies of 1998 by Industry Week.
The technology also earned SpectraCode the prestigious
Tibbetts Award and Henry Ford Technology Award in 1999.
SpectraCode, a research and manufacturing company
with close ties to Purdue University, was founded in 1994.
In its first year of incorporation, SpectraCode was
awarded a Phase I SBIR award from EPA to support de-
velopment of the RP-1. In 1995, EPA awarded the com-
pany a Phase II grant to continue developing and test-
ing the technology.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I. EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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Surface Treatment Technologies, Inc.
1600 Wicomico Street, Baltimore, MD 21230
(4 J 0) 332-0633 http://www.stt-inc.com
DESCRIPTION OF THE TECHNOLOGY
With support from the Environmental Protection Agency's
(EPA) Small Business Innovation Research (SBIR) Pro-
gram, Surface Treatment Technologies, Inc. (ST2) adapted
two novel methods of applying coatings for the protection of
metal surfaces from wear and corrosion to address the is-
sue of hard chrome replacement. Invented and patented
by the University of Tennessee Space Institute, Laser In-
duced Surface Improvement (LISISM) uses patented laser
beam optics to produce an alloy of the substrate on the sur-
face. Electro-Spark Alloying (ESA) is a micro-welding pro-
cess by which coatings are applied in short pulses from an
electrode to deposit nano-grained microstructure coatings
to metal substrates. Both coating processes are distinctive
in their ability to provide an engineered surface that is
melallurgically bonded to the substrate material, thereby
giving them a clear advantage in adhering to the substrate
when compared with traditional coating methods.
The LISISM process has been applied primarily to steel and
aluminum substrates to protect from wear and corrosion.
The process is carried out by first spraying the substrate
with a "paint" of metal powders composed of the alloying
elements to be melted into the surface. The key to LISISM
is the beam geometry that then passes over the sprayed
area in adjacent Lines, creating an instantaneous melt pool
to create the desired alloy mix with the substrate and
precursor alloy powder. The resulting surface is a uniform
layer roughly 500 microns thick of the new surface alloy
metallurgically bonded to the substrate.
ESA is a micro-welding process in which the deposition of
material from electrode to the substrate is controlled by
computer to form a very uniform, complex coating chem-
istry without inducing heat into the substrate metal being
coated. The consumable electrode is brought into direct
contact with the part being coated, and an onboard com-
puter controls the deposition of the coating, offering the
following unique capabilities: (1) a full metallurgical bond
between the electrode coating and the substrate metal;
(2) no heat affected zone in the base alloy; (3) an amor-
phous to nano-grained structure in the coating; (4) the abil-
ity to coat very small internal diameters, down to 0.2 inches;
and (5) the ability to coat non-line-of-sight areas. Moreover,
the ESA process can be readily coupled to multi-axis tooling to
become a highly reproducible manufacturing process.
SIGNIFICANCE OF THE TECHNOLOGY
Both LISISM and ESA are environmentally friendly pro-
cedures. Applications of LISISM range from wear surfaces
* ST2 adapted two novel and environmentally friendly methods of applying coatings for the protection of
metal surfaces from wear and corrosion.
*• LISP1 uses patented laser beam optics to produce an alloy of the substrate on the surface. ESA is a
micro-welding process in which the deposition of material from electrode to the substrate is controlled
by computer to form a very uniform, complex coating chemistry without inducing heat into the substrate
metal being coated.
+ Both LISP1 and ESA are distinctive in their ability to provide an engineered surface that is metallurgi-
cally bonded to the substrate material, thereby giving them a clear advantage in adhering to the sub-
strate when compared with traditional coating methods.
* Applications of LISP1 range from wear surfaces for aluminum engine cylinders to replacing chrome
plating in large-caliber gun barrels.
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LISISM uses patented laser beam optics to produce
an alloy of the substrate on the surface.
for aluminum engine cylinders to replacing chrome plat-
ing in large-caliber gun barrels. LISISM:
Permits precise selection of the area to be modified.
Requires a very small amount of modifier alloy.
Results in extremely rapid heating and cooling of
the surface.
Produces a wide variety of chemical and microstruc-
tural states outside of typical phase diagrams.
Produces no distinct bondline; will not delaminate.
Requires little or no surface preparation for certain
applications.
Produces a minimal hazardous waste stream.
Can be performed remotely with robotics and fiber optics.
Performs at rates between 20-50 ftVhr.
COMMERCIALIZATION SUCCESS
Under EPA funding, the ESA process has been applied
to the interior bore of small arms gun barrels For the
U.S. Army M249 Squad Automatic Weapon to evaluate
the ability to replace chrome plating as a wear-resis-
tant surface. A key element of this approach is the abil-
ity to coat barrel blanks prior to forging to form the
rifling. Under Phase II funding, ESA was successfully
ESA is a micro-welding process by which coat-
ings are applied in short pulses from an elec-
trode to deposit nano-grained microstructure
coatings to metal substrates.
used to produce full-scale barrels with five different
coatings thai underwent live-fire testing. Larger quan-
tities of coated barrels were produced for longer-term
live-fire evaluation by the U.S. Army. After this testing,
the Army will determine if the technology should pro-
ceed into the next phases toward ultimate mass produc-
tion quantites.
In a typical year, the U.S. Army purchases approximately
200,000 M249 gun barrels produced using chrome plat-
ing. Replacement of chrome plating for this application
could result in a measurable reduction in the hexavalent
chrome waste stream that stems from this process. If
proven to be acceptable for the M249, additional reduc-
tions could be achieved through application of the ESA
process for other small arms barrels.
COMPANY HISTORY
ST2 was founded in 1998 as a new source for emerging
coating and surfacing technologies for metals and alloys.
At present, the company offers LISP1, which represents
an advancement in laser surface alloying, and ESA, which
offers an unsurpassed combination of benefits in wear,
erosion, repair, and corrosion protection for metals and
alloys. ST2's goal is to innovate, develop, mature, and
transition to industry advanced surface treatment tech-
nologies for wear, erosion, thermal, and corrosion pro-
tection of metals arid ceramics.
EPA's Small Business Innovation Research (SBIR) Program was created to assist small businesses in
transforming innovative ideas into commercial products. The SBIR Program has two phases—Phase I is
the feasibility study to determine the validity of the proposed concept and Phase II is the development of
the technology or product proven feasible in Phase I, EPA also offers Phase II Options to accelerate the
commercialization of SBIR technologies and to complete EPA's Environmental Technology Verification
(ETV) Program. For more information about EPA's SBIR Program and the National Center for Environmental
Research, visit http://www.epa.gov/ncer/sbir.
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Small Business Innovation Research Program
Contacts
Jim Gallup
gallupjames@epa.gov
Marian Huber
huber.marian@epa.gov
April Richards
richards.april@epa.gov
Nora Savage
savage.nora@epa.gov
Julie Zimmerman
zimmerman.julie@epa.gov
\ Small Business Innovation
/ Research Program
http://www.epa.gov/ncer
U.S. Environmental Protection Agency
National Center for Environmental Research
Performance claims in the success stories are those of the technology developers. EPA does not verify the accuracy of these claims.
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www.epa.gov/ncer/sbir
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