Alytech AIOLOS High-Precision Dynamic Gas Dilution System

Overview

The Alytech AIOLOS High-Precision Dynamic Gas Dilution System is an engineered solution for traceable, reproducible generation of certified reference gas mixtures in real time. Based on the principle of dynamic mass flow-controlled dilution—where calibrated thermal mass flow controllers (MFCs) precisely meter primary standard gases into a carrier stream—the AIOLOS delivers stable, gravimetrically traceable concentrations across wide dynamic ranges. Unlike static cylinder-based standards, this system enables on-demand synthesis of multi-component gas blends without reliance on pre-filled cylinders, eliminating storage risks, shelf-life constraints, and logistical overhead. Designed for metrological integrity in regulated environments, it supports primary and secondary calibration workflows compliant with ISO/IEC 17025, EPA Method TO-15 and ASTM D6196, and serves as a critical tool in laboratories and field-deployed monitoring stations requiring rigorous gas standard traceability.

Key Features

• Modular architecture supporting 2–4 independently controlled gas channels, each equipped with individually calibrated MFCs featuring multi-point NIST-traceable calibration curves.
• Dilution capability spanning 1:4000 (standard) to 1:10,000 (extended), enabling sub-ppb to low-ppm concentration generation from high-purity source gases.
• Robust fluidic design compatible with inert, reactive, corrosive, and liquefied gases—including Cl₂, NH₃, H₂S, HF, and LNG—subject to material compatibility verification per application.
• Integrated thermal management with optional heated tubing (up to 120 °C) prevents condensation and adsorption losses for moisture-sensitive or low-volatility analytes (e.g., VOCs, siloxanes).
• Real-time response time <5 s (t₉₀) ensures rapid transitions between concentration steps during multi-point calibration sequences.
• Compliance with ISO 6145-7 (Gas analysis — Preparation of calibration gas mixtures using dynamic volumetric methods) verified through third-party metrological assessment.

Sample Compatibility & Compliance

The AIOLOS accommodates a broad spectrum of gas matrices, including ultra-high-purity (UHP) nitrogen, argon, helium, synthetic air, and certified standard gases at concentrations from 1 ppm to 100%. Its stainless-steel 316L wetted path and chemically resistant seals support long-term exposure to aggressive species such as hydrogen chloride, sulfur dioxide, and ozone—provided appropriate gas-specific material certifications are reviewed prior to deployment. All configurations undergo factory leak testing to ≤1×10⁻⁹ mbar·L/s (He). The system meets CE marking requirements for electromagnetic compatibility (EMC Directive 2014/30/EU) and low-voltage safety (LVD Directive 2014/35/EU). For GxP-regulated environments, firmware and GasMix™ software support 21 CFR Part 11-compliant user access control, electronic signatures, and immutable audit trails.

Software & Data Management

Alytech GasMix™ v4.x is a Windows-native application providing full instrument orchestration via USB 2.0. It enables both manual single-step dilution and fully automated multi-sequence protocols—including ramped concentration gradients, cyclic stability tests, and timed injection triggers synchronized with external analyzers (e.g., GC-FID, FTIR, PID). Each run generates timestamped .csv logs containing MFC setpoints, actual flows, temperature/pressure compensation data, and operator metadata. Audit trail records capture all parameter changes, user logins, method executions, and system events—exportable in PDF or XML for internal QA review or regulatory submission. Sequence files (.gmx) are digitally signed and version-controlled; rollback functionality permits restoration of prior validated configurations without requalification.

Applications

• Environmental Monitoring: Calibration of ambient air analyzers (O₃, NOₓ, SO₂, CO, VOCs) per EN 14625 and EPA PS-12 protocols; field validation of continuous emission monitoring systems (CEMS).
• Petrochemical & Refining: Dynamic preparation of surrogate refinery gas standards for online GC and FTIR process analyzers; sulfur compound calibration for UOP methods.
• Automotive Emissions Testing: Generation of transient exhaust gas mixtures (e.g., diluted diesel particulate matter surrogates) for chassis dynamometer and engine test cell validation per ISO 8714 and UN-ECE R83.
• Semiconductor Manufacturing: Precise delivery of dopant gases (e.g., PH₃, B₂H₆, AsH₃) and etchant blends (NF₃, ClF₃) into glovebox and ALD/CVD tool interfaces.
• Pharmaceutical & Food Safety: Controlled headspace gas generation for residual solvent analysis (ICH Q2(R2)) and modified atmosphere packaging (MAP) composition verification.

FAQ

What certification documentation is provided with the AIOLOS system?
Each unit ships with a Factory Calibration Certificate (traceable to national metrology institutes), ISO 6145-7 conformance statement, CE Declaration of Conformity, and full electrical safety test report.
Can the AIOLOS be integrated into an existing LIMS or SCADA infrastructure?
Yes—via OPC UA server add-on (optional) or custom REST API integration; GasMix™ supports Modbus TCP and direct database logging to SQL Server or PostgreSQL.
Is routine recalibration required, and what is the recommended interval?
Annual recalibration of MFCs is recommended per ISO/IEC 17025; Alytech offers accredited on-site or return-to-factory services with NIST-traceable reference standards.
How does the system handle gas reactivity or adsorption during low-concentration delivery?
By combining passivated 316L pathways, optional heated transport lines, and programmable flow stabilization periods, the AIOLOS minimizes surface interactions and ensures representative sampling at outlet ports.
Does the system support hazardous area classification (e.g., ATEX or IECEx)?
Standard units are rated for Zone 2 / Class I Div 2; explosion-proof variants (ATEX II 2G Ex db IIB T4 Gb) are available upon request with customized engineering review.