REWITEC Surface Technology for Tribological Systems

REWITEC Surface Technology
Reconditioning and durable wear protection for
metal surfaces in tribologic systems

A Partnership with NanoLandGlobal

info@nanolandglobal.com +44 20 3287 9234

That is our world


REWITEC-Technology

REWITEC presents the unique possibility

to coat, to protect and to recondition new and worn out
metal surfaces!


Technology: The coating process

Friction and pressure in engines The soft Nanoparticles remove The final result is a new and very
and gearboxes generates high dirt from the rubbing metal smooth metal surface structure.
temperatures on metal surfaces surfaces and react with the These properties, in turn, give
that trigger the chemical metal atoms to form a smooth the machine more power, higher
bonding process of REWITEC. and protective layer on the efficiency and longer life.
surface.


What happens to the lubricant?


Targets of REWITEC Technology

Replacement of the friction pair „metal-metal“ by „metal ceramic-
metal ceramic“

Advantages:

Reduction of abrasion and wear of rubbing metal surfaces

Coating process during system is running, without down time

Obvious improvement of the original material properties

Prolongation of machine life time


Advantages of REWITEC Technology

Reduction of friction, vibration and noise

Cost saving by:

Extension of lifetime
Reduction of repairs
Prolongation of maintenance intervals

Improvement of efficiency:

Savings of energy and fuel up to 11 %

Reduction of emissions (Diesel soot, CO2, HC und NOx)

Emergency running properties in case of oil loss


Damages of gear wheels before Rewitec

Repair, freeze, better prevent demages!


Damages of gear wheels after Rewitec

Repair, freeze, better prevent demages!


Gear before and after REWITEC Treatment


Microsection of a ball bearing surface

Rewitec Coating

Origin metal

The microsection shows the running surface of a ball bearing of a planet gear box after 250 hours of
operation in an area of fatigue. The Rewitec Coating up to 30µm could be obviously recognized.


Test on 2 gears of company Tandler
HL HWS A1 3.1 III
Tests with Rewitec

140
Fill in of the oil with the Rewitec concentrate at
the start temperature of 113,5º Celsius

120

Temperature Oil 1 107,7 ºC
Temperature Oil 2 103,5º C
100

[°C] 23/1
[°C] 23/2
80 [°C] 23/3
[°C] 23/4
[°C] 28/5
[°C] 27/6
60 [°C] 27/7
[°C] 27/8
[°C] 27/9

40

20

0

Time in hms

Temperature trend of the 2 Tandler gears with 2 different oils with and without Rewitec
- Temperature reduction of 6 - 10 ºCelsius


Bearing load test comparisen
OEM grease versus REWITEC treated OEM grease in a 20.000 N
bearing load test

Bearing Load Test

120 Complete Failure

100

80
--- Grease without
--- Rewitec
60
--- Grease treated with
--- Rewitec
40

20

0
1 423 845 1267168921112533 2955 3377 3799 4221 4643 5065 5487 5909 6331 6753 7175 7597 8019
Time/ sec.

Temperature measurement at axial bearings type 81105:
Results: Bearings with untreated grease failed after about 43 minutes load test. Bearings with
Rewitec treated grease did not fail for over 120 minutes. The bearings running with Rewitec
lasted for around 2.7 times longer.


Bearing load test comparisen
OEM grease versus REWITEC treated OEM grease in a 20.000 N
bearing load test

Bearing Load Test

40

35 Complete Failure
30

25

20
--- Grease without
--- Rewitec
15 --- Grease treated with
10 --- Rewitec
5

0
1 352 703 1054140517562107 2458 2809 3160 3511 3862 4213 4564 4915 5266 5617 5968 6319 6670
7021737277238074
-5
Time/sec.

Friction measurement at axial bearings type 81105:
Results: Bearings with untreated grease failed after about 43 minutes load test.
Bearings with Rewitec treated grease did not fail for over 120 minutes. The bearings
running with Rewitec lasted for around 2.7 times longer.


Load Test of Ball Bearings

running surfaces
of the balls

Photos of the inner races of two ball bearings after 50 hours of operation in a range of fatigue

This ball bearing shows damage due to wear and This ball bearing does not show any wear. The running
tear. The running surface of the balls clearly surface of the balls clearly shows a wear resistant
shows pitting coating.

Bearing type: No. 6205 (d=25mm D=52mm) Bearing type: No. 6205 (d=25mm D=52mm)
Lubricant: Special bearing grease Lubricant: Special bearing grease treated with REWITEC
Operating time: 50 hours Operating time: 50 hours
Rotational speed: 500 min-1 Rotational speed: 500 min-1
Nominal load: 5000 N radial (range of fatigue) Nominal load: 5000 N radial (range of fatigue)


Range of applications

Industry
Shipping
Automotive


Products of REWITEC Technology

Industry
Shipping
Automotive


Range of REWITEC applications

Industry:

Gears
Combustion engines
Compressors
Bearings
Hydraulic pumps/ -motors
Vacuum pumps
Chain drives
Gear racks, pinions


Range of REWITEC applications

Utility vehicles: Railways:

Gasoline- and diesel engines Diesel engines
Gears Gears
Rear axles, differentials Compressors
Universal shafts Bearings
Compressors
Roller-, slide bearings


REWITEC applications in shipping business


Test report of University of Applied Science Frankfurt

VW Passat 1,9 TDI:

Die University of Applied Science in
Frankfurt examined on a VW Passat
1,9 TDI the effects of a engine
treatment M2 and a gear treatment
G5 in relation to fuel consumption
and emissions.



Results:

All measurements were showing a noticeable decrease in fuel
consumption up to 11 %!

Furthermore there was also a decrease of CO2- und particle emissions!



VW Touran:

Together with a taxi company
in Frankfurt/ Germany the University
of Applied Science investigated
the influence of M2 to the fuel
consumption and emissions
on a VW Touran.



Results:

Reduction of fuel consumption up to 4,2 %!

Reduction of particles exhaust of 63,6 %!


REWITEC Technology in practise


Treatment of a thermal power station from Sachs

Savings of about 5,000 Euro
Problem: Treatment costs are 99 Euro
Extreme high oil consumption, loud noise and high costs of repair

Result:
Decrease of oil consumption during 2.700 rhs from 7 litres to 1 litre. Obvious reduction of
noise. Cost savings due to the REWITEC treatment of about 1.600,00 €!


Treatment of 2 drill head gears at Volkswagen engines
produktion line in Salzgitter

Savings of about 100,000 Euro p.a.
Problem: Treatment costs are 149 Euro per gearbox
Short lifetime, extreme high costs in case of idleness and breakdown (25.000,-€), higher oil
temperature (51°C). Emergency run problems due to oil leakage.

Result:
Oil and oil filter are clean with nearly no metal particles. After REWITEC coating oil
temperature was reduced by about 6°C to max. 45°C. Due to a system leakage drilling
emulsion went into the gearbox. The REWITEC Nanocoating prevented the system against
damages.


Coating of a wind turbine gearbox of a Tacke TW250

Goal of application:
- Rebuilding of worn out teeth surfaces Savings of about 80,000 Euro
- Reduction of grey stoking Treatment costs are 1,200 Euro
- Protection against further wear and prolongation of life time

Results after about 700 hours operating time:
- The teeth surfaces are much smoother and more shiny (replicas before and after)
- The damages are without sharp edges
- The coated teeth surfaces had a higher electrical resistance of about 50 Ω


Coating and analyses of a 600KW wind turbine gearbox

- Reduction of grey staining
- Protection against further wear and prolongation of life time Savings of about 150,000 Euro
Treatment costs are 2,560 Euro
Condition after 64 days operating time:
- The damages are without sharp edges


Coating and analyses of 1MW Windturbine gearbox

Before Rewitec treatment at 17.03.2009 After Rewitec treatment at 23.09.2009
Topography
Results after 150 days:
-3D-Topografie-Analyses of NanoFocus AG with µsurf-Technology proves that the surface smoothening/
refinement and results in a 18-times bigger load carrying tooth area!


Coating of a AN Bonus 1MW wind turbine gearbox

Goal of application
- Rebuilding of worn out teeth surfaces and Reduction of grey stoking
- Anaylsis via µ-Sen CMS

Results after about 700 hours operating time:
- µ-Sen CMS shows a 20% reduced damage frequency and noise in the system


Coating of a AN Bonus 1MW wind turbine generator bearing

- Wear protection of generator bearing, due to use of Rewitec coating grease in December 2008
- Anaylsis via µ-Sen CMS (Condition Monitoring System)

Results after 6 months:
-µ-Sen CMS shows clearly the stop of the progressive increase of the damage frequency in generator bearing


Economy of the Nano Coating in case of breakdown

Turbine Power 1.500 kW

Output per year 4.500.000 kWh
Output per day 12.329 kWh
Commission 9,5 Ct/ kWh

Commission per day 1.171,- Euro
Costs of treatment 6.400,- Euro

Amortization time 5,5 days

*Output related to referenz location with a medium yearly wind speed of 6,5m/s


Treatment of compressors and separators of
Hapag Lloyds „Tokyo Express“

Problem:
Carbonization of the valves due to water in the oil caused by different air humidity. High oil
temperatures, damages of valves, piston and rings.

Solution:
REWITEC-Nanocoating reduced the internal friction and oil temperature. Carbonization and wear
was reduced. Lifetime of valves, piston and rings were doubled.


Treatment of Sulzer 2-stroke engine 6 RTA 62U
of “MV Gloria”

Problem: Strong cylinder liner and piston ring wear after 18.000rhs, due to bad fuel and
material problems. Piston ring wear was recorded via a monitoring system.

Solution: Cylinder liner and piston ring life time was extremely improved to 30.000rhs. The
monitoring system recorded a coating on liner and rings.


Treatment of one cylinder of a Sulzer 2-stroke
engine 6 RTA 62U

Problem: Strong cylinder liner and piston ring wear after 18.000rhs, due to bad fuel and
material problems. Liner wear was recorded via a condition monitoring system.

Solution: Cylinder liner wear and piston ring life time was extremely improved. After 2.5 years
CMS detected nearly no wear in the scrape down oil in cylinder 6.


Treatment of 2 GMT auxiliary engines of the “Constance N”

Problem:
Extreme high lube oil consumption and bad compression in 2
auxiliary engines Yanmar T 260-ST , 105 ltr. cylinder capacity

Solution:
The REWITEC Nanocoating improved the static cylinder
compression from ø20 bar to ø27 bar and reduced lube oil
consumption with 20-30%


Possible Fuel Reduction due to REWITEC Coating

Starting situation: 3 Auxilary Engines per vessel, max. daily 72 running hours
Assuming runnig hours/ day: 48 rhs (AE1=8rhs, AE2=16rhs, AE3=24rhs)
Runnig hours/ year: 17.520

Fuel price: 500 US $/ ton

Engine:
MAN 6 L 28/32 H 118 litres displacement
Fuel consumption: 180 g/kWh
Engine Power: 1.260 kW

Fuel consumption/ year/ vessel 3.974 tons

Possible savings due to REWITEC 3%
119 tons
59.603 US $

Costs of Rewitec treatment 14.897 US $

Possible yearly savings/ vessel 44.706 US $


Treatment Hatlapa winch gear of offshore vessel “Janus”
Before Rewitec Treatment 06/2008

8 weeks after Rewitec Treatment

Problem:
Extreme high gear teeth wear, reduced life time. High down time and repair cost.
Solution:
After the first treatment it is already recognizable that the Rewitec coating took place. The
gear teeth with pitting and wear are looking quite smooth and optimize the load carrying
area and prolonged life time.


Proof of REWITEC Technology

• Surfaces pictures, endoscopies

• Oil analyses

• Measurements of the electrical resistance of the coated surfaces

• Imprints of tooth- and bearing surfaces

• Condition Monitoring


Proof of REWITEC Technology

Impronts of tooth- and bearing surfaces with REWITEC Replica-Set:


28. Innovation Award of German Economy Wirtschaft

0n 19th of January 2008 REWITEC was announced as finalist of 28. German Innovation Award 2007.
The Award for one of the best innovations in 2007 was presented to REWITEC from the Ministry of
Economics and Technology in the „Old Opera“ in Frankfurt.


1st Husum WindEnergy Award 2009

REWITEC was Finalist of the 1st HUSUM WindEnergy Award 2009. REWITEC‘s
„Nanocoating for Tribosystems“ is belonging now to one of the best innovations for
wind industry.


Present Cooperations and Customers

Leonhardt Blumberg

Hatlapa
Peterson Söhne Marine Equipment

Zollern ThyssenKrupp


Thank you for your attention!


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