Enhanced mechanical performance

REWITEC Surface Technology

Reconditioning and durable wear protection for

metal surfaces in tribologic systems

A Partnership with NanoLandGlobal

[email protected] +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 and gearboxes generates high temperatures on metal surfaces that trigger the chemical bonding process of REWITEC.

The soft Nanoparticles remove dirt from the rubbing metal surfaces and react with the metal atoms to form a smooth and protective layer on the surface.

The final result is a new and very smooth metal surface structure. These properties, in turn, give the machine more power, higher efficiency and longer life.


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

100 Temperature Oil 2 103,5º C

[°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

120 100 80 60 40 20

0 1 423

Complete Failure

--- Grease without

--- Rewitec

--- Grease treated with

--- Rewitec

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 30 25 20 15 10 5 0

-5

Complete Failure

1 352 703 1054140517562107 2458 2809 3160 3511 3862 4213 4564 4915 5266 5617 5968 6319 6670

Time/sec.

--- Grease without

--- Rewitec

--- Grease treated with

--- Rewitec

7021737277238074

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 tear. The running surface of the balls clearly shows pitting

Bearing type: No. 6205 (d=25mm D=52mm) Lubricant: Special bearing grease Operating time: 50 hours

Rotational speed: 500 min-1

Nominal load: 5000 N radial (range of fatigue)

This ball bearing does not show any wear. The running surface of the balls clearly shows a wear resistant coating.

Bearing type: No. 6205 (d=25mm D=52mm) Lubricant: Special bearing grease treated with REWITEC Operating time: 50 hours

Rotational speed: 500 min-1

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

Goal of application: - 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 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 100 Ω


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:

- The teeth surfaces are much smoother and more shiny (replicas before and after) -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 - 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 coated teeth surfaces had a higher electrical resistance of about 50 Ω - µ-Sen CMS shows a 20% reduced damage frequency and noise in the system


Coating of a AN Bonus 1MW wind turbine generator bearing

Goal of application: - Wear protection of generator bearing, due to use of Rewitec coating grease in December 2008 - Anaylsis via µ-Sen CMS (Condition Monitoring System) - Protection against further wear and prolongation of life time 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!
