НАНОПРОМ Промышленные инновации NANOPROM SHORT COMPANY AND TECHNOLOGY...

НАНОПРОМПромышленные инновации

NANOPROM

SHORT COMPANY AND TECHNOLOGY PRESENTATION

Moscow, 2010


THE FORSAN® TECHNOLOGY PRINCIPLES

THE COMPANY’S IMPLEMENTATION EXPERIENCE AND COMPETENCE

ABOUT NANOPROM

THE TECHNOLOGY APPLICATION AREAS

ECONOMIC EFFECT CALCULATION SAMPLES


NANOPROM’S MISSION AND MARKET

NANOPROM is a solution provider in the resource & power saving market based on FORSAN® Industrial nanoceramic technology.

We ensure:

machines & technical infrastructure maintenance costs reduction

accident rate and downtime reduction

ecology metrics improvement

RESOURCE AND POWER SAVING

BUSINESS RELIABILITY AND CONTINUITY

ECOLOGY


ABOUT NANOPROM

Over 10 years of successful implementation of resource & energy saving solutions in industry and transportation

Unique proprietary FORSAN® Industrial technology of creatingnanoceramic layer for equipment protection and recovery

The technology certified and approved by The All-Russian Scientific Research Institute Of Railway Transport, Gubkin Russian State University of Oil and Gas, the Admiral Makarov State Maritime Academy, and by other research centers, institutes, laboratories and enterprises

Manufacturer recommendations

Dozens of successful tests and implementation

Rosneft, Lukoil, Siberian Coal Energy Company, Navoi Ore-Dressing and Processing Enterprise, Moscow River Steamship Company, Admiralty Docks,

Baltic Fleet, Russian Water Canal, MosTransAvto, MosGorTrans, Tutaev Engine Plant and many others


NANOPROM MAIN AREAS OF BUSINESS

• Industrial: Implementation of integrated projects for industrial customers in various areas including resource/power audit, equipment processing, and further technical maintenance

• Infrastructural: Partnering with manufacturers of parts, mechanisms and machines in order to market new products with improved consumer characteristics

• Consumer: Production and marketing of consumer products for cars distributed through retail channels as well as professional service centers and automotive dealer centers


THE CORE OF FORSAN® INDUSTRIAL SOLUTION

FORSAN® Nanoceramics technology allows for creating an extremely thin nanoceramic protective layer on the surface of the metallic friction pairs without dismantling, which has four unique features:

The technology is applicable in any climate and weather

Recovery(defect elimination) of worn surfaces

Friction reductiondramatic power inputs reduction (efficiency improvement)

Improvement of the lubricants usage effectiveness

Wear-and-tear reductionthe parts’ resort is increased due to surface strengthening


FORSAN® INDUSTRIAL PRINCIPLE OF OPERATION

The microscope allows to see that the friction part surfaces are not ideally flat

Metal part surfaces

Grease (oil)

FORSAN® particles are introduced into the friction pair using a lubricant (motor oil or consistent grease)

A complicated process of the

metalloceramic layer formation

on the surface of the parts

The resulting surface is characterized with low roughness and high hardness levels


FORSAN® LAYER PICTURE MADE USING A MICROSCOPE

Basic metal

Surface defect recovered through the FORSAN® technology deployment


FORSAN® LAYER PICTURE MADE USING A MICROSCOPE

Metal surface before processing with FORSAN®

Metal surface after processing with FORSAN®


THE TECHNOLOGY WAS TESTED AT RESEARCH CENTERS

• The All-Russian Scientific Research Institute Of Railway Transport (ARSRIRT)

• Gubkin Russian State University of Oil and Gas

• The St. Petersburg Institute of Mechanical Engineering

• V.P. Goryachkin Moscow State Agro-Engineering University

• St. Petersburg State Polytechnic University

• The Institute for Problems in Mechanics, Russian Academy of Sciences

• The Admiral Makarov State Maritime Academy

• The Central Naval Scientific Research and Design Institute


SAMPLE RESEARCH RESULTS (ARSRIRT*)

• The research of FORSAN® influencing the friction in the diesel engine blocks:

• “…The roughness level of the surfaces … tested using … FORSAN® is significantly lower as compared to tests without … FORSAN®. Micro-roughness of the ОА20-1 alloy is 12% higher. The babbit wear decreases by 22%.”

• “The Institute recommends FORSAN® for trial operation for internal-combustion engines, compressors and other blocks having plain bearing, both new and those that have not yet reached limiting wear.”

• The research of the FORSAN® flange lubricant influence on the tribotechnical characteristics of the rail-wheel pair:

• “…The solid lubricating Forsan coating affects effectively the wear-and-tear of the pair rollers: tire steel – rail steel. The level of the tire steel wear lowers by 5 times, and the rail steel wear decreases by 4 times.”

• “The Institute recommends Forsan for trial operation for wheel flange lubricating.”

* - AllRussian Scientific & Research Institute for Railways Technologies ("VNIIZT”)


MANUFACTURERS RECOMMEND FORSAN®

• Tutaev Engine Plant – manufacturer of heavy diesel internal-combustion engines for civil and military platforms including KAMATSU and BelAZ

• Borisov AvtoGygroUsilitel Plant – manufacturer of steering booster pumps for domestic cars, buses and trolleybuses


THREE FORSAN® Nanoceramics BASIC PRODUCT LINES

FORSAN® Nanoceramics

Protection & Restore

FORSAN® NanoceramicsProfessional

FORSAN® Nanoceramics

Industrial

Retail products for new and second-hand vehicles

Products for professional processing of motor vehicles in a maintenance center environment

Products for use by engineers within the industry and for industrial transport based on various block and unit types


MAIN TECHNOLOGY PATENTS

1. The patent for invention “Method of creation of antifriction layer of contacted friction surfaces,” № 2204623, priority date March 4, 2004

2. The patent for invention “Method of processing the metal parts surface” №2209852, priority date February 18, 2002

3. The patent for invention “Method of ultrasound metal surface processing” № 2209851, priority date February 18, 2002

4. The patent for invention “Composition for metal modification and metal surfaces recovery” № 2169208, priority date August 31, 2000


MAJOR TECHNICAL AND ECONOMIC EFFECTS OF FORSAN®

Forsan® Industrial implementation allows for:

Electricity consumption reduction (up to 5-10% and more)

Cutting oil and lubricants consumption (up to 5-15%)

Units useful life increase (up to 20-100%)

Repair and maintenance expenses reduction (up to 20-70%)

Worn-out parts and mechanisms recover (in some cases to normal)

Environmental metrics improvement

Increase sale-off price of used equipment in case of its sale in the market (up to 2-10%)


TWO KEY BASIC EFFECTS

FRICTION REDUCTION

SURFACERECOVERY

The eventual economic bottom-line is related to different influences caused by these two key effects in various usage patterns and mechanisms.

Peak positive results (which percentage is expressed in two-digit figures) are reached in case of the combined effect of the two factors.


THREE DIMENSIONS OF FORSAN® ECONOMICAL EFFECTS

TYPES OF ECONOMICAL AND ORGANIZATIONAL EFFECTS

TECHNICAL SYSTEMS TYPES

• Internal-combustion engines• Compressors• Transmissions• Reduction gears• etc

• Motor vehicles• Locomotives• Cranes and reach truckers• Pumps and compressor units• Ore & mining equipment• etc

• Reduction of fuel/energy consumption• Repair and maintenance costs decrease• Reduction of accident rates and downtime• Service quality improvement• Environment• etc

9

CLASSES OF EQUIPMENT


VALUE OFFERED

Direct economic effects are only a base for creating significant additional value!

• Repair and maintenance cost reduction

• Machinery life-time increase

• Reduction in power and fuels and lubricants costs

• Profitability and performance increase

• Accident rate and downtime decrease

• Reduction of the infrastructure total cost of ownership

• Environment

• Business processes continuity, security and reliability

• Competitiveness increase

• Creation of new value-added products


FORSAN® IMPLEMENTATION EFFECTS

DIRECT EFFECTExample: Fuel or power cost reduction

TOTAL EFFECTSExamples:

• Ensuring a reliable production program fulfillment based on the reduction of repairs, failures and off-schedule downtime

• Decreasing the risks of payments related to non-performance

• Reduction of losses caused by profit deficiency

• Competitiveness growth

INDIRECT EFFECTSExamples:

• Repair and maintenance cost reduction• Cutting expenses for equipment

purchase due to a higher productivity factor of the equipment

T >> I >> D

I

D

T


NANOPROM PROJECTS ORGANISATION

AUDIT & DIAGNOSTICS

PAYBACKCALCULATION

EQUIPMENT PROCESSING

MAINTENANCE & SUPPORT

Equipment map

Objects classification

Decision about the applicability of FORSAN®

Savings

Technical and economic assessment (feasibility study)

Project schedule

Technical systems and blocks processing

Additional diagnostics if required

Measurements and reports

FORSAN® products shipments and maintenance when required

Scheduled equipment processing

Check measurements

Delivery of FORSAN® products when required


APPLICABILITY FOR TECHNICAL BLOCKS

Internal-Combustion Engines

Reduction Gears Bearings

Pumps & Compressors Transmissions Turbines

Railway wheel flanges

Wheels and axes


MAIN INDUSTRIAL APPLICATIONS

Industry, Power engineering, Oil & Gas :• Machinery/Equipment useful life extension• Machine maintenance costs reduction• Emergency shutdown risk reduction

Railway transportation: • Prolongation of locomotive engines useful life• Fuel costs reduction• Rails/wheels wear & tear prevention

Vehicle fleet & Auto transportation: • Vehicle operation life extension• Fuel maintenance costs reduction• Long-term protection of internal-combustion engines

and vehicle blocks

Utilities: • Pumps operation life increase• Reduction of energy consumption• Reduction of water delivery emergencies

Fleet: • Reduction of fuel & maintenance costs• Freight cost price reduction • Emergency risk reduction

Agriculture: • Agricultural machinery operation life extension• Accident rate and downtime decrease• Cost price reduction

• Fleet• Railways• Motor transport• Agriculture• Utilities• Power Engineering

• Heavy Industry• Metallurgy• Ore & Mining• Paper Industry• Chemical Industry• Food industry


EXAMPLES OF INDUSTRIAL SOLUTIONS: OIL PRODUCTION

• intended for processing reduction gears of pumping units

• provides for power consumption reduction (by over 6%)

• extends reduction gears service life

• is developed specifically for reduction gears of pumping units

• ensures the retaining of the effect for one year

• easy to use

• is applied annually

• is used for Rosneft and Lukoil projects

The period of direct payback is from 4 to 7 months

FORSAN® Nanoceramics PURE


EXAMPLES OF INDUSTRIAL SOLUTIONS: RAILWAYS

Locomotive internal-combustion engines

Box blocks

Reduction gears of wheel-and-engine blocks

Rail/Wheel flange pairs

FORSAN® APPLICATIONS

FORSAN® ECONOMIC EFFECTS

Reduction in diesel fuel consumption in the locomotion internal-combustion engines by 5-10% and more

Reduction in motor oil burn-off waste in the locomotion internal-combustion engines by 15%

Decrease in scheduled repairs and the number of off-schedule repairs*

Increase in reliability of the rolling stock units and blocks

Wheel and rail flange wear-and-tear decrease

• For example, the number of scheduled repairs of the internal-combustion engine liners decreased by 3.5 times, and that of the base bearings and the connecting-rod bearings in the internal-combustion engine was reduced by 2.5 times


EXAMPLES OF INDUSTRIAL SOLUTIONS: RAILWAYS

FORSAN® FLANGE LUBRICATORS

• A solid-state flange lubricating rod based on the FORSAN® technology for wheel flange lubrication

• FORSAN flange lubricator has the best protective and environmental characteristics compared to traditional greasing substances

Test Results by the All-Russian Scientific Research Institute Of Railway Transport:

-the level of the tire steel wear-and-tear lowers by 5 times, and the rail steel wear decreases by 4 times.

-the rate of the FORSAN® rod consumption is 4-5 mm per 6 hours of testing (over 20.000 km run per a single rod)

-FORSAN® trial operation for wheel flange lubricating is recommended.


EXAMPLES OF INDUSTRIAL SOLUTIONS: MOTOR TRANSPORT

FORSAN Pro is a product intended for professional use at maintenance centers

FORSAN Pro ensures the extension of the vehicle parts useful life and allows for a long-term retaining of rated performance characteristics.

FORSAN Pro USAGE EFFECT:• Long-term prevention of a vehicle engine and transmission wear-and-tear (for a year or longer)• Fuel consumption reduction (from 5 – 15%)• Steering booster service life extension (from 2 to 3 times) • Recovery of the vehicle worn metallic parts• Improvement of the exhaust system environmental characteristics (СО-СН)• Easy start in any climatic conditions


SAMPLE PRACTICAL ECONOMIC EFFECT ASSESSMENT

A coal-mining enterpriseA Russian vertically integrated oil production

company

A transportation company (railway) within a large metallurgical plant

Direct fuel cost savings, RUR115 million

Repair and downtime reduction, RUR210 million

65%

35%

35%

19%

45%

Direct fuel and power cost savings, RUR0.27 billion

Downtime decrease, RUR0.5 billion

Repair cost reduction, RUR0.63 billion

15%

85%

Direct fuel cost savings, RUR21 million

Downtime decrease, RUR112 million


SAMPLE FORSAN® ECONOMIC EFFECT ASSESSMENT

Example 1: An industrial holding with regional presence: •embraces 7 enterprises throughout Russia•uses multiple pumping equipment•incurs high energy costs•is unable to raise prices in order to increase profits•participates in state tenders for industrial assets management which also include the technologies in use

Principal equipment: pumping units, air blowers, superchargers

Power consumption decrease(3…7%)

Bearings service life Increase (30..100%)

Fuels and lubricants consumption

decrease (10-20%)

Repair downtime reduction


FORSAN® EFFECTIVENESS

The assessment of the total economic effect in Kaluga branch: direct savings: $306.000 per year expenditures: $102,000 per yearTOTAL economic effect: $204.000 per year

Kaluga branch

Barnaul branch

Krasnodarbranch

Omskbranch

Orenburgbranch

Tverbranch

Tyumenbranch

Assessment of the economic effect across the holding: direct savings: $2.142.000 per yearexpenditures: $714.000 per yearTOTAL economic effect: $1.428.000 per year

EXAMPLE:AN INDUSTRIAL HOLDING


FORSAN® EFFECT ASSESSMENT IN KALUGA BRANCH

Type К, 144 units

Type D, 67 units

Type SМ, 56 units

Other types, 175 units

Type NS/SD, 162 units

140.000roubles

4.720. 000 roubles

370. 000roubles

890. 000roubles

1.080.000roubles

Total annual: 7.200.000 roubles


Type of equipment (pumping unit): Type D 6300/27 D 630/95 NS 160/45 SM 150-125-315

Capacity, kilowatt 630 230 37 45

Power consumption decrease (%) 3 3 3 3

Power saving (kilowatt) 185 6,9 1,1 1,35

Annual power saving (kilowatt) 165 564 60 444 9636 11826

Number of motor hours per year (kilowatt-hour) 8760 8760 8760 8760

Cost of 1 kilowatt-hour (roubles) 2,13 2,13 2,13 2,13

Saving per one unit per year (roubles) 352 651 128746 20525 25189

Number of units 2 23 58 17

Savings per the water supply channel (roubles) 705 302 2961 158 1 190450 428213

FORSAN® EFFECT CALCULATION FOR SINGLE BLOCKS

Conservative estimation of economical effect:

• Power consumption reduction rate 3% (ниже минимального значения)

• Ignore other economy factors (such as repairs, downtime, spare parts and tools, labour expenditures, etc)


SAMPLE FORSAN® ECONOMIC EFFECT ASSESSMENT

Example 2: A transportation company: •maintains public passenger transportation in the metropolitan area•operates buses of different brands•incurs high diesel fuel and fleet repair expenditures•suffers losses resulting from bus breakage downtime•has to comply with ever-toughening environmental standards

Principal equipment: internal-combustion engines, transmissions (gearboxes), reduction gears

Fuel and lubricants consumption decrease

(5..8%)

Increase of useful life before overhaul

(by 20..50%)

Exhaust opacity reduction

(by 2-3 times)

Repair and maintenance

downtime reduction


Main vehicle types

Mercedes Sprinter 100 units

Setra S319 100 units

Total annual economy for the vehicles in question

9.954.000 roubles

1.835.400roubles

1.872.600roubles

3.545.900roubles

GAZel 2755 100 units

LiAZ 5256 100 units

2.700.100roubles

FORSAN® EFFECTIVENESS IN A TRANSPORTATION COMPANY


FORSAN® EFFECT CALCULATION FOR INTERNAL COMBUSTION ENGINES

Minimum guaranteed economy - 5% (only internal-combustion engines are processed)

Comprehensive vehicle processing (mechanical gearbox, axle reduction gears) ensures fuel savings up to 10%

Other savings are not included (repairs, downtime, spare parts and tools, labour expenditures, etc.)

Type of vehicle GAZel Mercedes Sprinter LiAZ-5256 Setra S319

Average fuel consumption, L/100 km 14,5 12,5 28,5 35,5

Average mileage per year, km 108 000 108 000 72 000 72 000

Average fuel consumption per year, L 15 660 13 500 20 520 25 560

Guaranteed fuel consumption economy(5%) per year, kg 650 560 852 1061

Average oil burn-off waste per year(1% of the fuel consumption), kg 156,6 135 205,2 255,6

Guaranteed oil burn-off waste economy(15% of the oil consumption) per year, kg 23,5 20,3 30,8 38,3

Fuel/Oil cost, roubles per year 22/50 20/80 20/50 20/80

Guaranteed fuel economy (5%) per year, roubles 14 300 11 200 17 040 21 220

Guaranteed fuel and lubricants economyper year, roubles 15 475 12 825 18 580 24 284

Enterprise’s economy due to comprehensive processing (average of 10%), roubles 29 775 24 024 35 620 45 504


RAILROAD IMPLEMENTATION EXAMPLES


EXAMPLES OF IMPLEMENTATION IN OIL PRODUCTION SECTOR

UdmurtNeft, OJSC

EquipmentPumps NB-125 – 5 unitsConventional pumping units – 5 units

Main deployment resultConventional pumping units: Average power saving of 6.2%Pumps: Average power saving of 10.8%

UdmurtNeft, OJSC recommends using FORSAN® Industrial technology for Conventional pumping units and NB-125 pumps for power consumption economy.


EXAMPLES OF IMPLEMENTATION IN OIL PRODUCTION SECTOR

LUKOIL – Volgogradneftegaz, LLC

Equipment TsЗNK reduction gears – 450 – 6 unitsTs2NSh reduction gears – 315 – 10 units

Main deployment result•Average power savings for the conventional pumping units group (complete processing): 8.2%•Average power savings for the conventional pumping units group (reduction gear processing only ): 5.9%


FLEET IMPLEMENTATION EXAMPLES

Moscow River Steamship Company, OJSCRechnoi-87 tugboat primary motor

Main implementation results: • Average compression pressure increase by 5%• Average fuel consumption reduction by 5.9%

Baltic Fleet, LLCD-120-N-8V diesel engine (in a pre-fault condition)

Main implementation results: • Cylinder compression became equalized and grew by 16.3% on average• All technical characteristics were restored to normal

FORSAN® nanoceramics is recommended for Baltic Fleet, LLC boat engines processing


MECHANICAL ENGINEERING IMPLEMENTATION EXAMPLES

According to the tests results, Tutaev Engine Plant, OJSC officially recommends FORSAN® for friction pairs recovery and reconstruction including for the plants’ products.

Tutaev Engine Plant, OJSC

SAN 4500 KOMATSU press base bearings

Main implementation results:

• the operability of the previously broken press recovered • the base bearing heating decreased by 4.5 times• power consumption reduced by 50%


NANOPROM, OJSC 109428, Moscow, building 1, 8a, Ryazansky avenue

tel/fax: (495) 232-05-68, E-mail: [email protected]

THANK YOU FOR YOUR COOPERATION!

НАНОПРОМ Промышленные инновации NANOPROM SHORT COMPANY AND TECHNOLOGY...

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