Have you ever thought what is common between a spoon and thousands - - PowerPoint PPT Presentation

Have you ever thought what is common between a spoon and thousands of things that surround you?

The electrolyte-plasma polishing — the first world’s ecologically clean method of conducting materials’ processing

The investment project

2 ¡

Mechanical polishing

The existing alternatives

Cons of the polishing:

1 2 3

Restrictions on the complexity

• f the surface

Abrasives are introduced into the structure of the metal Harmful Resource using

4

• Number of stages
• Various settings
• High time costs
• Complexity of the process managing

Types: Sandblasting, abrasive disks, tapes with polishing paste, drum and vibration machine 3 ¡

Chemical polishing

The existing alternatives

Cons of the polishing:

1 2 3

The technological complexity A high percentage of defects Toxicity and flammability Corrosion of equipment Costly waste disposal

4 5

4 ¡

Electro-chemical polishing

Cons of the polishing:

1 2 3

High energy using Toxicity, explosion, flammability The technological complexity Limitations of the range of metals The long process

4 5

5 ¡

The existing alternatives

Comparison of the technologies

Mechanical ¡ Chemical ¡ ¡ Electro- Chemical Electrolytic Plasma ¡

Productivity Medium Low Medium High The restriction on the geometry Simple profile Complex profile Complex profile Complex profile Changing of is possible the material Exposure to implementation

• f accidental particles

Unevenness of treatment, etching Poor handling of flat surfaces Hardening of the material The complexity

• f processing

Medium Medium High Medium Ability to automatisation Yes No No Yes The cost of materials Low High High high Amortization period 25 years 5 years 20 years 20 years Occupied manufacturing area Low Medium Medium Medium Ecological level Low Low Low High Flammability Low High Medium Low Energy Consumption Medium Low High High Qualification of workers Low Medium Medium Medium

6 ¡

The history of development

• f the method

1972 — the effect of heating in the electrolyte. 1985 — the first result, "it shines!", was obtained in BNTU. 1989 — the first introduction of EDO "Orgstankinkprom“. 1992 — the first implementation of the technology of 4 power plants 250 kW, manufactured by Research Laboratory, "Sosni" in Nytvinskiy Metallurgical Complex (city Nytva, Permskiy region). 1992-2011 — The technology is suitable for 50 types of metals, alloys and more than 1 000 species of plants. The implementation of up to three installations a year at the plants in Russia, the Ukraine and Belarus. Technological maintenance.

7 ¡

The finish polishing

Application

Reduction of surface roughness up to Ra = 0,04 m Polishing with an accuracy

• f up to 12

Improvement of the reflective properties of the surface up to 70%

8 ¡

Cleaning of the surface

Application

Removal: – oil – colors – scale – rust/oxide – abrasive implants The processing time from 30 seconds. The opportunity to polishing right after the cleaning simply by changing the regime (mode)

9 ¡

Blunting of the edges and deburring

Application Fast processing of deburring up to 0.3 mm Treatment of complex shapes Treatment of great quantities of products for large stamping lines The rapid process for non-ferrous metals (30-50 seconds)

10 ¡

Preparation for the application

• f vacuum-plasma coverings

Application Three effects in one operation:

1 2 3

Deoiling Etching process Activation of the surface

11 ¡

The sharpening of tools

Application Pre-sharpening without heating and the physical impact Polishing and sharpening at the same time Сost reduction of the operation

• f mechanical sharpening

12 ¡

Treatment of Semiconductors

Application High accuracy class of polishing Exception of several

• perations

Treatment of ultrathin wafers

13 ¡

Ecological compatibility & safety

Advantages of the technology

Does not require the utilization

• f hazardous wastes

1

Does not harm to the health

• f workers

Reduces industrial injuries Compliance with sanitary and fire regulations

2 3 4

14 ¡

Economic efficiency

Advantages of the technology

The speed of processing (an average of 2-5 min.)

1

A minimum of manual operations (the possibility of full automation) The increase in productivity up to 700% Low resource intensity The universality of equipment

2 3 4 5

15 ¡

Technological effectiveness

• f the process

Advantages of the technology 1 2 3

Low consumption of materials Compactness of the installations The low percentage of defects The absence of multiple stages Automation and ease

• f management

4 5

16 ¡

Improvement of the material

Advantages of the technology

Process without overheating (tmax= 90°C)

1

The effect of surface hardening No force action Polishing materials do not penetrate in the structure of the metal The surface takes on anti-corrosion properties Using to remove impurities from the surface

2 3 4 5 6

17 ¡

The accuracy of polishing

Advantages of the technology

The possibility of polishing the articles of small size

1

The possibility of using in specific industries

3

– Nuclear Industry (polishing of fuel element) – Electronics (manufacturing

• f semiconductors)

– Medicine (micro-implants)

18 ¡

Latitude of using

Advantages of the technology

Almost all metals and alloys

1

Easy integration with automated production lines Non-waste technology for the polishing of precious metals (the ability to recover the metal from the sediment)

2 3

19 ¡

How does it work?

Description of technology 1 2 3

Workpiece Electrolyte Operating cell

20 ¡

The electrolyte-plasma mode

Description of technology

Allocations of hydrogen, ammonia, oxygen, water vapor.

Electrolysis Switching regime Electrolyte-plasma treatment

21 ¡

The technological process of electrolyte-plasma polishing for non automated lines

Description of technology

Preparation of a detail to the polishing

1

Manual loading to the suspension

2

Automated operations:

3

• Supply of voltage on a raised suspension
• The slow descent into the electrolyte
• Excerpt 2 ... 8 minutes
• Lifting the suspension with the details
• Off voltage

Flushing in warm water

4

Drying with warm air

5

Manual unloading

6

Monitoring

7

22 ¡

Technical characteristics

Description of technology

Time: 3…5 minutes. The current density: 0,2…06,6 A/сm2 Temperature: 60…90 °С Voltage: 200…350 V Removal rate up to 1,5…3 microns/min. The acid intensity of the solution: pH 4…8 The concentration of salts in the electrolyte: 0,5…10% Achievable surface roughness up to Ra 0,04 microns

23 ¡

Types of materials to be treated

Black (carbon) steel

1

High-speed steel

2

Monocrystal silicon

3

Precious metals (gold, silver)

4

Non-ferrous metals and alloys: Chromium, Titanium, Nickel, Bronze, Brass, Aluminium, Melchior, Tungsten, Magnesium, Manganese

5

Stainless and alloyed steels

4

24 ¡

Products and their properties

Only conducting materials Products in the loading area must not exceed the limit

• f the installation

For each type of product is recommended to calculate the optimal treatment time, stress and chemical composition of the electrolyte Can not be processed silicon alloys (for example gray cast iron) The maximum class of accuracy is 12, the improvement is not more than 3 classes The product can be processed by parts, and in several stages

25 ¡

Business spheres for the implementation

Business strategy

Aircraft industry

1

Shipbuilding

2

Robotics

3

Machine tool building

4

Production of interior items

5

Rocket and Space Industry

4

Weapon industry

3

26 ¡

1995 – № 984 "The device for polishing of metallic hollow parts" 2005 – № 7291 “The electrolyte for the electrolyte-plasma polishing of products made of aluminum and its alloys" – № 7570 “The electrolyte for polishing products made ​of titanium and its alloys" – № 8424 "The method for electrochemical treatment of metal products, mainly copper and copper alloys for galvanic coatings" – № 8425 "The method of the finish electrolyte-plasma polishing of products, mostly from high- carbon steel and zinc alloys" 2007 – № 9204 "The device for electrolyte-plasma treatment of the inner surfaces of the hollow elongated articles with holes" 2008 – № 11206 "The method of electrolyte-plasma treatment of semiconductor materials" 2009 – № 11808 "The method of electrolyte-plasma polishing of metal products" – № 11809 "The method of electrolyte-plasma polishing of metal products" 2010 – № 12957 "The method of electrolyte-plasma treatment of metal surfaces before applying

• f a coating"

The patents

27 ¡

• Ltd. 'Morion'

Success story

The brand "Zlatosfera“. Trekhgorny, Chelyabinsk Region, Russia www.zlatosfera.ru www.morion.biz

2000 Had been solved the problem of polishing of stainless steel sheets, followed by the application of decorative coatings for the churches’ domes and church utensils, which is widely used in the restoration and construction of churches all over Russia

28 ¡

• Ltd. 'Yurga Machine Building

Plant'

Success story

2003 Had been solved the problem of polishing of spools of hydraulic mining machinery equipment, and the resource spools increased in 5 times

Yurga, Kemerovo region, Russia www.yumz.ru 29 ¡

• Ltd. 'Sevmash'

Success story

2004 Had been solved the problem of polishing furniture components made ​

• f aluminum for the submarines,

which could not be solved by using

• ther known techniques

Severodvinsk, Arkhangelsk region, Russia www.sevmash.ru 30 ¡

EPP-I EPP-II EPP-III EPP-IV EPP-V

Duration of treatment, min. 2 – 8 The maximum area of for one download polish, сm2 400 1800 4000 11000 20000 The volume of jperating cell, m2 0,1 0,4 0,6 1,5 2,7 Operating temperature of the electrolyte, ºC 60÷80 Power, kW 15 100 250 500 800 Anode current density, А/сm2 0,2 – 0,6 Overall dimensions of installation, mm: length / width 2500 / 2000 3000 / 2500 5000 / 3000 6000 / 3500 8000 / 4000

The equipment

31 ¡

The product portfolio

Business strategy

The devices Installations of electrolyte- plasma polishing Materials The concentrates of electrolytes for different metals and types of treatment Services Engineering and manufacturing application

32 ¡

The processes

Negotiations

1

Terms of Reference

2

The amount and timing

3

Production

4

Commissioning (process integration)

5

The calculation

4

Testing

4 Business strategy

33 ¡

Plasma Craft Mission

To popularize the technology of electrolytic-plasma treatment of materials To become the first in the world and the largest CIS provider ecologically clean and effective technology of polishing of conductive materials. To support development of scientific and technical explores in the area of nuclear energy, nanotechnology and coating of metals surface. To continue research in the application of electrolytic-plasma processing

• f materials.

Business strategy

34 ¡

Business Focus

Business strategy

Private workshops SMB 20 – 250 employees Enterprise from 250 employees Why not Why yes!

The presence of means in the "innovation funds" Possibility of automation the processes The interest in ways to reduce costs for the production The strong influence of the "effect of scale" Rejection of partners’ services through diversification of production Piece parties There are no "effect of scale" The relatively high cost of equipment The limited capacity of the substation – – – – – – – – –

35 ¡

The main geographical markets

Business strategy

36 ¡

SWOT (Russian market)

Strengths Weaknesses

Leadership in technology Lack of experience of mass production Experience in sales and implementation Technology developers’ Age 60 + Strong personnel (holders of patents for invention), the students of developers lack of the relations with key partners: not have been established distribution channels Integration with the suppliers of component parts lack of the basic production workers Scientific and technological knowledge base - the results of supplier years of research Decentralization - Research Laboratory and a major in Minsk, and production in Russia The preconditions for the development of technology and countries the development of new technology projects (transfer to a new level according the latest laboratory results) Lack of producing experience in Russia and other CIS Profitable Resource Partner Self-sufficiency in the production of components and improvement of technology

37 ¡

SWOT (Russian market)

Opportunities Threats

Reduced prices for transformers in the supply of Russian producers Dependence on suppliers of materials and components Replace existing inefficient processing technology Dependence on technology customers: inactivity in the implementation of innovations Participation in major international programs Appearance of competitors in the industry The use of cheap labor force Protectionism from authorities Choice of the suppliers of components Advantageous logistics position Wide market (many sectors to implement)

38 ¡

The most [modern] method of polishing of metals

E c

• n
• m

i c

Unique Selling Proposition

39 ¡

Positioning

The group ‘Information motives’ Makropositioning (XYZ) — «central»: "Benefit of Z the best in the category of X»

The main factor of increasing competitiveness by reducing costs, ecological friendliness and technological leadership

40 ¡

Tactical Plan '18 weeks'

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Week Registration of the legal entity Organization of production Recruitment, training

• f staff

The test assembly Search for clients Search for suppliers of materials Construction of financial scheme Active marketing 41 ¡

Resources and Geography

Organization

1 2 3

Production – town Velikie Luki Laboratory – city Minsk Office and representation – city Moscow

42 ¡

Calculation of the investment amount

Overhead costs for the organization of production € 10 000 Salary of founders (four months) € 16 000 Legal registration / consulting € 3 000 Office rental € 60 000 Renting of production space + heating € 30 050 Manufacturing Equipment € 90 000 Office equipment and other fixed assets € 10 000 Repair of industrial buildings € 20 000 Salary of workers (1st month) € 6 600 Stocks of materials + transporting € 308 800 Laborabory € 22 000 Marketing € 100 000 Total € 676 450

43 ¡

Comparative effectiveness — 258% Cost — € 25 140 Profitability — 100%

TEP (setting EPP-III)

Electrolytic- Plasma polishing Electrochemical treatment

Capacity, m2/h. 3,2 Capacity, m2/h. 0,6 Recycling, €/m2 Recycling, €/m2 0,95 Electricity, €/m2 1,92 Electrolyte and electricity, €/m2 2,86 Amortization, months 120 Amortization, months 120 Electrolyte, €/m2 0,022 Utilization / purification, €/m2 0,948 Cost of treatment 1m2 2,29 Cost of treatment 1m2 8,19

44 ¡

Investor's share of income — 15% Payback period — 25 months The average capital gains — 77%

Investment attractiveness (2012-2022)

45 ¡

TEP (installation EPP-III)

Year Number Income of the investor Cumulative income of the investor

1 50 € 251 000 € 251 000 2 80 € 402 000 € 654 000 3 100 € 503 000 € 1 156 000 4 150 € 754 000 € 1 910 000 5 180 € 904 000 € 2 815 000 6 200 € 1 005 000 € 3 820 000 7 200 € 1 005 000 € 4 826 000 8 200 € 1 005 000 € 5 831 000 9 200 € 1 005 000 € 6 836 000 10 200 € 1 005 000 € 7 842 000

46 ¡

The main about us

20 years of research More than 30 successful projects in 5 countries 15 patents Developers — the recognized scientists

47 ¡

Development trends of plasma treatment

48 ¡

The world is being polished ...

+375 33 306 93 90 info@plasmacraft.ru