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Innovation projects: From Sputtering and Energy Saving to Skolkovo. Changing the society Aleksandr Shchukin “Russian-German Institute of Polymers”, deputy chief engineer; LLC "SPF "Pilot“, an executive director; Komsomolskaya pravda +7 921 407 77 05
About me I am 28 I am an executive director LLC "SPF "Pilot" I am an deputy chief engineer • "Komsomolskaya pravda“ • Russian-German Institute of Polymers I like to create something new
The way I develop myself and the others In search of something new I initiate and I participate in different projects Creation of the nanocenter of constructional materials Power saving and new materials
SPF “Pilot” The LLC "SPF "Pilot" was created in 2002. Main activities of the company include management of the production process of items of thermosetting plastic materials. LLC "SPF "Pilot“ is a part of Polymer Cluster on the base of Business polymeric park on platform of "Processing of plastic” "Komsomolskaya pravda“ We have wide experience in production of press and extrusion items with different geometry. The company presents decisions considering clients’ requirements and introduces a professional view on technologies of production. We use technologies of direct pressing and piston extrusion. The team of skilled professionals is willing to give you guidance in the market of items of thermosetting plastic materials, fluoropolymers, silicones, rubbers including those with inset elements and to present an optimum decision meeting your requirements.
IOFFE PHISICAL TECHNICAL INSTITUTE «Physicotechnological Center of nanoelectronics» PURPOSE: Working out, introduction and manufacture of devices of modern opto and nanoelectronics in the field of solar and hydrogen power, power electronics, laser instrument making, diagnostic and medical equipment for modern medicine. Creation of a high-efficiency centre of designing and manufacture of collective access to Russia’s instrument-making branch TASKS: ü Manufacture of modern microcircuits of all classes with flesh-memory as background serial products for the world market; ü Manufacture of solar elements for independent power supply systems. ; manufacture of photoreceptions CCD and bolometric matrixes; ü Manufacture of semi-conductor lasers; ü Manufacture of LED and photo diodes; ü Working out and manufacture of the process equipment for electronic and medical instrument making; ü Working out and manufacture of microsystems of individual diagnostics of a person;
Ioffe PTI National academy of sciences of Belorus R&D company on plastic processing named after “Komsomolskaya Pravda” Fourth generation installation producing fullerenes and nanocomposites ROSNANO
Ioffe PTI National academy of sciences of Belorus R&D company on plastic processing named after “Komsomolskaya Pravda” ROSNANO The centre of collective use of nanocarbon materials and fullerenes production: • Equipment complex (including the equipment use license) for nanomaterials manufacture; • Nanomaterials production know-how (including the design and operational documentation); • Technological possibilities of processing materials into products; • Laboratory complex for materials and production quality check. Strategic task of the Center: Commercialisation of scientific solutions and attraction of strategic customers. At present the agreement is being prepared with the Ministry of Economics of Finland on starting up production of fullerene-containing nanocarbon materials with a polymeric matrix and fullerene-containing modifiers. Appropriate applications have been submitted to Rosnano.
National academy of sciences of Belorus Ioffe PTI R&D company on plastic processing named after “Komsomolskaya Pravda” ROSNANO Line of fullerenes and nanocomposites production Line of prepregs production Nanomodifying of binding agents The line of hotmelt dipping of binding agents fillers Grinding of prepregs Laboratory complex (quality assurance) Block diagramme of the centre functioning WAREHOUSE FOR READY PRODUCTION AND MATERIALS CONSUMERS: JSC «RZD» Krylov Shipbuilding RI CRI of structural materials “Prometey” SUE”Metropoliten” and others Line of composite products Line of tubular products coiling: - HOT FORMING Line of processing nanomaterials: - JET MOLDING; - PRESS MOLDING; - EXTRUSION; - COATING.
Sputtering techniques we have mastered Application of coating by a gasflame method Application of coating by electrostatic and tribostatic methods Application of coating by polyurethane foam
Polimeric coating of garrets and basements Use of rigid polyurethane sputtering technique Reduction of thermal losses during a cold season Reduction by means of sputtering rigid polyurethane foam in garrets of buildings and constructions - Sputtering in basements (coating for foundations by means of various PUF properties) - In 2010 the works on sputtering PUF on gypsum board roofs are planned (reduction of thermal losses and repair of bituminous roofing) - Which led to reduction of consumption of thermal energy in the form of heating of the given buildings in number of 0, 435 g. Kal/hour – 323, 64 gkal/month. According to city tariffs it makes 198 200 rubles/month. Recoupment - 3 -3, 5 years
Use of physical vapour deposition technology UHMWPE A ROBOTIZED INSTALLATION WITH AUTOMATED MANAGEMENT MEANT FOR APPLICATION OF OVERCOATING ON THE INTERNAL SURFACES OF FREIGHT CARS FOR PROTECTION OF CARGOES FROM FREEZING-ON R 3 м robot manipulator A layout view of the installation meant for application of overcoating on an internal surface of a car Robot manipulator with a 3 m working zone radius
Use of technologies of high pressure sputtering of PU and UHMWPE for creation of antiicing, anticorrosive, chemically proof, weathertight coating Creation of nanocomposites on the basis of UHMWPE and PU for various methods of sputtering Improvement of the available domestic and foreign equipment according to requirements of the customer
Teamwork with Incorporated institute of mechanical engineering of Academy of sciences of Belarus Mixes for sputtering on the basis of superhighmolecular polyethylene with various fillers, including nano dimension. At the first stage carbon nanotubes 9. 5 nm in diameter and 1. 5 mkm in length are considered as fillers. The process of conducting and uniform distribution is quite complicated.
Work with universities and business incubators Chemistry department The government grant Pilot Researches on new technologies and materials New ideas and developments Students and post-graduate students
Power inspection of the enterprise JSC “KP" The following papers have been made by the results of the given inspection : - The certificate (report) on the carried out power inspection; - Instrumentally confirmed fuel and energy balance; - The instruction (recommendations) on carrying out of a plan of measures directed on effective TER utilisation - The power passport of TER consumer
Improvement of the system of cooling of major equipment Re-equipment of system of turnaround water supply on modern refrigerating facilities : Economy of el/en is up to 65 % Reduction of consumption of technical and potable water on 98 % that decreases sewage dump into the city collector (improvement of ecological conditions) Stability of technical indicators of the heatcarrier has reduced the cycle of manufacture of one unit of a product Use of occasionally allocated heat when operating the refrigerating facilities on heating the operational building during cold seasons Recoupment period - 1 year and 2 months
Application of new materials in municipal transport Major disadvantages of a fiber composite roller • produced by technology of the 60 th • Constant cracking of a ready roller • Г 2 class of material combustibility • Short term of operation As a result of pre-production operation of an auxiliary roller it is revealed that since 18. 05. 09 there have been no failures, no rubber layers separations, no loosening in the mounting seat. Major advantages of a UHMWPE roller: - Longer operation term - Smaller weight - Considerable reduction of expenses at preprocessing of a roller before installation - Combustibility class - ПВ 0
Reduction of electricity comsumption - Replacement of lighting fixtures by lightemitting diode fixtures of general purpose in household and operational buildings, flights of stairs and corridors (reduction of electricity consumption to 40 %) Improvement of ecology at the expense of refusing from luminescent fluorescent lamps containing mercury Recoupment period from 3, 5 to 4 years - Installation of a control system of light exposure in common premises reduces the recoupment period to 3 -3, 5 years
Investing in power savings and ecological programs (according to decisions of the Boards of directors of polymeric cluster companies): Replacement of the system of turnaround water supply in refrigerators – 2 100 thousand rbl. Polymeric coating of garrets (thermal protection, fireproof processing and repair of rigid roof): - Industrial 3 200 thousand rbl. - Administrative 2 100 thousand rbl. - Auxiliary 1 000 thousand rbl. - Warehouse constructions 1 500 thousand rbl. - Replacement of compressor equipment – 700 000 rbl. - waterproofing of basements-400 000 rbl. - introduction of optoelectronics in factory management and test laboratory – 350 000 rbl.
Results • The tariff increase for 1 m ³ of potable water in comparison with 2008 has made - 8, 5 % • The tariff increase for 1 m ³ of technical water in comparison with 2008 has made – 13, 5 % • The tariff increase for 1 m ³ of water removals in comparison with 2008 has made - 8, 5 % • The tariff increase for 1 kw of electric power in comparison with 2008 has made - 39 % • The tariff increase for 1 m ³ of natural gas in comparison with 2008 has made - 30 % Today the polymeric cluster has a closed cycle of water use We do not waste water!
Work with Russian Railways I participated in project “Building Noise Shield in Sablino” for Corporation Russian Railways
Polymer product for Russian Railways During several years my work was coherent with development of polymers product and technologies for corporation Russian Railways These technologies include • Sputter • New materials • Surfaced job • New construction elements
Project: THE TEST STAND OF THE «CENTER OF DYNAMIC TESTS» This project is planned to be based in new innovation zone Innograd Skolkovo Stands are equipped with special measuring equipment and software
Conclusion The technologies we are developing allow to use resources more effectively It is only through our own real projects that we can achieve success in the form of new products or introduced technologies
Thank you for the attention Aleksandr Shchukin “Russian-German Institute of Polymers” LLC "SPF "Pilot" St. -Petersburg, Smoljachkova 4/2 +7 921 407 77 05