Metal Revitalization to Reduce Wear and Energy Costs

Rising fuel costs are driving companies and organizations to seek out approaches to improve efficiency. For existing buildings, for example, one can increase insulation and reduce heating and cooling bills. Machines and production platforms might be optimized in a number of ways to gain improvements.

The concept of the energy balance is a useful way to consider energy utilization in machines. Basically, if you put 100 units of energy into a process, you would like to receive 100 units back out as useful work. That would be 100 % efficient but this is hard to achieve because of various losses. Energy is always conserved in the macro world, so, if only a portion of energy out is useful, then the balance of un-useful might be addressed.

Consider the EPA Vehicle Energy Balance Chart which shows

Input Energy
100 %
Output Energy
Engine Heat Losses
Engine Mechanical Losses
16 %
Drive Train Mechanical Losses
10 %
Useful Output
12 %

Much of the output losses are due to friction, or metal pairing losses. When metal pieces rub against one another friction between those pieces contributes to heat and sound losses and, by wearing down the pieces, tolerances are expanded and performance is lost. Lubricants are one answer as are improved surface coatings. If machines are already in use, the coatings idea is not economical since disassembly labor and downtime are required. Lubricants have been the traditional answer but they get tired and contaminated and, over time, rubbing surfaces ultimately wear out, regardless.

Is there a better way to address friction?

Yes, there is, thanks to some observations and technical developments started in the Soviet Union. The observations were that, while deep drilling for oil, drill bit surfaces stopped wearing and actually appeared to rebuild under certain conditions. Those conditions were a combination of crystalline elements and the friction energy caused by the drill bits. Scientists were able to reproduce those circumstances and synthesize a product deliverable that similarly can rebuild surfaces of any metal rubbing pieces. Under these circumstances, friction, instead of causing waste of material and energy, becomes the enabler for improvement. It is sort of like the automatic gun analogy, where, the undesireable wasted recoil energy of an exploding shell was utilized to automatically load the next cartridge.

The product, patented and trademarked as CerMet, using friction as a catalyst, performs at the near atomic level to revitalize surfaces with a ceramic-metal edge. Irregularities, when the metal has yet to be used (new break-in period), or after the fact, are rebuilt to a smoother surface with closer clearances. The upshot is clear - friction is reduced, heat and sound energy losses are reduced and efficiency is improved. When efficiency is improved, the amount of useful output we receive is better per unit of input. This means we get better utilization from input energy, which for an engine, would be less fuel used per unit output i.e. better MPG.

The Proof

The Cermet product has undergone years of use and is commercially available. Numerous test cases have been recorded and the results are available by reference and on the Cermet website. These are not testimonials. They are "before and after" test cases which show definitive improvements in machine efficiency. Below is the result on one such case done by Sysco Foods Detroit where the improvement in MPG was 11 %. That's a lot of fuel money saved over a multi year period for a fleet of trucks. Using the savings versus the product costs yields extremely short paybacks and high ROIs.

Many executives want to know first hand what improvements can be expected, particularly if they feel their environment or circumstances are different than others. As a regional dealer for the Cermet product, The Energy Advisor would welcome the opportunity to set up the test case environment with you. Simply email to: Information on Cermet Technology.