The ratio between the active power and the apparent power cos Ǿ is known as the power factor. 

The line current drawn by induction motors consists of two components, Magnetizing current and Power-producing current. 

The magnetizing current is the current which is required to produce the magnetic flux, and this component is lagging the voltage vector by 90 Deg (Lagging because vector rotation is anticlockwise) 

The power-producing current is the current which reacts with the magnetic flux to produce the machine’s output torque of the motor, and this component is in the time phase with the voltage. This means that the phase of the motor current (vector sum of the magnetizing and power-producing current) will be displaced about the network voltage by the angle Ǿ 

Why raise the power factor? – 

A motor running under no-load consumes almost only reactive power. 

Active power: The power consumed in an AC circuit is called active power. Active power is the power that continuously flows from source to load in an electric circuit. 

Reactive power: Reactive power is the power that continuously flows from source to load and returns to the source in an electric circuit. 

Plants containing many motors consume a considerable amount of reactive power. If the machines run at no load for a more extended period. In that case, the reactive power requirements will also be large compared with the need for active power, and the power factor can become very low, affecting the power tariffs. In this condition, it is a must to correct the power factor.  

By improving the power factor, we can achieve extensive savings. 

The total apparent power of the utility power will reduce, reducing the generating losses throughout the complete supply and distribution system. 

A higher power factor reduces the load on transformers and distribution equipment.  

The losses in transformers and distribution cables are proportional to the square of the line current. So, a high-power factor will result in a direct saving of electric power. 

How to improve the power factor: – 

The reactive power component (KVAr) must be reduced to improve the power factor for a given load.  This component of reactive power lags the power component by 90 Deg.  So, one way to reduce the effect of this component is by introducing a reactive power component that leads the power component by 90 deg. This can be accomplished by using a power capacitor, as shown in the power diagram resulting in a net decrease of the angle Ǿ=Ǿ1-Ǿ2 of an increase in the power factor. 

The amount and location of the corrective capacitors must be determined from a study of the distribution system and the source of the low-power factor loads. 

Where to locate capacitors: 

The power factor correction capacitors should be connected as close to the low-power factor load as possible to reduce the system losses. 

In some cases, the capacitors can be located at a specific power feeder. 

In other cases, with large motors, the capacitors will be connected as close to the motor terminals as possible. 

The power factor capacitors are connected across the power line in parallel with the low-power factor load. 

The circuit diagram, power capacitor connected to the motor terminals. 

Connecting the power capacitors at the motor terminals and switching the capacitors with the motor load is a very effective method. No extra switch or protective devices are required and the line losses are reduced from the point of connection back to the power source. Corrective capacitance is supplied only when the motor is operating. 

The following points have to be considered. 

It is necessary to reduce the overload relay setting to maintain proper overload protection. 

Never connect the capacitors directly to the motor when open transition starting is used such as star-delta and autotransformer. 

In this case, self-excitation voltages or peak transient currents can cause damage to the capacitor and motor. 

In these types of installations, the capacitors should be switched with a contactor interlocked with the motor starter 

Size of the capacitor to be installed: 

The size of the capacitor should not be too large if the power factor correction on the motor is directly applied.  When the motor is disconnected from the supply, it runs as a generator as long as it rotates and the capacitor supplies the magnetizing current. 

If the capacitor is too large, it will produce a higher magnetizing current than expected, generating a higher voltage than its rated voltage. 

The selection of capacitors should be with a maximum rating corresponding to 90% of the no-load output of the machine. 

Air compressors consume significant amounts of energy to supply power for industrial applications. If you consider all the costs of running capacity, you will realize that any savings therein will lead to a positive impact on your overall power cost management. 

With continuous efforts by compressor manufacturers to lead the market on energy efficiency, superior performance, and reliability, it is critically important that the users of air compressors are aware of the advanced product options available in the market. The technological advances in control systems and the evolution of the Internet of Things (IoT) provide further motivation to upgrade the air compressors at the right time. Typically, Air Compressor Upgrades happen in every 3-4 years by manufacturers to improve energy efficiency, reliability, advanced features, etc., and it is worth the while to evaluate the need for upgrading your compressors.

Five critical factors to consider while upgrading your compressor

Energy Efficiency: Energy costs contribute to over 75% of the total life cycle cost (LCC) of a compressor, and is therefore the key factor in upgrading an air compressor. Once the energy cost of the existing compressor is determined (through air audit or a simpler total input power measurement), the benefits of a new compressor, in terms of energy costs, can be evaluated. In cases where the user’s duty cycle of the air compressor has increased significantly over time due to additional production activities, the savings will be more beneficial with shorter return on investment. Additionally, if the plant needs a higher flow for expansion, it is an opportunity to consolidate the need and evaluate for upgradation. The size of the machine (in kW) should also be considered, as the larger the size of the unit, the higher the savings potential.

Advanced features: Significant improvement in controller features, more intelligence through additional sensors, and evolution of IoT capability are further reasons to consider an upgrade. These features result in improved uptime, insights for improvement in energy efficiency, and inputs for optimized operational settings in addition to 24×7 remote monitoring from anywhere in the world. In plants where the failure of a compressed air system can result in heavy losses in productivity, these features are particularly critical. Improvement in consumables’ life and/or reliability is another factor. Recently, ELGi had doubled the life of oil filters used in its oil lubricated rotary screw compressors in several models. All these features not only make the compressors more efficient but also significantly more reliable and advanced.

Breakthrough products: Compressor users must also look out for breakthrough products that will result in superior performance. ELGi has recently launched a product, AB Series with a disruptive oil-free technology that will bring down the life cycle cost of an oil-free compressor significantly. Such breakthrough improvements provide an opportunity to improve overall plant efficiency and performance while meeting the users’ needs effectively. Growing production needs in a plant will also need a different compressor technology such as the transition to centrifugal compressors for larger volumes of compressed air as an example.

Unplanned maintenance costs: As compressors age and when they need frequent attention to keep them running reliably, the unplanned maintenance or repair costs will also increase. If the cost of repairs reaches a certain level (~40-50% of the compressor value), along with the lower energy efficiency of older products, it is an appropriate time to evaluate and upgrade your air compressor.

Return of Investment (RoI): Another important factor to be considered while upgrading the compressor is the RoI. With improv energy costs, the RoI can be evaluated to meet the customer’s target.

Executive Summary

When a leading India-based power equipment rental company had a demand for compressed air in the construction & mining industry, it reached out to ELGi. The company has procured hundreds of exceptional air compressors to date, which has helped grow its rental customer base across industries.

Overview of the Industry

Construction & Mining activities are the backbone of all industries and contribute significantly to a country’s economy. However, they are prone to fluctuations due to the frequent rise and dip in demand, geopolitics and recently the pandemic. That said, sustained efforts by countries and their economic boosters ensure a steady need for machinery. According to ICRA,1 the Mining and Construction Equipment industry was estimated to grow by 15-20% in 2021.

Though the projected growth applies primarily to manufacturers, indirect demand can accelerate the growth of auxiliary equipment providers too.

The Construction and Mining industry is labour intensive, equipment-driven, and requires dependable machinery that performs in demanding environments. Due to heavy capital investment, changing nature, demand for machinery, dynamic market conditions, and high need for proactive maintenance, corporations prefer hiring or leasing equipment over owning them.

About the Company

Our customer is the leading provider of power and cooling equipment in India, has 35+ years of experience and 500+ employees. The company provides high-end generators, transformers, air conditioners, chillers, compressors, load banks, fuel tanks, etc on rent. They offer turnkey solutions for short and long-term customer needs, catering to different sectors, including construction, mining, oil & gas, and food & beverage.

Based in 450 locations, the company has 350+ customers across India, catering to the needs of critical infrastructure development in the country. They focus on maintaining leadership in the energy equipment rental space. They achieve this by continuously upgrading their equipment and providing the latest, cutting-edge, ready-to-install equipment – while ensuring high reliability.

Our client’s equipment plays a critical role in the operations and overall productivity of their customers, placing a high demand for perfect rented or leased equipment. To achieve this aim, they procure only the best-in-market equipment for their customers. Providing quality after-sales service is equally critical to maintaining their market reputation while catering to the robust customer demand.

Customer Challenge

The company’s construction & mining customers use heavy machinery and frequently operate in remote locations in adverse conditions. The labour-intensive nature of the industry requires the best equipment and operations safety while ensuring high productivity.

Core processes like running ventilation systems, powering critical on-site pneumatic tools, lifting and handling operations, site cleaning and digging, and heavy-duty blasting require a steady flow of compressed air. Operations come to a standstill when these conditions are not met. Thus, it is imperative to provide 100% reliable air compressors as an operations and safety requirement.

Business Solution

The customer initially approached ELGi to procure two air compressors (ELGi PG600-230 and PG450-150) in 2018. As the demand for compressed air increased, the company procured hundreds of air compressors from ELGi over the next three years.

This exponential increase was also because ELGi provided immediate fulfilment and on-time service. ELGi air compressors helped the team meet demands at customer facilities while ensuring technical and industrial compliance at application sites.

After the initial satisfaction with the ELGi’s equipment and service quality, the company acquired the complete range of ELGi portable air compressors (both diesel and electric models) from 300 CFM to 1100 CFM free air delivery capacities. ELGi has also supplied two oil-free ELGi OF 275 screw air compressors for deployment at two customer sites in the food & beverages and oil & gas segments.

Business Benefits

The swift support provided by ELGi for new equipment procurement and on-site maintenance at end-consumer sites across India, satisfied our client’s expectations. Here are some benefits of choosing ELGi:

Increased Customer Demand: The authentic performance of ELGi air compressors at end-consumer sites has led to more orders for air compressor rentals.

Better Customer Satisfaction and Equipment reliability: With rented air compressors, the client ensures higher uptime and reduction in downtime for its customers.

Business Growth: Due to its successful venture into the air compressor rental business in the construction and mining sectors, the client is presently exploring opportunities in the oil and gas, pharmaceuticals, general engineering, and food and beverage industries. Our client also aims to offer oil-free air compressors to its customers.

Conclusion

“The rental industry is very promising and will boom once the pandemic is over. I’m confident that with ELGi’s technologically superior compressed air systems, along with our strong relationship with the ELGi team, we will be able to cater to the needs of our customers across various segments in the next few years. My mind is at peace as ELGi’s service team proactively takes care of our products at customer sites. I don’t worry about the service or downtime at all. By partnering with ELGi, I have taken the best decision at the right time,” said a representative of the client.

ELGi believes that ensuring a customer’s success determines ours and strives to provide superior equipment in the market. From procurement to after-sales service, ELGi takes pride in partnering with customers to ensure maximum productivity and reliability.

One of Egypt’s leading emulsion polymers’ producers was seeking a robust and reliable air compressing solution for constant air supply with variable pressure compression. That’s when they adopted ELGi’s eco-friendly, energy-efficient EG Series Screw air compressors to increase reliability and ease of use at its manufacturing operations. 

According to reports, the polymer emulsion’s market size is expected to rise from USD 25.2 bn in 2020 to USD 38.1 bn by 2025.1 Despite the shock from COVID-19, considered unparalleled since the great depression and the IMF warning of an uneven slump ahead, the growth prediction of 8.6% CAGR is heartening for all stakeholders. 

The prediction is based on solid fundamentals and is not just a result of biased speculation. Market growth is driven by regulatory mandates, emerging energy disruptions, shifting consumer dynamics, and growing end-user industries, principally from emerging countries. 

Strict regulations are fuelling product demand. Stringent pro-environment guidelines around toxic chemical emissions and directives regarding the usage of water-based emulsion polymers over synthetic products. Various end-user industries like paper, textile, and consumer durables are adopting polymer emulsion to control noxious emissions. Additionally, the auto industry, coupled with the construction industry, is driving the global polymer emulsion market. Owing to a growing demand for green buildings, the global construction market is poised to grow by 85% to $15.5 trillion worldwide by 2030.² 

The Polymerisation Process 

Often called ‘products by process,’ emulsion polymers signify that the composition of the bulk polymer is as important as the process of making it.  

Alcohol is an emulsifying and dispersing agent for paper coating, board coating, water-soluble film, textile sizing agent, paper and wood adhesive, release liners and carpet coating among others.     

The emulsion polymer manufacturing process is very complicated. 

With traditional energy-guzzling installations, mounting pressure loss increased startling load, and rigidity in temperature compromising air quality, the need was for advanced air compressors with high-end design and advanced features. The company was seeking a partner to help deploy compressed air systems that can withstand the harshest of environmental conditions while saving energy, costs, and reducing Co2 emissions. 

From 2018, the company started leveraging ELGi’s total compressed air solutions to achieve best-in-class energy efficiency.  

ELGi’s eco-friendly, energy-efficient EG Series Screw Compressors delivered constant air supply with variable pressure compression. Through its in-house, proprietary η-V profile rotors designed to run at optimum speeds, it reduced pressure losses and increased efficiency. ELGi’s 1000 litre high-pressure air receiver, designed to ASME standards and built-in ELGi’s dedicated facility, acted as an enabler between the compressor and the variable pressure caused by demand waves helping reduce the loading and unloading cycle pressure on the compressor. 

Airtime refrigeration, air dryers, and filters prevented real-life problems like unwanted abrasive sludge, corrosion of piping, and erosion of pneumatic tools.  

ELGi’s Airtime refrigerated air dryer has ensured longer life of compressed air system through the efficient removal of the condensate and contaminants. As per international protocol, ELGi uses ozone-friendly R 134A gas as the refrigerant which has zero ozone-depletion potential. 

The organisation specifically selected the ELGi EG Series compressor on account of its following features and benefits: 

• Reduced startling load: The new generation intake valve system is designed for low losses. 
• Moisture-free air: The EG Series air compressor, with its custom-designed centrifugal type moisture separator and automatic drain, removed over 99% of bulk water from the compressed air. 
• Cool air: Efficient air cooling from an integrated fan-motor maintains a low temperature, resulting in the increased lifespan of the motor.  
• Robustness and reliability: Designed to perform in extreme temperatures, the compressors have performed well in cold, hot, and humid, as well as arid conditions.     

CONCLUSION 

The partnership with ELGi has enabled the organisation to address various operational requirements, including the need for clean, moisture-free, oil-less (1ppm) air that is free of other contaminants as well. The emulsion polymer maker has also been able to reduce the life cycle costs for its air compressors, besides realising significant energy savings and uptime warranty. 

To know more about our offerings in the manufacturing sector, do reach out to us at communications@elgi.com or call us 1800-203-3544 (Toll-free, India). 

1. Polymer Emulsion Market worth $38.1 billion by 2025 – Exclusive Report byMarketsandMarkets™

https://www.prnewswire.com/news-releases/polymer-emulsion-market-worth-38-1-billion-by-2025–exclusive-report-by-marketsandmarkets-301124978.html 

2. Global Construction Market to Grow $8 Trillion by 2030: Driven by China,USand India 

https://www.prnewswire.com/news-releases/global-construction-market-to-grow-8-trillion-by-2030-driven-by-china-us-and-india-544142522.html 

However, not many are aware that compressed air is a major power source in the healthcare sector and saves many lives. It is a key component that enables the functioning of modern medical equipment. Be it artificial respirators or surgical instruments, air compressors power a number of systems in hospitals and dental clinics.

Let us look into some of these in more detail:

Operation theatre

Medical-grade compressed air, free from contaminants such as oil, dust particulates, bioburden and water vapour, is administered to patients for anaesthesia and inhaled medications during surgeries. It keeps them with breathing and makes them feel comfortable during invasive procedures. Air compressors also help run several handheld medical tools and pneumatic devices in the OT.

Treatment of severe respiratory conditions in the ICU

Life support systems in Intensive Care Units (ICUs) are powered by air compressors. Medical grade air compressors deliver clean and dry air while running ventilators. They also power the incubators that provide a safe space to new-born babies as their vital organs develop. The controlled flow of air helps reduce unsafe levels of oxygen exposure and enables easy breathing for patients.

Dentistry

Air compressors are also at the core of dental treatments and surgeries. They help operate drills, scalers and other handhelds used by dentists in tooth extraction, root canal process, teeth cleaning and other invasive procedures.

Besides providing the cleanest of air for equipment, dental air compressors must also function without making much noise – this is necessary to enable dentists to focus on their work and the patients to stay relaxed. Small air compressors with filter silencers can significantly reduce the noise a unit makes.

Hospital maintenance

Compressed air is the best resource to clean dusty surfaces in any facility, making it useful for hospitals that must be kept very clean. Air compressors also power a number of other tools used in the repair and maintenance of medical equipment such as nail-guns, impact hammers and others.

Hospital maintenance teams also use air compressors to inflate mattresses and the tyres of wheelchairs, stretchers and service carts.

Air compressors that supply medical-grade air

Medical air compressors are specially designed to distribute air that does not have any traces of fine particles, oil, odour or moisture. Such air is used only for patient care and calibration of devices for respiratory applications.

Oil-free air compressors are the best models to supply medical-grade air Since they use materials like Teflon for lubrication, there is no trace of harmful oil in the air output of these compressed air systems.

It is also critical to eliminate water from healthcare compressed air systems because moisture is corrosive and can cause significant harm to the units. Besides damaging distribution pipelines and air receivers, it may lead to mould growth on equipment used in medical treatments. Water can also freeze in control lines during cold weather, resulting in faulty operation of associated applications.

Regardless of airborne moisture or vapour from system condensation, water in any form is harmful to systems run by medical air compressors and can lead to multiple breakdowns and repair bills.

More alarmingly, any bacterial contaminant or pathogens mixed with moisture, put patients’ lives in danger, defeating the very purpose of using compressed air in medical facilities.

Smooth functioning of air compressors

The key component requiring maintenance to avoid water in medical air compressors is the air dryer. While buying accessories, ensure that you choose the right size of dryers and fit them carefully, considering the amount of moisture that they can hold.

Service or replace the dryers when required because, in time, they tend to lose their ability to stop vapour from passing through the air compressor.

As part of your routine air compressor maintenance, check the condensate drains to prevent them from carrying moisture downstream into the linked medical systems. Get the clogged drains cleaned thoroughly and if there are any other signs of damage, contact a professional to make necessary repairs or replacements.

ELGi offers air compressors and accessories for the healthcare industry for select applications and to support your facility maintenance tasks. To know more about these models or to sign up for an annual maintenance package, contact our team at 1800-425-3544 (India tollfree) or write to us at communications@elgi.com .

Inspite of the availability of spare parts in the market at attractive prices, it is critical to procure your air compressor’s components only from original equipment manufacturers (OEMs).

Purchasing spares from authorised dealers will give you benefits like:

• Warranty
• High product quality
• Longer lifespan
• Higher productivity
• More energy savings
• High reliability
• Ease of service and maintenance

The parts that need to be replaced or replenished include:

Their distinct features can be understood in terms of:

If you plan to buy an air compressor for your industrial application, you need to mull over several factors that best suit your needs. One important consideration is the air pressure requirement of the equipment that the air compressor will operate.

The free air delivery in an air compressor is measured in cubic feet per minute (CFM). It is the amount of air generated by the air compressor at a certain pressure level. Another parameter considered along with CFM is the amount of pressure that the air compressor can offer, which is measured in bar, kg/cm2 or PSI.

For instance, small pneumatic tools usually need up to 5 CFM at 4.8-6.2 bar. Larger equipment, on the other hand, demand more than 10 CFM at 6.9-8.2 bar. Remember that when you have multiple applications with different airflow demands, you should add up their individual requirement and consider the total usage to be 40-50% higher than the obtained number. This is to ensure the air compressor doesn’t run at full capacity at all times.

Take a look at the airflow required for some common air compressor applications:

Air compressors convert normal air into its high-pressure, denser form for uses in a wide range of environments.

From small, portable models for safe supply on-the-go, to huge commercial installations that fuel complex industrial processes, they vary considerably in size and configuration to best suit all kinds of needs.

ELGi offers compressed air solutions to multiple industries, and here’s a list to name a few:

Today, let’s read about a global leading elevator manufacturer, which chose ELGi’s EG Series screw air compressors for their newest plant in Pune to achieve their ambitious production targets for market expansion in India.