Building the Future

Steel is one of the world’s most essential materials in engineering and construction. Steel components are utilised in almost everything- from vehicles to domestic appliances to surgical scalpels! 

The vast applications of the metal are attributed to its durability and flexibility. The World Steel Association forecasted that steel demand will increase by 2.2% in 2023 to reach 1,881.4 million tonnes (MT).  

India is currently the world’s 2nd largest producer of crude steel in January – December 2021, producing 118.20 Million tonnes (MT) crude steel with growth rate 17.9% over the corresponding period last year (CPLY). Source 

A leading steel manufacturer  

Our customer is a leading steel manufacturer, which began operations in 1998. Ranked as one of the top in India, the organization is also recognized as the second largest value creator in the world.  

The diversified portfolio of steel products comprises steel plates and coils, angles and channels, wire rods, round bars, rails, parallel flange beams, and fabricated sections. The product line is in high demand across 22+ countries owing to its durability and quality. 

From Scrap to Steel 

Steel is a sturdy iron alloy with chromium, manganese, and nickel elements. Our customer’s production process typically involves these steps:  

•   Raw material sourcing: Iron ore, coal, and lime are the primary raw materials used to produce steel. The company owns coal and iron-ore mines to source the raw materials. 

•   Sinter plant: The raw material is subjected to an agglomeration process in the sinter plant. The fine mineral particles are combusted into a porous mass known as sinter. 

•   Blast furnace: The sinter contains 70% to 80% of the iron. The charge is transferred from the sinter plant to the blast furnace, which is melted to produce hot metal or liquid iron.

•   SMS: Refractory lined vessels called LD Converters are used to produce steel from the liquid iron. Impurities such as carbon, silicon, phosphorus, and sulphur are removed by blowing oxygen through a hot metal bath. The molten steel is continuously cast at the radial type continuous casting machines.

•   The finished product: Steel is moulded into slab, strip, billet, bloom, and beam blanket as the final product. These are descaled, tested for quality, sorted by weight, and stored for shipment.

Chinks in the Armour 

Steel manufacturing plants need high-pressure and high-quality air to descale the final products. The hydro-mechanical descaling process eliminates impurities from the product. Special descaling nozzles form jets arranged on spray headers in the steel mill. The finished products are then subject to a working pressure ranging from 80 to 300 bar for descaling application. 

The process involves converting sheets into heat-rolled slabs. Iron oxide or mill scale is deposited on the sheets and must be removed repeatedly to clean them. The challenge was deploying an air system that could descale the sheets properly. The highest quality of high-pressure compressed air was required to ensure the best surface finish was achieved, as it directly impacts the product quality.  

Making Things Right  

Our customer switched to an ELGi Sauer high-pressure air compressor in 2017.  

A unit of the Hurricane Series Model WP4341L was installed for the descaling application process at the rolling mill. The Hurricane Series high-pressure compressors are renowned for engineering superiority and production expertise. Founded on outstanding military design experience and continuous innovation, this is one of the most cost-effective and reliable air-cooled industrial compressors in the market ranging from 115 to 400 bar. 

The installation of the ELGi Sauer air compressor came with so many benefits:  

•   Descaling the final product:  Descaling to deliver high-quality finished products with maximum shine.

•   Heavy duty performance:  Delivering performance even under extreme environmental conditions.

•   Minimal downtime: The reliable compressor performance, low downtime, and swift maintenance by the ELGi Sauer service team ensured high availability of the compressor to deliver high-quality products consistently. 

“ELGi Sauer’s high-pressure compressor satisfies our needs and helps us deliver high-quality products consistently. It is durable and reliable, and we are happy with its performance. It is easy to operate, and we can use this machine for our heavy-duty applications with full confidence. Partnering with ELGi Sauer was the best decision for our business.”  

Our customer feedback  

The trouble-free performance, ease of maintenance of the compressor package and lower operating cost has won the user’s confidence. Repeat orders in 2019 reflected customer satisfaction. To provide the complete trouble-free availability of the compressor considering criticality in the plant, ELGi Sauer has taken the compressors under maintenance ensuring they are attended to by qualified service engineers conforming to prompt and timely periodic service ensuring superior performance.  

“At ELGi Sauer, we understand the customer and application needs very well and consistently deliver the best-performing and most suitable equipment. Our products are built with reliability and lower life cycle cost, making them the most preferred choice of the customers. With prompt product support through service contracts, we keep our customers stress-free, enabling them to focus on enhancing their business growth,” said  Satish Kini, Chief Executive Officer of ELGi Sauer Compressors Limited.   

Technology and innovation in focus for ELGi Sauer  

The latest in-built technology with ELGi Sauer compressors makes them future-ready and the most preferred by customers. Advanced control systems, compressed-air treatment systems, and accessories are available to meet the customer’s specific needs. 

ELGi Sauer has significantly expanded its business portfolio in the past decade and has become the most preferred choice across major industry segments in India. Delivering state-of-the-art products and customized solutions to steel, auto, power, general engineering and oil & gas segments, ELGi Sauer helps its customers achieve high productivity at low maintenance cost.   

Speak to our experts for customised solutions for your industry applications. Share your requirement here.

Sources:

World-Steel-in-Figures-2022.pdf (worldsteel.org) 

ELGi’s Oil-Free Air Expert addresses query frequently asked by users from various industries. 

Q1. I am setting up a new pharmaceutical bulk drug manufacturing plant. Which compressor should I select? 

The quality of compressed air is critical in applications where the air comes in direct contact with the end product. It should not contain contaminants like oil particles. One more requirement of the pharma segment is uninterrupted operation. Hence, the most suitable solution will be an Oil-Free screw air compressor which is best suited for continuous duty application and delivers compressed air, free from oil contaminants. 

Q2. How is an Oil-Free compressor different from a lubricated compressor? 

In the lubricated compressor, oil is injected into the compression chamber, also called the Airend, during the compression process. This lubricating oil mixes with air, and this Air-Oil mixture is further treated. 

Whereas in an Oil-Free compressor, during compression, there is no injection of oil into the Airend.  Hence, the compressed air does not contain any traces of oil. 

Additionally, Oil-Free air compressors are also eco-friendly since there is no oil spillage from the compressor drain or oil carryover in compressed air. 

Q3.I have fluctuating airflow demand. How can I reduce my operating cost? 

While some setups have a fixed airflow requirement, many factories might be experiencing fluctuating demand. This situation allows us to reduce our operating costs significantly. 

As a best practice, if your airflow demand is not constant, we recommend installing a VFD-equipped air compressor. If you have a fixed air compressor installed already, you can opt for a Retrofit VFD kit matched to your compressor power, which can help regulate the airflow as per plant requirements and reduce power costs. 

Q4. What are the different cooling methods used in Oil-Free air compressors? 

Electrical energy is converted into thermal energy during the compression process. Cooling systems are designed to maintain the system temperature within acceptable limits. 

ELGi offers Oil-Free air compressors in both Air-cooled & Water-cooled variants. 

Q5. My application is critical. How can I be sure that the compressor delivers Oil-Free air all the time? 

The compression process occurs in the compressor chamber called the Airend. An Airend has two sides, the airside and the oil side, which are completely isolated by air & oil seals, which prevent oil from mixing with air. 

ELGi Airends have an additional safety arrangement, wherein even if the seals, for some reason, malfunction, the oil will go back into the sump and not mix with air. Thereby always guaranteeing 100% Oil-Free compressed air. 

Q6.  What all industries use Oil-Free compressors? 

Specific industries require air that directly contacts the end product or is used for sophisticated machines. The presence of oil traces in such scenarios is highly undesirable. 

ELGi offers 100% Oil-Free compressed air solutions to Pharmaceuticals, Food & Beverage, Textile, Automobile, Electronics, FMCG, Oil & Gas, Power, and many more. 

Q7. How does ELGi ensure the high quality of its air compressors? 

Air compressors from ELGi are designed to offer the highest product quality & system reliability to our customers. 

We are one of the very few manufacturers in the world who have their Airend design and build them entirely in-house. 

 Another example of our efforts to go the extra mile is our state-of-the-art foundry set-up to achieve the highest quality in casting. 

Q8. How do I select a suitable air compressor for my application? 

Air compressor selection depends on several factors. A few questions to ask before finalizing one for yourself are – 

– What is the airflow or SCFM required by your pneumatic machines? 

– What is the operating pressure? 

– Does your application need Oil-Free air? 

– Is your airflow demand fluctuating?  

With so many factors to consider, the selection process might seem overwhelming. ELGi offers a wide range of air compressors – Oil-Free and lubricated piston and screw air compressors.  

ELGi’s compressed air experts can help you identify the right solution for your application. We also conduct extensive air audits to map airflow demand accurately to get the most efficient solution. 

To know more, click here.

“The whole purpose of education is to turn mirrors into windows.”

– Sydney J. Harris

Situated in Singarampalayam, India, the ELGi Vocational Training School is a training centre that serves as a perfect example of skill development. The institution strives to provide holistic development to young students from underprivileged backgrounds, by equipping them with technical training and on-the-job skillset.

At the centre, the students receive technical training. Daily, through a practical-based approach, they get to learn basic engineering concepts and production technologies. This is augmented by the centre’s facilities, such as the multimedia classrooms and training spaces for fitting shop, machining, welding, and electrical work.

Apart from this, they also get access to yoga centres and sports facilities, which is instrumental for their physical and mental wellbeing.

For the duration of their course, the students are provided with free boarding and receive a monthly stipend, which helps them provide critical financial support to their families.

Today, let us take a look at the stories of four of our students, whose professional careers have been deeply enriched by the EVTS experience.

There are several parameters to keep in mind while buying an air compressor. Apart from deciding the size, rating expressed in CFM (for airflow), and bar (for air pressure), you also have to choose between an oil-free and oil-lubricated system.

The choice depends on the kind of applications where you intend to operate your air compressor. This is why, it is good to understand how these compressed air systems work and the applications that they’re used for.

According to historians, it is believed that sandblasting was first patented after the observation of what appeared to be sand-laden winds. Apparently, this seemed to significantly affect objects or surfaces they met. This observation was made by none other than Benjamin Chew Tilghman – the person who invented the first air compressor.

Sandblasting is also known as abrasive blasting. It is the operation of forcibly propelling a stream of abrasive materials against a surface. It is done under high-pressure to smooth out a rough surface, roughen a smooth surface or shape the same to remove its contaminants.

The abrasive material for this operation is chosen based on the finish required on the surface.

To get the best performance from your sandblaster, you need to select the right compressor for the job.

Choosing your compressor:

Compressors and sandblasters are sized based on:

• Flow: Defined as the volume of air that the system can move in a minute, the flow is dictated by
  • Number of users
  • Hose length
  • Hose diameter
  • Nozzle size and type
• Pressure: The pressure generated by the system is dictated by media, hose length, & diameter
  One must consider both numbers to make sure the compressor and sandblaster will work together. The size of the sandblaster and nozzle will determine what size of the compressor should be used for the operation.

How sandblasters work:

To select the right size of the compressor for the operation; it is necessary to understand how exactly a sandblaster works. They clean out rough surfaces by abrading them with sand that is fired out of an air-powered gun at high velocity.

• Different types of projection systems that can throw abrasive using compressed air:
  In pressurised projection systems, both abrasive pot and air mixing champers are under the same pressure, sweeping the abrasive material along in the blast hose.
• In suction systems, compressed air is injected into the gun through a nozzle which creates a partial vacuum that sucks a mix of air and abrasive materials from the pot.
• In gravity systems, the abrasive material enters the mixing chamber by gravity and is then pushed by compressed air into the nozzle.

This industry has not only lived up to Dubai’s love for pushing the limits of human ingenuity, but also met its constant requirement for construction materials to feed the high demand. One such material is cement, the lifeblood of the real estate and construction industry.

To power this journey, ​one of the ​largest​ ​producers ​of​ ​cement​ ​in​ ​the United Arab Emirates (UAE)​, has been at the forefront of this sector fulfilling heavy demand, and making heavy investments in technology including state-of-the-art air compressors.

You would find literally everything you need or did not know you needed at a supermarket. Choices of brands, products, sizes, weights, you name it! And while you find yourself spoilt for choice, there is one thing common with all these offerings and that is the packaging. Each of these products is ready and safe for use because of compressed air.

Compressed Air in Packaging Industry

As online shopping continues to rise, the packaging sector sees an expansion in its industry. Compressed air assumes a pivotal role in the manufacturing and packaging operations across various global sectors. Its applications span from cleansing, aligning, shaping, to sealing a wide array of packaging items.

Compressed Air in Food Industry

Last year, the global food packaging market crossed over US$ 302 billion in market value. Compressed air plays a vital role in safely transporting food items and other products around the factory or to their desired location, without any contamination or deterioration in quality. Compressed air is used to shape and seal cartons and boxes, manufacturing products like PET bottles and thoroughly clean all containers before they can be filled with liquids.

Oil-free compressors are indispensable in the food and beverage industry, ensuring product safety and quality by delivering contaminant-free compressed air. They are utilized for tasks like pneumatic conveying, bottling, and packaging, where maintaining a pristine and hygienic production environment is paramount.

Use of Compressed Air in Pharmaceutical Industry

In the pharma industry, oil-free compresses are used to manufacture products including pills and tablets. These tablets or pills are then safely placed in bottles, after the moisture has been removed, and then sealed airtight- maintaining the highest level of clean and sterile compressed air.

Please know more about the significance of oil free air in pharmaceutical industry.

The French fry from Belgium

So, how did the French-fry get its name? Back in the 1600s, as lore goes, villagers living in Meuse Valley, accustomed to frying and eating fish, fried potatoes as well – the same way they prepared fish. This is how the first fry is said to have been created. A few decades later, during WW1, American soldiers stationed in Belgium were introduced to the potato fry. The official language of the Belgium army at the time was French, which is why the American soldiers nicknamed the potato snack ‘french-fries.’ From then to now, this name has stuck.

Businesses around the world have chosen ELGi as their trusted partner for:

1. RELIABLE PRODUCTS

400+ compressed air solutions to suit your requirements.

To power a portfolio of over 400 products, ELGi has state-of-the-art manufacturing facilities in India, Italy and USA. With in-house technology, ELGi air compressors are engineered to deliver maximum uptime, energy efficiency and reliability at one of the industry’s lowest total cost of ownership

While businesses focus on optimising production and reducing unnecessary costs, air compressor breakdown due to incorrect start-stop might lead to huge operational losses. Here is the need to work on a business continuity plan capable of handling the fast-moving variables of an outbreak like COVID-19.

As some countries across the world are going into lockdown while others are resuming business activities, it is important to follow few steps to ensure proper shut down and start-up of your air compressor and related accessories.

Re-evaluate your energy cost during operation and invest in energy saving products like ELGi Heat Recovery System.Know More