Why recover heat? 

All the electrical power used during the compression process is converted to heat. This heat, if not recovered, causes a waste of energy- which contributes to global warming. When heat is recovered, the cost of power is reduced, which, in turn, reduces the overall cost to companies. When heat is not recovered, it is released into the atmosphere, thus causing wastage. 

When the heat recovery system is plugged into an air compressor, the energy recovered can be used to heat water for use in showers and boilers.  

How is the heat generated in the compressor system used? 

In an average compressor, 96 per cent of the heat can be theoretically recovered – this includes heat from the oil cooler, the after cooler, and the drive Motor. The heat released by the oil cooler can be used for the purpose of heating water. On the other hand, the heat generated by the aftercooler and the drive motor are used for supplemental space heating.  

Why choose ELGi’s heat recovery system? 

ELGi’s heat recovery system recovers upto 78 per cent of the heat generated. This eliminates the need for additional equipment that would lead to more energy consumption and CO2 emissions. With ELGi you are also assured of a greater return on investment.  

ELGi’s Heat Recovery System is an accessory that can be plugged into the EG series rotary compressor – owing to its fully enclosed design. This system is crucial to the functioning of various industries- automotive, cement, textiles, and steel making, to name a few.  

In line with ELGi’s efforts towards sustainability, the Heat Recovery System leads to extra savings and reduced carbon emissions 

The HRS from ELGi saves 69% of the fuel and provides faster ROI* 

 A thorough understanding of how your compressed air system works helps in improving its performance. To know more about  the energy management solution or the heat recovery system, please contact our sales team. 

*this may vary as per site conditions and end-use. 

ELGi is committed to developing green facilities comprising of green belts and landscaped gardens at all factory locations, using the Miyawaki technique. Aside from planting over more than 100 varieties of native species to promote biodiversity.  

The United Nations Sustainable Development Goals are the blueprint for achieving a better and more sustainable future. Comprising 17 goals and 169 targets, these are a call for action for global economies, governments, businesses, other organizations, and individuals to work towards mitigating the world’s most pressing challenges.   

Today, we are looking at Goal 15 – Life on land.   

So, what does the goal mean?  

The United Nation’s Sustainable Development Goal 15 urges us to protect, restore and promote sustainable use of terrestrial ecosystems, sustainably manage forests, combat desertification, and halt and reverse land degradation and halt biodiversity loss.   

How has ELGi aligned with the goal in the past year?  

 ELGi is committed to developing green facilities:  

1. We developed green belts and landscaped gardens at all factory locations, using the Miyawaki technique.  
2. Planted multiple varieties of native species to promote biodiversity.  

What is the Miyawaki Technique?  

The Miyawaki technique was developed by Japanese Botanist Akira Miyawaki to grow dense forests of native plants. This innovative technique, which involves planting a forest, is utilized to reforest cities globally. This technique produces forests that grow quickly, contain dense vegetation, and over time require little to no management. When growing wood on tiny landholdings, the Miyawaki approach and related strategies are incredibly effective.  

Prerequisites for Afforestation through the Miyawaki Method:   

1. The Miyawaki afforestation technique only needs a very small area—at least 20 square feet. 
2. To save space and encourage dense plant growth, seeds must be planted relatively close together. This will also enable young trees to defend one another and stop sunlight from infiltrating the forest floor, inhibiting the growth of parasitic plants.  
3. This approach must result in vegetation that is 30 times denser and growing 10 times more quickly than usual. 
4. The Miyawaki approach requires that such a forest be maintained for a minimum of three years.   

What is afforestation?  

Afforestation involves planting trees in areas that haven’t recently had any tree cover, in order to create a forest. The type of land planted could include areas that have turned into a desert (through desertification), places that have long been used for grazing, disused agricultural fields, or industrial areas.  

The main goals of afforestation are to serve as a method to reduce atmospheric CO2, increase soil quality, and either avoid or reverse desertification. The forests created through afforestation also provide habitat to local wildlife, create windbreaks, support soil health, and may also help improve water quality. Afforestation is one of the most “natural” and technologically simple ways to reduce carbon dioxide emissions.  

ELGi recognizes the contribution of biodiversity to the reduction of emissions. Carbon emissions can be absorbed by the ground thanks to forests. Since 2016, ELGi has created green belts at all factory locations, using the Miyawaki technique. The ELGi team and their family members have contributed to this program by planting more than 6,000 different tree species so far, with the goal of planting more than 30,000 trees over the next three years.  

Energy costs account for approx. 30% of a production facility’s operating budget. That means nearly a third of all the money organizations invest into their plant, goes straight to the power bill. Power cost is a pivotal determinant of the overall cost to companies. 

Globally, business owners have embraced sustainable techniques to ensure   convenience, and efficiency in their facility, but is it possible to go too green? Absolutely. 

Considering the implications of global warming, ELGi introduced a Heat Recovery System, which enables the reuse of heat energy generated during the compression process for tasks like heating water. 

Refine Your Compressed Air System with ELGi’s Heat Recovery System 

ELGi’s Heat Recovery System can assist in using 78% of the waste heat generated by the compressor for other facility operations, such as heating water. As a result, there is no longer a need to purchase additional equipment to heat water, thus lowering CO2 emissions. The Heat Recovery System is an accessory which can be used with the ELGi EG Series rotary air compressor. Customers can easily plug the HRS into an air compressor to warm water and air for use in showers and boilers by using the heat produced by the air compressor.  

In a typical compression system, the theoretical recoverable heat is 96% of the overall electrical energy consumption. It consists of heat dissipated in the oil cooler (78%), the after cooler (13%) and the heat radiated from the drive motor (5%). The heat dissipated by the oil cooler can be used for heating water and the heat dissipated by the after cooler and drive motor can be used for supplemental space heating. The remaining 4% heat cannot be recovered, since 2% radiates through the canopy and the other 2% vents inside the canopy. 

Robust Operations Across Industries 

The Heat Recovery System finds its operation in industries like automotive, textiles, cement, paper & pulp, machine tool shops, steel making and the food processing industry where there is a need to heat / pre-heat water to a certain temperature ELGi’s HRS can significantly reduce energy costs by eliminating the use of special heating equipment or by offering the initial heat to start the heating process where higher temperatures are required. 

Elgi is a global air compressor manufacturer with an expansive line of innovative and technologically superior compressed air systems. ELGi has consistently ensured that its customers achieve their productivity goals while keeping the environmental impact low. Our product innovation for the Heat Recovery System is driven by the potential for savings and by examining the carbon footprint of an air compressor. ELGi firmly believes that sustainable technology is at the heart of positive environmental change.    

Explore our portfolio of sustainable & efficient solutions here: http://www.elgi.com 

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.

Executive summary  

Rapid urbanisation has resulted in increased demand for energy-efficient residential and commercial air conditioners across India.  One of the leading manufacturers in India, meets this demand by deploying high-quality ELGi Sauer air compressors across its production and testing facilities.  

Industry Overview  

In the 21st century, people live, work, and play in highly customised interior spaces. Unique in design and application, they reflect the new-age consumer and their evolved needs. The most important parameters are the interior temperature and advanced HVAC (Heating, Ventilation, and Air Conditioner) systems that provide comfort and reprieve from increasing heat and external weather conditions. 

In India, where the average summer temperature ranges between 32-40° Celsius, air conditioners are fast becoming a vital commodity for homes, offices, and industrial units. This is especially true in urban regions in the northern part of the country, where the HVAC industry share is the highest.[1] 

Additionally, the emergence of inverter technology in appliances and IoT-enabled temperature control systems is predicted to strengthen the demand for air conditioners even further. 

Furthermore, while residential air conditioners in the country are available in the window and split formats,  light air conditioners, variable refrigerant flow (VRF) systems, and chillers are the most common product types in the commercial segment. However, there is demand for air conditioners in segments that utilise inverter technology resulting in reduced energy consumption, operating costs, and carbon impact. Besides, increased awareness and growing environmental concerns are changing the HVAC industry. In addition, energy regulations and policies that promote energy efficiency are also evolving.  

About the company 

 One of the most popular and energy-efficient air conditioner brands in India, the company understands the importance of individualised space and comfort in the 21st century, and its HVAC products reflect this philosophy.  Having its manufacturing facility in Kadi, Gujarat, the company manufactures a wide range of products, including but not limited to the following: 

• Residential air conditioners – New technological breakthroughs enable the manufacturers to provide energy-efficient and reliable window and split air conditioners

• Commercial air conditioners – A wide range of large-scale HVAC systems for industrial and residential project needs, including chillers, cassette air conditioners, ductable air conditioners, telecom air conditioners, and VRF systems

The customer challenges 

The manufacturer aims to deliver high-quality, efficient air conditioners, that are reliable and environment friendly. Innovative engineering and manufacturing support the company’s vision of safety, comfort, and sustainability. 

One critical utility that the company relies on for manufacturing and testing is the uninterrupted supply of high-pressure compressed air, which is necessary for testing the condenser coils of air conditioners.   

The solution 

To meet its demand for high-pressure, high-flow, and high-quality compressed air, the company installed ELGi Sauer air compressors at its manufacturing facility. It installed the Passat Series 3-stage air-cooled direct-driven compressors that demonstrate exceptional endurance, even under the most stringent operating conditions of up to 55°C ambient temperature. The ELGi Sauer air compressor models provide an even distribution of pressure ratio per cylinder, resulting in lower cylinder compression temperatures. This increases the life of internal components, providing a long-lasting and high-quality supply of compressed air. 

Business Benefits 

Since the manufacturing company installed ELGi Sauer air compressors, there has been an increase in energy efficiency and production output. With ELGi’s direct-drive technology, reduced power consumption per cubic metre has led to a 40% reduction in energy consumption, boosting the factory’s profitability. The machines are practically maintenance-free. ELGi Sauer also provides standard maintenance routines at regular intervals to ensure efficiency, despite high uptimes during peak seasons.            

“ELGi Sauer’s air compressors have boosted the firms air conditioner testing capacity. With the delivery of high-pressure compressed air coupled with high energy efficiency and zero breakdowns, ELGi Sauer compressors power Hitachi’s production plans consistently.” – Mitesh Trivedi, Assistant Manager, Plant Engineering.  

Speaking about successful installations of high pressure compressors across the nation, Satish Kini, CEO, Elgi Sauer Compressors Limited said, “Over the past decade, ELGi Sauer has significantly expanded its business portfolio in the industry and offshore markets, continuing its strong foothold in the defense business. ELGi Sauer has become the most preferred choice across major industry segments in India, such as steel, auto, power, general industry, and oil & gas.” 

“Looking ahead at the growing business prospects in the key focus markets, ELGi Sauer has started to build a greenfield manufacturing facility expected to be operational by the end of 2022. The new plant would support the organic growth and cater to the engineering and product testing requirements of its joint venture partner Sauer, Germany, and its subsidiaries. This expansion will contribute significantly to double the business turnover in the next five years to over INR 800 million. Today, ELGi Sauer covers most of the SAARC countries and explores more business prospects in upcoming years.”  

[1]https://www.techsciresearch.com/report/india-air-conditioners-market/3319.html#:~:text=India%20air%20conditioners%20market%20stood,for%20residential%20and%20commercial%20spaces.  

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.

It is the day our Mother Earth gets the spotlight and this spotlight should never be switched off, for it is critical for every stakeholder to embark on a behavioural change for the better.

Why, you may ask.

Essentially, our global health is under pressure!

If healthy people, a healthy society and a healthy planet are to be obtained, it is important to implement the Farm to Fork strategy, which is an integral part of the European Green Deal.

“We don’t have to engage in grand, heroic actions to participate in change. Small acts, when multiplied by millions of people, can transform the world.”
– Howard Zinn

Sustainability lies at the core of ELGi’s business. Whether it is developing energy-efficient products or creating eco-friendly green hubs for workspaces, sustainability is integral to the corporate identity and is actively advocated by employees.

This is why, to honour the 50th Anniversary of World Earth Day on 22nd April 2020, ELGi launched the ‘Steps For Change’ programme, a purpose-driven engagement activity. Through the initiative, employees across the globe were encouraged to take small, yet significant measures and make a difference towards the environment.

According to the report, ‘All India installed capacity (in MW) of power stations’ published on 31st March 2020, India’s installed utility-scale hydroelectric capacity was 46,000 MW. This accounted for 12.3% of its total utility power generation capacity.

In the future, it is estimated that India’s hydroelectric potential shall reach up to 148,701 MW. Furthermore, it is said that an additional 6,780 MW from smaller hydro schemes which have capacities of less than 25 MW can be deemed as exploitable.

Apart from this, a total of 56 sites for pumped storage schemes with an aggregate installed capacity of 94,000 MW have also been identified.