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South32 Warns Against IR Changes

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South32 chief executive officer Graham Kerr has joined other mining executives in warning industrial relations (IR) reforms, including the ‘same job, same pay’ policy, would potentially harm the industry. “I think the industrial relations reforms are going to probably set back productivity and not take it forward,” Kerr said. The Australian Government’s ‘same job, same pay’ legislation law will require host employers to pay labour hire workers the same rate as direct employees performing the same job. A number of mining companies have expressed concern that the legislation, which is set to be enacted by the end of 2023, will put additional pressure on what is already a fragile labour market. After releasing its financial year (FY23) results yesterday, South32 said it expects production costs across its global operations to increase over the coming financial year – which is likely to impact financing required for manufacturing growth as well.

In addition to increasing costs, Kerr believes the IR changes ran the risk of dampening Australia’s attractiveness to foreign investment. He said the company invests in its workers, offering fair pay. South32 is the latest company in the Australian mining industry to warn against the reforms, with the Minerals Council of Australia (MCA) calling for the legislation to exclude service contractors. “The Government must listen to the legitimate concerns of all businesses, given the impacts of this proposal reach into all corners of the economy,” the MCA said.

BHP Australian President Geraldine Slattery recently told the American Chamber of Commerce higher pay is not sustainable when mining already offers some of the highest paid careers in Australia. “Australia has one of the highest labour costs in the world (including costs of mining plant and equipment) – around 12% higher than in the US,” Slattery said. “We are proud to be a high-paying industry. Changes to industrial relations policies are of particular concern, and like many businesses such as steel fabrication in the mining industry – we believe they will have a negative impact on Australia’s competitiveness and jobs.

Slattery raised concerns that pipe fabrication operations at BHP’s Olympic Dam copper mine in South Australia could be harmed by the reforms. “We believe ‘same job, same pay’ could increase the operating costs of our existing operations (in SA) by nearly $200 million per year and maybe up to $500 million in a worst-case scenario,” she said. “The hit to the value of any potential growth plans in SA could be anywhere up to $US2 billion ($2.98 billion) and this would make it much harder for any South Australian investment case that has to compete with alternative options in other parts of the world.”

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Boeing’s SME Graduates Win Contracts

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Seven Boeing contracts, including agreements with three new steel fabrication suppliers, have been awarded to small and medium-sized Australian businesses which have just graduated from Boeing Australia’s first Capability Up-Lift Program. The year-long program supported companies which might not have received prior exposure and experience in a defence environment. Scott Carpendale, Vice President and Managing Director, Boeing Defence Australia (BDA), said the program’s participants graduated with tools needed to increase business maturity and improve overall performance, and BDA looks forward to growing capability for the defence industry with contributions from diverse suppliers such as these.

“SMEs bring significant value to the defence industry including agility and innovative technologies in key areas such as manufacturing, cyber security and extended reality products,” Carpendale said. Queensland companies featured strongly in the program which was delivered in collaboration with Defence Jobs Queensland, and AusIndustry, and the Office of Defence Industry Support from the Department of Defence.  Participants received the following grants and awards upon graduation:

  • Two Brisbane-based businesses – HINDSITE Industries and Raytracer – received AUD $2.8 million in grants and funding to commercialize their technologies for aerospace, in areas such as augmented reality technology and on-orbit vehicle servicing, assembly and manufacture as part of Australia’s Moon to Mars Initiative.
  • Three Queensland businesses – HINDSITE Industries, Brisbane-based LOGiT and Toowoomba-based JRS Group received their first Boeing contracts.
  • Seven SMEs received ten industry awards at both state and national levels.

“The Boeing Capability Up-Lift program has exposed us to the defence and aerospace fabrication industries and provided greater understanding of how we can ensure our business is best placed to compete and win on contracts,” said Liam Scanlan, HINDSITE Industries managing director. “Our participation broke down barriers to entry, and we were delighted to secure multiple contracts, including with Boeing, and federal grants – all made possible through access to key training and events where we could build and foster relationships with other participants and industry experts.” The collaborators delivering the program shared resources and access to industry experts to provide SME participants with advisory services (such as heat induction bending services), mentoring and access to major events to enhance business readiness and defence maturity.

“The program builds on Boeing’s commitment to fostering a diverse, resilient and sustainable sovereign supply chain, and has resulted in Boeing Defence Australia (BDA) awarding contracts to both new and established SMEs including veteran, women and Indigenous-owned businesses,” said Carpendale. Boeing Australia represents the broadest portfolio of products and services in the Australian aerospace industry and one of the company’s largest operational footprints outside the US. Based on its 96-years’ experience, Boeing plays an integral role in aerospace and defence industry as a leader in advanced manufacturing for commercial airplane components, defence systems and sustainment, training and services, research and development, and uncrewed systems.

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Technofast Addresses Giant Nuts Challenges for Heavy Industries

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Heavy industries such as mining, shipbuilding, and power generation have specific requirements for extremely large nut and bolt fasteners. These pose huge difficulties with applying specified bolt tensions because, for example, a nut weighing thirty kilograms will not be tightened with hand tools. Such nuts are installed or removed with sledgehammers, stud heaters, or torque wrenches, which can weigh as much as the person using them. Installation of such large fasteners is extremely time-consuming, can be hazardous to workers, and may not result in even tightening of every fastener to the precise tension required for long and safe joint life. Disassembly for maintenance can be equally slow, hazardous, and damaging to equipment and production schedules.

A proven best-practice solution is the use of the Technofast EziTite® family of hydraulic fasteners. Assembly and removal times are 15-20 times faster than conventional means in structural steel fabrication, and cut downtime while enhancing safety and joint precision. The fasteners are so efficient and swift in operation – including in hazardous, hot, underground, and confined spaces – that they are used in nuclear energy plants where short exposure times to workers are of critical importance. Technofast fasteners are also commonly used in some of the largest and most difficult critical bolting applications in machinery: in electricity generation, steel fabrication in mining, quarrying, materials handling and high temperature processing applications throughout Australasia, SE Asia, and the USA.

“EziTite technology replaces conventional mining and energy methods in situations where time is money, and safety is paramount,” says Technofast Founder and CEO, John Bucknell. Technofast also retains the NQA-1 nuclear manufacturing standard for supply to the Korean Hydro and Nuclear Power (KHNP) organization and supplies operationally critical bolting for their nuclear fueled electricity generating plant. Technofast EziTite was used to tension boiler feed pump bolting at electricity generating plants in South Korea. The application involved 12 large M110 X 4.0 studs, which were 110mm (4.33in) in diameter with an outside diameter of 200mm (7.87in). EziTite® TR High Temperature Hydraulic Nuts were used as an alternative to the former method of large torque wrenches weighing more than 125kg. The Technofast EziTite method resulted in a total installation time of approximately one to two hours, using two personnel, compared with eight hours and three or four personnel using the previous method.

“Large nuts of this diameter can require terrific torque forces to achieve the desired tensioning or require multiple jack bolts on each stud to bring the job within the power range of hand tools for metal work. Really big nuts – such as those widely used in mining (including mining plant and equipment), energy, and other industries – can easily have 24 jack bolts in total per nut, as did the nuts at the electricity generating plant in Korea,” says Bucknell. “Also, when jack nut fasteners need to be removed, operations staff must untighten the jack bolts in a strict sequence to avoid failure. If they do not, individual jack bolts can break and then the entire assembly would need to be cut off.”

Many new air compressors pressure pumps close up

Belmont Timber gets new ELGi Compressed Air Systems

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A new compressed air system featuring two ELGi EG series oil-lubricated screw air compressors has delivered reliability and energy efficiency gains to a building products manufacturer in Sydney. Belmont Timber, a manufacturer of engineered frames and trusses for the building industry, needed to modernise its ageing compressed air equipment, which was causing manufacturing delays and increasing costs. ELGi Equipments, one of the world’s leading air compressor manufacturers and renowned for enhancing the energy efficiency of its air compressors, with partner Pulford Air & Gas, came to their assistance with two ELGi EG series oil-lubricated screw air compressors for Belmont’s factory in Sydney. To fabricate engineered frames and trusses for the building industry at its 20,000 m2 site, Belmont Timber needs a reliable supply of compressed air to power the machinery. The older compressed air equipment was unreliable and needed increasing maintenance, and was causing a noticeable rise in power consumption. Belmont Timber called on Pulford Air & Gas, its long-standing compressed air partner and one of ELGi’s authorised partners, for a new compressed air solution. On the advice of Pulford Air & Gas, Belmont Timber selected two ELGi EG30 oil-lubricated screw air compressors with refrigerated dryer, oil-water separator, downstream filtration, and heat induction bending services to meet their needs.

Gary Walker, Managing Director at Belmont Timber, said, “Compressed air is essential to our productivity and much of our manufacturing process is dependent on a reliable supply of compressed air. Take for example, our nailing guns used in preassembly. If the compressed air pressure is incorrect, the nails will hang out of the timber, requiring additional work to be carried out to ensure that quality management remains in place. “We had started to get some issues with the reliability of the ageing compressed air equipment, and it required more maintenance. In addition, we noticed that our power consumption was going up significantly. “Pulford Air & Gas has been looking after our compressors for a very long time, so we trusted them to present the best solution to meet our requirements. Since installation, the ELGi EG30’s has provided a reliable supply of compressed air. And, while we haven’t run the numbers yet, we expect to see energy savings as a result of the upgrade.”

The ELGi EG series of oil-lubricated screw air compressors deliver best-in-class energy efficiency. ELGi’s high-efficiency airends are equipped with in-house eta-V profile rotors, with the 4/5 lobe combination, designed to run at optimum speeds. This unique design reduces pressure losses, and together with the OSBIC process (Oil Separation by Impact Centrifugal action) 3-stage separation, increases efficiencies. Ramesh Ponnuswami, Executive Director, ELGi OSEA, said, “Pulford Air & Gas worked with Belmont Timber’s requirements to specify the best compressor solution for optimum energy efficiency and reliability. Aside from delivering energy efficiency gains, the robust EG series compressors also presented a reliable solution. “Designed to meet Australian conditions, they are well suited to performing at extreme temperatures, from cold to hot and from dry to extremely humid conditions, ensuring maximum uptime.” The EG series is backed by ELGI’s industry-leading warranty, which includes a 10-year warranty on the airend, and a 5-year warranty on the compressor package, including the motor, cooler, separator tank, pressure vessel, fan motor, and controller.

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Centrally Controlled Automation helps WA Kaolin scale up

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A new kaolin mining operation in Wickepin, Western Australia, is utilising an integrated automation solution to reduce overall costs of mining plant and equipment, improve scheduling, and deliver ongoing benefits to operations. Kaolin, which is becoming increasingly valuable, is a soft white clay that has been surging in demand, with uses in applications including paper and plasterboard, ceramics, fiberglass, paints and coatings, plastics, rubber, pharmaceuticals and medicine, cosmetics, concrete construction materials and agriculture. WA Kaolin – an ASX-listed mineral exploration, extraction, and processing company – has developed a proprietary dry processing method known as K99, which turns raw material into market-suitable feedstock for global customers. Combined with the high quality of the ore reserve, the K99 process delivers high-quality ultra-bright kaolin at a lower cost than conventional chemical bleaching and magnetic separation processing.

WA Kaolin has constructed a Stage 1 commercial processing plant on a three-hectare site in Wickepin, about 200 kilometres southeast of Perth, Western Australia. There is a strategic plan in place to expand production capacity to exceed 400,000 tonnes per annum (tpa) after 36 months using steel fabrication to boost mining operations, so WA Kaolin selected engineering and planning consultancy, Willyung Electrical & Controls Engineering (WECE) to manage the process of steadily scaling up. WECE analysed the requirements, and selected Rockwell Automation’s PlantPAx® Distributed Control System (DCS) to provide a single, plant-wide control system, with the flexibility to make better and faster business decisions and a scalable solution for future expansion.

Centralised, plant-wide control

Rockwell Automation’s PlantPAx DCS will monitor and run the facility from a single point of control, providing seamless integration into control and power systems and heat induction bending services, and outputting data that is easy to analyse. The latest version of PlantPAx DCS has been designed to be an integral part of a digital transformation strategy that boosts productivity and profitability, while reducing operational risk. “Large projects like the WA Kaolin Wickepin processing plant are complex, and it’s easy to come in over-budget or off-schedule if the right automation technology isn’t implemented upfront,” said Raj Singh, channel manager, Rockwell Automation. By seamlessly integrating process, power, and information across the plant right from the outset, WA Kaolin was able to achieve better automation benefits and a faster time-to-market, and the system can readily be scaled up as production increases.

Faster time-to-market

One of the major benefits of Rockwell Automation’s PlantPAx DCS for new facilities is a faster time-to-market, which means plants can begin producing quicker. “Having total plant visibility in the planning stage means that from inception to delivery, total time is reduced. After analysing WA Kaolin’s robust and ambitious scale-up plans, we determined that Rockwell Automation had the best automation solution for the project and for the future,” said Chris Bock, managing director and principal electrical engineer, WECE. “As a system integrator, being able to deliver to the end user in a reduced timeframe is a major win. Rockwell Automation’s technology has been instrumental in enabling us to achieve these gains,” added Bock.

Hydrogen Storage Fuel Background

Public-Private Partnership backs Hydrogen Engineering

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In what the Queensland government believes is Australia’s biggest investment in green hydrogen so far – almost $117 million — has been made by the Queensland and federal governments and a consortium to fund the front-end engineering design for the Central Queensland Hydrogen (CQ-H2) project at Gladstone. When completed, the engineering design will bring the project closer to a final decision, expected late next year. Green hydrogen can decarbonize oil and gas, manufacturing, heavy haulage, shipping, aviation, heat induction bending services, and other industries.  The project will be powered by renewable energy and is expected to produce 200 tons of hydrogen a day by 2028, rising to 800 tons a day by 2031. That is equivalent to fueling more than double Australia’s fleet of heavy vehicles. The hydrogen needs to be liquified or converted to ammonia for export and potentially local industry offtake.

The Australian Renewable Energy Agency (ARENA) will provide $20 million in funding, $15 million will be from the Palaszczuk Government and the remainder $81.8 million from consortium partners which are passionate about green hydrogen. These consortium partners are: Iwatani Corporation (Japan), Kansai Electric Power Company (Japan), Marubeni Corporation (Japan), Keppel Infrastructure (Singapore) and Queensland’s publicly owned Stanwell Corporation. Federal Minister for Climate Change and Energy, Chris Bowen, said projects such as this are critical to scaling up Australia’s green hydrogen industry. “The government is committed to making Australia a global hydrogen leader. Projects like the CQ-H2 Project could lead the way in exporting renewable hydrogen to the international market.

“Japan, Korea and China are three of our largest trading partners and have all made clear commitments to increase the use of hydrogen, with a focus on establishing international supply chains for imports,” said Minister Bowen.  Queensland Premier, Annastacia Palaszczuk said the international partnership highlights Queensland’s position as a global hydrogen heavyweight. “Because of the investments we’re making, the Queensland economy will reap the benefits of the global clean energy transition, while ensuring Queensland has more and cheaper, cleaner renewable energy to power our businesses and homes,” she said.  Developing a green hydrogen export industry in Gladstone will create significant economic opportunities for Queensland: project is expected to create almost 9,000 jobs, including in the steel fabrication industry, and over $17.2 billion in hydrogen exports in its 30-year life.

Queensland Treasurer and Minister for Trade and Investment Cameron Dick said it was the largest green hydrogen investment of its kind in the nation’s history. “It is … an endorsement of the Palaszczuk Government’s Energy and Jobs Plan,” he said. “The Palaszczuk Government is working hard to drive the state’s hydrogen industry forward, to create highly skilled jobs, especially in regional Queensland. “That’s why, through the Treasury’s Queensland Renewable Energy and Hydrogen Jobs Fund, we invested $15 million into this stage of the project.” The Queensland government believes the public-private partnership in the CQ-H2 project is within the top 10 hydrogen projects in the world, which includes the EU plan to replace Russian fuel with hydrogen. The project will complement other planned investments in a renewable hydrogen industry in the Gladstone region, including the Commonwealth Government’s Regional Hydrogen Hubs program. Michael O’Rourke, CEO of government owned energy generator and provider Stanwell Corporation said the project could create thousands of jobs and deliver billions of dollars in economic benefit. “We are proud to be leading the CQ-H2 project with our partners, which demonstrates our commitment to driving the development of Queensland’s hydrogen industry and other new technologies.

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Old Tyres and Boots Used in Next-Gen Australian Steel Manufacturing

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Old tyres, conveyor belts and rubber safety boots have been used in a novel steel manufacturing process commercialized by Australian steel manufacturer Molycop, which will be offered for export to global EAF operators. The process is the result of a collaborative project between Molycop, the UNSW SMaRT Centre, footwear manufacturer Crawford Boots and the Advanced Manufacturing Growth Centre (AMGC). It involves maximizing the recovery and use of waste rubber as a substitute for imported carbonaceous material (‘coke’) used in Molycop’s Electric Arc Furnace (EAF) in Newcastle. Australia’s waste tyre export ban, which began in December 2021, has been a catalyst for companies to find innovative new processing capabilities (such as water tanks) to reduce the huge tyre landfill problem. The development of this new technology reduces the company’s reliance on imported carbonaceous materials from China by up to 20 per cent. It also removes up to 90,000 tyres from landfill and reduces the steel maker’s electricity consumption and scope one carbon emissions.

Molycop, alongside its steel fabrication partners, has developed a means to maximize the use of rubber crumb (polymer) as a source of carbon and hydrogen needed in the steel-making process. Molycop produces over 240,000 tons of steel each year for train wheels, billet steel, steel bar and grinding media. Sustainability is core to the company’s strategy and integrated into how Molycop does business, said the company’s President of Sustainability, Ian Tooze. Displacing fossil carbon materials is also a key objective in Molycop’s decarbonization pathway. “We are investing in innovative solutions that improve the ways we reduce the consumption of virgin raw materials, recover valuable materials from waste streams, minimize waste and reduce our carbon footprint while we perform quality management. “What we have developed is yielding results and delivering outcomes for Molycop, our customers and communities in which we operate.” The AMGC said the innovation will help Australia’s steel manufacturing sector to be more competitive, through lowered production and import costs, and be more sustainable through decreased emissions and energy consumption.

AMGC’s Managing Director, Dr Jens Goennemann said commercializing great manufacturing ideas is where Australia’s future prosperity lies. “Australia has an opportunity to transform from being a lucky country to a smart one through the commercialization of great ideas that have local and global relevance. While the US has floated new steel tariffs based on carbon emissions, Molycop, UNSW and Crawford Boots together have manufactured a product that will reduce emissions and address waste in steel making, while generating more jobs and revenues for the nation – what more could you ask for?” Director of the UNSW Sustainable Materials Research and Technology (SMaRT) Centre, Professor Veena Sahajwalla said it is crucial for manufacturers and researchers to work to tackle environmental issues, while delivering commercial outcomes. “By working collaboratively with Molycop we have been able to prove that polymer injection works and is commercially viable. It is only through partnerships like this that we can truly achieve positive environmental outcomes at scale. I encourage all manufacturers to engage with your local research institution and challenge them with a business issue that needs solving.”

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Train Jack System for Perth Metro Meets Deadlines

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Vector Lifting and Bonfiglioli collaborated last year on a 15-month installation for the Perth Transport Authority (PTA), successfully delivering a high-performance lifting solution to deadlines. The PTA had introduced a new fleet of trains and opened a new maintenance facility in Perth which needed 24 lifting jacks to be installed for the Perth Metro Network. Vector Lifting was awarded the tender for the supply and installation of a turnkey jack system, which elevates the train body off the track so the chassis and wheel set can be inspected, repaired, or exchanged as part of quality management. “This a new train with new requirements,” says Clinton Capelli, Mechanical Engineer, Vector Lifting. “Our jacks are synchronised and run through a controlled PLC system to lift all 24 jacks at the same time, same speed and to the right height.” “One of the reasons we were selected for this steel fabrication project – besides the fact that this is a highly specialised application – is that we are a local specialist manufacturer and are competitively priced,” adds Capelli.

To complete the jack system, Vector Lifting sought gearboxes from its long-time supplier, Bonfiglioli. “We have developed a good relationship with Bonfiglioli because we believe in their product – it is robust and reliable. Bonfiglioli’s short lead time and rapid manufacture of custom gearboxes is ideal. They always offer us very good product and technical support, and understand the pressures of our business,” says Capelli. Bonfiglioli supplied Vector Lifting with 24 A Series helical gearboxes in one consignment, ensuring that Vector Lifting would meet PTA deadlines in spite of the pandemic’s challenges. “Bonfiglioli offer local stock and assembly and, for large orders which may require an import, they achieve a quick turnaround because of their wide international footprint and manufacturing set-ups,” says Capelli.

Fred Whalley, Bonfiglioli’s State Sales Manager, says the A Series is suited to the jack system design so it required minimal adaption.  “The helical bevel gear units offer a wide torque range and high efficiency in a compact and durable design,” says Whalley. “This enables smooth, easy handling of goods, even under the most demanding conditions. We have a large local stock holding but in the case of larger orders we can bring them in from Italy in a very short period.” Vector Lifting and Bonfiglioli have collaborated for 22 years. “Vector’s is a tried and tested model – they always order the right product for the application,” says Whalley about the Australian job crane specialist. “They boast a professional engineering team which is well-versed in the principles of mechanical engineering. We enjoy working with them.”

The pairing with Bonfiglioli has benefited Vector Lifting, in return. “Customers choose our products because we collaborate with Bonfiglioli and other suppliers which help us deliver a good product that can stand the test of time,” adds Capelli. “We feel that Bonfiglioli mirrors what is important to us in their own company ethos and how they interact with customers.” He points to the gearbox supplier’s comprehensive customer support offering, which benefits Vector Lifting customers. This is a prolific partnership, with plans underway for further collaborative projects. One is the roll-out of specialised winches (fitted with Bonfiglioli gearboxes) across several West Australian mines using mining plant and equipment, to provide functional and safety enhancements. “We are also in the process of designing specialised lifting equipment for other international rail operators,” concludes Capelli.

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Australia PM does the honors at DECO

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DECO’s new Testing Laboratory and the DECO Innovation Centre were officially opened today by the Prime Minister of Australia, the Hon Anthony Albanese MP. The new facilities showcase the investment made by this Australian, family-owned manufacturer in innovative, premium aluminium building system products and metal finishes. The newly NATA-accredited laboratory and award-winning display Centre showcases the exceptional investment the family-owned Australian manufacturer of premium aluminium building products and metal finishing and coatings has made to enhance their commitment to quality and innovation.

Founder and director of DECO Australia Ross Doonan was honored to have the Prime Minister officially open the facilities. “It is an honor to have the Hon. Anthony Albanese MP here today to officially open the DECO Innovation Centre and our new NATA Accredited Testing Laboratory. These facilities are both extremely important investments for our business and ensures we can meet requirements from both our customers and accreditation authorities.” At the opening, Deco announced a new agreement to supply lower-carbon aluminium through Capral’s LocAl® Green aluminium initiative. “Alongside quality and innovation, sustainability in steel manufacturing is at the forefront of our business. Thanks to our new agreement with Capral, we are excited to be able to reduce our and our customers’ environmental impacts.” said Doonan.

DECO’s new Testing Laboratory received accreditation from the National Association of Testing Authorities last year. The laboratory plays a critical role in DECO’s quality control, which involves a range of essential tests and control processes. These internal functions ensure compliance with accreditations such as ISO 9001, ISO 17025 and Qualicoat, as well as customer-specific process control plans, operational and inspection requirements. “DECO prides itself on providing the highest possible quality products and metal finishes in the market. The new testing laboratory is not only essential for meeting accreditation criteria, it also supports our ongoing innovation, research, and development as well as our day-to-day quality controls for our customers across the structural metal product manufacturing industry in Australia.” said Doonan.

Completed in 2020 during the pandemic, the DECO Innovation Centre was designed by Deco and architectural firm Clarke-Hopkins-Clarke and has become a must-visit destination for people looking for building inspiration in real-life applications, to explore DECO’s product range up-close and to select their perfect finishes and colors. “The DECO Innovation Centre has been well received by our steel fabrication partners and customers; it has been fantastic to see how it inspires people to bring their own design visions to life. We have had people travel interstate just to visit the Centre. Our investment int this facility has been completely worthwhile,” said Doonan. DECO’s extensive range of aluminium timber-look building products are tested to Australian Standards for non-combustibility and fire safety. DECO also supplies industrial surface finishing solutions to the engineering, commercial food, and defense industries.

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ELGi Enhances Energy Efficiency of Air Compressors

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ELGi Equipments, one of the world’s leading air compressor manufacturers, has enhanced the energy efficiency of its AB series oil-free screw air compressors, realising improvements in specific power consumption and increases in free air delivery across the range. For additional energy savings, the three larger models in the range now include a super-premium efficiency IE4 motor as standard. Contaminant free and high-quality compressed air that meets the stringent requirements of ISO 8573-1 “Class 0” standards is critical for many sensitive applications that operate across a broad range of industries such as in the food and beverages sector, the pharmaceuticals and medical sector, and the electronics sector. Available from 11 to 110 kW, the water injected AB ‘Always Better’ series of oil-free screw air compressors from ELGi meet these stringent requirements, delivering certified “Class 0” high quality air in compliance with ISO 8573-1 and ISO 8573-7.

ELGi has recently enhanced the performance of the AB series models, delivering improvements in terms of both specific power consumption and free air delivery. This includes an average 10 percent improvement on the turn down ratio across the variable frequency drive (VFD) range. For the customer the result of these improvements is twofold: enhanced energy efficiency and reduced power consumption. In addition, the 75 to 110 kW models are the first in the series to now come as standard with super-premium efficiency IE4 motors, which exceed the current Minimum Energy Performance Standards (MEPS) of Australia and New Zealand for 3 phase electric motors. These motors deliver further energy efficiency and reliability gains as well as a higher service factor and lower waste heat output and are being gradually used in energy-efficient electric vehicles as well. The AB series has been engineered using heat induction bending services to deliver maximum uptime and reliability, while bridging the gap between energy efficiency and low cost of ownership.

ELGi’s uniquely designed airends are equipped with in-house developed η-V profile rotors which reduce pressure losses and precise rotor clearances resulting in best-in-class energy efficiency compressors with higher flow and lower specific power consumption. Compared to other water-injected units, the AB series airends run at slow speeds. The result – long bearing life, high reliability, low noise levels and reduced wear & tear. The AB series has a closed loop circuit developed via pipe fabrication which does not need RO water or any other form of water purifying system. They also come with an auto water replenishment mechanism, as well as built-in sensation cycle. This reduces power consumption, eliminates any requirement to replace an RO element which therefore reduces maintenance costs. The use of roller bearings as opposed to the conventional use of hydrodynamic bearings additionally contributes to an overall low cost of ownership. This eliminates the requirement for an additional water pumping circuit. It ensures consistent airend performance, and it also results in up to a 14% lower unload power and energy cost savings, as well as lower rotor and bearing wear.

Whereas traditional oil-free compressors have 2 stage airends with 2 pole motors, the AB has a single stage airend and 4 pole motor, significantly reducing associated maintenance requirements and costs. Maintenance costs are also kept low thanks to no requirement for intercooling, a splash lubrication system, as well as less number of consumable and wearing parts. Superior energy efficiency and zero mineral oil residue ensure a minimal environmental impact, thereby lowering the customer’s carbon footprint. Reliable, energy efficient with best-in-class life cycle cost, the AB series produce high-quality air, free of microbiological contaminants, with free air delivery (FAD) from 0.82 to 15.85 m3/min.

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