ROSTFREI STEELS PRIVATE LIMITED

Prithla, Palwal, Haryana

S tanks are Glass Lined Steel ks, also known as Glass-Fused-steel tanks. The reason of sing glass with steel is to hance the properties of latter. ingle Steel is vulnerable to nvironrnental conditions, hence he fusion is required. After fusing he steel with glass, the strength increases, the acceptable bracket of PH value for alkaline solutions widens, and the resistance of abrasion inflates.

PROCESS AND ITECHNOLOGY :

The tank panels are lined inside and outside with the glass enamel. The enamel is a solid, smooth and shiny cover of silicate. It is fused in a special furnace having a temperature ranges from 780 to 900 degree Celsius. The Steel rounded (cylinder) shell of the tank is built from two layer glass-fused sheet coated on both the sides. The sheets are attached , with special high grade bolts and sealed by constantly flexible sealants. The connecting material and shell accessories are equipped by the surface treatment. The glass-fused tanks can be used to store fluid or loose material. The tanks are also a fundamental building element of environmental technological facilities such as Waste Water Treatment, and Biogas Stations.

CHARACTERISTICS OF ROSTFREI GLASS-FUSED-TO-STEEL TANKS :

• Glass-Fused Tanks serve for more than 40 years.
• Abrasion and Chemical resistance is quite high.
• Construction methodology is very quick and safe.
• Pre-built tank is easily relocatable.
• Ecologically safe.

Advantages GFS Tank :

• Cost effectiveness Low investment costs and minimal costs of maintenance
• Flexibility Adaptability to remodel, extend and dismantle the tank
• Free of maintenance
• Hygienic as there is no culture medium for bacteria and other organisms at enamelled surfaces.
• Subsequently modification of utilisation An extension or treatment is also realisable after years.
• Sunfast UV-exposure is not able to fade the colour of the enamel.
• Easy to clean.
• Small weight of. carriage
• Numerous applications
• Quick assembly
• Environmentally friendly
• Fully recyclable
• Hard and scratch resistant

Applications :

• Waste water treatment plants (WWTP)
• Water treatment plants (WTP)
• Process water storage
• Biogas digesters
• DM Water storage
• Rain water storage
• Molasses Storage
• Fire water storage
• Sewage treatment plant (ETP)
• Diesel tanks
• Effluent Treatment plants etc.

Zincalume is the new cutting edge technology that has given our tanks the best enhanced and aesthetic features. Our expertise in manu- facturing Zincalume tanks sets us apart from others. "Zincalume tanks" are fabricated using the highest grade of "Zincalume steel" which lasts up to four times longer than galvanized steel and ensures superior performance and durability. Powered by hot galvanised AZ150 coating of 43.5% Zinc, 55% Aluminium and 1.5% Silicon, this extensive research technolo- gy makes Rostfrei takes 30% to 40% more corrosion resistant than hot galvanized Z275 steel. With an increasing demand for its durability, resil- ience and sustainability, Zincalume is bound set the next generation standard in the coming years.

BOLTED TECHNOLOGY :

The well-devising bolting and welding features makes our tanks much easier to install and relocate. Unlike conventional tanks. our tanks do not require sealing and coating on-site.

CUSTOMISABLE :

We provide tailored formations based on geographical and environmental conditions and also as per the requirements of our esteemed clients.

Grain storage silos are widely used in the agricultural industry to store and preserve grains such as wheat, corn, rice, barley, oats, and soybeans. The storage needs of farmers, agricultural cooperatives, and grain processing facilities.

Rostfrei silos features

• There are two types of grain silos : Hopper bottom & flat bottom
• Hopper bottom silos range from capacities of 20 metric ton  to 1000 metric ton
• Flat bottom silos range from capacity of 50 MT to 15, 000 MT. Diameters ranging from 4.57 meters to 36.54 meters
• Our silos are designed as per standards : Ansi / Asae 2008 & ss EN1993-4-1:2011
• All our silos model go through structure stability test & design calculations have been vetted by a government authorised IIT Lab
• Rostfrei silos are designed to stand up to strong winds of 250 kmph, & in seismic zone-4
• Rostfrei silos roof are supported by rafters & supports. We give s shaped rafters with z shaped crossing to make high strength structure
• Zincalume steel of our silos are coated with specially developed passivation and resin coating as separate layers that makes it scratch resistant
• Rostfrei steels silos undergo structure stability analysis tests & all silos designs are vetted by government authorised labs

Aeration & ventilation system

Aeration, ventilation and fumigation are sized properly in rostfrei silos so that the environment inside the silo can be controlled to maintain topmost grain quality.

Purpose of aeration :

• Remove excess heat & moisture from grain
• Maintain uniform temperature in every area of grain inside the silo to stop moisture migration & hot-spot development
• Reducing fungi, insect growth & discolouration of paddy
• Removing odours from grain
• Air flow of aeration fans are selected based on silo volume and type of grain being stored
• Vents and roof exhausters are sized to 2.5 times the flow of all aeration fans put together

Anti-condensation Unit

Humidity sensors are given at the topmost Part of silos to detect humid air/ Moisture movement from the grains. Roof exhausters receive input from sensors and expel out excessive humid air out of the silo so that no condensation / Spoilage of grains occur

Fumigation system

• Most insects enter grain silos from the top and stay there within 1-2 meters for weeks. Fungi are already present in paddy at the time of harvest and grow rapidly at temperature 20 to 40 degrees and moisture more than 14%
• Fumigation is a most essential activity for safe storage of grain inside silo. Hence rostfrei silos are properly designed to carry out effective fumigation
• Rostfrei steels uses closed loop fumigation system in grain silos for effective fumigation using phosphine gas. Closed loop fumigation system consists of gas fan, upvc pipes, inlet outlet valves and electronic gas monitors.
• In process, phosphine gas concentration levels are made to  reach and be maintained at 300 parts per million (PPM) For seven days (When grain is above 25°c).
• This ensures killing of  grain pests at all stages of their  life cycle
• Once the fumigation cycle is over, silo must be de-sealed and aeration fans must be kept running until the phosphine levels drop down to 0.3PPM
• We size the fumigation system in such a way that pressure drops are minimum and fumigation is effectively achieved with proper safety precautions as phosphine gas is explosive when its concentration reach more than 17900 PPM.

Temperature monitoring system

• Temperature monitoring cables are there to monitor temperature inside the silo.
• Each sensor is present at every 2.5 meters to monitor grain quality
• If moisture migration, discolouration, insect infestation, hot-spot occurs, temperture of that area of grain increases by 2-3 degree celcius. Operator is alerted on  plc monitor screen
• This enables operator to take suitable actions on right time to save grain quality.
• Action 1: Aerate the grain for adequate time
• Action 2 : If aeration could not  remove hot-spots, then fumigation of 6-7 days

Rostfrei make material handling equipments

• Sweep augers rotate 360 degrees around the base of the silo from central motor Unit to push remaining grain towards silo’s discharge gates
• Rostfrei steels manufactures durable and high quality GI 275 grade elevators and conveyors. These are equipped with all the necessary sensors and safety switches
• Rostfrei steels specialises in “inception to comissioning” of grain storage & management greenfield turnkey projects. 

Timeline of project

• 5000 MT x 2 maize silo complete by 55 days
• 250 MT x 2 soyaben silos complete by 30 days
• Recieveing hoppers by 10 days
• Cleaner erection and complete arrangement done in 8-10 days
• Elevator and conveyors in 10-15 days
• Complete project erection and comissioning within 75 days
• Dispatch from the date of po issue Will be within 60 days

VOLUME :

Rostfrei tanks range from 10 cubic meters to 5000 cubic meters.

PREFABRICATION

Our prefabricated design allows the tank to be dis-assembled and relocated as many times as desired.

LINER

Rostfrei offers a range of state-of-the-art liner technologies suitable for almost all applications. Our reinforced liners are capable of supporting water pressures of more than 2kg/cm2 and are capable of storage of wide variety of liquids.

Standard Liners

Manufactured from reinforced, multi-layered, food-grade anti-algae, UV stabilized PVC liner with a woven multifacent nylon scrim, the Rostfrei liner is primarily used for installation in lighter commercial and rural domestic tank designs. Con-sisting of three bonded layers of PVC fabric, it ensures a homogenous bond between each layer. The inert nature of the PVC prevents it from affect-ing the stored liquids.

CORRUGATION TECHNOLOGY

Our tanks come in a strong corrugated profile and are stiffened with unique 'W' stiffeners with much higher strength and reliability than normal one. Our unique corrugation technology of uniform pitch and depth makes it a premium one as it acts as a structural reinforcement and shock absorber for earth movement or soil subsidence.

Fusion Bond Epoxy Coated Prefabricated (FBE) Tanks are Manufactured by Fusing Epoxy to Preheated Mild steel plates. The reason of fusing epoxy with steel is to enhance the properties of later. Bare Steel is vulnerable to environmental conditions, hence the fusion coating is required. After fusing the steel with epoxy, the resistance against atmospheric weathering & corrosion increases and the acceptable bracket of PH value widens. Epoxy (FBE) Tanks can be used to store wide range of liquids like clear Water, Waste water, Organic waste, Oil etc.

CHARACTERISTICS/BENEFIT OF ROSTFREI FBE TANKS :

FBE tank serves for more than 30 years Suitable for potable water & all clear water & sewage water applications Installation process is quick, safe & eco friendly Pre-fabricated design is easily relocatable & extendable, if more capacity required in future New & better technology globally.

PROCESS & TECHNOLOGY :

The tank Panels are fused with epoxy coating both inside & outside. The fusion process is carried out in a special furnace having temperature range from 120 to 240 Degree Celsius under controlled environment. The Steel rounded (cylindrical) shell of the tank is built up by overlapping two panels and nut bolting with Special high grade nuts & bolts and constant application of flexible sealant/ Liner. The connecting material and shell accessories are equipped by the various surface protection treatment. The Fusion Bond Epoxy tanks can be used to store fluid or loose material. The tanks are also a fundamental building element of environmental technological facilities such as Waste Water Treatment and Biogas Plants.

Grain storage silos are widely used in the agricultural industry to store and preserve grains such as wheat, corn, rice, barley, oats, and soybeans. The storage needs of farmers, agricultural cooperatives, and grain processing facilities.

Rostfrei silos features

• There are two types of grain silos : Hopper bottom & flat bottom
• Hopper bottom silos range from capacities of 25 MT to 900 MT and diameter of 2.78 meters to 12.79 meters
• Flat bottom silos range from capacity of 25 Metric Ton  to 15000 Metric Ton
• Our silos are designed as per standards : Ansi / Asae 2008 & ss EN1993-4-1:2011
• All our silos model go through structure stability test & design calculations have been vetted by a government authorised IIT Lab
• Rostfrei silos are designed to stand up to strong winds of 250 kmph, & in seismic zone-4
• Rostfrei silos roof are supported by rafters & supports. We give s shaped rafters with z shaped crossing to make high strength structure
• Zincalume steel of our silos are coated with specially developed passivation and resin coating as separate layers that makes it scratch resistant
• Rostfrei steels silos undergo structure stability analysis tests & all silos designs are vetted by government authorised labs

Aeration & ventilation system

Aeration, ventilation and fumigation are sized properly in rostfrei silos so that the environment inside the silo can be controlled to maintain topmost grain quality.

Purpose of aeration :

• Remove excess heat & moisture from grain
• Maintain uniform temperature in every area of grain inside the silo to stop moisture migration & hot-spot development
• Reducing fungi, insect growth & discolouration of paddy
• Removing odours from grain
• Air flow of aeration fans are selected based on silo volume and type of grain being stored
• Vents and roof exhausters are sized to 2.5 times the flow of all aeration fans put together

Anti-condensation Unit

Humidity sensors are given at the topmost Part of silos to detect humid air/ Moisture movement from the grains. Roof exhausters receive input from sensors and expel out excessive humid air out of the silo so that no condensation / Spoilage of grains occur

Fumigation system

• Most insects enter grain silos from the top and stay there within 1-2 meters for weeks. Fungi are already present in paddy at the time of harvest and grow rapidly at temperature 20 to 40 degrees and moisture more than 14%
• Fumigation is a most essential activity for safe storage of grain inside silo. Hence rostfrei silos are properly designed to carry out effective fumigation
• Rostfrei steels uses closed loop fumigation system in grain silos for effective fumigation using phosphine gas. Closed loop fumigation system consists of gas fan, upvc pipes, inlet outlet valves and electronic gas monitors.
• In process, phosphine gas concentration levels are made to  reach and be maintained at 300 parts per million (PPM) For seven days (When grain is above 25°c).
• This ensures killing of  grain pests at all stages of their  life cycle
• Once the fumigation cycle is over, silo must be de-sealed and aeration fans must be kept running until the phosphine levels drop down to 0.3PPM
• We size the fumigation system in such a way that pressure drops are minimum and fumigation is effectively achieved with proper safety precautions as phosphine gas is explosive when its concentration reach more than 17900 PPM.

Temperature monitoring system

• Temperature monitoring cables are there to monitor temperature inside the silo.
• Each sensor is present at every 2.5 meters to monitor grain quality
• If moisture migration, discolouration, insect infestation, hot-spot occurs, temperture of that area of grain increases by 2-3 degree celcius. Operator is alerted on  plc monitor screen
• This enables operator to take suitable actions on right time to save grain quality.
• Action 1: Aerate the grain for adequate time
• Action 2 : If aeration could not  remove hot-spots, then fumigation of 6-7 days

Rostfrei make material handling equipments

• Sweep augers rotate 360 degrees around the base of the silo from central motor Unit to push remaining grain towards silo’s discharge gates
• Rostfrei steels manufactures durable and high quality GI 275 grade elevators and conveyors. These are equipped with all the necessary sensors and safety switches
• Rostfrei steels specialises in “inception to comissioning” of grain storage & management greenfield turnkey projects. 

Timeline of project

• 5000 MT x 2 maize silo complete by 55 days
• 250 MT x 2 soyaben silos complete by 30 days
• Recieveing hoppers by 10 days
• Cleaner erection and complete arrangement done in 8-10 days
• Elevator and conveyors in 10-15 days
• Complete project erection and comissioning within 75 days
• Dispatch from the date of po issue Will be within 60 days