Static can be a big issue, whether it is shocking operators, causing jamming of machines, or collection of dirt and debris. This is especially true in the colder months. At EXAIR we have a wide… More
James Clerk Maxwell and the Physics Behind the Vortex Tube
Some names in science instantly feel larger than life. Newton. Einstein. James Clerk Maxwell often sits just outside that spotlight, but his influence runs deep in modern engineering. If you work with compressed air, heat, or energy transfer, you are already working with ideas that trace directly back to Maxwell.
Maxwell was a 19th century Scottish physicist best known for a set of equations that unified electricity and magnetism. Those equations helped make electric motors, power generation, and modern communications possible. Less discussed, but just as important, was his work on gases and thermodynamics. Maxwell was one of the first scientists to explain that temperature and pressure come from the motion and energy of individual gas molecules, not just from the bulk properties of air.
That shift in thinking matters in industrial applications. Compressed air is not just pressure in a pipe. It is stored energy made up of countless fast-moving molecules. When that air expands, the energy redistributes. Sometimes it becomes work. Sometimes it becomes heat. Under the right conditions, it can separate into hot and cold streams. That is where the Vortex Tube enters the conversation.
A Vortex Tube takes compressed air and introduces it into a chamber where it spins at extremely high velocity. As the air rotates, energy separates within the flow. Hot air migrates toward the outer wall while cold air remains closer to the center. The result is two air streams at dramatically different temperatures, created without moving parts or electricity.
Because of this behavior, the Vortex Tube is sometimes nicknamed Maxwell’s Demon. The name comes from a famous thought experiment Maxwell proposed to explore how energy and entropy behave at the molecular level. In the experiment, a tiny demon selectively allows faster, hotter molecules to move one way and slower, cooler molecules another. While the Vortex Tube is not violating any laws of physics, the visual result feels similar. Energy appears to be sorted within the air stream, producing distinct hot and cold outputs from the same supply.
What makes this more than a clever analogy is that the Vortex Tube operates entirely within the principles Maxwell helped define. The cold air is not created from nothing. It comes from redistributing energy already present in the compressed air. The geometry of the tube and the controlled expansion guide that separation in a predictable and repeatable way.
At EXAIR, Vortex Tubes are used every day for spot cooling, enclosure cooling, and process temperature control. They are valued because they are compact, reliable, and well suited for industrial environments where electrical cooling is impractical or undesirable. With no moving parts to wear out, they offer a simple solution built on solid physics.
Maxwell’s broader legacy is his system-level thinking. He did not study heat, energy, or motion in isolation. He focused on how they interact. That same mindset is essential when designing compressed air solutions today. A Vortex Tube is not just a cold air device. It is part of a complete compressed air system where flow, pressure, temperature, and efficiency all matter.
James Clerk Maxwell never saw a modern factory floor, but his work is still there. Every time compressed air expands, transfers energy, or changes temperature, it follows rules he helped explain. That is why his ideas have endured for more than a century.
The next time you see a Vortex Tube producing cold air with no moving parts, it is worth remembering that it is not a trick. It is applied physics, rooted in Maxwell’s work, and still doing practical, reliable work in industry today.
Tyler Daniel, CCASS
Application Engineer
E-mail: TylerDaniel@EXAIR.com
Back to Basics: 6 Week Recap
When I kicked off this blog series a few weeks ago, my goal was simple: break down compressed air optimization into clear, actionable steps. Over the years, I’ve seen countless facilities struggle with the same challenges—air leaks, wasted energy, oversized compressors running nonstop—and I’ve also seen how small, deliberate changes can transform an operation.
Walking through these six steps has been a chance to not just share tools and techniques, but to reflect on the conversations I’ve had with customers who put them into practice. In some cases, it was the first time they truly measured their air use. In others, the turning point was when a simple change—like installing a regulator—let them turn off a secondary compressor altogether. Those are the moments that make optimization “click.”
Here’s a quick recap of the journey we’ve taken:
Step 1 – Measure Usage
You can’t improve what you don’t measure. Using the EXAIR Digital Flowmeter, we establish a baseline to see where the air is going and how much is being consumed.
Step 2 – Find and Fix Leaks
Leaks are like the silent thieves of a compressed air system. With the Ultrasonic Leak Detector, you can hear what your ears normally can’t and start reclaiming wasted energy.
Step 3 – Implement Engineered Solutions
Replacing open pipes and homemade blow offs with EXAIR Air Knives, Super Air Nozzles, and other engineered solutions is often where customers first see the savings—not just on the utility bill, but in quieter, safer operations.
Step 4 – Turn Air Off When Not Needed
Why run air if the process isn’t calling for it? The Electronic Flow Control (EFC) makes sure compressed air only flows when it’s truly needed.
Step 5 – Use Intermediate Storage
Like a capacitor in an electrical circuit, receiver tanks help buffer demand spikes. This keeps systems balanced and compressors from overworking.
Step 6 – Regulate Pressure at the Point of Use
Sometimes the simplest fix is the most powerful. A small reduction in pressure can equal double-digit energy savings—without affecting performance. Pressure regulators are the perfect point of use method to achieve this.
Wrapping It All Up
Looking back, these six steps aren’t just a checklist—they’re a roadmap. Each one builds momentum for the next, and together they can change how you think about compressed air entirely. For me, the most rewarding part of this series is knowing that these are the same strategies I’ve watched customers apply successfully in real-world situations.
At EXAIR, we want to make optimization practical, approachable, and sustainable. Whether you’re measuring, fixing, upgrading, or just looking for ways to cut waste, we’re here to help guide the process.
If you’d like to talk about where your system stands today, or which step might make the biggest impact for you, feel free to reach out.
Brian Farno, MBA – CCASS Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF
Physics and the Tank Cleaning Nozzle
After boot camp, the Navy sent me to Machinist’s Mate A-School to learn about shipboard steam propulsion plants. The first week was a course called Propulsion Engineering Basics. Since we were learning about how to use steam to move something (turbine blades), the class started off with a lesson on Hero’s Engine:
1,500 years before Isaac Newton put his Third Law of Motion in writing, Hero (or Heron) of Alexandria described this device that would demonstrate that, for every action (in this case, steam discharging from the tubes’ nozzles) there is an equal and opposite reaction (rotary motion of the apparatus), just like Newton said. Some say Hero made one and displayed it for public amusement, but evidence of that is sketchy. In any case, it DOES work.
Another demonstration of Newton’s Third Law is familiar to golfers & lawn care enthusiasts: the rotating sprinkler:
Another practical application of Newton’s Third Law is an industrial one: tank cleaning. Some tanks have access ports or utility holes, so personnel can physically enter, or at least stick a sprayer inside to clean the walls. Oftentimes, though, they might contain materials that are toxic, harmful, or just plain messy, and any penetrations in the tank that need to be covered or sealed off are potential leak points. So, instead of manually sticking a spraying device inside & moving it around, you need something that’ll fit through a small opening and sprays in every direction.
BETE Spray Performance Engineering (a division of EXAIR) offers a number of solutions for tank cleaning/washing, in both stationary (sprays in all directions all the time) and rotating (kind of like the rotating sprinkler in the video above). If you want to know more about the stationary ones, my buddy Jordan Shouse wrote a detailed blog about The Power of the BETE HydroClaw recently.
If you want to know about the rotating types, you’re in luck because I’m going to get to those RIGHT NOW. The BETE HydroWhirl® series come in a variety of configurations and materials of construction. We’re going to look at four of them specifically:
HydroWhirl Stinger — these compact, rotating tank cleaning nozzles are made of 316L Stainless Steel with a 32 Ra surface finish, so they’re FDA compliant. They’ve got Zirconia ceramic bearings, so they’re made for long service life and extreme chemical corrosion resistance.
HydroWhirl Mini — like the Stingers, they’re FDA compliant, with 316L Stainless Steel construction with a 32 Ra finish. They have PEEK slide bearings for longevity and minimal maintenance. They’re suitable for small tanks (up to 6.5 feet in diameter.)
HydroWhirl Poseidon — these are made of FDA compliant, corrosion resistant PTFE, these are ideal for CIP (Clean-In-Place) applications commonly encountered in food, beverage, and pharmaceutical facilities. The slower spinning design makes for longer dwell times for the spray, for greater cleaning impact.
HydroWhirl Disc — this one’s made of 316L Stainless Steel with a PTFE slide bearing. It’s fully submersible, self-flushing, and suitable for small-to-medium size tanks. The rotating, high impact spray produces a pattern with consistent repetition for highly efficient & effective tank cleaning.
Lastly, since we’ve been watching videos, here’s one that shows a HydroWhirl Stinger in action:
If you’d like to find out more, give me a call.
Russ Bowman, CCASS
Application Engineer
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Intellistat® Ion Air Gun™: Features and Benefits
The Gen4® Static Eliminators were designed for rugged areas to remove static in industrial environments. EXAIR decided to take the next step in eliminating static in more “sensitive” areas, like labs, clean rooms, electronics, medical items, glass etc. In this blog, I will cover the features and benefits of the Intellistat Ion Air Gun.
The EXAIR Intellistat Ion Air Gun is a patented handheld air gun for static elimination in sterile environments and clean rooms. We have earned an ISO 14644-1 Class 5 Clean room Rating, making it ideal for static elimination in clean rooms with delicate processes. There are some processes that require certain cleanliness standards for operation, such as scientific research, solar panel manufacturing and biotechnology industries. This means that any tool or material that they use in this process has to meet a certain standard. EXAIR’s Intellistat was engineered to do just that.
The polycarbonate construction makes the unit very lightweight and ergonomically safe for extended periods of use without fatigue. This lightweight tool provides rapid static decay with a simple squeeze of a short-throw trigger, reducing 5,000 volts to 500 volts in under one second. It comes complete with a low voltage power supply and compressed air tubing. The power supply is a 24Vdc output that connects to 110Vac or 220Vac primary voltage with universal plug-ins. The 6mm tubing has a standard length of 3 meters with an option to go to 6 meters. The Intellistat comes packed in its own box for fast delivery.
A feature that I really like is the red and green LED lights to signify ionized air production. It gives feedback that ions are being created. It has a voltage balance of +/- 30 volts, and the ion point is interchangeable. It comes standard with a hangable hook for easy storage; and, for safety, we use an OSHA safe nozzle to provide low noise levels and remove dead-end pressure.
Here are some benefits of the Intellistat. They are useful in applications that require non-conductive materials such as circuit boards or electronic manufacturing. They provide ionized airflow useful for removing dust, static, and particulate contaminants in sterile environments within clean rooms, laboratories, and scientific testing. For certification, they are UL listed, CE and RoHS compliant; and it uses only 5.8 SCFM (164.2 SLPM) of compressed air at 80 PSIG (5.5 bar).
Some applications would include precision parts assembly, printed circuit boards, preserving cleanliness in electronic manufacturing, removing debris from medical products, and neutralizing glass containers, slides and lenses. The Intellistat Ion Air Gun is also a great tool for Quality Control to manually clean parts before checking.
EXAIR continues to expand solutions for our customers. If static removal is needed in “sensitive” types of areas, the Intellistat Ion Air Gun can be a solution for you. EXAIR manufactures a large line of Static Eliminators. From now until March 31st, 2026, EXAIR will be giving a free AC Sensor, a $77.50 value, as a promotional item with a qualified purchase of any Static Eliminator. If you would like to discuss your application and potential static issues, you can contact an Application Engineer at EXAIR. We will be happy to help.
John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb