EXAIR has been making a comprehensive line of Static Eliminators for decades. Like any air blowing application, the first consideration in selection is the size & shape of the airflow that’s needed to get the… More
Extend Refractory Life with an Unusual (and Practical) Cooling Fix
How an EXAIR Super Air Amplifier can reduce hot-spot damage and save thousands in unplanned downtime.
Hot spots on refractory walls are common in high-heat operations, but premature refractory failure need not be. If you can quickly pull heat out of a problem area (without touching the lining), you can reduce thermal stress and keep your furnace running longer.
Figure 1. Targeted, non-contact cooling helps stabilize refractory hot spots before they become cracks or spalls.
The problem: localized hot spots
During heat cycles, refractory walls rarely heat perfectly evenly. Burner impingement, scale buildup, airflow changes, and normal process variation can create concentrated hot spots. Left unchecked, these areas run hotter than the surrounding area, accelerating wear that shows up as cracking, spalling, and ultimately downtime.
The solution: EXAIR Super Air Amplifier
A Super Air Amplifier converts a small amount of compressed air into a high-velocity, high-volume stream of ambient air. Aimed at a hot spot, the airflow impinges on the outside surface of the refractory to carry heat away quickly without contacting or mechanically disturbing the lining.
Because cooling is targeted and non-contact, it can reduce peak temperatures and thermal gradients in critical areas. The result: less thermal stress, slower localized erosion, and a better chance of getting maximum life from your refractory lining.
The payoff: more uptime and real savings
Even small gains in living life matter. Extending a campaign by days, or even hours, can help you delay an early reline, reduce emergency maintenance, and keep the furnace in production when it counts.
In many operations, that additional runtime translates into thousands of dollars savedthrough fewer relines, less lost production, and more predictable maintenance planning.
A simple cooling upgrade with a significant impact.
The EXAIR Super Air Amplifier is a dependable, low-maintenance solution for addressing refractory hot spots, protecting your furnace investment, and improving your bottom line. If hot spots are shortening your lining life, it’s worth considering as part of your standard operating response.
Neal Raker, Application Engineering Manager
nealraker@exair.com
Spot Cooling Solutions for Semiconductor Manufacturing: How EXAIR Vortex Tubes Improve Process Reliability
Semiconductor manufacturing is one of the most demanding industrial environments in the world. From wafer fabrication and lithography to inspection, packaging, and testing, process stability often depends on maintaining precise temperature control. Even minor temperature fluctuations can impact yield, equipment performance, and product quality.
As semiconductor facilities continue to increase throughput and process complexity, engineers are constantly evaluating cooling solutions that improve reliability while minimizing maintenance requirements. One technology that has gained traction in targeted cooling applications is the vortex tube.
What Is a Vortex Tube?
A vortex tube is a compact device that converts compressed air into two separate air streams—one hot and one cold—without the use of electricity, refrigerants, or moving parts.
EXAIR vortex tubes utilize this principle to generate cold air temperatures as much as 100°F (56°C) below the inlet compressed air temperature. The resulting cold air stream can be directed precisely where cooling is required, providing an efficient solution for localized heat management.
Because vortex tubes contain no moving components, they offer exceptional reliability in environments where maintenance access is limited or contamination concerns are critical.
Semiconductor Applications for Vortex Tube Cooling
Cooling Vision and Inspection Systems
Automated optical inspection systems rely on cameras, sensors, and electronic components that can generate heat during continuous operation. Excessive temperatures may affect measurement accuracy or shorten component life.
Vortex tubes provide a simple method of delivering clean, cold air directly to sensitive electronics, helping maintain stable operating conditions without introducing liquid cooling systems.
Wafer Handling and Processing Equipment
Many wafer handling systems contain motors, drives, sensors, and control electronics operating in confined spaces. Localized heat buildup can lead to premature component wear and unexpected downtime.
Targeted vortex tube cooling can help remove heat from critical areas while avoiding the complexity associated with chilled water loops or mechanical refrigeration systems.
Cooling During Semiconductor Testing
Testing equipment often runs continuously and generates substantial heat loads. Maintaining consistent operating temperatures helps ensure repeatable test results and improves equipment reliability.
Vortex tubes can be deployed to cool fixtures, instrumentation, and electronic assemblies where traditional cooling methods may be difficult to implement.
Packaging and Assembly Operations
Semiconductor packaging processes frequently utilize adhesives, coatings, and thermal interface materials that can be sensitive to temperature variations. Cold air generated by a vortex tube can assist with process stabilization, spot cooling, and accelerated cooling between production steps.
Advantages of EXAIR Vortex Tubes
No Moving Parts, Clean Operation, Compact Installation, Instant Cooling, Reliable Operation in Harsh Environments
The simplicity of vortex tube technology makes it particularly attractive for applications involving vibration, dust, or challenging operating conditions where conventional cooling equipment may struggle.
The semiconductor industry depends on precision, repeatability, and uptime. EXAIR vortex tubes provide a straightforward and dependable method for localized cooling without the complexity of mechanical refrigeration. For engineers seeking a low-maintenance solution to cool electronics, sensors, fixtures, and process equipment, vortex tube technology remains a proven option for improving thermal control in critical semiconductor manufacturing operations.
Jordan Shouse
Application Engineer
E: JordanShouse@exair.com
O: (513) 671‑3322
F: (513) 671‑3363
A: 11510 Goldcoast Dr Cincinnati OH 45249
www.exair.com
Find time on my calendar by scheduling a meeting here.
ATEX Cabinet Coolers for Dependable Heat Protection in Explosive Areas.
EXAIR Cabinet Cooler Systems have been delivering dependable heat protection for electrical and electronic panels for many years. These systems feature no moving parts or electrical components that can fail, ensuring a long lifespan as long as they are supplied with clean, moisture-free compressed air. This design allows them to function nearly indefinitely without the need for maintenance.
EXAIR’s ATEX Cabinet Cooler® Systems provide an effective and cost-efficient solution for maintaining optimal temperatures in electrical enclosures located in hazardous ATEX classified environments. Now offered in robust aluminum construction, these coolers are specifically designed for use in Zones 2 and 22. They have undergone UL testing, are CE compliant, and adhere to rigorous ATEX standards for purged and pressurized enclosures.
ATEX Cabinet Coolers, with cooling capacities reaching up to 5,600 BTU/Hr., are specifically designed to prevent overheating in electrical cabinets located in explosive environments. These systems are suitable for a variety of applications, including industrial control panels, specialized electrical enclosures, and sensitive electronics in hazardous areas, ensuring that your equipment remains cool, safe, and fully operational. The ATEX Cabinet Cooler is easy to install, fitting through a standard electrical knockout while maintaining NEMA 4 integrity in challenging conditions. Additionally, optional thermostat controls help minimize compressed air consumption, and cold air distribution kits promote uniform cooling throughout the cabinet.
EXAIR offers a comprehensive lineup of Cabinet Cooler Systems for NEMA 12, 4, 4X, hazardous location and ATEX applications. Built with no moving parts, every system is CE compliant, UL-listed, and designed for long-term reliability in the most challenging conditions. From control panels and motor centers to laser housings and surveillance equipment, EXAIR Cabinet Coolers protect your investments and keep your operations running smoothly. Prices start at $1,615.
If you have questions about the ATEX Cabinet Coolers, or anything regarding EXAIR and our products, please do not hesitate to reach out.
Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk
Protecting Electrical Enclosures Safely and Reliably with Cabinet Cooler Systems
As summer temperatures increase, so does the volume of calls we get about Cabinet Cooler Systems. A typical call goes something like this:
“One of our control panels has a drive in it that’s overheating. If it goes down, so does the whole line. How soon can I get a Cabinet Cooler System?”
All of our Cabinet Cooler Systems — including the UL Classified HazLoc and ATEX models — are in stock and available for same day shipment.
“Great! How do I get one?”
With just a few key pieces of information, I can quickly and accurately calculate the heat load of your panel, and specify the right Cabinet Cooler System. You can input that information into our Sizing Guide online, or you can call me. It only takes a minute to do the calculations, and we do it over the phone all the time. Here’s what we need to know:
- Panel dimensions: Grab your favorite tape measure & write down the height, width, and depth of the panel. We’ll calculate the heat transfer surface area from that.
- Current internal & external air temperatures: Take a thermometer to where the panel is. Write down what it reads when you get there — that’ll be the ‘external’. Then, put it inside the panel, and write down what it reads after a few minutes — that’ll be the ‘internal.’ We use those to calculate the internal heat load — how much heat is being generated by the components inside the panel.
- Optional: if you have accurate heat dissipation data for the housed components, we can use that instead of the temperatures. This is how we do it if the panel isn’t currently in operation.
- Important note: if we ARE using temperatures, it’s important to measure the AIR temperatures, as opposed to using a heat gun to ‘shoot’ the surface temperature of a component. The formulas we use are based on tried-and-true HVAC formulas, and we’ve been proving their accuracy for decades.
- Maximum external air temperature: How hot does it get on the hottest day of summer? We’ll use that to calculate the external heat load — how much heat the panel absorbs from the environment.
- Desired internal air temperature: Many electrical/electronic component manufacturers specify a maximum operating temperature of 104°F (40°F), so the ‘industry standard’ in panel cooling is to maintain an internal air temperature of 95°F (35°C), so that’s where we pre-set our Thermostats. If you know for a fact that the components inside your panel need a cooler environment to operate in, the Thermostats can be reset. Keep in mind, we may need to provide a Cabinet Cooler System with a higher cooling capacity in those cases. Or, if you know for a fact that your equipment can handle a higher operating temperature, the Thermostats can be adjusted…and you can save on your compressed air usage.
If there are fans circulating outside air through the panel, we’ll need to know about them too. They’re providing a finite (sometimes substantial) amount of cooling, and they’ll have to be removed, and their holes covered, for proper operation of the Cabinet Cooler System. If not, that’s like running your air conditioner with a fan in the window.
The other considerations are all about where the panel is, and what it’s exposed to:
- NEMA ratings are all about keeping the environment out of the panel:
- If it’s a UL or ATEX Classified area, we have systems for that:
If you have an electrical or electronic panel that needs reliable, durable heat protection, you might need an EXAIR Cabinet Cooler System. To find out more, give me a call.
Russ Bowman, CCASS
Application Engineer
Visit us on the Web
Follow me on Twitter
Like us on Facebook