Dust Suppression with an EXAIR Atomizing Nozzle

img_0378

An EXAIR Atomizing Nozzle used to minimize dust in the feed bowl of a cement mixer.

One of the most difficult aspects of handling and working with dusty materials is suppression of airborne contaminants.  Small particles can easily become a dust cloud, minimizing visibility and decreasing the quality of working conditions.  This then leads to lower productivity, low morale, and a missed opportunity to maximize the potential of personnel and equipment.

Our distributor in New Zealand recently assisted one of their customers facing this set of problems when working with cement and microsilica as it was poured into a mixer.  An exhaust fan was in place, but failed to extract the dust sufficiently, so a new approach was needed to minimize the dust.

 

circle-image

An AN2010SS No Drip Atomizing Nozzle provides the needed dust suppression in this application.

 

The solution was to use an EXAIR AN2010SS No Drip Internal Mix Atomizing Nozzle, shown above in the red box, to produce an atomized water mist.  The dust produced during pouring is captured by the small droplets of atomized water produced with this nozzle, reducing the dust and allowing proper use of the mixer.

 

ssh-image

The 9218 Stay Set Hose positions the atomizing nozzle where it needs to be.

 

In order to position the nozzle exactly where it needs to be, an 18” Stay Set Hose, shown above with the red arrow, was used to position the nozzle.  This hose is built specifically to have “memory” of the desired position, allowing for quick, easy, and repeatable position of the nozzle attached to the hose.

This simple setup is controlled through a timer to ensure water and compressed air use realize maximum efficiency.  It’s an easy solution to a painful problem for this customer.

If you’d like to explore how an EXAIR solution can solve problems in your facility or application, please contact an EXAIR Application Engineer.

 

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Taming The Dust Cloud With EXAIR Atomizing Spray Nozzles

Have you ever dropped one of your nice dinner plates on a tiled kitchen floor? And noticed how they seem to go in slow motion as they hurtle to their doom? I never cease to be impressed at how far some of the smaller pieces can go. I recently had to replace our oven, and I found broken dishware shards (and an impressive amount of trash scraps, pet toys, and ‘dust bunnies’) all the way against the back wall.

Curiously, as small as the pieces can be when a dinner plate meets its end, it started its life in even smaller pieces…as a fine ceramic powder, pressed into a mold and heated to a temperature that is WAY hotter than when the server at your favorite restaurant warns you that plate “might be hot.”

I’m writing about this because recently, I had the pleasure of assisting a maker of ceramic dishware with a messy little problem…this fine ceramic powder is moved from where it’s produced, to the various mold stations (dinner plates, salad plates, saucers, etc.) on a vibratory belt conveyor. The vibration keeps the powder loose and homogenous, both of which are extremely important to the molding & firing process. It also causes a cloud of dust to rise along the entire length of travel, and they wanted to minimize this. Their chemists had told the engineer who called me that they could live with a small amount of moisture, as long as it wasn’t enough to make the powder clump up – this would evaporate out at a point closer to the molds anyway.

This was an ideal application for the EXAIR Atomizing Spray Nozzles…they produce a fine mist of liquid that is precisely controllable…one Model AW1010SS Internal Mix, Wide Angle Round Pattern Nozzle was installed near the beginning of the line, and once they find out how long it takes the dust-suppression supplied by the misted water to evaporate away, they will install more nozzles accordingly.

EXAIR Atomizing Spray Nozzles are a perfect solution for dust suppression.

EXAIR Atomizing Spray Nozzles are a perfect solution for dust suppression.

EXAIR Atomizing Spray Nozzles are ideal for situations where you need a fine liquid mist and fine adjustment of the flow & pattern. With ninety models to choose from, we’ve got the one you’re looking for. Call me if you want to find out more.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

 

Proper Air Supply Is Key To Optimal Performance

I recently worked with a customer who was using our 36″ aluminum Super Air Knife to remove dust and light debris from a conveyor but wasn’t seeing good performance. They initially called because they read in their catalog that increasing the shim gap would increase their force and flow and wanted to know what kind of increase in performance they would see.

The Super Air Knives are shipped from EXAIR with a .002″ shim installed and the performance data shown in the catalog reflects this gap setting. The shim sets, for aluminum knives, include a .001″, .003″ and .004″ shim and by changing to the .003″ shim, the force and flow would be 1.5 times as great and using the .004″ shim would double these amounts. While some applications do require the additional force and flow, trying to blow off dust or light materials typically wouldn’t fall into this category.

sak-shims

Replaceable shims provide varying levels of force and flow.

Switching our focus to the supply side of things, it turns out they were using 1/4″ hose and only plumbing one end of the unit. This poses 2 concerns that relate directly to the mentioned poor performance. The first would be the 1/4″ hose is severely undersized for a 36″ Super Air Knife. We recommend 3/4″ Schedule 40 pipe if the length of supply from a main header is 10′ or less and a 1″ pipe up to 50′ of supply run. It is possible to use hose but that hose needs to be at least 1″ ID to be able to carry enough volume to support a 36″ unit. Secondly, for knives that are 24″ in length or longer, you need to plumb air to both ends to maintain an even, laminar flow across the length of the knife.

With the proper supply, the Super Air Knife is going to produce an exhaust air velocity of 11,800 feet per minute when operated at 80 PSIG, which is more than enough to eject lightweight material from a flat surface (in fact you could most likely clean dust and light debris at a lower pressure). If the customer did increase the shim gap dimension, the increase in  air demand would only worsen the problem of undersized supply lines.

Pipe sizes

Recommended supply line sizes per the IOM – Installation and Operation Manual.

This is just one example of how proper supply line size and installation is key to achieving optimal performance. If you are experiencing similar issues or need any assistance with a product or application, give me a call, I am glad to help.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

Bench Testing with Blowoff Kits

Last week, a customer connected with us online via the chat option.  He explained that he was working on a project to remove dust from parts on a table conveyor, situated in a 3 x 5 array. He had purchased the EXAIR Blowoff Kits model 1909SS and model 1910 and had been able to bench test and develop a blowoff system that was successful.  He was ready to scale the up design and procure a set of nozzles and swivels that would work in the automated process.

1909SS Blowoff Kit

Model 1909SS – Stainless Steel Blowoff Kit

blostation

Model 1910 – Instant Blowoff Station

 

The Blowoff Kits such as the Model 1909SS offer an easy way to explore the various nozzle types that EXAIR offers and to test the performance of each for Force, Flow and Sound Levels in your process or test environment.  Each nozzle will have particular traits, and identifying the one that most perfectly matches all your criteria can be done.

The Model 1909SS Blowoff Kit contains (7) different nozzles, all with stainless steel construction.  Included are (4) sizes of the Super Air Nozzle (10, 14, 35 and 60 SCFM capacities), the Micro Air Nozzle, the Adjustable Air Nozzle, and lastly, the 2″ Flat Super Air Nozzle.  A similar Blowoff Kit, model 1909, is available with materials of construction of zinc aluminum alloy, aluminum, and brass.

We have put together a detailed review of blowoff applications, available in the Third Edition of the Air Nozzles Blowoff Guide.  Inside, you can find the technical specifications of all of the Nozzles, Blowoff Kits, Flexible Stay Set Hoses, and Safety Air Guns, that might be of interest to you and your application.

blowoff guide

To Request a copy of the EXAIR Blowoff Guide click here

To discuss your application and how the EXAIR Nozzle and Jets can benefit your process, feel free to contact EXAIR and myself or one of our other Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

Send me an email
Find us on the Web
Like us on Facebook
Twitter: @EXAIR_BB

 

Will an EXAIR Vacuum Work with This Material?

img_9239

Activated carbon pellets in need of vacuuming

At the heart of EXAIR’s dry vacuum systems are a modified design to our Line Vac air operated conveyors.  These units convert a compressed air supply into a powerful vacuum source with no moving parts and thus no components to wear out.  This, in turn, translates to an instantaneous vacuum supply that is both durable and maintenance free.

These aspects of our vacuum systems led a pharmaceutical research company in Macau to contact us about using a Heavy Duty Dry Vac in one of their applications.  The complete details of the application were proprietary, but information about the specific use was made available.

What this customer needed to do, was to vacuum activated carbon chips in batches of ~300kg (660 pounds) into a contained drum or bag.  The ultimate question in the application was whether an EXAIR Heavy Duty Dry Vac system can vacuum 300kg of activated carbon.  And, if it can, how long will it take?  To answer these questions we turned to a bit of data about the activated carbon, and the potential vacuuming rate of the Heavy Duty Dry Vac System.

Activated carbon has a bulk density of ~0.52 g/cm³ (~32.5 pounds/ft³), and the Heavy Duty Dry Vac can vacuum this type of material at a rate of ~30kg/min. or more (~66 pounds/min. or more).  This means that we’ll be able to vacuum the full 300kg of activated carbon in ~10 minutes!

But, where will it all go?

If we were to use a 55 gallon Heavy Duty Dry Vac, we could vacuum ~105 kg. (232 pounds) of this material before filling the drum.  But, if we use a 110 gallon system, we will double this capacity while keeping the performance and compressed air demand of the system exactly the same.

The multiple sizes of EXAIR vacuum systems provided a wide array of solution options in this application.  After discussing these options and receiving a request for distributor contact in China, we passed this customer over to our Chinese distributor.

Providing solutions for industrial applications is the forte of EXAIR Application Engineers.  It doesn’t matter if the application is here in the States, or overseas, we’re available for any questions our customers have.

If you’d like to discuss your application with an EXAIR Application Engineer we’re available by phone, email, or online chat.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Video Blog: Assembling the Dual Cabinet Cooler Hardware Kit

Dual Cabinet Cooler Systems consist of two Cabinet Coolers and a model 4908 Dual Cabinet Cooler Hardware Kit.  This hardware kit will connect the Cabinet Coolers together for a single compressed air supply port. This video shows you how to assemble the hardware kit to the Cabinet Coolers, and then illustrates installing the Dual Cabinet Cooler System on an enclosure.

John Ball
Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Two Vacuums For The Price Of One

I recently noticed on my mortgage statement that I own more of my house than the bank does now. That made me feel good, and it also gave me pause for a moment of reflection on all the adventures I’ve had as a suburban American homeowner.  Good times…then, another adventure happened:

I’m in the middle of a major (to me) construction project in our house. Now, if you’ve ever worked with drywall, you know that anything you do to it creates dust….sometimes in great volume. No worries, though – I’ve got a real nice portable wet/dry vacuum that makes light work of drywall dust & scrap. So, when I’m done for the day, I leave the area as dust-free and tidy as it was before (“tidy” is relative…there are two teenagers and a dog in my house.)

For the record, the dog was more interested in the new hole in the wall than the teenagers.

For the record, the dog was more interested in the new hole in the wall than the teenagers.

Anyway, the adventure happened last Saturday morning, when the basement sump high level alarm went off. I had to get the water out of the sump, and fast, so I could find out what was wrong with my sump pump. No problem…I’ve got that real nice portable wet/dry vacuum, right? That was full of drywall debris. So, I hastily dumped it into the garage trash can (making another mess I had to clean up later) and removed the particulate filter so I could drain the sump. Which it did, like a champ. It was a stuck float on the sump pump, which I remedied quickly, and all was well with the world again. At least in my (and my bank’s) almost 1/4 acre of it.

Speaking of the different things you can use vacuums for, I had the pleasure of talking with a caller the other day about industrial vacuum applications. When they wash down a particular area of their facility, they end up with puddles of water, mixed with lots of solid debris, all over the floor. They were using electric wet/dry vacuums (like mine) but had a recent scare involving a damaged power cord on a wet floor. Luckily, someone saw it before anything bad happened, but it made them think about other options…like compressed air operated Industrial Vacuums.

They looked at some dual Venturi systems, which would indeed replicate the function of their electric vacs, but at a considerable rate of compressed air consumption…over 100 SCFM (over 25HP worth of typical industrial air compressor load.) Their compressed air system simply didn’t have the capacity for this. They already had an EXAIR Reversible Drum Vac, and had plenty of capacity to run it since it only requires 19 SCFM @80psig (about 5HP worth of compressor load,) but it wasn’t greatly effective at picking up the solid debris. That’s where the EXAIR Chip Vac comes in to our story…it uses only 40 SCFM @80psig (about 10HP worth of compressor load) to clean up the solid debris that doesn’t get sucked up with the puddles of water & sludge that the Reversible Drum Vac takes care of.

Reversible Drum Vac (left) and Chip Vac (right) – two EXAIR Industrial Vacuums for lower cost (purchase AND operation) than wet-dry combo air operated vacuums.

And…(back to the title of this blog)…a Reversible Drum Vac AND a Chip Vac STILL cost less to purchase than the dual Venturi system they were looking at. Lower purchase cost. Lower operating cost. Two independent systems. That’s a win-win-win.  If you have wet…dry…or wet & dry…messes to clean up, give me a call.

Russ Bowman
Application Engineer
Find us on the Web
Follow me on Twitter
Like us on Facebook

%d bloggers like this: