Intelligent Compressed Air: Static Electron Theory

Did you know that the discharge you’ve likely felt on a cold winter day after walking across a carpeted surface and touching a door knob is a result of static electricity? To understand how this static electricity is generated, let’s first go back to basic chemistry class and talk about the atomic structure of an atom.

An atom consists of three basic particles: protons, neutrons, and electrons. The protons (positively charged) and neutrons (neutral charge) form the nucleus. Outside the nucleus, electrons (negatively charged) are quickly zipping around in orbits at specific distances from the nucleus. These electrons are bound to the nucleus due to electromagnetic force. Opposite charges attract, since the protons in the nucleus carry a positive charge this acts on the negative charge of the electrons and keeps them in orbit. The closer the electron to the nucleus, the stronger the bond and the more energy required to break that electron from its original orbit.

When an atom gains or loses an electron, it affects the balance that occurs within an atom. If an atom gains an electron, it now has more electrons than protons. This results in a negatively charged atom. The opposite can be said if an atom loses an electron, it now carries a positive charge. This charge imbalance is where static electricity comes from. Both positive and negative charges will remain statically charged until contacted by or comes into close proximity to a conductive or grounded surface.

The strength of this charge will depend on a few different factors: the types of materials, surface area, environmental conditions, etc. will all play a role in the generation of a static charge. The triboelectric series is a scale, listing various different materials and their tendency to become positive or negative. Those at the far end of the spectrum have an increased propensity to gain or lose an electron, while those in the center are more likely to remain balanced. When two materials on opposite ends of the spectrum come into contact with one another, it poses the greatest risk of generating high levels of static electricity. The chart below shows some common materials and where they fall on the tribolectric series.

When materials carry a static charge, a variety of problems can ensue during manufacturing. These can manifest in the form of painful shocks to operators, materials jamming or tearing, sheet feeding problems, discharges causing imperfections in the material appearance, etc. To remove the charge, we need to introduce static eliminating ions to balance out the charge on the material. EXAIR’s line of Static Eliminators create an equal number of both positive and negative ions to saturate the surface of the material and neutralize any charge present.

With a wide range of different solutions all available from stock, EXAIR has the solution to your static problems this winter. Give us a call and we’ll be happy to discuss the application and help to identify the best method to mitigating any static issues in your processes. Take advantage of EXAIR’s current promotion (now through the end of March) and receive a free AC Sensor with your Static Eliminator purchase!

Tyler Daniel, CCASS

Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

Atom photo courtesy of janjf93 via Pixabay Creative Commons License

OSHA 1910.95(a) Explained: Occupational Sound Exposure

Hearing loss due to high noise levels is a common problem in many industrial facilities. Without the use of proper PPE, hearing loss can occur quickly. This is a serious concern as hearing loss is permanent and once the damage is done there’s no way to reverse it. Due to this risk, OSHA strictly enforces standard 29 CFR-1910.95(a).

This directive discusses the effects of noise and limits exposure based on the dBA. The table below indicates the maximum allowable exposure time to different noise levels. Sound levels that exceed these levels should first be addressed by proper engineering controls such as isolating the source of the sound from personnel or replacing the cause of the sound with something like an engineered compressed air nozzle. When such controls aren’t feasible, proper PPE must be worn to protect the operator.

Hearing loss can occur in as little as 30 minutes when exposed to sound levels 110 dBA or greater. Operators have a tendency not to use PPE as directed, if an OSHA inspector comes to your facility and notices that the sound levels exceed the maximum allowable level without protection hefty fines will be soon to follow. In this example from the United States Department of Labor, a company was fined a total of $143,000 for failing to protect their employees.

In order to identify the places or processes in your facility that are causing the problems, you’ll need a tool to measure the sound level. EXAIR’s easy to use Digital Sound Level Meter allows you to measure and monitor the sound level pressure in a wide variety of industrial environments. The source of the loud noise can then be identified and isolated so that corrective action can be taken. For compressed air related noise, EXAIR manufactures a wide variety of engineered compressed air products that can reduce the sound level dramatically. In many cases, EXAIR products are capable of reducing noise levels by as much as 10 dBA. Since the dBA scale is logarithmic, this equates to cutting the sound level in half!

If there are processes within your facility that are above these limits, and you’d like to eliminate relying on proper PPE, give an Application Engineer a call. We’ll help walk you through the selection process and make sure that when the OSHA inspector comes knocking you’re prepared!

Tyler Daniel, CCASS

Application Engineer
E-mail: TylerDaniel@exair.com
Twitter: @EXAIR_TD

EXAIR Products Entrain FREE Ambient Air For Maximum Force and Flow

Air entrainment is a term that we bring up quite often here at EXAIR. It’s this concept that allows many of our products to dramatically reduce compressed air consumption. The energy costs associated with producing compressed air make it an expensive utility for manufacturers. Utilizing engineered compressed air products that will entrain ambient air from the environment allow you to reduce the compressed air consumption without sacrificing force or flow.

Products such as the Super Air Knife, Super Air Nozzle, Air Amplifier, and Super Air Wipe all take advantage of “free” air that is entrained into the primary supplied airstream. This air entrainment occurs due to what is known as the Coanda effect. Named after renowned Romanian physicist, Henri Coanda, the Coanda effect is used in the design of airplane wings to produce lift. As air comes across the convex surface on the top, it slows down creating a higher pressure on the underside of the wing. This creates lift and is what allows an airplane to fly.

EXAIR Super Air Nozzle entrainment

This is also the same principle which is allowing us to entrain ambient air. As the compressed air is ejected through a small orifice, a low-pressure area is created that draws in additional air. Our products are engineered to maximize this entrained air, creating greater force and flow without additional compressed air. Super Air Amplifiers and Super Air Nozzles are capable of up to a 25:1 air entrainment ratio, with just 1 part being the supplied air and up to 25 times entrained air for free!! The greatest air entrainment is achieved with the Super Air Knife at an incredible ratio of 40:1!

This air entrainment principle allows you to utilize any of these products efficiently for a wide variety of cooling, drying, cleaning, or general blowoff applications. In addition to reducing your compressed air consumption, replacing inefficient devices with engineered products will also dramatically lower your sound level in the plant. Sound level in some applications can even be reduced down to a point that would eliminate the need for hearing protection with the OSHA maximum allowable exposure limits set at 90 dBA for an 8-hour shift.

If you have inefficient blowoff devices in your facility, give us a call. An Application Engineer will be happy to help you select a product that will “quietly” reduce your compressed air consumption!

Tyler Daniel, CCASS


Application Engineer
E-mail: TylerDaniel@EXAIR.com
Twitter: @EXAIR_TD

All the Hoses, Tubing, and Accessories Necessary for Your Intelligent Compressed Air Products®

In order to make sure you’re able to get the most out of your Intelligent Compressed Air Products from EXAIR, we offer a wide variety of various hoses and tubing to complement several of our product lines.

For any Line Vac Pneumatic Conveyor application, you may need appropriate tubing to handle the intake and outlet flow of the conveyor. EXAIR offers a clear reinforced PVC hose from stock in sizes ranging from 3/8” to 3” ID for use with our smooth Aluminum, Stainless Steel, and Heavy Duty Line Vacs. The PVC hose is available in lengths up to 50’ in 10’ increments and is on the shelf ready to ship, alongside the Line Vacs themselves. The hose is very flexible with a smooth internal bore that eliminates material build up. The reinforced, heavy wall of the clear hose provides visual confirmation that the material is moving when compressed air is supplied to the Line Vac. These hoses are rated for use in temperatures ranging from -4 to 150°F (-20 to 66°C).

 To help supply air to your Safety Air Guns, we offer (3) different styles of 12’ (3.6m) coiled hoses to help keep the area free of tangled air lines. Sizes are available in 1/8 NPT x ¼” ID, ¼ NPT x 3/8” ID, and 3/8 NPT x 3/8” ID. Each coiled hose has swivel fittings installed on either end for ease of installation.

If you need a bit longer length to supply your point-of-use products, or need a larger diameter hose, we also have both 3/8” and ½” ID compressed air hoses. These are manufactured with a reinforced synthetic rubber to assure long life and protection against ozone, weathering, and temperatures up to 158°F (70°C). Hose lengths are available in 10’, 15’, 20’, 30’, 40’, and 50’.

For EXAIR’s E-Vac Vacuum Generators, polyurethane vacuum tubing (along with various push-in fittings) is available to help connect to the necessary vacuum cups. The tubing comes in either ¼” ID or 3/8” ID in lengths ranging from 10’ to 50’. This allows you to build up a complete vacuum system when including the mufflers, vacuum cups, and generator itself!

All of these options are available from stock to ship alongside any Intelligent Compressed Air Product. If you need help determining the proper hose sizes based on your point-of-use products get in contact with an Application Engineer today for help!

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

Twitter: @EXAIR_TD