The 3 Types of Static Generation

Static electricity is something that we talk about often here at EXAIR, particularly during the colder winter months. When an atom gains or loses an electron from its outer shell, it becomes electrically imbalanced. A material’s propensity to either gain or lose an electron is “ranked” on a list known as the Triboelectric Series. So how does static actually generate, or what causes these atoms to either gain or lose an electron? There are three types of static generation: contact, detachment, and frictional static build up.

Contact static build up is one of the simplest methods of static generation. In this type of static generation, a charge is generated simply from two objects contacting one another and separating. This often results in an instantaneous static charge as the electrons are transferred from one object to another in accordance with the Triboelectric Series.

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As a layer of material is peeled off, electrons are transferred from one sheet to another.

The second type of static generation is known as detachment static buildup. The principle behind the type of static electricity is the same as contact static buildup, but the materials are already in contact with one another and the charge is generated as the surfaces are separated. During the separation, not all of the electrons are able to get back to their original molecule. The amount of static generated in detachment static buildup is generally far greater than contact static buildup due to the large surface area.

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The last type of static generation is frictional static buildup. When two objects have friction between one another, electrons in the outer valences of the molecules can easily pass from one atom to another. If the force pressing the objects together increases, even more molecules come into contact with each other and increase the charge that is generated. Just as detachment static buildup, frictional static buildup generally produces higher charges than contact static buildup.

Gen4 Static
Gen4 Static Eliminators

Regardless of the type of static generation occurring in your process, EXAIR has a Static Eliminator that is suitable for neutralizing that charge and mitigating any issues that you’re having as a result. With a team of Application Engineers standing by to help and our unconditional 30 day guarantee, there’s no reason to not give us a call and try one out!

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

Static Electricity: What Is It And The Products To Solve Industrial Process Problems

The lower relative humidity associated with the cold, dry air of winter results in a significant increase in customers  with problems related to static. Luckily, EXAIR has a wide-range of Static Eliminators that are designed specifically to address static issues in a wide variety of industries. So, what exactly is static and how is it generated? Let’s take a quick trip down memory lane to elementary school science class….

An atom consists of three basic particles: protons, neutrons, and electrons. The protons (positively charged) and neutrons (neutral charge) form the nucleus. Outside of 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 static until contacted by or in close proximity to a conductive or grounded surface. Materials such as paper, plastic, or textiles will normally contain an equal number of both positive and negative ions. When subjected to friction, this balance can be disturbed if the atoms gain or lose an electron.

The static charge will then exert a force on nearby charged objects or grounded conductors (including personnel). These issues can also manifest in the form of dust clinging to product, product clinging to itself, rollers, machine beds or frames, materials jamming, and sheet feeding problems.

To eliminate these charges, EXAIR’s Static Eliminators produce an equal amount of both positive and negatively charged ions. This allows us to neutralize either charge quickly and effectively.

For applications that allow you to install close (generally within 2”) to the surface of the material, we offer our Ionizing Bar in lengths ranging from 3”-108”. If a wide area of coverage is necessary, but you can’t get close to it, the same Ionizing Bar is installed on the Super Ion Air Knife to help deliver those ions over a greater distance.

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Gen4 SIAK

The Ionizing Point is another product that can be used without the need for compressed air. A compact, single point ionizer, this product is ideal for winding, rewinding or slitting operations. It can also be mounted through a duct to neutralize static charges due to moving air or materials.

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Gen4 Ionizing Point

The Ion Air Gun combines incredibly fast static decay rates with low compressed air consumption. With a 10’ flexible armored cable and ergonomic handle, the Ion Air Gun is best for applications where an operator will perform the blowoff process.

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If the airflow pattern from the Ion Air Gun is conducive to your application, but you’d prefer to automate the blowoff or maintain a continuous usage, both the Ion Air Jet and the Stay Set Ion Air Jet provide an identical airflow pattern. The Stay Set Ion Air Jet comes with a magnetic base and Stay Set Hose, allowing you to precisely position the static eliminating ions in your process.

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The Ion Air Cannon delivers a quit, efficient, and concentrated flow of ionized air. It is ideal for hard to reach spaces or confined areas that necessitate a solution to static problems. Designed with a sturdy stand, the pre-drilled holes can be wall, bench, or machine mounted. It incorporates a swivel adjustment for directing the airflow.

Our Gen4 Static Eliminators have all undergone independent laboratory tests to certify that they meet the rigorous safety, health, and environmental standards of the USA, European Union and Canada that are required to attain the CE and UL marks. If there’s a process in your facility that could benefit from a solution to static problems, please give us a call. Any of our Application Engineers will be happy to help select the best option for your process.

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

The Impact of Cold Temperatures and Lower Humidity on Static Electricity

This time of the year it is not uncommon to feel a slight shock after walking across a carpeted surface and touching a door knob. This little “jolt” is a result of fast-moving electrons leaping from your body to the door knob, or vice versa. As your feet shuffle across the surface of a rug or carpet, your body will either gain or lose electrons. Touching a conductive surface then causes these electrons to leap from one place to another. This is known as static electricity.

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If you notice, this happens to occur much more often during colder winter months (if you’re one of those fortunate people to live outside of this sensation we call “cold” please don’t rub it in!). The reason that you experience static shocks more frequently during winter is due to the relative humidity. At colder temperatures, air does not hold as much moisture as it does when it’s warm and moisture helps to conduct electrical charges. Even though you’re heating your house to a similar temperature, the air that is being drawn into your home and heated is still the dry cold air containing less moisture.

The amount of moisture in the air is expressed as relative humidity. This value is given as a percentage of water vapor in the air, compared to how much it could hold at that temperature. In conditions of lower relative humidity, static charges build up much easier. When the relative humidity is high, there’s a higher concentration of water molecules present in the air. These water molecules “coat” the surface of the material, allowing electrons to move more freely and form a layer over the material. This layer of water molecules acts like a lubricant, reducing the forces that cause static to generate. This is why static is much more noticeable during the winter months.

Gen4 Static
Gen4 Static Eliminators

There are many applications that static only appears when the seasonal climate changes. Issues can manifest in the form of nuisance shocks to operators, materials jamming, tearing or curling, product sticking to itself and to rollers, dust clinging to product, and many more. If static is causing problems in your processes, we have a wide variety of Static Eliminators available from stock. Don’t just deal with the problems until humid conditions return, get a permanent solution in place that’ll neutralize the static and eliminate a troublesome application. Contact an EXAIR Application Engineer today and we’ll help to diagnose the root cause of the problem and recommend the best solution.

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

 

Photo courtesy of Ken Bosma via Flickr Creative Commons License

Installing Secondary Receiver Tanks: Step 5 in Optimizing Your Compressed Air System

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The 5th step in the 6 steps to optimizing your compressed air system highlights the use of intermediate storage of compressed air near the point of use. Secondary, or intermediate Receiver tanks are installed in the distribution system to provide a source of compressed air close to the point of use, rather than relying on the output of the compressor.

Compressed air receiver tanks are an integral part to many compressed air distribution systems. Compressed air is stored at a high pressure after drying and filtration, but just upstream of point of use devices. The receiver tank is charged to a pressure higher than what is needed by the system, creating a favorable pressure differential to release compressed air when needed.

Think of a compressed air receiver tank as a “battery”. It stores the compressed air energy within a system to be used in periods of peak demand, helping to maintain a stable compressed air pressure. This improves the overall performance of the compressed air system and helps to prevent pressure drop.

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They can be strategically placed to provide a source of compressed air to intermittent high volume compressed air applications. Rather than having to pull from the compressor, a receiver tank can be sized to provide the short-term volume of air for a particular application. In a previous post, we’ve highlighted how to calculate the necessary receiver tank based on the air consumption and duration of the application.

EXAIR offers from stock a 60-gallon receiver tank designed specifically for these higher-usage intermittent types of applications. Model 9500-60 can be installed near the point of high demand so that you have an additional supply of compressed air available for a short duration. The tank comes with mounting feet and is designed to stand up vertically, saving floor space. The tank meets American Society of Mechanical Engineers (ASME) pressure vessel code.

If you have an application in your facility that’s draining your compressed air system, a receiver tank could be the ideal solution. Give us a call and one of our Application Engineers will be happy to help evaluate your process and determine the most suitably sized receiver tank.

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

Video Blog: How to Replace Gen4 Power Supply Fuse

With winter in full swing in North America, humidity is dropping and causing an increase in static charges. EXAIR’s line of Static Eliminating products are a necessary tool for dealing with troublesome static electricity in a variety of different industrial processes.

EXAIR’s Gen4 Static Eliminators utilize a new Power Supply to produce static eliminating ions. A new feature of the redesigned Power Supply was the ability to replace a couple of different parts rather than having to purchase an entirely new unit. In a previous video, we showed you how to replace the rocker switch if necessary. In this video, I’d like to show where the fuse is located on the new Power Supply and how to replace it if blown.

If you have any questions about your Gen4 Static Eliminators, or would like to discuss a potential application, give us a call today. Our Application Engineers are standing by waiting to help you determine the most suitable product for your application.

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

 

EXAIR’s Long Super Air Knives Dry Auto Bodies

I was recently contacted by an automobile manufacturer that was looking for a quote for a system of Super Air Knives for a current process they were replicating at a new facility. The customer had an existing application where they’re using the Super Air Knife to dry the body of the car after a washing operation and before it enters into an oven. Any large water droplets remaining when the body enters the oven cause water spots that must then be cleaned off, adding an additional step in their process.

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The solution was working well to dry the bodies, they just needed a quote so that they could implement the very same process in the new plant. As this was an installation that had been in place for many years, they had an older style of Long Super Air Knife that consisted of two shorter knives coupled together. In 2014, EXAIR began manufacturing our Long Super Air Knives in one single piece (available from stock up to 108”!!).

So, now, rather than having two individually coupled knives they could order (1) single 84” knife with a consistent flow all the way across and no dead spots. They ordered one for the top, one for each side and replicated the already successful application.

EXAIR’s industry leading Super Air Knife dramatically reduces compressed air usage and noise when compared to other blowoff methods. The Super Air Knife is available in lengths ranging from 3”-108” and in Aluminum, 303 Stainless Steel, 316 Stainless Steel, and PVDF for corrosive applications. Even at high pressures of 80 psig, the Super Air Knife is able to maintain a sound level of just 69 dBA for most applications! Air is entrained from the ambient environment at a rate of 40:1, maximizing the force and flow from the Super Air Knife. In addition, these knives meet or exceed OSHA maximum dead-end pressure and noise requirements.

Adjustability of both the force and flow from the Super Air Knife is infinitely adjustable. Right out of the box from the factory the Super Air Knife comes stock with a .002” thick shim installed. This sets the gap between the body and cap of the knife and determines how much compressed air can flow through the precise, slotted orifice.

An accessory that EXAIR has available for the Super Air Knife is the shim set. For the aluminum knives, a .001”, .003”, and .004” plastic shims come in the shim set. To reduce the flow and force, a .001” can be used. If more force is required, a thicker shim can be installed. For the stainless steel and PVDF knives, (3) .002” shims are included in the set. Stainless steel shims for the stainless knives and a PTFE shim for the PVDF. These, as well as the plastic shims, can be stacked on top of one another to create an even larger gap. One thing that is important to keep in mind however, the larger the air gap the greater the air consumption. Installing a .004” shim in a Super Air Knife will double the force, flow, and consumption of the knife when compared to the stock .002” shim.

If you have a new application (or need to replicate an existing one) for the Super Air Knife, don’t hesitate to reach out to an EXAIR Application Engineer for assistance. With a highly-trained team coming from multiple different industry backgrounds, we’re ready to help.

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

Vortex Tubes can be Customized to Suit Your Application

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EXAIR’s Vortex Tubes are a low-cost, reliable, and maintenance-free solution to a variety of industrial spot cooling problems. With just an ordinary supply of compressed air, the Vortex Tube produces two streams of air: one hot and one cold. This is achieved without any moving parts or refrigerants!!

The Vortex Tube is capable of achieving a temperature drop/rise from your compressed air supply ranging from -50°F to +260°F (-46°C to +127°C). Flow rates range from 1-150 SCFM (28-4,248 SLPM) and refrigeration of up to 10,200 Btu/hr. With all Vortex Tubes constructed of stainless steel, they’re resistant to corrosion and oxidation ensuring you years of reliable, maintenance-free operation.

How A Vortex Tube Works

In addition to providing a range of different Vortex Tubes available to ship same-day from stock, EXAIR also has a few options available for cases where a stock Vortex Tube may not be the right solution. The standard Vortex Tube is suitable for use in environments with ambient temperatures up to 125°F (52°C) due to the plastic generator and Buna o-rings. For more extreme environments and ambient temperatures up to 200°F (93°C), we install a brass generator and replace the Buna o-rings with Viton seals.

All standard Vortex Tubes are adjustable. A small valve is located at the hot air exhaust end of the tube. Using a flat-tipped screwdriver, you can adjust the amount of air that is permitted to exhaust from the hot end. As more air is allowed to escape, the temperature at the cold end of the tube drops even further. The volume of air at the cold end as the temperature drops will also decrease. The percentage of air exhausting from the cold end relative to the total air consumption is referred to as the cold fraction percentage. Lower cold fractions will produce lower temperatures, but there won’t be as much volume. Finding the proper setting for your Vortex Tube can take some adjusting.

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As we all know, if there’s a knob to turn, button to press, or adjustment that can be made an operator is inevitably going to tinker with it. Day shift will blame the night shift, night shift blames the day shift, and it can present a problem when the Vortex Tube has been specifically tested and set to achieve the desired cold fraction. If you know the cold fraction you need, but would prefer to prevent it from being able to be adjusted, EXAIR can install a precisely drilled hot plug to set the cold fraction percentage to your specifications and eliminate any potential for it to be changed.

If you’d still prefer to keep the adjustability, but don’t have the capabilities to measure and set it yourself, we can also set any Vortex Tube to the desired cold fraction with the adjustable valve and send it to you ready to be installed. We’ll provide you with a special model number so you can rest assured that any time you need another it’ll come set to your specification.

At EXAIR, we’re committed to providing you with the best solution possible for your application. Sometimes that isn’t going to be achievable with a standard stock product. Just because you don’t see it in the catalog or on our website, doesn’t mean we can’t do it. If you have a unique application and would like more information on getting a special Vortex Tube, contact an Application Engineer today.

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