Category: Customer Service

Understanding Deliquescent Dryers

Published on by EricKuhnash@EXAIR.comLeave a comment
Deliquescent Dryer

Deliquescent dryers can sometimes be confusing. Some compressed air dryer vendors use the terms deliquescent and desiccant synonomously as if they were interchangeable in describing their equipment. The deliquescent dryers are not a complex drying system and found most commonly in the petrochemical industry.

Unlike any other dryer, a deliquescent dryer is also used to reduce or remove moisture before it turns to liquid water. These dryers can be installed indoors, outdoors, offshore or any remote location. They do not require electric for operational purposes or have any moving parts, making them easy to maintain and economically more efficient. In a deliquescent dryer, moist air (gas) passes over a layer of deliquescent tablets which absorb moisture from the air. The pressure dew point lowers as the tablets slowly dissolve, the condensation falls into the drain area, and the drier air flows through the outlet into the piping system.

The best deliquescent materials are salts with a strong attraction for moisture. Deliquescent desiccants (drying tablets) are formulated from calcium chloride, magnesium chloride, potassium chloride and lithium chloride. Not all deliquescent desiccants are equal. The final formulation and properties of the desiccant can have significant impact on the design of a dryer tank. That is, the surface of the desiccant chemical, often beads or pellets, will liquefy, and the resulting liquid will flow to the bottom of the vessel. There is either a drain (manual or auto) at the base of the deliquescent dryer which is used to expel the collected fluid.

Some factors that will affect the consumption of the desiccant are the type of adsorbent, type of adsorbate, the size of the adsorbent bead or pellet, the concentration of the adsorbate in the compressed air stream, and the temperature of that air stream.

You will want to have a water trap, also known as a general purpose compressed air filter plumbed in line just upstream from the deliquescent dryer. Otherwise, any liquid water flowing with the compressed air into the air dryer will make short work of the desiccant chemical, requiring a more frequent – and expensive – recharge.

The compressing of air generates heat. That hot, moist compressed air will consume the desiccant chemical in the deliquescent dryer much more quickly. Best practice is to ensure the air flow to the dryer is as cool as possible with, if possible, a long air line and a dwell tank prior to the deliquescent dryer to allow the air to cool and have water saturate out naturally.

A deliquescent dryer can be expected to reduce the compressed air dew point by 20 – 30 deg. F, or so. The degree of drying depends how saturated the airflow is going in and on the type of deliquescent chemical used.

Unlike other forms of compressed air dryers, a deliquescent unit doesn’t guarantee the air will reach a certain dew point. The amount of water vapor in the air that exits the dryer is completely predicated on how much water vapor is in the air going into the dryer.

I hope this helps increase your understanding of deliquescent dryers. EXAIR has many Intelligent Compressed Air tools and accessories. We would love to help you learn more about our products. Please contact us as we are eager to help.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK

Eliminating Injection Molding Particulate In Secondary Operations

Published on by EricKuhnash@EXAIR.comLeave a comment
Some applications call for a fixed-in-place solution, like the (above, from left) Super Ion Air Knife, Super Ion Air Wipe, Ion Air Jet, and Ion Air Cannon.) Others are best suited to the hand-held convenience of the Ion Air Gun

My career has always involved working with customers and helping problem solve to success. Back in the early 90’s, I was talking with a customer and asked their buyer what his worst job was with regard to price, scrap and overall headache and if he would let me quote it for him. He then showed me a car horn button assembly for a well known automaker. He just sourced this job out, but his current supplier could not make the daily rates, was overpriced and lacked consistent quality. He said if I could meet his objectives that he had other business coming up that he would let us bid and consider us as a new supplier.

I left my customer with the part drawing, yes part drawing because this was before our company had CAD, and we had to hand calculate everything for a quote, oh the good ole days. So I went back and had a discussion with my tooling engineer. We devised a system to manufacture this horn button assembly with a vertical molding machine and incorporate a hot stamp in the mold then assemble at the turntable. After this discussion we hit the Thomas Registry back then known as “Green Books” to find reputable vertical molding machines that would incorporate a rotating table for this operation.

Upon visiting 5 machine manufactures and 3 hot stamp suppliers we made our decisions and completed our quote all within 2 weeks, can you believe 2 weeks was a fast turnaround for a complex quote back then? Green books, part drawings, no cell phones, no GPS, no Internet, but I believe we did have a fax machine back then. So off we went on a three-day road trip to visit our suppliers of choice. We quickly made decisions and confirmed our pricing with our customer. He thought we were crazy and asked us to reevaluate our pricing as we were way too low compared to his current supplier. We felt comfortable with our quote and said we do not need to evaluate, and our price was good. He then told us that our price eliminated 11 operators when compared to our competitor. The customer officially awarded us the project when we guaranteed our price and delivery.

We ordered our equipment, built our molds and assembled our hot stamp machine to the rotary table of the vertical injection molding machine. Within 6 weeks we were ready for our first trial, it was almost an instant success. We did not account for static issues before hot stamping the horn button face. We were seeing contaminants under the hot stamped products, so we went back to our “Green Books’ and found EXAIR right in our own backyard. We talked with EXAIR over the phone, and they directed us to their Ion Air Jet and said this was a perfect application for this project and was also a stock item. We were just 30 miles from EXAIR, so we jumped in our car to pick up the “Will Call” order. EXAIR helped us resolve the static issue all within the same day eliminating our 4.5% scrap rate and all within hours of our initial phone call to EXAIR.

We then asked our customer to visit and watch our run rate, so our buyer would feel comfortable with our quote, quality and production rate. He mentioned through the entire process that he did not think we could hold our price or meet the annual requirements of 480,000 sets (LH and RH). He was pleasantly surprised with our work and saw first hand that we had a system that gave him a good run at rate, quality and competitive price.

Ion Air Jet on a Stay set hose.

EXAIR’s GEN 4 Ion Air Jet delivers a concentrated airflow that can cover a precise spot without disturbing other areas. This quiet, focused airstream provides incredibly fast static decay rates and cleaning ability. The EXAIR Ion Air Jet made a nice addition to the impressive engineering that went into this horn button assembly project.

Our customer was impressed with the solution, and it helped them keep their customer happy. Ultimately, we were able to get significant, future business from this customer. Without the help of EXAIR having competent products in stock, we might not have had such a good outcome. If you have the need for static eliminating products and not sure which one is right for you, please contact one of our Application Engineers. We can suggest which static eliminator is best for your application, answer your questions and provide material to help you decide on the best course of action.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK

Porous and Non-Porous E-vac Generators

Published on by EricKuhnash@EXAIR.comLeave a comment

Having an injection molding background I saw many uses for parts pickers using many different sizes from 90 – to 3000 ton injection molding machines and a vast amount of part sizes and shapes that varied from items as small as dinner plates to as big as municipal refuse containers. I dealt mainly with non-porous applications but EXAIR offers both porous and non-porous E-vacs to accommodate wide range of part sizes and weights.

EXAIR has High Vacuum Generators for Non-Porous Applications with high vacuum units up to 27″ Hg (91 kPa) with vacuum flows up to 15.8 SCFM (447 SLPM). The plastic products I was moving were all non-porous, meaning air or liquids would not permeate into the surface of my product. Other examples of non-porous material including plastic sub-straights include glass, steel sheet, ceramics, vinyl, sealed tiles and varnished wood.

Porous applications use a low vacuum generator. Low vacuum units up to 21″Hg (71kPa) with flows up to 18.5 SCFM (524 SLPM) are typically used for porous materials such as corrugate, wood, fabrics, cinder block, etc… The relatively lower level vacuum for porous materials prevents warping, marring, dimpling or disfiguring of the surface due to excessive vacuum. This style generates more vacuum flow to overcome porosity and leakage while maintaining control over the object being handled.

Referencing the previously mentioned refuse container application, I performed the weight and movement analysis and determined that four of our model 900754 vacuum cups and two of our model 810006M Non-porous E-vacs would have been more than adequate to unload and lift my 95 gallon refuse container lids from the injection molding machine and move them to the hot stamp center. I recall the vacuum cup system we had in place back then, would frequently drop out and lose control over the product. This was not only a real process headache, but also made for a legitimate safety issue as well.

EXAIR E-vacs actually have other interesting uses. They have been used in applications for bag and package opening, label placement, vacuum forming, leak testing and many other applications.

EXAIR also has accessories to round out vacuum cup systems including vacuum cups themselves, mufflers, check valves, vacuum tubing and fittings. We would have interest to discuss your application. If you have questions regarding which E-vac style and size is proper for your project please contact any of our Application Engineers to help you with selection and design of your system.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK

EXAIR’s Safety Air Guns are the Ergonomic Answer

Published on by EricKuhnash@EXAIR.comLeave a comment
In addition to a variety of engineered Air Nozzles, you can customize your EXAIR Safety Air Gun with Chip Shields, Extensions, Stay Set Hoses, etc., to meet the particular needs of a specific application.

EXAIR has a nice selection of Safety Air Guns. The VariBlast Precision and Compact, Soft Grip, Heavy Duty and Super Blast Safety Air Guns are available with a variety of air nozzles, chip shields and pipe extensions. They are durable and comfortable and ergonomic to use.

These Safety Air Guns are designed with durability and comfort in mind while also ergonomically safe to use. Safe operation is assured along with low air consumption and noise levels.

EXAIR Engineered air nozzles are available in Type 316 stainless steel for superior corrosion resistance and mechanical wear, Type 303 stainless steel for corrosion resistance, PEEK thermoplastic for non-marring and chemical resistance or zinc/aluminum alloy for general purpose applications.

Flying Debris? – Chip Shields are durable polycarbonate shields that protect the operator from risk of flying debris often seen when blowing off chips from machined parts. They are also useful to prevent coolant from splashing back, creating a mess during drying processes.

The Chip Shields are available for EXAIR’s VariBlast, Soft Grip and Heavy Duty Safety Air Guns. The Chip Shield can be used on Safety Air Guns with or without an aluminum extension. They may be purchased as part of a new air gun system, or retrofitted as a Chip Shield Kit.  Consult an Application Engineer for selection assistance.

If you have a blow-off process where the air is to be directed at a distance away from the operator, or into a hard to reach location an extension is the solution. Available in lengths from 6″ (152mm) to 72″ (1829mm), with sizes as to meet most requirement can be found. To add an extension to an air gun, simply add -xx to the current part number..

EXAIR’s Stay Set Hoses are available from 6”-36” in lengths with ¼ NPT male threads on each end, or a ¼ NPT male on one end and 1/8 NPT female on the other. The Stay Set Hoses are rigid and allow you to maintain precise positioning of the blow off nozzle. The hoses have “memory” and will not creep or bend.

 If you need a 12′ coiled air hose, to use with your Safety Air Gun, we have them available and in stock. Available with 1/8 NPT, 1/4 NPT or 3/8 NPT male end swivel connections. Avoid tangled and messy air lines and keep things neat!

If you have ab application and need help deciding which EXAIR Safety Air Gun and/Nozzle you need. Please contact us and ask for any Application Engineer. We are always happy and eager to help.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK