Energy Rebates and EXAIR Products

In case it goes unnoticed, EXAIR focuses on engineered compressed air point of use products to ensure that our customers are utilizing their costly utility as efficiently as possible.  The main benefits to purchasing EXAIR products are the support you receive from us at EXAIR, the quality of the product, the savings in compressed air, and the increase in safety.  Another added benefit is a large number of utility companies are offering rebates on the purchase of engineered nozzles, just like the Super Air Nozzles that EXAIR offers.

Many energy providers offer these energy rebates for commercial or industrial users.  Here in the Cincinnati area, Duke Energy offers rebates on items such as lighting, air compressors, engineered air nozzles, heaters / dryers for extrusion machines, energy management systems, variable frequency drives, data center equipment, even food service equipment, custom incentives, and many other items.

Duke Energy Rebate

Example of our local energy rebate offering for Engineered Nozzles

For each engineered compressed air nozzle that is installed, in order to meet the rebate requirements they must flow less than or equal to given flow rates in SCFM at 80 psig inlet pressure. The pipe sizes, flow rates, and EXAIR equivalents are shown below.

EXAIR Engineered Air Nozzle Part Number EXAIR Flow Rate @ 80 psig
#1102/#1103 – 1/8 NPT 10 SCFM
#1100/#1101 – 1/4 NPT 14 SCFM
#1108SS-NPT/#1109SS-NPT/#1110SS-NPT
All are 1/8 NPT
2.5, 4.9, 8.3 SCFM
respectively
#1003 – 3/8 NPT 18 SCFM

By just replacing the nozzles the customer saved 2.7 SCFM per nozzle.If we take an example such as the EXAIR Case Study  shown below for 1/4″ copper tube that was being used as an open ended blow off.  The copper tubes were consuming 19.6 SCFM at 100 psig inlet pressure, there were 10 machines with one line per machine operating 40 hours, 52 weeks per year.   The customer retrofitted the open pipes with a model 1100 Super air nozzle and was able to reduce the air consumption by 2.7 SCFM per nozzle.  If they were to purchase these nozzles this year, current list price for a model 1100 Super Air Nozzle is $36.00 USD, then apply for the energy rebate offered by Duke Energy and receive $20.00 per nozzle replaced.  The total savings and return on investment is shown below.

Case Study 1561

EXAIR Model 1100 Super Air Nozzle Replaces Open Copper Pipe Blow Off

10 nozzles x 2.7 SCFM = 27 SCFM  x 60 minutes per hour x 8 hours per day x 5 days per week x 52 weeks per year = 3,369,600 SCF of compressed air saved per year.

3,369,600 / 1,000 SCF x $.25 = $842.40 USD savings in compressed air per year.

Cost Savings per week = $16.20 USD

Total purchase cost is  $36.00 x 10 nozzles = $360.00 USD

Energy Rebate = @20.00 per nozzle x 10 nozzles  = $200.00 USD in rebates.

$360.00 USD purchase price – $200.00 USD energy rebate = $160.00 USD final purchase cost.

Return on investment at a savings of  $16.20 USD per week is

$160.00 / $16.20 = Less than 10 weeks pay back!

By applying for the energy rebate this customer could reduce the ROI of this air savings project from just over 22 weeks (which is still very good) to less than 10 weeks.

If you would like to learn more about whether there are Industrial energy rebates available in your area, contact an Application Engineer and let us know where you are located and who your energy provider is.

We will help you determine the correct engineered solution to save your compressed air as well as help you to apply for eligible energy rebates in your area.

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

 

Heavy Duty Line Vac is a Simple Solution When Mechanical Conveyors Fail

 

Line Vacs can convey many things.

Line Vacs can convey many things.

 

A manufacturing plant had a machine that would process 6mm ceramic beads into small medical components.  They used a screw type conveyor to move the ceramic beads from a large container into a hopper above the machine.  In this situation, the customer called EXAIR prior to determining which mechanical component failed.  They contacted the conveyor manufacturer for assistance.  Because of the complexity of the conveying system, it would take time to evaluate.  They had to determine if it was the motor, the gear box, the shaft, or electrical system.  Depending on which item that failed, there was a good chance that it would not be in stock.  With this length of downtime, it would cost the company much money and delays in shipments. The operation had to be shut down until they could find a way to keep the hopper filled with ceramic beads.  Being that they were under the gun, they contacted EXAIR to see if we could help.

Heavy Duty Line Vac

Heavy Duty Line Vac

In discussing their layout, the hopper was 10 feet away from the supply container, and the opening of the hopper was 10 feet above the floor.  These lengths were well within the limits of the EXAIR Air Operated Conveyors.  I suggested the model 152200 Heavy Duty Line Vac Kit.  This unit has the highest conveyance rate, and it can move items in the range of plastic pellets to steel shot.  It does not have any moving parts, so it makes it very simple, reliable, and long lasting.  The Heavy Duty Line Vac is made of a hardened steel that makes it very resistant to abrasion.  The next question he asked was if we had it in stock.   We did!!!  EXAIR stocks every cataloged model number for same day shipping with orders placed before 3 p.m. EST.  We were able to ship the Heavy Duty Line Vac that same day to get his operation back up and running.  He did mention to me afterwards that he wished he had at least one Heavy Duty Line Vac on his shelf as a backup system.  It could have saved his company an entire day of downtime.

If your company relies on mechanical conveying systems to move product, you may want to have an EXAIR Air Operated Conveyor on hand just in case of an emergency.  When things go wrong, you do not want to be down any longer than needed.  If you need help in sizing the correct Line Vac for your application, you can contact an Application Engineers at EXAIR.

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

Super Air Wipe Exceeds Expectations

20160714_155430L

This forming application needed a way to remove excess oil (currently being collected by paper towels)

In the application shown above the end user needed to remove excess lubricant from the outside of a tube after a forming process.  The existing setup offered no removal of the excess oil, and as the tubes exited the machine, oil would fall from the tubes and drip onto the floor.  To prevent these oil drops from reaching the floor and accumulating into a potential safety hazard, paper towels were placed at the exit of the machine to catch the oil and replaced as needed.

Considering that a blow off solution was needed to provide coverage to the full OD of the formed tubes, this application was an excellent candidate for a Super Air Wipe.  The Super Air Wipe provides 360° blowoff for the tubes, removing excess oil as the tubes pass through the air stream of the Super Air Wipe.

20160714_155422L

The “wet” side of the application

An added benefit for this application in blowing the excess oil back into the machine was the need for lubrication on the machine components on the “leading” side of this application.  As the tubes exit the machine, no oil is desired; but on the preceding side of the machine, oil is very much needed.  Using the Air Wipe to remove excess oil from the tubes and simultaneously blow this oil back into a needed workspace made this product the perfect fit.

The exact model chosen for this application was the 2404, 4” Super Air Wipe.  Available from stock with same-day shipping, we were able to meet the needs of this application while exceeding customer expectations.

If you have a similar application or would like to discuss your application needs with us, contact an EXAIR Application Engineer.  We’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

A Great Application For…Something Else

Some applications just sound like textbook situations – a caller wants to remove static charge from, and blow off a large, flat surface. That’s PERFECT for the laminar, high velocity ionized air curtain produced by a Super Ion Air Knife. All you have to do is pick the length, and we have them from 3 inches to 9 feet long.

Large, flat surfaces - perfect for a Super Ion Air Knife, right?

Large, flat surfaces – perfect for a Super Ion Air Knife, right?

Twice in the past week, I’ve been interrupted in my zeal to present the Super Ion Air Knife in these ideal situations by:

“…but I can’t move the product – I need to have something portable.”

And that’s OK. This is where it’s good to have a variety of offerings, including the portable, versatile, high performance Ion Air Gun. It’s durable and lightweight, so, if you can’t move the part, you can easily move the Ion Air Gun AROUND the part.

While it might be a "perfect" application for a Super Ion Air Knife, the Ion Air Gun works better if the product is stationary.

While it might be a “perfect” application for a Super Ion Air Knife, the Ion Air Gun works better if the product is stationary.

EXAIR Application Engineers are trained, and focused on, providing solutions. Even when something sounds “textbook,” there’s usually another way (or several) to look at it. And we’re really good at that. If you’d like to find out how to fit an EXAIR product into your compressed air needs, give me a call.

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

6″ Super Ion Air Knife Provides Separation Of Solar Panel Plates

I was recently working with a solar energy research center who was experiencing a static issue with their solar panel building process. They currently take a stack of small, silicon wafer plates, measuring approximately 6″ long X 6″ wide and 2 mm thick, and take the top plate from the stack and place it on the assembly table. The issues they were experiencing was that when they went to lift the top plate, static was making the plates cling together, resulting in several plates being picked up at one time. In some cases, they were able to get separation, but were seeing dust and dirt settle on the surface. This was causing two negative effects. First, when the plates get stuck together, they try to manually separate them which would cause them to crack or completely break. If they did get them separated without cracks, the second issue was contamination from foreign particulate would cause an operator to have to manually clean the plate, prolonging the assembly and reducing the daily production. Trying to remedy the situation, they decided to use a small open airline blowing at the side of the plates to get separation between the plates as they are lifted. While this did help a little with separation it did not remedy the particulate issue and they still weren’t able to achieve a desired result.

OLYMPUS DIGITAL CAMERA

Built Solar Panels

I recommended the customer use our Model # 111206, 6″ Super Ion Air Knife Kit in the application. The Super Ion Air Knife is our Super Air Knife with an Ionizing Bar attached to produce a laminar sheet of ionized air across the entire length of the unit. By directing the airflow at the side of the stack, the ionized air would release the static charge, allowing the individual plates to separate and as they are lifted, blow away any remaining unwanted fines on the surface of the plates. In addition, the kit includes a pressure regulator which would allow the customer to increase or decrease the supply pressure, providing some control of the exhaust air velocity and flow so they aren’t moving or disrupting the stack.

Super Ion Air Knife

Super Ion Air Knife produces uniform sheet of ionized air. Available in stocked lengths from 3″ up to 108″.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Solar Panels image courtesy of Slim Dandy via Creative Commons license.

Stainless Steel Super Air Knife Used in Mango Processing

SS SAK mango

303 Stainless Super Air Knife in Mango de-watering process

Recently, I was working with a customer who specializes in post-harvest fruit processing. In this case, they were processing mangos from complete fruit down into cubes which are subsequently cleaned and packaged into plastic bags and then cardboard boxes for use in other food products.

When the customer contacted me, they were using a stainless steel pipe with holes drilled into it to de-water the fruit chunks after being sprayed to clean the individual pieces. They were using stainless steel pipe as they had a requirement for stainless steel construction due to being food grade facility. The problem with the pipe was that the airflow didn’t provide an even blowing force across the full, 30 inch width of the vibratory conveyor. The pipe solution also used quite a lot of compressed air. Unfortunately the customer could not measure what it was, but they gave me the number and size of the holes drilled into it. From that information, we could determine that they were using about 150 SCFM of compressed air at this one location.

And so, with the ineffectiveness of the pipe as well as the high air consumption, the customer went looking for something better. That’s when they found EXAIR Stainless Steel Super Air Knives on our web site. After some quick discussion to sort out the width of the conveyor and to establish what the need was, we settled on model 110030SS (30” 303 Stainless Steel Super Air Knife) to be mounted across the width of the conveyor (see photo above).

With the Super Air Knife installed, the customer was able to achieve the effectiveness he needed for the de-watering and at an airflow rate that was 42% less compressed air use than what he had before. Some of the other benefits that they were able to achieve without even being conscious of it were the enhanced safety of the OSHA compliant Super Air Knife and the sound level was cut dramatically as well.

EXAIR’s Super Air Knives are used many times in processing and packaging applications to provide a non-contact method for de-watering, blowing off dust, moving product off to one side, drying, ejecting and many more applications like these.

Neal Raker, International Sales Manager
nealraker@exair.com
@EXAIR_NR

 

When Sizing Long Pipe Runs, Make Sure to Add in the Pipe Fittings

IM on Compressed Air Line Sizes for Cabinet Cooler

Installation and Maintenance information on Compressed Air Line Sizes for Cabinet Cooler

 

EXAIR uses this statement in their installation manuals to help determine the correct size pipe for our products. The above statement came from our large NEMA 4-4X Cabinet Cooler installation manual.  There are some important factors to consider when using this guideline to ensure proper air flow.

A customer installed a model 4840 EXAIR NEMA 4 Cabinet Cooler, and he was not getting the proper cooling. In diagnosing compressed air issues, one of the first things that we ask our customers is “What is the air pressure at the device?”  He attached a pressure gauge at the Cabinet Cooler, and he was reading 45 psig; much too low for proper cooling.  He sent me a photo of the setup and some details of the compressed air system supplying the Cabinet Cooler.  We needed to find the restriction to properly supply enough compressed air to the unit.

Westinghouse Cabinet Cooler

In the details that he sent, they ran 43 feet of 1/2” copper compressed air tubing from the header to the Cabinet Cooler. He mentioned that they had one angled Safety Valve at the beginning and twelve elbows in that run.  (Apparently they had to get around and through things to reach the location of the Cabinet Cooler).  They did have a pressure gauge in the header that read 105 psig.

The first thing that I noticed was that they were using compressed air tubing instead of compressed air pipe or hose. Tubing is measured by the outer diameter while the compressed air hoses are measured by the inner diameter.  So, in the statement above when it references ½” I.D. hose, ½” tubing will have a much smaller I.D., and in this case, it had a 3/8” I.D.  With this smaller flow area, this will increase the restriction.  In calculating the pressure drop in 43 feet of ½” tubing, it would be roughly a 27 psi drop at 40 SCFM.  If they have 105 psig at the header, they should be reading 78 psig at the Cabinet Cooler.  Being that they were only reading 45 psig, where is the rest of the restriction?

The answer to that question is in the fittings. When you have pipe fittings like elbows, tees, reducers, etc., they will add pressure drop to your system as the compressed air travels through them.  There is a method to calculate compressed air runs with pipe fittings in terms of Effective Length.  Effective length is a way to estimate the same pressure drop through a similar length of pipe to a pipe fitting.  This can be very important when running compressed air lines for EXAIR products.  Once we have the effective length of a pipe, then we can use the requirements in the installation manual for sizing compressed air lines properly.  The chart below shows the equivalent lengths by fitting category.

Equivalent Length

In the application above, the customer used 43 feet of 3/8” I.D. line, 12 pcs. of 3/8” regular 90 deg. elbows, and one 3/8” angled valve. The equivalent length of pipe can be calculated as 43 feet + 12 * 3.1 feet + 1 * 15 feet = 95.2 feet.  As you can see, with all the fittings, the equivalent length of pipe extended from 43 feet to 95.2 feet.  If we recalculate the pressure loss for 93.2 feet of ½” tubing, then we get a pressure loss of 58 psi at 40 SCFM.  From the header, this will equate to a pressure of 47 psig at the EXAIR Cabinet Cooler.  This is very close to the reading that he measured.  He asked me to recommend the proper size pipe, and by using the equivalent length and the installation manual, I suggest that he should use either ½” NPT pipe or 5/8” O.D. copper tubing for a 95 feet run.  This would only create a 5 psi pressure drop which would properly supply the model 4840 Cabinet Cooler with 40 SCFM.

If you are wanting to use tubing in your compressed air lines, you will need to use the inner diameter for sizing. Also, if you have many fittings, you can add them to your pipe lengths to get an equivalent overall length.  With the above methods to correctly size the compressed air lines, your EXAIR products will be able to work effectively and properly.

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

 

Follow

Get every new post delivered to your Inbox.

Join 23,408 other followers

%d bloggers like this: