Custom Pneumatic Conveyors for Unique Applications

Published on by John BallLeave a comment

EXAIR’s Line Vacs, or Air Operated Conveyors, provide an efficient method of converting ordinary pipe, hose or tubes into powerful in-line conveyors.  To accommodate the wide variety of unique problems manufacturers face, EXAIR has the ability to customize and tailor Line Vacs to different specifications.  Certain processes may require customizations like unique sizes, shapes and materials in order for the product to be a perfect fit for their system.  EXAIR will work in collaboration with the customer to fabricate the best possible Line Vac solution for easy and efficient conveyance.

I worked with a customer to design a special Line Vac.  They needed 3” ANSI 150# Flanges on a 3” PDVF Line Vac.  So, we had a special material with special ends to suit their specific needs.  The PVDF with Hastelloy hardware was for chemical resistance, and the flanges were used to mount onto their piping system.  As with many of our Line Vacs, we can turn a normal piping system into a conveyance system for waste, parts, or bulk materials.  For this customer, they needed a backup system for a fume hood.  With electrical vacuums and blowers, loss of power or motor failures can cause a momentary lapse in fume removal.  Since the chemical material that was used in the hood was dangerous, they needed a reliable source to extract the fumes.  The Line Vac does not have any moving parts or require electricity.  The Line Vac only uses compressed air or gas to make it operate.  For this customer, they attached nitrogen to the special Line Vac to work when there was a power failure to protect the workers in the area. 

For customers with space limitations, smaller sizes can be created while still offering the same capacity for conveyance.  In situations where the Line Vac requires a specific flange mounting option, EXAIR can accommodate.  Locations requiring custom mounting holes, brackets or inlet positions are possible.  For applications where stock aluminum, or 303 and 316 stainless steel won’t work, alternate materials like PVDF, PVC or PTFE can be utilized.  Even in extreme environments, EXAIR can produce both heavy-duty or high-temperature iterations to handle even the toughest material or conditions.  Other details like the customer’s particular hose size, or pipe threading are specifications that EXAIR will have no problem accommodating.

Stock Line Vac models include standard, Heavy Duty, Ultra Duty, Light Duty and Sanitary Flange.  All versions can be customized with different connections and materials to meet customer’s specific needs.  If there’s a process in your facility that could benefit from a product like the EXAIR Line Vac, act fast! Now through October 31st, you’ll receive a FREE 1104 3/8” Super Air Nozzle as a promotional item with the purchase of any EXAIR Line Vac with a qualified order in the U.S.  For any help solving specific conveyance problems, you can contact an Application Engineer.  We will be happy to help. 

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

Compressed Air Pipe

The Power of Deliquescent Driers in Compressed Air Systems

Published on by Jordan T ShouseLeave a comment

In industrial manufacturing, compressed air is the unsung hero powering tools, machinery, and processes across manufacturing, painting, blasting, and beyond. But here’s the catch: moisture. That sneaky water vapor lurking in your compressed air lines can wreak havoc, causing corrosion, freezing, and contaminating sensitive equipment. Deliquescent driers are low-maintenance systems designed to tackle humidity head-on. In this blog, we’ll dive into what makes these driers tick, their pros and cons.

What Are Deliquescent Driers, Anyway?

Picture this: a simple tank packed with hygroscopic (water-loving) salt tablets that dissolve into a brine as they absorb moisture from compressed air. That’s the 1000-foot view of a deliquescent drier. Unlike refrigerated or desiccant dryers that rely on complex refrigeration cycles or regeneration, deliquescent driers use chemistry to do the heavy lifting. The process is elegantly straightforward:

  • Incoming air enters the bottom of the vessel, preheated from compression and loaded with water vapor.
  • It flows upward through a bed of deliquescent desiccant—typically formulated from salts like calcium chloride, lithium chloride, or potassium chloride.
  • The salts “deliquesce” (hence the name), attracting and dissolving water vapor into a liquid brine that collects at the base.
  • Dry air exits the top, with a pressure dew point suppressed by about 15-20°F below the inlet temperature, depending on conditions.

No electricity, no moving parts—just pure, passive drying. These driers have been a staple since the 1940s, especially in rugged settings like petrochemical plants, outdoor blasting ops, or mobile equipment where reliability is the largest concern.

Why Choose Deliquescent Driers? The Pros (and a Few Cons)

Deliquescent driers aren’t for every scenario, but when they fit, they’re a game-changer. Let’s break it down:

The Advantages:

  • Zero Energy Consumption: No power required means lower operating costs and no electrical hazards in wet or explosive environments. Ideal for remote sites or intermittent use.
  • Rugged and Portable: Mount them indoors or outdoors—they thrive in extreme temps, even subzero conditions, with the right setup. Perfect for mobile contractors in painting or abrasive blasting.
  • Low Maintenance: Just drain the brine every 8-hour shift and top up the desiccant a few times a year. A sight glass lets you monitor levels at a glance.
  • Cost-Effective Upfront: Cheaper to buy and install than high-tech alternatives, with no filters or separators to fuss over.

The Drawbacks:

  • Limited Dew Point Control: They suppress dew point by a fixed amount (e.g., 20°F), so hot inlet air means warmer outlet air—fine for many apps but not ultra-dry needs.
  • Corrosion Potential: The brine is salty and corrosive, so vessels need robust coatings, and downstream lines require after filters to catch salt carryover.
  • Pre-filtration Required: Oil from compressors can foul the desiccant, so a coalescing pre-filter is a must.

In short, if you’re blasting in humid conditions, painting in the field, or running air tools in cold weather, deliquescent driers deliver freeze-proof, reliable performance without the fuss.

At EXAIR Corporation, we’re keen on compressed air efficiency. The attention to detail we pay to our products – from design, to manufacturing & assembly, to availability, and right on through to technical support – bears out our commitment to helping you get the most out of your compressed air system. If you’ve got questions, Give me a call.

Jordan Shouse, CCASS

Application Engineer

Send me an email
Find us on the Web 

Image courtesy of Brian S. Elliott, Wikimedia Commons Creative Commons Attribution-Share Alike 4.0 International License

Halloween Blast from the Past: Milling Frozen Human Body

Published on by Tyler DanielLeave a comment

Every now and then, an application comes across our desks that’s a little out of the ordinary. With Halloween around the corner, it felt like the right time to revisit one of the strangest (and certainly most memorable) uses of EXAIR products we’ve ever come across.

Several years ago, a research group reached out with an unusual request. They were involved in a project studying human anatomy through a process that required milling a cadaver and then photographing each layer to build a precise, three-dimensional representation of the body. Each pass removed only about 300 microns of material, meaning that hundreds of layers were milled and documented throughout the process.

For the imaging to be accurate, each freshly milled surface had to be completely clean and evenly prepared before a photo was taken. Any debris or uneven surface finish could distort the final image, and repeating a cut or photo sequence was time-consuming. That’s where EXAIR came in.

To remove dust and debris left behind from the milling process, they incorporated a Stainless Steel Super Air Knife (Model 110012SS). The knife delivers a clean, uniform curtain of air across the surface, removing any residue without physically touching or damaging the material. Immediately following the blowoff, an Atomizing Spray Nozzle (Model EB1020SS) applied a fine mist of isopropyl alcohol across the surface to improve imaging contrast and clarity.

A Stay Set Hose (Model 9212) allowed the nozzle to be positioned precisely where it needed to be and to stay there through long hours of operation. This combination replaced a previous setup that relied on a liquid-only spray, which often left uneven coverage and required rework. With the EXAIR system in place, the team achieved consistent, repeatable preparation of each layer and saved significant time by eliminating variability in their process.

While it’s not every day we see our products used in anatomical research, this one stuck with us. It’s a great example of how compressed air solutions can improve consistency and control in highly specialized applications.

So, in the spirit of the season, we thought it was worth dusting off this story as a reminder that EXAIR products show up in all kinds of places. Whether you’re cooling, cleaning, coating, or even preparing something for a close-up, there’s usually an efficient way to do it with compressed air.

Have an unusual application of your own? We’d love to hear about it. Reach out to an Application Engineer today.

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD

Theory of a Dead Man

Published on by jasonkirbyLeave a comment

Georges-Joseph Ranque was born on February 7, 1898, in Ambérieu-en-Bugey, France, to Léon-Joseph Ranque, a railroad engineer. This familial background naturally fostered his passion for physics. He attended the esteemed Lycée Saint-Louis, a selective post-secondary institution, where he furthered his understanding of the subject. Subsequently, he gained admission to École Polytechnique, continuing his academic journey. During his work on an industrial pump, Ranque became intrigued by the Pantone carburetor and discovered what is now referred to as the Ranque effect. This phenomenon serves as the foundational principle behind industrial vortex tubes, where the tangential injection of compressed gas at high velocity results in the creation of two distinct streams: one hot and one cold.

The unique physical phenomenon of the Vortex Tube principle generates cold air instantly, and for as long – or short – a time as needed.

This cold airflow is effectively employed in various industrial applications for spot cooling and enclosure cooling, thanks to its straightforward and dependable nature. The only requirement is a source of compressed air. In 1931, Georges patented his vortex tube, but it did not gain much traction until physicist Rudolf Hilsch revisited the concept. Hilsch enhanced the design, which he referred to as the “Wirbelrohr,” or “whirl pipe” in English. Consequently, the term “Ranque-Hilsch tube” is often used interchangeably with “vortex tube” due to Hilsch’s contributions.

Compressed air enters the tube and flows through a series of nozzles positioned tangentially to the internal counter bore. This nozzle configuration induces the air to rotate in a vortex at speeds reaching up to 1,000,000 RPM. As the air spins, it makes a 90° turn, where a valve at one end permits a portion of the heated air to escape. The remaining air continues down the tube in the inner stream, losing heat before exiting as cold air at the opposite end.

How a Vortex Tube Works

Both streams in a vortex tube rotate in the same direction and at an identical angular velocity. According to the principle of conservation of angular momentum, the rotational speed of the inner vortex is expected to increase. This phenomenon can be effectively illustrated through Olympic figure skating: when a skater extends her arms, her spinning slows down, but as she pulls them in, her rotational speed increases significantly. In the case of a vortex tube, however, the inner vortex maintains a constant speed as it has lost angular momentum. The energy dissipated during this process is released as heat from the hot side of the tube. This heat loss facilitates the cooling of the inner vortex, enabling it to be harnessed for various industrial applications.

The theory behind Vortex Tubes is applied in standard Vortex Tubes as well as in a range of other products designed with specific features tailored to various applications. EXAIR offers a selection that includes Cabinet Coolers, Cold Guns, Adjustable Spot Coolers, Mini Coolers, and Vortex Tubes, all of which function based on this fundamental principle.

 If you have any questions about Vortex Tubes, or anything regarding EXAIR and our products, please do not hesitate to reach out. We would love to hear from you!

Jason Kirby
Application Engineer
Email: jasonkirby@exair.com
Twitter: @EXAIR_jk