Two Types of Air Amplifiers – Volume and Pressure

When the topic of Air Amplifiers comes up, there are two avenues to consider –  is it the air pressure or the air volume that you wish to amplify?  There exists technologies to amplify either parameter, and we will examine them both.

There may be equipment or processes within a facility that operate best at air pressures higher than can be delivered, due to air compressor limitations or the supply system. An Air Pressure Amplifier can take the existing compressed air supply, and boost the pressure allowing for the higher needed air pressure without requiring a dedicated compressor capable of operating at the higher pressure.

An Air Pressure Amplifier is basically an air pump, driven by a portion of the compressed air supply.  The pump cycles and compresses the remaining amount of compressed air to a higher outlet pressure. This higher output pressure can be used to operate the equipment or process that required the pressure levels that the base system could not supply. The drawback is that the pump system consumes a good amount of the compressed air volume, to power the pump which reduces the amount of air available for other equipment or processes.  This drives up the compressed air consumption for the system, and requires the extra capacity to operate.

The other type of Air Amplifier is the kind that amplifies the air flow volume. EXAIR manufactures this type of amplifier.

AirAmplifiers

The air flow amplification works by taking compressed air (1) and directing into an annular chamber (2). It is then throttled through a small ring nozzle (3) at high velocity. This primary stream of air adheres to the Coanda profile (4) and is directed through the outlet. A low pressure area is created at the center, inducing a high volume flow (5) of surrounding air to be drawn in and added to the main air stream. The combined flow of primary and surrounding air exits as a high volume, high velocity flow.

salworksani

EXAIR manufactures (2) types of Air Amplifiers, the Super Air Amplifier and the Adjustable Air Amplifier.  In addition, a special model for High Temperature applications is available.  Sizes range from 3/4″ (19mm) to 8″ (203mm) to meet most air flow requirements.  Air amplification ratios start at 12:1 for the 3/4″ model and increase to 25:1 for the 4″ and 8″ models.

Charts and tables are available to help determine the right Air Amplifier for the job.

If you have questions about the Air Amplifiers, or would like to talk about any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Super Air Amplifiers – Adjustability for Blowoff, Drying, Cooling, Circulation and Ventilation

The Super Air Amplifier is a powerful, efficient, and quiet air mover. Applications currently in place include blowoff, drying, cooling, circulation and ventilation. Sizes from 3/4″ to 8″ are available to best match the air volume that is necessary to achieve the process goals. There are a couple of ways to change the performance of the Super Air Amplifier if either a small or large change to the output flow is required.AirAmplifiers

The chart below shows the Total Output Flow for each of the 6 models. As an example, the Model 120021 or 121021, when operated at 60 PSIG of compressed air supply, will have a total output flow of 120 SCFM. These same devices when operated at 80 PSIG will have a total flow of 146 SCFM. By simply using a pressure regulation device on the compressed air supply, the output performance can be tuned to match the desired outcome.

Capture

For those applications where much greater flow and/or force is needed, the option of installing a thicker shim is available.  The Super Air Amplifiers are supplied with a 0.003″ shim installed (the 8″ model 120028, has a 0.009″ shim as standard) and can be fitted with shims of thicknesses of 0.006″ or 0.009″ (the 8″ model has an optional 0.015″ shim.) Installation of a thicker shim increases the slotted air gap, allowing for a greater amount of controlled air flow.  As a general rule, doubling the shim thickness will double the air flow rates.

Super Air Amplifier Shims
Patented* Shim Design for Super Air Amplifiers

The Super Air Amplifier design provides for a constant, high velocity outlet flow across the entire cross sectional area,.  The balanced outlet flow minimizes wind shear to produce sound levels that are typically three times quieter than other air movers. By regulating the compressed air supply pressure and use of the optional shims, adjustability and flexibility of the unit is wide ranging and sure to meet your process needs.

If you have questions regarding the Super Air Amplifier, or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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*Patent #5402938

Air Amplifiers – What is an Amplification Ratio?

On Friday my colleague, Russ, blogged about the Super Air Amplifier (see that BLOG here, including a video demo)  In discussing the Air Amplifiers, the topic of amplification was mentioned. Today, I’d like to expand a bit further the amplification aspect of the Air Amplifier performance.

As the name of the device implies, the compressed air used by the Air Amplifier is added to, and thus ‘amplified’, the total output flow of the unit. Depending on the size and type of Air Amplifier, the amplification ratio starts at 12:1 and goes up to 25:1, with the ratio being the output flow to the compressed air usage.

AirAmplifiers.jpg
Super Air Amplifier and Adjustable Air Amplifier

EXAIR offers (2) types- the Super Air Amplifier and the Adjustable Air Amplifier.  The Super Air Amplifier uses a patented shim technology to maintain a precise gap, which controls the compressed air flow and expansion through the unit.  As the expanded air flows along the Coanda profile, a low pressure area is created at the center which induces a high volume flow of surrounding air into the primary air-stream.  The combined flow of primary and surrounding air exhausts from the Air Amplifier in a high volume, high velocity flow.  The larger diameter units have a greater cross sectional area with larger low pressure areas, resulting in greater amplification ratios.

The Below table shows the amplification ratios.

SuperAirAmplifierPerformance

The Adjustable Air Amplifier does not use a shim, but rather has an infinitely adjustable gap, allowing for fine adjustment of performance.  Force and flow is changed by turning the exhaust end to adjust the gap, and is then locked into place. The method of the amplification is the same as for the Super Air Amplifier, and the amplification ratios are similar and shown below.

AdjustableAirAmplifierPerformance

The Super Air Amplifiers and Adjustable Air Amplifiers are ideal for use in applications and processes that require cooling, drying and/or cleaning of parts, or the ventilation of confined areas or weld smoke or the exhausting of tank fumes.

If you have questions regarding the Air Amplifier, or would like to talk about any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Air Amplifiers – Vent, Exhaust, Cool, Dry, Clean – With No Moving Parts!

As an Application Engineer, one of the interesting aspects of working with customers on applications is the varied types of solutions an EXAIR product can provide.  The Air Amplifier family – Super Air Amplifier, Adjustable Air Amplifier, and the special High Temperature Air Amplifier can be used in a wide variety of process and applications.  Below highlights several of those from past experiences.

A defense contractor was performing maintenance service on a Navy ship, and the ventilation system had to be shut down.  To keep the personnel cool and safe, an auxiliary ventilation was to be supplied.  Rather than use a cumbersome blower assembly, which has to mounted on the top deck, and ducted down to the lower decks, they chose to utilize (2) 4″ Super Air Amplifiers.  They are very portable and can be set up in minutes.  This solution provided the necessary air flow, providing a safe environment for the maintenance crew.

Super Air Amplifier
EXAIR Air Amplifiers use a small amount of compressed air to create a tremendous amount of air flow.

A light bulb manufacturer needed a better solution for a cooling operation.  During manufacturing of a mercury lamp, the bulb must be cooled from 700°C to 600°C in just 15 seconds.  The current method, an open brass pipe, was working but the noise level was too high (95 dBA.) The goal was to maintain the 15 second cooling time, but reduce sound levels to 85 dBA.  By utilizing (2) of 3/4″ Adjustable Air Amplifiers, the customer was able to maintain the cooling rate, and reduce the noise level down to 80 dBA, a 15 dBA reduction.

adjustable Air Amplifier
Adjustable Air Amplifier

A garbage collector presented a problem that needed a solution.  The garbage was incinerated and when the furnaces were first started up, there tended to be issues with getting the flue to draft properly.  Using the High Temperature Air Amplifier, the high velocity air flow and draw provided the needed draft until the stack warmed up and the natural draft would be established.  Since the unit is capable of handling temperatures up to 700°F, it was able to withstand the heat of the process after the compressed air was turned off.

These and other Applications for the Air Amplifiers and all other EXAIR products can be found on the EXAIR website on the Products page, under the Related Info section toward the bottom of each page.

If you have questions regarding Air Amplifiers or any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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Air Amplifiers Speed Up Cooling Of Cast Parts

Do you like soup? I like soup. Especially on cold days in the winter. Living down south apparently ruined me for cold weather, because, even though I’ve been here in Ohio for 25 years, I still get a chronic chill in early November that won’t let go until about April. March, if I’m lucky. A nice, hot bowl of soup gives me a temporary respite from that dreaded chill, though, so yeah…I like soup.

Sometimes (OK; most of the time) I like it so much I don’t want to wait for it to cool (just slightly) to a temperature that won’t scald my tongue, so I resort to the age-old practice of blowing on those first few spoonfuls. Even though my breath is a fairly consistent 98.6F (give or take,) it’s still quite effective at transferring enough heat out for pain-free consumption. There are two reasons I’m thinking about this right now:

First reason: I’ve been working with an engineer at a large automotive plant…they were cooling a production run of metal cast parts with a series of fans. It ran pretty slowly, and they had a line of those pedestal mounted fans “waving at the parts as they went by.” The thought was, they could direct a stream of cooling air by using the focused flow of an Air Amplifier, and this might just allow them to speed up the line. And they were right. They tried a few Model 6041 1-1/4″ Aluminum Adjustable Air Amplifiers, with very favorable results. So favorable, in fact, that they ordered (40) more to outfit other casting lines in the plant, in arrangements similar to this:

With (16) models to choose from, EXAIR Air Amplifiers are a quick and easy way to provide a tremendous amount of cooling air flow from a compact, lightweight product.
With (16) models to choose from, EXAIR Air Amplifiers are a quick and easy way to provide a tremendous amount of cooling air flow from a compact, lightweight product.

Just like it might take more than one “blow” to cool off a spoonful of soup, they have installed multiple Air Amplifiers, in succession, on the lines, depending on the size, shape, and mass of the part. And the precise adjustability of the Adjustable Air Amplifiers allows them to dial in the optimum air flow, while minimizing their compressed air consumption. So the Production and Facilities folks are all very happy.

And (because I know you’re wondering) the second reason I’m thinking about conductive/convective heat transfer via air movement:

I trust you had already guessed what was for lunch today.
I trust you had already guessed what was for lunch today.

Russ Bowman
Application Engineer
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Stainless Steel Adjustable Air Amplifiers Replace Blower in Exhaust Hood Application

Vent hood
EXAIR Stainless Steel Adjustable Air Amplifiers model 6034

 

I was working with our Indonesian distributor the other day on an interesting application in the sugar refining industry.

The application was in a sugar refining plant. As the sugar cane is cooked down, the resulting gas vapor is pulled up through a vent hood and exhausted outside the building. The customer was using a 16” diameter blower to create the needed draft to draw the vapors. The problem is that the vapors are corrosive and sticky when cold. The effect is that the blower blade becomes caked with deposits which, in turn corrode the blade and it must either be cleaned and/or replaced at frequent and regular intervals.

The customer wanted to get away from having to deal with the blower issue if they can, so they turned to our distributor for ideas on how to solve the problem using EXAIR equipment. Turns out that a cluster of (3) model 6034 4” Adjustable Air Amplifiers operating at 5 BARG input pressure are able to generate the necessary flow to replace the blower in this system.

The keys to success in the application were the fact that the Adjustable Air Amplifiers are constructed of Stainless Steel to resist the corrosive effects of the gas vapor. Also, there isn’t any deposits on the blade that need to be dealt with. While cleaning of the Air Amplifiers is recommended in this application, the maintenance interval was able to be much longer between cleanings.

In many industrial applications, blower driven or electric motor driven equipment is usually preferred in an effort to save energy. This was a good example of a case where the quality of having no moving parts was able to offset other maintenance costs that made use of a blower actually more expensive for the user.

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

 

EXAIR Can Customize for Your Application

Once again this week, I had a customer call in with a special request on one of our products.  The customer had purchased a 6030 Adjustable Air Amplifier to cool plastic components after they were formed in a previous process.  These components are made continuously and the only way to test the cooling capabilities was during a production run.  If there was any error in the system, a whole batch of product was rejected, so the customer needed to be able to fine tune the process easily.  The space was very confined, so the customer had taken the 3/4″ outlet and connected a 3/4″ hose with hose clamps in order to direct the air to the proper area.  From the 3/4″ hose, they had necked down the line to 3/8″ hose to fit into their process.  By necking down the outlet of the air amplifier, the customer was limiting the output of the 6030, but it was enough air to get there job done.  Now that he had successfully used the 6030, the customer wanted to rollout the idea to other product lines and create a more robust system than hose clamps and homemade reducers.  Fortunately, for this customer and many others, EXAIR has the skill and flexibility to manufacture custom solutions.

air amp

The customer wanted to roll the project out into 25 production lines, and create a more robust system.  The first idea that came to mind was using a threaded Line Vac to replace the Air Amplifier.  This would be a stock item that would produce a similar amount of air flow as the air amplifier through a 3/8″ hose.  Obviously, the Air Amplifier would produce more airflow in free air, but since we are restricting that flow with a 3/8″ hose, the Line Vac and the Air Amplifier would produce similar air flow in this application.  Unfortunately, the customer didn’t have the ability to test the process with the Line Vac, because of his production schedule and the risk of losing a batch of product during the testing.  Because of these requirements, the customer asked us to produce (25) Special Air Amplifiers with threaded outlets to replace his 6030 that he was currently using.  The Adjustable Air Amplifier would give the customer the ability to adjust the air flow by changing the air gap in the Air Amplifier to his exact specification.  This adjustability means he can set the Air Amplifier to meet his current requirements, and adjust if the conditions change on his production line.  Also, the system would now be threaded so he could install hard pipe to make a permanent and robust system throughout the facility.

Special Air Amplifier

Dave Woerner
Application Engineer
davewoerner@exair.com
@EXAIR_DW