Super Air Amplifier Increases Airflow In Vaccum Hood For Fume Extraction

A couple days ago I  took a call from an extrusion company who was looking to increase the airflow in their plating operation. They manufacture several different shapes and styles of aluminum extrusions by the way of 8 large extrusion presses. On one of the presses they make a specialty line of products that are sent to a finishing operation to be anodized.

Above the anodizing process tanks they use a vacuum hood to capture fumes and send them to a scrubber system so the air can be cleaned before being exhausted. They were starting to see an increase in the level of VOC (Volatile Organic Compound) gases in the area and, after some internal testing, determined the existing system wasn’t moving enough air through the system for the gases to be adequately delivered to the scrubber tank.

Example of a scrubber system

After further discussion, the customer ordered our Model # 120022 2″ Super Air Amplifier to test under our Unconditional 30 Day Guarantee.  Air Amplifiers are one of the most efficient products in the EXAIR catalog. Using a patented internal shim, they use a small amount of compressed air that passes through an internal chamber where it is exhausted through a thin gap at high velocity. This directed airflow creates a lower pressure at the intake side which draws in a large amount of free air. The 2 combining air flows result in a large volume of “amplified”, high velocity exhausting airflow, making them ideal for increased air movement.

Air Amplifiers entrain enormous amounts of “free” air, at ratios of up to 25:1!

If you have an application where you need to increase airflow or if you’re looking to vent or exhaust noxious fumes, an Air Amplifier is the ideal choice. For help selecting the best Model or to discuss a particular process, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Pueblo Chemical Agent-Destruction Pilot Plant Agent Processing Building courtesy of PEO ACWA via creative common license.

 

Intelligent Compressed Air: Utilization of the Coanda Effect

Henri Coanda was a Romanian aeronautical engineer most known for his work developing what is today known as the Coanda effect. The Coanda effect is the propensity of a fluid to adhere to the walls of a curved surface. A moving stream of fluid will follow the curvature of the surface rather than continuing to travel in a straight line.  This effect is used in the design of an airplane wing to produce lift. The top of the wing is curved whereas the bottom of the wing remains straight. As the air comes across the wing, it adheres to the curved surface, causing it to slow down and create a higher pressure on the underside of the wing. This  is referred to as lift and is what allows an airplane to fly.

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The Coanda effect is also the driving force behind many of EXAIR’s Intelligent Compressed Air Products. Throughout the catalog you’ll see us talking about air amplification ratios. EXAIR products are designed to take advantage of this phenomenon and entrain ambient air into the primary air stream. Compressed air is ejected through the small orifices creating air motion in their surroundings. Using just a small amount of compressed air as the power source, Super Air Knives, Air Nozzles, and Air Amplifiers all draw in “free” ambient air amplifying both the force and the volume of airflow.

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EXAIR Intelligent Compressed Air Products such as (left to right) the Air Wipe, Super Air Knife, Super Air Nozzle, and Air Amplifier are engineered to entrain enormous amounts of air from the surrounding environment.

Super Air Knives provide the greatest amount of air amplification at a rate of 40:1, one part being the compressed air supply and 40 parts ambient air from the environment. The design of the Super Air Knife allows air to be entrained at the top and bottom of the knife, maximizing the overall volume of air. Super Air Nozzles and Super Air Amplifiers also use this effect to provide air amplification ratios of up to 25:1, depending on the model.

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Air Amplifiers use the Coanda Effect to generate high flow with low consumption.

The patented shim design of the Super Air Amplifier allows it to pull in dramatic amounts of free surrounding air while keeping sound levels as low as 69 dBA at 80 psig! The compressed air adheres to the Coanda profile of the plug and is directed at a high velocity through a ring-shaped nozzle. It adheres to the inside of the plug and is directed towards the outlet, inducing a high volume of surrounding air into the primary air stream. Take a look at this video below that demonstrates the air entrainment of a Super Air Amplifier with dry ice:

Utilizing the Coanda effect allows for massive compressed air savings. If you would like to discuss further how this effect is applied to our Super Air Knives, Air Amplifiers, and Air Nozzles give us a call. We’d be happy to help you replace an inefficient solution with an Engineered Intelligent Compressed Air Product.

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

Adjustable Air Amplifier Keeps Sensor Cool

Our distributor in China has a customer who visited the United States, while their customer was in the US they saw an EXAIR product installed and wanted to replicate the setup in China. He saw the EXAIR label and reached out to our distributor for help in identifying the part. Taking a quick measurement of the inlet side of the Adjustable Air Amplifier led us to discern it was a Model 6041 1-1/4” Adjustable Air Amplifier.

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EXAIR Model 6041

The product was installed on a baghouse monitoring system. The sensor is used to detect minor leaks within the dust collection system before the leaks create a major problem. The environment in which the sensor was installed results in temperatures that are just above the normal operating temperatures during warmer months and can result in erroneous readings. When this occurs, production is shutdown to prevent a failure of the dust collection system while the filters can be inspected. By installing the Adjustable Air Amplifier to provide a large volume of air and a low level of compressed air consumption, the temperature is able to be maintained within typical operating range for the sensor. This alleviates the need for unnecessary shutdowns (or unnecessary filter replacement), while ensuring that the working environment remains dust-free.

EXAIR’s Adjustable Air Amplifiers are available in both Stainless Steel and Aluminum from sizes ranging from ¾”-4” on the air outlet. The outlet can be ducted as seen in this application, or it can be used as-is. The air gap of the Adjustable Air Amplifier is infinitely adjustable, allowing you to regulate both the air consumption and outlet flow from a “breeze” to a “blast”. In addition to the standard Adjustable Air Amplifiers, we also have a Model 121021 High Temperature Air Amplifier available that is capable of withstanding temperatures as high as 700°F.

Air Amplifiers can be used in a variety of different applications. Not only can they be used in applications requiring cooling, but the air entrainment properties of the amplifier can be used to exhaust smoke as discussed in this application at a foundry. An Adjustable Amplifier can also be used for drying or cleaning parts as well as for conveying light materials.

Regardless of the application, EXAIR has a suitably sized Air Amplifier to fit your needs. If you need an efficient and reliable way to vent, cool, clean, or dry parts give us a call. An Application Engineer would be happy to take a look at your application and provide the best recommendation.

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

EXAIR’s Super Air Amplifier Removes Scrap Label Trim

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Placement of the Super Air Amplifier tucked away in the machine

Recently I worked with our distributor in Peru that had a customer who was experiencing a nuisance issue one of their production lines. The company is a graphics company that serves many different food manufacturers in the Peruvian market. In this case, they were making a label for a salad dressing company. During the converting process, scrap trim is produced. This was falling to the ground, building up over time, and eventually would need to be cleaned up. To do so, they had to stop production and have an operator manually clean up the mess before restarting the machine.

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EXAIR’s Model 120021

Enter EXAIR’s Model 120021 Super Air Amplifier. The customer positioned the amplifier so that it would catch the scrap trim and convey it away from the machine. They positioned a waste receptacle about 6’ away and ducted the amplifier to carry the scrap to this bin. This eliminated their need to stop production and allowed them to run continuously. Before installing the Super Air Amplifier, they had to stop the machine approximately 4x or more per day for cleanup. At 10 minutes per, this was 40 minutes of lost production time per day! After proving the concept on this machine, the customer now plans to outfit another 3 with the same setup.

Because the material was so light and was only traveling a short distance, the Super Air Amplifier was a suitable solution. We’ve blogged in the past about similar applications where scrap trim is conveyed using a Line Vac. This is also a suitable solution, the Line Vac can be sized to accommodate your material and prevent excess scrap from accumulating and causing problems in your processes.

If you have a converting application that produces scrap trim, give us a call. We can help size an appropriate solution and make sure you’re not wasting valuable production time cleaning up the mess!

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

Flat Super Air Nozzles – Quiet and Forceful and Adjustable

The 2″ Flat Super Air Nozzle is a very powerful yet quiet engineered nozzle.  Operation at 80 PSIG of compressed air pressure yields a strong 1.38 lb. of force, at only 77 dBA of sound level.  Compare this with many of the plastic flat nozzles that blow air through a series of holes, with sound levels ranging form 78-83 dBA, not to mention some might violate the OSHA dead ended pressure standard and results in fines being levied.

The patented technology utilizes a changeable shim to generate the high flow of air in a smooth and laminar flow, to keep noise down and power and strength up. With (6) stainless steel shim thicknesses available, the 2″ Flat Super Air Nozzle offers a very flexible package that can be set and tuned to meet exacting performance criteria, while using the minimum amount of compressed air, and at the quietest possible sound levels.

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2″ Flat Super Air Nozzle

The model 1122 is offered in a zinc aluminum alloy body and cap, and the 1122SS is constructed from type 316 stainless steel.  All shims are stainless steel. The shim thickness for the 1122/1122SS is 0.015″ thick.

Also available, for extra blowing force, are the HP1125 and HP1125SS.  The nozzles utilize the same zinc aluminum alloy or stainless steel body and cap and have the 0.025″ shim installed – and deliver 2.2 lbs of force, while only increasing sound levels to 83 dBA.

Shim sets for any of the 2″ Flat Super Air Nozzles are available.  The 1132SS shim set includes shims of thickness of 0.005″, 0.10″, and 0.020″.  For higher force levels, the HP1132SS shim set includes the 0.020″ and 0.030″ shims.

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Shims are available, from 0.005″ up to 0.030″ for maximum versatility and performance tuning

As you can see- for a versatile, forceful and quiet engineered air nozzle, it is hard to beat the EXAIR 2″ Flat Super Air Nozzle.  If a 1″ wide nozzle better suits your needs, the same flexibility and power can be found in the 1″ Flat Super Air Nozzle as well.  Check it out as well.

If you would like to talk about Flat Super Air Nozzles or 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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Twitter: @EXAIR_BB

Super Air Knives – A Plethora of Materials and Sizes

EXAIR manufactures the line of air knives known as the Super Air Knife. We pride ourselves on the wide array of material types and lengths that we offer, all from stock.

The Super Air Knife is the latest generation of engineered air knife that dramatically reduces compressed air usage and noise when compared to other blowoffs.  It is a very efficient way to clean, dry, or cool parts, webs, or conveyors.  It delivers a sheet of laminar air flow across the entire length, with a smooth and consistent delivery of air.

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In order meet process environments that may be hot or corrosive in nature, EXAIR offers the Super Air Knife in four standard materials.  The materials for stock air knives are aluminum, Type 303 stainless steel, Type 316 stainless steel, and PVDF (Polyvinylidene Fluoride.) Aluminum is well suited for a wide variety of environments where corrosion or contamination is not a factor. Type 303 stainless steel is a very common grade of stainless steel, and is good for mildly corrosive environments up to 400 °F. Type 316 stainless steel offers excellent corrosion resistance, better strength properties, and resists pitting. It can handle temperatures up to 800°F.  Lastly, the PVDF air knives offer many benefits including resistance to UV light, inorganic chemicals, solvents, ozone, acids, weak bases and salts and can withstand temperatures up to 275°F.  If there is a certain material required, EXAIR can also do custom Super Air Knives and have done them in PVC and other plastics.  Check out this write up about a very unique custom material Super Air Knife that we made.

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Glass Filled PEEK Super Air Knife with Brass Hardware and PTFE Shim (Click Here or on Photo)

Not only is there a wide offering of materials of construction to meet the process needs, the Super Air Knives are available in many lengths to fit into the space available. From stock, we offer Super Air Knives in these lengths-

3″, 6″, 9″, 12″, 18″, 24″, 30″, 36″, 42″, 48″, 54″, 60″, 72″, 84″, 96″, and 108″

If a special length knife is needed, or one longer than the 108″, the Super Air Knives can be coupled utilizing the stocked Air Knife Coupling Kit to join multiple air knives as needed. If space is an issue, and certain length that is not stocked is needed, just give us a call –  we can manufacture them to your specifications, to the exact length that you need.  It takes just a few days and then the Super Air Knife of exactly the proper length will be on its way.

If you have questions about the Super Air Knives, 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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Twitter: @EXAIR_BB

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.

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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

Send me an email
Find us on the Web 
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Twitter: @EXAIR_BB