Dust Suppression with an EXAIR Atomizing Nozzle

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An EXAIR Atomizing Nozzle used to minimize dust in the feed bowl of a cement mixer.

One of the most difficult aspects of handling and working with dusty materials is suppression of airborne contaminants.  Small particles can easily become a dust cloud, minimizing visibility and decreasing the quality of working conditions.  This then leads to lower productivity, low morale, and a missed opportunity to maximize the potential of personnel and equipment.

Our distributor in New Zealand recently assisted one of their customers facing this set of problems when working with cement and microsilica as it was poured into a mixer.  An exhaust fan was in place, but failed to extract the dust sufficiently, so a new approach was needed to minimize the dust.

 

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An AN2010SS No Drip Atomizing Nozzle provides the needed dust suppression in this application.

 

The solution was to use an EXAIR AN2010SS No Drip Internal Mix Atomizing Nozzle, shown above in the red box, to produce an atomized water mist.  The dust produced during pouring is captured by the small droplets of atomized water produced with this nozzle, reducing the dust and allowing proper use of the mixer.

 

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The 9218 Stay Set Hose positions the atomizing nozzle where it needs to be.

 

In order to position the nozzle exactly where it needs to be, an 18” Stay Set Hose, shown above with the red arrow, was used to position the nozzle.  This hose is built specifically to have “memory” of the desired position, allowing for quick, easy, and repeatable position of the nozzle attached to the hose.

This simple setup is controlled through a timer to ensure water and compressed air use realize maximum efficiency.  It’s an easy solution to a painful problem for this customer.

If you’d like to explore how an EXAIR solution can solve problems in your facility or application, please contact an EXAIR Application Engineer.

 

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

Taming The Dust Cloud With EXAIR Atomizing Spray Nozzles

Have you ever dropped one of your nice dinner plates on a tiled kitchen floor? And noticed how they seem to go in slow motion as they hurtle to their doom? I never cease to be impressed at how far some of the smaller pieces can go. I recently had to replace our oven, and I found broken dishware shards (and an impressive amount of trash scraps, pet toys, and ‘dust bunnies’) all the way against the back wall.

Curiously, as small as the pieces can be when a dinner plate meets its end, it started its life in even smaller pieces…as a fine ceramic powder, pressed into a mold and heated to a temperature that is WAY hotter than when the server at your favorite restaurant warns you that plate “might be hot.”

I’m writing about this because recently, I had the pleasure of assisting a maker of ceramic dishware with a messy little problem…this fine ceramic powder is moved from where it’s produced, to the various mold stations (dinner plates, salad plates, saucers, etc.) on a vibratory belt conveyor. The vibration keeps the powder loose and homogenous, both of which are extremely important to the molding & firing process. It also causes a cloud of dust to rise along the entire length of travel, and they wanted to minimize this. Their chemists had told the engineer who called me that they could live with a small amount of moisture, as long as it wasn’t enough to make the powder clump up – this would evaporate out at a point closer to the molds anyway.

This was an ideal application for the EXAIR Atomizing Spray Nozzles…they produce a fine mist of liquid that is precisely controllable…one Model AW1010SS Internal Mix, Wide Angle Round Pattern Nozzle was installed near the beginning of the line, and once they find out how long it takes the dust-suppression supplied by the misted water to evaporate away, they will install more nozzles accordingly.

EXAIR Atomizing Spray Nozzles are a perfect solution for dust suppression.

EXAIR Atomizing Spray Nozzles are a perfect solution for dust suppression.

EXAIR Atomizing Spray Nozzles are ideal for situations where you need a fine liquid mist and fine adjustment of the flow & pattern. With ninety models to choose from, we’ve got the one you’re looking for. Call me if you want to find out more.

Russ Bowman
Application Engineer
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Finding The Right Solution Through Dedicated Engineering Support

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Plastic crate in need of blow off after washing

An OEM of crate washing equipment in Lebanon recently contacted me about an application on one of their conveyors.  The conveyor carries a plastic crate out of a washer and excess water on the crate was presenting a problem in the application.  In order for the crate to move on to the next step in the machine, a blow off solution was needed, but the exit rate from the washer was inconsistent.  In a given minute there could be 5 crates exit the washer, or there could be 20.  So, the ideal solution needed to have intermittent control options with instantaneous on/off functionality.

We immediately began discussing Super Air Knives, not only because we show plastic crate blow off in one of our many videos, but also because these units are instant on/off with full compatibility with a flow control device.  Utilizing a flow controller, such as the EXAIR Electronic Flow Controller or PLC device, will allow for precise control of the blow off solution, limiting compressed air use to a minimum.

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The first blow off system design

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This layout utilizes Air Knives on each side of the blow off as well as the top

After discussing application details we came to the design shown above, using one 24” Air Knife on the top of the crate and two 9” Air Knives on the sides.  However, this OEM had purchased numerous 2” Flat Stainless Steel Super Air Nozzles in the past (model 1122SS) and had a number available on site.  Modifying the system to utilize the nozzles already on-site, we came to this design:

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The finalized layout for this blow off system. Click for a larger view.

This layout utilizes (1) 24” Stainless Steel Super Air Knife on the top of the crate and (2) sets of (3) 2” Flat Stainless Steel Super Air Nozzles on the sides, held in place with EXAIR Stay Set HosesNotice the independent pressure regulators for the nozzles and the knife.  This is to allow the customer to balance the air flows, because the 2” flat nozzles will create a higher force than the Air Knife when operating at the same pressure.

In this application we were able to help a returning OEM solve their problem with the right mix of needed products.  Exploring the problem and discussing numerous viable solutions led to the best fit for the application and customer.  That’s precisely why EXAIR Application Engineers are available for any application call or question.  If you’d like to explore an EXAIR solution we’ll be happy to help.

Lee Evans
Application Engineer
LeeEvans@EXAIR.com
@EXAIR_LE

 

“(Stay) Set It And Forget It”

The Stay Set Hose is a popular, and practical, accessory for use with many of our blow-off products. Thread one end onto a compressed air supply connection, thread a Super Air Nozzle (or maybe even a small Air Amplifier or short Air Knife) onto the other end, and you’ve got an easily repositionable blow off…which will reliably hold its position.

That last part was of considerable importance to a caller I had the pleasure of assisting recently. Some of the CNC machines in their shop were fitted with flexible plastic tubing (commonly used for coolant & cutting fluid,) supplied with compressed air to blow off chips & debris from the tooling as the parts were being machined. They use our Super Air Knives in other blow off processes (where they used to use costly & loud open blow off devices,) and wanted to see if engineered products might reduce their compressed air consumption & noise levels in the machine shop too. (spoiler alert: Yes, they can.)

Thing is, they really needed the flexibility of the modular hose, but it’s not rated for the pressure supply required for a Super Air Nozzle. This is what makes our engineered products so efficient; they use the Coanda effect to amplify the compressed airflow..and they use the supply pressure to do that. So they can’t install a Super Air Nozzle on what they have now.

Enter the Stay Set Hoses: They’ll bend to direct the nozzles’ air flow right where you need it, and they’ll keep it there until you bend it again. Which (back to what’s most important to this caller) is exactly what they needed. With our efficient & quiet Super Air Nozzles, they’re saving compressed air and improving the conditions of their work environment. With the Stay Set Hoses, they’re able to quickly & easily rig the air flow before running a job, knowing they won’t have to worry about it until the job’s done.

EXAIR Stay Set Hoses hold their position as long as you need them to. All day, every day.

EXAIR Stay Set Hoses hold their position as long as you need them to. All day, every day.

“Set it and forget about it” is a benefit you can realize from many EXAIR Intelligent Compressed Air Products. If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
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Finding What You Want – A Black Friday Blog

In the United States, today is the day that we traditionally call “Black Friday” – the retail industry’s unofficial “start of Christmas gift shopping season” – where stores made a habit of opening up early with deep discounts on select items. Here’s the deal: these are SELECT items (that THEY select) and the hopes are, you’ll buy more stuff (that may or may not be on sale) while you’re there. If you know exactly what you want, it can be a good deal for you. If you don’t, it can be a good deal…for the store.

Although we don’t have Black Friday sales events (in fact, we – and I believe most others in the industry, are closed today,) it still makes good sense to know what you’re looking for before you start shopping.  Let’s consider something basic, like an air gun.

Left-right: Precision, Soft Grip w/Stay Set Hose, Heavy Duty w/Rigid Extension, & Super Blast Safety Air Guns. With so many to choose from, we've got the one you're looking for.

Left-right: Precision, Soft Grip w/Stay Set Hose, Heavy Duty w/Rigid Extension, & Super Blast Safety Air Guns. With so many to choose from, we’ve got the one you’re looking for.

Price: this can be a real two-edged sword…not much is cheaper than a commercial grade air gun that you can buy at just about any hardware store. But, they can use upwards of 50 SCFM.  By comparison, our Model 1210 Soft Grip Safety Air Gun uses only 14 SCFM (@80psig supply pressure.)  And in any typical industrial blow off application, it’ll do the exact same thing, and cost WAY less to operate.  Use this calculator to find out.

Sound level:  you won’t find a quieter blow off product on the market.  At 80psig, the 1210 Safety Air Gun is only running at 74dBA.  Others can be well over 100dBA…that’s up to 3 times as loud, and well in excess of OSHA’s limits published in Standard 29CFR1910.95(a).

Safety: OSHA also limits the dead-end pressure of compressed air blow off devices used for cleaning purposes, to 30psig.  Unless it’s fitted, or designed, with a relief feature, you can’t supply it with any more than 30psig compressed air…which won’t really do a lot, when you think about the jobs you want to use an air gun for.  Ours can’t be dead ended, so you can supply them with 80-100psig for strong performance AND safety…by design.

Durability: You get what you pay for.  Normally, I would say “’nuff said,” but for further proof of this, I submit this blog, from the archives, on our Durable, Safe, and Efficient Safety Air Guns.  ‘Nuff said (now, anyway.)

If you’d like to talk about your compressed air product application, and how an EXAIR Intelligent Compressed Air Product might be the solution you’re looking for, give me a call.

Russ Bowman
Application Engineer
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How To Not Use Any More Compressed Air Than You Have To

It should be no secret that EXAIR is all about compressed air efficiency. Our Super Air Knife is the most efficient (and quietest) blow off product on the market today. Our Application Engineering team is tech savvy, highly trained (continuously,) and dedicated to the goal of making sure you get the most out of our Intelligent Compressed Air Products and your compressed air system.  All of our products are engineered with efficiency and value in mind…and if it’s in the catalog, it’s right here in stock, so you can get it right away.  So that’s one way to not use any more compressed air than you have to…start saving it RIGHT NOW.

If you care about your compressed air use, you need one of these. Click here to get one sent to you today!

If you care about your compressed air use, you need one of these. Click here to get one sent to you today!

In addition to the highly efficient design of the Super Air Knife, we also help you to not use any more compressed air than you have to by offering them in any length you need.  We’ve got sixteen lengths in stock because, again, why wait to start saving?  We can also custom cut a Shim for any of those to get you just the air flow you need, or we can fabricate a custom length Air Knife if you’re space-limited.  You can have either of those in just three days.

Buy a Super Air Knife before December 31, 2016, and get a FREE Safety Air Gun!

A FREE Safety Air Gun is another great way to not use any more compressed air than you have to.

With sixteen stock lengths to choose from, product selection oftentimes comes down to which one(s) a user thinks will solve their application.  Such was the case just last week, when a major manufacturer of packing/shipping materials & supplies was building a new blow off station.  Based on their intended design, they ordered four Air Knives: (2) Model 110018 18″ Aluminum Super Air Knives, and (2) Model 110024 24″ Aluminum Super Air Knives.  I’ve written before about how something might have “looked good on paper,” and that’s what happened here…they found out that despite their design considerations, they just didn’t need all 24″ worth of air flow from two of those units, so they wanted to get two more 18″ Super Air Knives to replace them.  And it was an easy fix: this morning, we processed the order for (2) more 18″ Super Air Knives, and arranged for the return of the (2) 24″ ones…which we will issue full credit for, per the terms of our 30 Day Unconditional Guarantee.  They’ll start not using any more compressed air than they have to tomorrow, and it’s not costing them a dime.

You too, dear reader, can start saving quickly by calling me now to discuss your compressed air use, and which EXAIR Engineered Compressed Air Product is right for you.  Why wait?

Russ Bowman
Application Engineer
EXAIR Corporation
(513)671-3322 local
(800)923-9247 toll free
(513)671-3363 fax
Web: www.exair.com
Blog: http://blog.exair.com
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High Power Super Air Nozzles Provide Forceful Air Flow

When considering the application of a compressed air product, we have an awful lot of discussions with callers about the amount of force generated.  Now, if that’s all you want, you’re not going to get more force from compressed air flow from anything but an open ended blow off.  There are problems inherent with this: it’s unsafe, it’s loud, and it’s a horribly inefficient way to use compressed air.  By the time they’ve called EXAIR, they probably know this, but the main concern is still the same: solving their application.

Good news is, you don’t need a lot of FORCE for most blow off situations.  Think about it…how much do sawdust, machining chips, coolant droplets, etc., weigh, anyway?  All you really need to do is optimize the air flow, which is EXACTLY what EXAIR Intelligent Compressed Air Products are engineered & designed for.  So, we talk a LOT about how often a high amount of force isn’t needed in compressed air blowing applications.

Then…I got a call from a user who needed force.  They had an air knife installed to blow parts out of a mold, as the halves separated.  There’s a rectangular array of parts in a multi-cavity mold, and the air knife just wasn’t getting them all out, all the time.

The air knife, was, of course, originally chosen for its efficiency, but it just wasn’t delivering the needed “punch.” They even tried other shim thicknesses (which increases the outlet air gap) to increase the flow & force delivered, and that helped a little, but wasn’t 100% effective.

The solution came in the form of an array of HP1125-9212 2″ High Power Flat Super Air Nozzles, supplied with 12″ Stay Set Hoses.  They’re able to mount these closer to the mold than the air knife, and the ability for each nozzle to operate independently meant they were able to be aimed precisely where they can do the most good.  They are now able to evacuate the molds the first time, every time.

Sometimes, you DO need the high force of the HP1125 2″ High Power Flat Super Air Nozzle

If you have questions about how to get the most out of your compressed air use, give me a call.

Russ Bowman
Application Engineer
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