Flat Super Air Nozzles… Safe, Efficient, and Rebates?

1126 1" Flat Super Air Nozzle and 1122 2" Flat Super Air Nozzle
Left 1122 2″ Flat Super Air Nozzle and Right 1126 1″ Flat Super Air Nozzle

The EXAIR Flat Super Air Nozzles are manufactured to blow a wide, forceful stream of air.  Their engineered design creates a high-velocity, laminar air stream with minimal air consumption and low noise levels.  They come in two widths; 1” (25mm) and 2” (51mm).  EXAIR offers a standard Flat Super Air Nozzle and a High Force Flat Super Air Nozzle in two different materials: zinc-aluminum alloy and 316 stainless steel.  And with a metal construction, breakage is not a concern, and performance is not sacrificed even in the harshest of environments.  The unique patented shims inside the EXAIR Flat Super Air Nozzles will give you three improvements to the design and function.  First, they come in different thicknesses to create a wide range of forces.  In conjunction with a regulator, you can “dial” in the correct amount of force from a breeze to a blast without overusing your compressed air system.  The patented design also allows an even flow across the entire width of the air nozzle.  Lastly, the design helps to entrain the free ambient air, so that less compressed air is required, saving you money.  The EXAIR Flat Super Air Nozzles are effective in uniform blowing with safety and efficiency in mind.

Flat Super Air Nozzles have replaceable shims to vary performance.

To expand more on force adjustments with the Flat Super Air Nozzles, EXAIR has an easy way to change the shim to better suit your application.  You can increase or decrease the force of the nozzle by just removing two screws and changing the thickness of the shim inside.  EXAIR offers a Shim Set to give you a range of forces with the nozzles.  For the standard Flat Super Air Nozzle, they come with a 0.015” (0.38mm) shim for both the 1” and 2” sizes.  The corresponding Shim Sets will include a 0.005” (0.13mm), 0.010” (0.25mm), and 0.020” (0.51mm) shim.  The High Force Flat Super Air Nozzles will come standard with a 0.025” (0.64mm) shim, and the Shim Set will include a 0.020” (0.51mm) and a 0.030” (0.76mm) thick shim.  This is a unique feature, as the competition’s plastic flat nozzles do not have this option.

In addition to the features and benefits, the Flat Super Air Nozzles come with a lip for safety reasons.  Occupational Safety and Health Administration, OSHA, has a federal regulation, 29CFR 1910.242(b) to eliminate dead-end pressure.  This states that pressure over 30 PSIG (2 bar) can penetrate the skin and can cause injury or death.  With the safety lip on the Flat Super Air Nozzles, it eliminates that concern, even above 30 PSIG (2 bar) inlet air pressure.  Unlike pipes and copper tubes where the skin can cover and block the exit, the lip on the Flat Super Air Nozzles will allow the air to escape.  So, you cannot block the exit (reference photo above). 

EXAIR Safety Air Nozzles are engineered to be safe, quiet, and very efficient.  They are so efficient that many electrical companies offer rebates for efficient products to help reduce energy consumption.  EXAIR offers ways to calculate ROI (Return on Investment) and energy savings by using our products.  We even offer an Efficiency Lab to measure with calibrated equipment to do comparative analysis.  But if your local energy company has a rebate program, then you can receive even more money back.

EXAIR has partnered with Energy Star, a program of the U.S. Department of Energy (DOE) and the Environmental Protection Agency (EPA).  For statewide programs, The NC Clean Energy Technology Center has created a website that consolidates this information for you on their website: www.dsireusa.org.  “DSIRE is the most comprehensive source of information on incentives and policies that support renewable and energy efficiency in the United States”.  Since EXAIR’s products fall into this category, rebates can be applied to the use of our products. If there is a rebate available, you will find it on this site.

With the EXAIR Flat Super Air Nozzles, you can take advantage of their durability, safety, and efficiency for your blow-off devices.  And depending on the state that you are in, you may be awarded a rebate.  If you need any help with drawings, performance, or setup of our Flat Super Air Nozzles, you can speak with an Application Engineer at EXAIR.  We will be happy to help you.

John Ball                                                                                    

Application Engineer

Email: johnball@exair.com

Twitter: @EXAIR_jb

Engineered Compressed Air Nozzles and Utility Rebates

When EXAIR started to manufacture compressed air products, we created a culture in making high quality products that are safe, effective, and efficient.  Being leaders in this industry, we created a program, the Efficiency Lab, to compare blow-off devices with EXAIR products in noise levels, flow requirements, and force measurements.  With calibrated test equipment, we compare the data in a qualified report to share with our customers.  This information can be helpful to determine the total amount of air savings and safety improvements that EXAIR products can offer.

Flat SANs 1in
Zinc Aluminum models are suitable for general purpose blow off (left) and 316SS models are specified for food/pharma and high heat applications.

In conjunction with the Efficiency Lab, we created a Cost Savings Calculator.  It is a quick way to view payback periods and annual savings when using EXAIR products.  As an example, I used a 1” Flat Super Air Nozzle, model 1126, and compared it to a 1/8” open pipe.  (The reason behind the comparison is that the model 1126 can screw onto the end of the 1/8” NPT pipe.)  With an operation of 24 hours/day for 250 days a year, the amount of air used by an 1/8” open pipe is near 70 SCFM (1,981 SLPM) at 80 PSIG (5.5 Bar).  The model 1126 has an air consumption of 10.5 SCFM (297 SLPM) at 80 PSIG (5.5 Bar).  By putting the information in the Cost Savings Calculator, it determined that the ROI was in 2.1 days.  The annual savings was $5,355 USD per year.  Imagine if you replaced ten blow-off spots in your facility, the amount of money that could be saved.  Here is the worksheet below:

flat 1

The people that started to notice the savings were the utility companies that make electricity.  Depending on your location, electrical suppliers initiated a rebate program to use engineered nozzles in your facility.  Similar to other energy saving rebates, like LED light bulbs and high efficiency furnaces, the electrical providers notice a big savings when using EXAIR products.  If you qualify, the total cost to purchase and implement the EXAIR Super Air Nozzles are reduced.(Even if a rebate program has not been implemented in your area, the idea of saving energy and compressed air makes it very profitable and environmentally sound in changing over to EXAIR products).

To see if your utility offers rebates on compressed air optimizations, go to the DSIRE database. This database is easy to search and informative.

For Example, here in Ohio Duke Energy has a Prescriptive Incentive Program for its customers. The Prescriptive Incentive Program makes it easy for Duke Energy customers to receive an incentive for their natural gas and electric energy efficiency projects. Prescriptive Incentives are energy efficient measures paid per-unit, reimbursing the customer up to the total cost (including materials and labor) after the measures have been installed. See the image below for their incentives for using Engineered Nozzles;

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Ohio Duke Energy Prescriptive Incentive Program

https://www.duke-energy.com/business/products/smartsaver/industrial-equipment

To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process and save you money, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Jordan Shouse
Application Engineer

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