Cleaning Out Pipes, Extrusions and Blind Holes

Look at the picture below of a band saw cutting a piece of tubing.  The amount of debris and coolant that is coating the pipe on the inside diameter and outer diameter is substantial.  Cleaning off the outside of a pipe is fairly easy and straight forward.  Cleaning the ID can be difficult.  This is a single instance where one of the EXAIR Back Blow Air Nozzles can turn a cumbersome job into a quick and easy step in the process.

1 – Metal Cutting Bandsaw

The tubing in the photo appears to be around a 3 or 4″ ID tubing which makes it ideal to be cleaned out internally by the model 1006SS – 1/4″ Back Blow Air Nozzle.  This nozzle is ideal for passage ways ranging from a 7/8″ diameter up to a 4″ diameter.

1006SS – 1/4″ Back Blow Air Nozzle

While cleaning out the short section may be able to be obtained with a forward blowing Safety Air Gun, if this was being cut from a 20′ length of tube it would be difficult to remove the debris from the remnant section of tubing.  The advantage being the debris from the saw cut no longer has to be blown out or left in the longer lengths of the tube.   The Back Blow Air Nozzle can easily be inserted and remove debris back from the saw cutting end.  Lee Evans demonstrates this in a video below.

If you would like to discuss any compressed air application, please feel free to contact an Application Engineer.  We will gladly help you determine which EXAIR product may be right for your application.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

1 – Metal Cutting Bandsaw image – S.J. de Waard, Creative Commons License [CC BY 2.5 (https://creativecommons.org/licenses/by/2.5)%5D – https://commons.wikimedia.org/wiki/File:Metal_cutting_bandsaw_(02).JPG

 

Static Elimination for Hose, Pipe, Extrusion, Cable and Wire

EXAIR’s  Gen4 Super Ion Air Wipe provides a uniform 360 degree ionized air stream that clamps around a continuously moving part to eliminate static electricity and contaminants. It is ideal for removing dust, particulates and personnel shocks on pipe, cable, extruded shapes, hose, wire and more. This engineered product has undergone independent laboratory tests to certify it meets the rigorous safety, health and environmental standards of the USA, European Union and Canada that are required to attain the CE and UL marks. It is also RoHS compliant. New design features include a metal armored high voltage cable to protect against abrasion and cuts, a replaceable emitter point, integrated ground connection and electromagnetic shielding.

g4siaw_3mb

The Gen4 Super Ion Air Wipe uses a small amount of compressed air to entrain high volumes of ambient air. Two shockless ionizing points powered by our Gen4 UL Component Recognized 5kV Power Supply fills the air stream with static eliminating ions. That airflow impacts the surface of the material running through the air wipe and neutralizes the charge.

The Gen4 Super Ion Air Wipe, which compliments EXAIR’s complete line of Gen4 Static Eliminators, has an aluminum construction that is lightweight and easy to mount using the tapped holes provided. Two sizes include a 2 inch (51mm) diameter and a 4 inch (102mm). There are no moving parts to wear out. Visit EXAIR.com to see the entire Gen4 Static Eliminator product line and 1/2 inch through 11 inch Super Air Wipes for applications without static.

Purchase a Gen4 Super Ion Air Wipe through our online promotional before March 31st, 2019 and receive a fee AC Sensor.

absesqmaster_300sq

To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process, 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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Twitter: @EXAIR_JS

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.

 

EXAIR’s Industry Leading Super Air Knife Saves You Money

One common application that we get calls for each and every day centers around maximizing compressed air efficiency. I recently got to work with a customer who was using an inefficient blowoff method and was looking to replace it with an engineered compressed air solution. They had a total of (8) extrusion lines, each with (3) modular-hose style flat nozzles installed. Before a cooling bath they had one nozzle remove some of the heat, then as the extruded material exits the water bath another (2) nozzles blowoff any residual water. They were maxing out their compressor’s peak operating capacity and pressure drops across the system were causing problems elsewhere in other processes.

KIMG0161

They were operating each of the flat nozzles at 50 psi using a total of 17 SCFM per nozzle. We first calculated how much air the current method was using. The extrusion lines were run for one full 8-hr shift per day:

17 SCFM/nozzle x 3 nozzles/line = 51 SCFM per extrusion line

51 SCFM x 60 mins x 8hrs x 5 days x 50 weeks = 6,126,000 SCF

The extrusion lines accommodated product that ranged from 1”-2.5” wide. They wanted one single solution to use across all different products. We settled on (3) of our 110003 3” Super Air Knives. Let’s take a look at the compressed air requirement for (3) 110003 Super Air Knives, also operated at 50 psig.

A Super Air Knife will consume 1.9 SCFM/inch when operated at 50 psig:

1.9 SCFM/inch x 3 inches (per knife) = 5.7 SCFM/knife

5.7 SCFM x (3) total knives = 17.1 SCFM

17.1 SCFM x 60 mins x 8hrs x 5 days x 50 weeks = 2,052,000 SCF

Total savings per extrusion line – 6,126,000 SCF – 2,052,000 SCF = 4,074,000 SCF

4,074,000 SCF x 8 extrusion lines = 32,592,000 SCF

By replacing the (3) inefficient nozzles with EXAIR’s Super Air Knives, a whopping 4,074,000 SCF of compressed air is saved each year. With (8) total lines, this equates to a total of 32,592,000 SCF of compressed air. Most companies will know the cost of their compressed air usage per CFM, but a cost of ($0.25/1000 standard cubic feet) is a good baseline to use.

($.25/1000 SCF) x 32,592,000 SCF = $8,148.00 USD

By replacing (3) inefficient nozzles across all (8) extrusion lines with EXAIR’s industry leading Super Air Knife, they were able to save a total of $8,148.00 per year. In as little as (6) months, the Super Air Knives will have already paid for themselves!!

If you’ve been maxing out your compressed air system, don’t necessarily assume you need to increase your overall capacity. Put in a call to an EXAIR Application Engineer and we can take a closer look at the ways your using your compressed air throughout the facility. By replacing some inefficient methods with an engineered solution, we can help you save air and money!

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