Custom Air Amplifiers for Special Applications from EXAIR

The EXAIR Super Air Amplifiers and Adjustable Air Amplifiers are used in 100’s if not 1000’s of applications and locations across the world.  For cooling, drying, and cleaning of parts as well as venting and exhausting of smokes and fumes, or dust collection – the Air Amplifiers are sure to get the job done.

The Super Air Amplifiers are made of aluminum and are sized from 3/4″ to 8″ to cover a wide range of applications. Compact and lightweight, no electricity, no moving parts, and instant on/off are just a few of the features.

The Adjustable Air Amplifiers are made of aluminum or type 303 stainless steel and are sized from 3/4″ to 4″, and with adjustable output, provide a wide spectrum of performance.  They have the same great features of the Super Air Amplifier with the added benefit of varying force and flow.

2″ Super Air Amplifier and 2″ Stainless Steel Adjustable Air Amplifier

Even with the wide variety of types, sizes, and materials of construction, a customer may have a special need and there are numerous ways that EXAIR can customize the Air Amplifiers.  I’ll touch on several from the basics to the most complex.

  • The Super Air Amplifiers come with a stock shim that sets the performance seen in the catalog. There are other shim thicknesses available if more or less flow is preferred, and they can be installed at the factory if desired.
  • The Adjustable Air Amplifiers are designed for varying output by turning the plug further in to or out of the body. If there is a performance setting that is preferred, we can test, adjust and set it to meet that performance, allowing to be installed and ready for optimum results.
  • If the use of a special material will increase the benefit of the Air Amplifier, we can explore several options with you. One customer needed an Adjustable Air Amplifier with a PTFE plug to help draw a sticky material through a process and prevent the material from adhering to the surface of the Air Amplifier.
  • For those applications where the Air Amplifier is to be installed into a piping system, custom design with flanged ends can be done. Recent designs include stainless steel Adjustable Air Amplifiers with class 150 raised face flanges, and another with sanitary Tri-Clamp style.

Adjustable Air Amplifier with PTFE Plug, Class 150 Raised Face and Sanitary Tri-Clamp Flanges

  • A special High Temperature version was developed for moving hot air to surfaces requiring uniform heating while in a furnace or oven. This special design is rated for environments up to 700°F and its surface is protected from heat stress by a mil-spec coating process.  This special High Temperature Air Air Amplifier was so popular, it became a standard offering and is in stock!

high temp air amplifier1-1/4″ High Temperature Air Amplifier

For over 35 years, EXAIR has been designing and manufacturing the best performing and highest quality products in the marketplace. If you have a special requirement and in need of a custom solution, we’ve got the experience and history to solve most problems.

If you have questions about Air Amplifiers, custom Air Amplifiers, or any of the 15 different EXAIR Intelligent Compressed Air® Product lines, feel free to contact EXAIR and myself or any of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer
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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.

 

Don’t Cry, EXAIR Air Amplifiers Will Help Remove the Fumes

Bitumen is a black viscous product that is used in asphalt, road surfacing, and roofing materials. Much of this product is moved by either railcars or tractor trailers to other industries.  Some precautions are needed when handling this product as the fumes can irritate the eyes, throat, and nose.

Fumes coming out of hatch below platform
Fumes coming out of hatch below platform

 

A plant that manufactures bitumen contacted EXAIR to see if we had a product that could improve their existing system. They were using a 6” (15 cm) venturi type air mover that was large and cumbersome.  It had a funnel that extended from the outlet by 4 feet (1.2m), and it weighed over 22 lbs (10 Kg.)  The air consumption of this unit was 81 SCFM (2,294 SLPM) of compressed air at 80 PSIG (5.5 bar).  They had to maneuver this heavy device by hand around an elevated platform.  The platform was designed with two smaller platforms that are positioned over the vehicles that they are filled for transport. One platform extended over a rail for railcars and the other platform extended over a driveway for tankards.  The air mover had to be moved and positioned near the filling areas to capture the fumes.  It was heavy, awkward, and in the way.

Their filling procedure was to place the air mover near the opening of the hatch to remove the irritating fumes away from the operators. The filling pipe was 4 inch (10cm) in diameter, and it was spring assisted for easy positioning.  Depending on the vehicle type, they would open a hatch ranging from 12 inches (30.5cm) to 16 inches (40.6cm) in diameter to fill.  The operator would then position the air mover near the opening, insert the fill pipe, and start filling.  The air mover was turned on to draw the vapor coming out of the hatch.   Because of its weight and size, the air mover had to be positioned on the platform at the edge of the hatch opening.  This was not optimum as some of the fumes could still escape at the farthest point away from the air mover.  Once the railcar or tanker was filled, they would move everything to the opposite platform to fill the next vehicle. Because of the design of the platforms and the size and weight of the air mover, there was a high possibility for personnel to become injured from the re-positioning process.  The customer wanted a more effective and ergonomic solution.

Railcar Filling Area
           Railcar Filling Area

The customer added some additional details about his operation. Because bitumen is a tar-like substance, it sticks and gets on everything, they would place dirty parts in an oven to melt the bitumen off the surfaces.  With this high temperature requirement and the size of the opening of the hatches that had to be covered, I suggested a 4 inch (10cm), Stainless Steel Adjustable Air Amplifier, model 6034.

EXAIR Air Amplifiers, have a large amplification ratio (the ratio between the amount of ambient air being moved compared to the amount of compressed air used).  The suggested model, is set for a 24:1 amplification ratio.  This helps greatly to draw in the fumes and smoke in the surrounding area to increase overall effectiveness and to reduce compressed air consumption.  With the size and weight of the EXAIR Adjustable Air Amplifier being much smaller than their present solution, they could mount it directly onto the side of the spring-assisted pipe used to fill the tankers with the product.  (The weight of the model 6034 is only 9 lbs. (4.1 Kg))  This was a major ergonomic success.  They did not have to worry about their operators hurting themselves moving a big, heavy, air mover, and it allowed the mouth of the Air Amplifier to be positioned right over the opening of the hatch.  This helped to catch all the fumes.  As a bonus, the model 6034 consumes only 50 SCFM (1,416 SLPM) of compressed air at 80 PSIG (5.5 bar).  The Adjustable Air Amplifier allowed for a reduction of 38% in compressed air usage when compared to the old method.  By switching to the EXAIR Air Amplifier, it saved them time, pain, money, and tears from eye irritation.

EXAIR Adjustable Air Amplifier
EXAIR’s Adjustable Air Amplifier

If you have an application where smoke and fumes are a nuisance,  Air Amplifiers are a great way to pack a lot of power into a small space for a variety of blowing and venting applications.

John Ball, Application Engineer
Email: johnball@exair.com
Twitter: @EXAIR_jb

Super Air Amplifier Provides Needed Ventilation

Behold: The Power of the Microwave!!!
Behold: The Power of the Microwave!!!

Over the weekend, my wife and I were doing some “re-organizing” upstairs (actually throwing away some old toys and clothes), when our son decided to make a snack. I heard the pantry door close so I asked, “hey bud, what are you doing down there?”  He promptly replied, “I’m just making a snack dad. How long do you normally microwave my soup?” While we questioned making soup at 9:00 AM for a snack, I reluctantly replied 2 minutes and heard the microwave begin. Slowly, a strange (awful) odor started to fill the house so I went downstairs to investigate. To my horror, I opened the microwave door to discover that he wasn’t making a snack for him, he was actually heating up a can of dog food, so his partner in crime (our dog), “could have a warm meal like us”.  I immediately took the snack to the garbage outside and attempted to remove the stench from the house. I opened a couple windows and turned on the stove exhaust but this was still not working. That’s when I started thinking it sure would be nice to have a Super Air Amplifier handy, to help evacuate some of the odor and make the house livable again.

Using a small amount of compressed air, the Super Air Amplifier entrains a large volume of surrounding air and pulls this air through the unit, resulting in a high velocity, high volume of air on the exhaust side. The intake, or vacuum, side of the Super Air Amplifier pulls in 25 parts of surrounding air for every one part of compressed air. This high volume of ambient air being moved makes the Super Air Amplifier ideal for venting and exhaust applications.

Additionally, the vacuum and exhaust ends can be ducted, which makes this a good product for moving air from one place to another or from inside to outside. They are used in many applications for assisting air circulation and available in styles which are placed in ovens (and other high temp areas), corrosive environments, and remote locations. With the large volumes of air being moved, they are also an ideal choice where cooling and drying is required.

Our Air Amplifiers entrain enormous amounts of "free" air, at ratios of up to 25:1!
The Super Air Amplifier entrains large amounts of surrounding air, at ratios of up to 25:1.

Air Amplifiers are some of the most efficient products in the extensive EXAIR line of compressed air products. They use a patented internal shim to minimize air consumption and increase air volume on the output side. The operate exceptionally quiet, are OSHA safe and CE compliant.

If you have a ventilation or fume exhausting application, please contact an application engineer for assistance.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

Day 619 /365 – Radiation Burns, Jason Rogers  Link

Super Air Amplifier Removes Fumes In Plastics Machining

I recently took a call from a customer who was using our Model # 120022, 2″ Super Air Amplifier to remove an odor that is produced from trimming their plastic pump impellers. The impellers are made of carbon fiber reinforced plastic and when they turn the larger impellers the Super Air Amplifier “works great”. The fumes are captured by the amplifier and exhausted through 10′ of duct attached to the positive pressure side of the amplifier. However, as they increase the speed to trim the smaller sizes, the amount of fumes would increase and remain in the area, so they called EXAIR for help.

Using the Coanda profile, the Super Air Amplifier utilizes a small amount of compressed air to induce a large amount of surrounding ambient air and directs it into the primary airstream. The surrounding ambient air is pulled into the Super Air Amplifier from the large diameter (vacuum side) to the small diameter (positive pressure side). The result is a large volume of outlet airflow, making them the ideal choice for this type of application. While the units are shipped with a .003″ shim installed, we offer both a .006″ or a .009″ shim (available in a Shim Set) that allows you to increase the gap, resulting in more volume of vacuum and positive pressure flow, and force.

Super Air Amplifer w- shims
Super Air Amplifier and Shim Set

I recommended the customer order the Shim Set, allowing them to increase the gap to induce a larger amount of air to evacuate the area. They are now using one unit, capable of handling both jobs.

If you have a similar application or need help with your existing Air Amplifier, give us a call!

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Special Air Amplifier? Not A Problem!

This week I worked with two customers that wanted to boost their air flow with an Air Amplifier. One customer ended up going with a Special Air Amplifier. The second customer I ended up pointing to a different product line entirely. Keep reading to find out why.

The first customer needed to boost the exhaust flow through six inch duct.  The six inch duct was an open vent that allowed fumes to slowly escape from a vessel. During normal operation the vessel, was unmanned, so the fumes only need a path to escape, but could linger. The company wanted to do some maintenance work in the area while the machine was in operation. The vent met the necessary requirements for the air flow of the machinery, but left maintenance workers exposed to a variety of fumes while working in the vessel, if the unit was in operation.

The customer was interested in the model 6034 Stainless Steel Air Amplifier. With 0.002″ air gap and 80 PSIG of inlet pressure, the unit will flow 1,200 SCFM of compressed air at the outlet of the Air Amplifier, but the 6034 can be adjusted to much higher flows from there.  The Air Amplifier would easily be able to exhaust the fumes from the area to maintain a safe and comfortable working environment. The problem was mounting the 6034 Adjustable Air Amplifier. The 6034 is designed to be used in free air with the discharge side of the air amplifier connecting to a duct. The suction side of the Air Amplifier is as open as possible to entrain air, but my customer needed to connect the Air Amplifier to the outlet of the vent. We worked with the customer on designing an Air Amplifier to fit the 6″ Flange that they used to connect sections of their duct similar to the Air Amplifier pictured below.

special air amplifier
This special stainless steel flange-mount Air Amplifier was designed for exhausting hot flue gases from a furnace.

My other customer called to move the air inside a heated drying tunnel. The customer uses a process air heater to heat a large drying tunnel. Unfortunately, the air heater created hot air at the entrance of the drying tunnel. By the time the air reached the end of the drying tunnel the temperature was significantly higher at the top of the tunnel as opposed to the bottom from natural convection. To counter this effect the customer wanted to move air from the process heater half way down the tunnel and release the air. In this application, the customer wanted to duct both the inlet and the outlet of an Air Amplifier. The Air Amplifier is not well suited for ducting and you limit the amount of air that the Air Amplifier can entrain by connecting it to a duct.

For this customer, I recommended he use a Line Vac. The Line Vac typically conveys materials, but it will also move a good amount of air.  The customer was going to use heated compressed air and wanted to convey the air from the process heater to the other side of the drying tunnel. Another key benefit to the Line Vac is the discharge and suction side of the units are both the same size.  This makes it extremely easy to install for the customer and is off the shelf, ready to ship.

Two similar applications on the surface that result in different product recommendation. Not every application for an air mover is this complicated, but if you want to talk through your application EXAIR’s application engineer’s will be happy to help.

Dave Woerner
Application Engineer
@EXAIR_DW
DaveWoerner@EXAIR.com