The EXAIRSuper Air Knives are used in many applications ranging from part drying, to web cleaning, to conveyor blowoff, and many other uses. For most processes, the aluminum models provide the performance required and withstand the environmental conditions present.
Ambient temperature limits for the aluminum models is 180°F (82°C). EXAIR also offers the air knives in types 303 and 316 Stainless Steel, which increase the temperature limit to 800°F (427°C) and provides a great degree of corrosion resistance. For the harshest, most corrosive environments, an air knife constructed of Polyvinylidene Fluoride (PVDF) with a temperature limit to 275°F (135°C) is available.
But what can we do about those applications where the increased corrosion resistance isn’t needed and the temperatures do not approach anywhere near to 800°F (427°C)?
The solution to this situation is an aluminum air knife with a custom stainless steel shim. The aluminum material is rated to 400°F (204°C) and the shim is good to 800°F (427°C) so this knife can be used in those hotter environments up to 400°F (204°C). This option helps to keep the cost of the knife low, by utilizing the lower cost aluminum for the body and cap.
The table below details the materials of construction options for the Super Air Knife – a wide array of material offerings to suit even the hottest, harshest conditions.
We recommend consulting with an Application Engineer to review the application, process, and environmental conditions, and we can present best options.
And don’t forget, the shims can be further customized for special blowoff requirements. See the blog that my colleague, Russ Bowman, posted here.
If you have questions about Super Air Knives 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.
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!
1-1/4″ 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.
High Temperature – For enclosures that reside in high temperature ambient conditions such as near furnaces, boilers, or ovens, EXAIR offers a High Temp version, with special internal components designed to withstand the elevated temperatures. Cabinets near sources of high heat certainly need to be kept cool, and the EXAIR High Temperature Cabinet Cooler is specially suited to for use in these locations.
Non-Hazardous Purge (NHP) – Cabinet Cooler Systems with this feature provide a continuous positive purge within the enclosure to prevent contaminants from entering through small holes or conduits. Especially suited for dirty and dusty environments, the NHP Cabinet Cooler Systems provide a slight positive pressure inside the enclosure. This is done by passing 1 SCFM (28 SLPM) of air through the cooler when the the solenoid is in the closed position. When the thermostat reaches the set-point temperature and energizes the solenoid, the full line pressure of air is delivered to the Cabinet Cooler providing the full cooling capability, and still keeping the positive pressure. When the internal temperature cools to the set-point, the solenoid closes and the system returns to the 1 SCFM (28 SLPM) of air flow condition.
Type 316 Stainless Steel NEMA 4X Cabinet Coolers – For enclosures that are in food service, pharmaceutical, harsh, and/or corrosive environments, and any application where 316 stainless steel is preferred, the Cabinet Coolers are available in the Type 316 stainless material. The systems are UL Listed for wash down environments, ensuring the enclosure electrical contents remain cool and dry under any condition. Noted applications include on ocean going ships, power plants, medical device manufacturing facilities, and bakeries.
Please note that the High Temperature, Non-Hazardous Purge and Type 316 Stainless Steel Cabinet Coolers are each available from stock! No waiting for these special models.
The EXAIRAir Amplifiers are a powerful, efficient and quiet air mover, whose power can be harnessed for blowoff, cooling and ventilation applications. Using a small amount of compressed air, air amplifiers pull in large amounts of surrounding air to produce a high volume, high velocity outlet flow. Quiet and efficient, output flows with amplification ratios of up to 25 times are possible. There are two types, the Super Air Amplifier and the Adjustable Air Amplifier.
The Super Air Amplifier, with sizes ranging from 3/4″ to 8″, has a patented design (patent #5402938) that uses a special shim to maintain critical position of the components parts. It is through this critical gap setting that a precise amount of compressed air is passed at exact intervals controlled by the shim toward the center of the of the Super Air Amplifier. The jets of air create a high velocity flow across the entire cross sectional area, which in turn pulls in large amounts surrounding air, resulting in the amplified outlet flow. Because the outlet flow remains balanced and minimizes wind shear, sound levels are typically three times lower than other types of air movers. The shims are available in thicknesses of 0.003″ (supplied as standard), 0.006″ and 0.009″, and changing to a larger shim will increase the force and flow of the outlet air. The 8″ Super Air Amplifier is supplied with a 0.009″ shim, with a 0.015″ shim available.
2″ Super Air Amplifier and Patented Shim Design
For high temperature applications (up to 700°F/374°C) a special 1-1/4″ High Temperature Air Amplifier is available, with performance equal to the 1-1/4″ Super Air Amplifier. Its surfaces are protected from heat stress by a mil-spec coating process. The High Temperature Air Amplifier is highly effective at pushing large amounts of hot air to areas that typically remain cool.
The Adjustable Air Amplifier, with sizes ranging from 3/4″ to 4″, does not use a shim, and has an infinitely adjustable air gap, which regulates the air consumption and outlet flow from a light breeze to a powerful blast. A highly effective air mover, it can be tailored to meet the exact air flow and force of your specific application. They are available in aluminum and in stainless steel (Type 303) for food service, higher temperatures (400°F/204°C) and corrosive environments.
Force and flow of the Adjustable Air Amplifier is changed by loosening the knurled lock ring and turning the exhaust end to open or close the gap. Once the desired force and flow is achieved, the knurled ring can be tightened to lock the device at the current setting. Typically, an air gap of 0.002″ to 0.004″ provides the required performance.
The table below summarizes the key features of the Super Air Amplifier and Adjustable Air Amplifier. Please contact an Application Engineer if you need assistance in making a selection.
Note that EXAIR can manufacture special Air Amplifiers to your specification including special flanged mounting style or with a PTFE plug to avoid sticky material build up.
To discuss your application and how a Super or Adjustable Air Amplifier or any EXAIR Intelligent Compressed Air Product can improve your process, feel free to contact EXAIR, myself, or one of our other Application Engineers. We can help you determine the best solution!
EXAIRVortex Tubes are a low cost, reliable and maintenance free solution to a wide variety of industrial spot cooling problems. They only requirement is a supply of compressed air as the power source. Vortex Tubes have no moving parts and can produce temperatures that range from -50°F to +260°F (-46°C to +127°C).
Vortex Tubes produce two air streams one cold and one hot, the percentage of cold air flow from the inlet flow is referred to as the cold fraction. The cold fraction is adjustable by the hot valve on the hot discharge side of the vortex tube. Adjusting the hot valve results in both air temperature and air volume changes. The colder the air becomes, the volume of that cold air declines. So for very cold temperatures, a smaller volume of air is produced compared to a warmer air temperature.
For the vast majority of industrial cooling applications a larger volume of cool air will provide more efficient cooling than a lesser amount of very cold air. Generally speaking the highest Btu/Hr values are in the 70-80% cold fraction range.
The exception to this would be in labs or special cases where the coldest temperatures are desired. Adjusting a Vortex Tube is easy, simply insert a thermometer/thermocouple in the cold air exhaust and set the temperature by adjusting the valve on the hot end of the Vortex Tube. You will know when you reach max refrigeration (80% cold fraction) as the cold air temperature will be 50°F (28°C) lower than the compressed air supply temperature.
EXAIR Vortex Tubes are constructed from stainless steel. This ensures excellent wear resistance, corrosion resistance and assures years of reliable operation. They are offered in 3 different size ranges (small, medium & large). There are generators located inside the tube (user serviceable) that will change the volumetric flow. The generators are available in a plastic construction or brass construction for high temperature applications. The ranges 2 SCFM – 8 SCFM are designated as small Vortex Tubes, 10 SCFM – 40 SCFM are medium and 50 SCFM – 150 SCFM are large. This feature allows you to customize or change your Vortex Tube for greater flexibility in a wide range of applications.
Large Vortex Tubes are specified when a high flow of cold air is needed. There are 16 models to choose from in total. Capable of providing 3,400 BTU/HR up to 10,200 BTU/HR of cooling power. These have been used to cool high heat loads that are centrally located or to help cool samples of gases for testing.
Medium Vortex Tubes are the most popular – there are twenty to choose from, depending on the cold air flow rate and temperature you’re looking for. These can produce temperatures as cold as -40°F (-40°C) when set to a 20% Cold Fraction (which is the percentage of total supply air that’s directed to the cold end) and cold air flows as high as 32 SCFM when set to an 80% Cold Fraction, which will produce a cold air temperature of about 20°F (-7°C). Some common uses are cooling ultrasonic welds and brazed joints.
The Medium Vortex Tubes are so popular, in fact, that they’re incorporated into our Adjustable Spot Cooler and Cold Gun Systems. They come ready-to-go with mufflers, cold air hose kits, and magnetic bases, so they couldn’t be easier to use.
Small Vortex Tubes are great when low flows (less cooling power) will succeed, or if compressed air supply is limited. There are 12 models in total to choose from. These are specified for much smaller applications, like cooling the needle of a sewing machine, small drill bits, etc. You can also get one with a cold air hose & magnetic base…that’s the Mini Cooler System.
Last year I worked with a power company that was having issues with Position Feedback Sensors overheating causing erroneous readings and early failures. The sensors were located above a steam turbine, and the ambient temperatures reached 128°F with spikes to 140-150°F. The customer had called in looking for a way to keep the sensors cool, using minimal compressed air, and in a robust package. After reviewing the details, we recommended the High Temperature Vortex Tube, model HT3210. While using just 10 SCFM of 100 PSIG compressed air, the HT3210 provides 8 SCFM of cold air at a temperature drop of 54°F from the supply air temperature. Bathing the sensor with this cool air keeps prevents it from heating up and has eliminated the bad readings and prevented the early failures.
The customer recently implemented the same fix for another set of sensors.
The High Temperature Vortex Tube is a special Vortex Tube offering from EXAIR that utilizes a brass generator and hi-temp seal for use in ambient temperatures up to 200°F. Simply supply clean, dry compressed air, and get cold air starting at 50-54°F lower than the supply air temperature. With sizes ranging from 2 to 150 SCFM, there is a Vortex Tube that will meet most applications.
If you have questions about the Vortex Tubes, 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.
As an Application Engineer, one of the interesting aspects of working with customers on applications is the varied types of solutions an EXAIR product can provide. The Air Amplifier family – Super Air Amplifier, Adjustable Air Amplifier, and the special High Temperature Air Amplifier can be used in a wide variety of process and applications. Below highlights several of those from past experiences.
A defense contractor was performing maintenance service on a Navy ship, and the ventilation system had to be shut down. To keep the personnel cool and safe, an auxiliary ventilation was to be supplied. Rather than use a cumbersome blower assembly, which has to mounted on the top deck, and ducted down to the lower decks, they chose to utilize (2) 4″ Super Air Amplifiers. They are very portable and can be set up in minutes. This solution provided the necessary air flow, providing a safe environment for the maintenance crew.
A light bulb manufacturer needed a better solution for a cooling operation. During manufacturing of a mercury lamp, the bulb must be cooled from 700°C to 600°C in just 15 seconds. The current method, an open brass pipe, was working but the noise level was too high (95 dBA.) The goal was to maintain the 15 second cooling time, but reduce sound levels to 85 dBA. By utilizing (2) of 3/4″ Adjustable Air Amplifiers, the customer was able to maintain the cooling rate, and reduce the noise level down to 80 dBA, a 15 dBA reduction.
A garbage collector presented a problem that needed a solution. The garbage was incinerated and when the furnaces were first started up, there tended to be issues with getting the flue to draft properly. Using the High Temperature Air Amplifier, the high velocity air flow and draw provided the needed draft until the stack warmed up and the natural draft would be established. Since the unit is capable of handling temperatures up to 700°F, it was able to withstand the heat of the process after the compressed air was turned off.
These and other Applications for the Air Amplifiers and all other EXAIR products can be found on the EXAIR website on the Products page, under the Related Info section toward the bottom of each page.
If you have questions regarding Air Amplifiers or any EXAIR Intelligent Compressed Air® Product, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.