About Compressed Air Dryers – What Are They and Why Use Them

All atmospheric air contains some amount of water vapor.  When air is then cooled to saturation point, the vapor will begin to condense into liquid water. The saturation point is the condition where the the air can hold no more water vapor. The temperature at which this occurs is knows as the dew point.

When ambient air is compressed, heat is generated and the air becomes warmer. In industrial compressed air systems, the air is then routed to an aftercooler, and condensation  begins to take place. To remove the condensation, the air then goes into separator which traps the liquid water. The air leaving the aftercooler is typically saturated at the temperature of the discharge, and any additional cooling that occurs as the air is piped further downstream will cause more liquid to condense out of the air. To address this condensation, compressed air dryers are used.

It is important to dry the air and prevent condensation in the air. Many usages of the compressed air are impacted by liquid water being present. Rust and corrosion can occur in the compressed air piping, leading to scale and contamination at point -of -use processes. Processes such as drying operations and painting would see lower quality if water was deposited onto the parts.

dryers.png

There are many types of dryers – (see recent blogs for more information)

  • Refrigerant Dryer – most commonly used type, air is cooled in an air-to-refrigerant heat exchanger.
  • Regenerative-Desiccant Type – use a porous desiccant that adsorbs (adsorb means the moisture adheres to the desiccant, the desiccant does not change, and the moisture can then be driven off during a regeneration process).
  • Deliquescent Type – use a hygroscopic desiccant medium that absorbs (as opposed to adsorbs) moisture. The desiccant is dissolved into the liquid that is drawn out. Desiccant is used up, and needs to be replaced periodically.
  • Heat of Compression Type – are regenerative desiccant dryers that use the heat generated during compression to accomplish the desiccant regeneration.
  • Membrane Type– use special membranes that allow the water vapor to pass through faster than the dry air, reducing the amount water vapor in air stream.

The air should not be dried any more than is needed for the most stringent application, to reduce the costs associated with the drying process. A pressure dew point of 35°F to 38°F (1.7°C to 3.3°C) often is adequate for many industrial applications.  Lower dew points result in higher operating costs.

If you have questions about compressed air systems and dryers 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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Patented Nozzle is a 2016 Flow Control Magazine Innovation Awards Nominee!

No Drip Atomizing Nozzle
No Drip Atomizing Nozzle

The patented (no longer patent pending) EXAIR No-Drip Atomizing Spray Nozzles have been nominated and are a finalist in the Flow Control 2016 Innovation Awards.  The No Drip Atomizing Nozzles are just a portion of the entire Liquid Atomizing Nozzle products that EXAIR Offers.   The No-Drip’s patented liquid shut off valve design eliminates the need for a separate pilot air line to positively shut off liquid flow ensuring there are no drips or excess flow from the nozzle.  These are ideal when dealing with fine surface finishes, costly liquids, or intermittent spraying needs.  The nozzles are offered in both pressure fed liquid and siphon fed liquid versions.

For the pressure fed version, the nozzle will require both compressed air and a pressurized liquid source. Both pressures can be adjusted independently giving a large spectrum of adjustment to fine tune the spray pattern and droplet sizes.  The siphon fed nozzles can draw liquid up to 36″ vertically or be gravity fed up to 18″ overhead.  This makes installation quick and easy when a pressurized liquid source, or liquid pump is not at hand.

The No-Drip Atomizing Spray Nozzles have also proven themselves in many applications, you can even read about a few of them here on our blog, links below.

https://blog.exair.com/2013/11/13/no-drip-atomizing-nozzle-improves-deep-drawn-metal-process/

https://blog.exair.com/2016/03/22/atomizing-nozzles-have-added-benefits-that-can-really-help/

2013 Innovation Awards
2013 Innovation Awards

 

Some of the reasons the EXAIR No-Drip Atomizing Nozzles were selected for these applications are the patented no-drip valve, their ability to atomize liquids to a range of 22-71 micron droplet size, the ability to fit into a tight space as well as the many spray pattern options.   These features have ranked the nozzles as a finalist in Flow Control’s 2016 Innovation Awards.

We are very grateful if you choose to vote for our nozzle at the link below. Please vote.

http://www.flowcontrolnetwork.com/innovationawards/

Voting is only open through July 31, 2016.  We’ll make sure to keep you updated if we win!

Brian Farno
Application Engineer Manager
BrianFarno@EXAIR.com
@EXAIR_BF

The Bigger, The Better

One of my favorite hobbies over the summer months is going camping with my family. I grew up camping with my grandparents, brother and 2 cousins. My grandparents did have a camper but the majority of the time, the 4 of us kids, camped behind the trailer in tents. My wife on the other hand was a “newbie” to the whole camping scene so when we decided to begin this adventure we purchased a low-cost, lightweight hybrid style camper so she could have all the amenities to keep her comfortable – a bed, A/C, toilet and TV.

This year we were planning on going on an early vacation in May so I wanted to get the camper out of storage and prepare it before we left so when we got back we could start our weekend camping trips right away. I headed over to the storage lot only to find a tree branch had fallen through the roof! Needless to say, I was not a “happy camper” (pun intended). Not only that but it appeared it happened some time ago as the ceiling and certain parts of the floor were getting soft from rain. I immediately called my insurance company to file a claim and dropped the unit off at my local RV shop.

Roof 1
View of branch through the roof
Ceiling 1
Uuummmm – I need to speak to the “Branch Manager”

After about a week, I received the call from the RV shop advising of the repair costs which were about $3,000 higher than the actual value of the trailer. The insurance reviewed this information and determined the unit as a total loss and would be issuing us a check for the market value of the unit. We were somewhat bummed because we really liked our little camper and the memories we shared. Our oldest son learned to ride his bike w/o training wheels and he caught his first fish while camping in that trailer. Now that my wife is on board with camping and with the extra $ in our pocket, it’s time to shop for a bigger, new camper – I am thinking 5th wheel! This also means a truck upgrade to something bigger, at least a 3/4 ton, something I am sure will make my wife happy.

Keeping with the bigger theme, here at EXAIR we recently released our NEW 1/2″ Atomizing Nozzles. The larger size allows for higher flow rates and larger coverage areas.

Model EF5010SS
NEW Model # EF5010SS – 1/2″ NPT External Mix Narrow Angle Flat Fan Pattern Atomizing Nozzle

We offer the following options:

Internal Mix Narrow Angle Round Pattern – Flows up to 231 GPH, require pressurized liquid and air.

Internal Mix Wide Angle Round Pattern – Ideal for covering a large area, adjustable to a fine mist or heavy spray.

Internal Mix Flat Fan Pattern – Perfect for efficient output of costly liquids.

Internal Mix 360° Hollow Circular Pattern – Provides 360° even flow in all directions.

External Mix Narrow Angle Flat Fan Pattern – Able to handle thicker fluids than internal mix and providing independent air and liquid control.

Siphon Fed Round Pattern – For non-pressured liquid applications, up to 24″ of suction lift.

All of the above are also available with our No Drip feature to stop the liquid flow after the air supply has been turned off.

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

 

 

It’s as easy as Pi

First off, I would like to say happy Pi Day!  To anyone that has to deal with math every day, or if you are a nerd like myself (and most of the rest of the crew here), then you know your 8th grade math teacher wasn’t lying when she said you’ll use this when your an adult.

So here at EXAIR the wonderful Professor Penurious has graced us all with pie for Pi day.

CoOp-Pi Day1
Wow, there is a TON of pie around here today!!

As I sit here eating a wonderful piece of cherry pie, I am thinking of how I had a customer that was wanting to buy the smallest Atomizing Spray Nozzle we offer, they currently had a model EB1040SS which is our largest External Mix Wide Angle Flat Fan Spray Nozzle.  Due to the versatility of our Liquid Spray Nozzles, instead of buying an entire new nozzle, the customer was able to simply buy just an Air and Liquid Cap.  They were extremely pleased with this solution due to the fact it is merely a trial situation and they aren’t quite sure what they need to achieve their goal.  What they do know is, they can buy multiple caps to interchange on their single body and perform all the testing they wish to determine what will cover their plethora of applications.

EB1040SSAN1010SS

If you have any questions or would like see which of our versatile products will fit your application, please let me know.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

You Can Never Have Enough Information

In case you don’t normally read the EXAIR blog, the general consensus among all the engineers here is that you can never have enough information.  To ensure that we pass on as much information as possible to our customers we have added even more to our website.  This time, we have given a vast amount of information on our Atomizing Spray Nozzles.

EBwine_400px

All of the information can be found on the page shown below.

droplet size

This information will allow you to easier select the appropriate Atomizing Spray Nozzle for the application.  Whether it is spraying a liquid coolant onto a drill press to help cool and lubricate the operation or painting parts, the information is there to help better assist you the customer.

Take a look at the new page and if there is anything that you don’t see there, let us know.  We may still have it in our files, if not, maybe we can get it for you fast.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

What Else Do I Need?

This question comes up a good amount when a customer calls in and asks about an EXAIR Product.   What else do I need in order to get this thing up and running.   It will depend some on the application the customer is trying to solve and some on the equipment the customer may (or may not) have in house, and some on how convenient and easy the customer would like to make the whole process. Let us look at the Industrial Housekeeping products, more specifically the Reversible Drum Vac Systems. (Mainly because this is the most recent product I have had a customer ask what else he needs to buy.)

The customer had already chosen a 55 gallon system (other systems available include a 30 and 110 gallon). When we look at the three different 55 gallon systems we offer, there is a clear difference in the number of items included in each kit.  The #6196 is a basic Reversible Drum Vac Kit.  For a unit like this, all you need to do is to provide a compressed air source and a tightly sealed 55 gallon steel drum. The picture below will show each item that is included in the kit.

6196

If you are worried about some liquid spills on the floor and you would like to get some extra pick up tools and a dolly for the steel drum you are providing, then the #6296 Deluxe Reversible Drum Vac System is for you.   It will include everything from the basic system plus, a drum dolly, Spill Recovery Kit, magnetic tool holder, and extra plastic tools.  Again, the only items you will need to supply are the air compressor, and the tightly sealed 55 gallon drum.

6296

The final solution that EXAIR offers is everything you need, the whole kit and caboodle if you will. This kit prevents sourcing compressed air supply line and a closed top drum. It’s all in the box – with the exception of an air compressor. In the #6396 Premium Reversible Drum Vac System you will received the drum, everything in the Deluxe Kit, but some of the tools that were plastic get upgraded to aluminum tools.   This gives you the complete solution with a few clicks on our website.

6396

Throughout all of our product lines we give you the option to choose the best solution and most convenient package to get the problem solved quickly. We hold stock on all of our products (and accessories) so we can ship same day when we receive an order by 3:00 pm est.  We have the necessary accessories for you to get our units in and simply plug them in to your compressed air supply.  Why go to multiple sites or vendors when they are all in one place.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF

Recap Of Mother’s Day Week 2013

This has been a busy week; here at EXAIR and at home.  Between Mother’s Day on Sunday, EXAIR Softball Practice on Tuesday and Thursday, some new product releases and finally ending tonight with a night of me watching my daughters while my wife enjoys a night out with friends.

First, for Mother’s day I found a project to build a squirrel feeder out of a fence post and glass jar.   So I built the feeder and the present from our daughters is that they get to decorate it with their mom.  (The squirrels are lucky that we don’t own a bedazzler …yet).

20130512_204102

Second, as my blog last week mentioned, the Softball team is coming together.  A good number of us went to a local field and hit the ball around for a few hours Thursday. It was nice to leave all the titles behind and just be a group of friends playing ball.  I do have to mention that so far we have had no injuries, other than lots of soreness from unused muscles.

No drip

Third on the list is that EXAIR is offering a full line of No Drip Atomizing Liquid Spray Nozzles now,   if you have a precious liquid, or if you can’t have over spray or dripping of the liquid then our No Drip Nozzles are the solution to your problems. The new nozzles don’t require an extra valve or separate air line.  Simply install it just like any other Atomizing Spray Nozzle from our line and then when the air pressure reaches 30 psig the internal valve will open allowing liquid flow.  Simply turn off the compressed air to stop the flow and not a single drip of liquid will escape.

As for tonight, the plans will be determined by a three year old and I will simply be the chauffeur.

Brian Farno
Application Engineer
BrianFarno@EXAIR.com
@EXAIR_BF