Tag: mining

Big Dust Problem, Small Spray Nozzle Solution

Published on by Russ BowmanLeave a comment

A company that provides contamination control solutions to the mining industry needed to suppress dust from mined ore on a conveyor belt. Inexpensive spray nozzles supplied from the plant’s water system suppressed the dust, but resulted in a fair amount of runoff. This wasn’t an issue in a lot of their applications, but environmental regulations called for containment of the runoff from this particular material, so it was critical to minimize that runoff.

The conveyor belt was six feet (1.8 meters) wide and was relatively slow moving, so I specified two Model AF8020SS 1/8 NPT Internal Mix Flat Fan Pattern Air Atomizing Spray Nozzles, each capable of spraying up to 4.27 gallons per hour of water over a 47″ width at a distance of 15″ from the surface. This allowed for flexibility in mounting, and some overlapping spray in the middle, where dust suppression was needed most – and any excess spray would be contained in the bulk of the material.

Internal Mix Atomizing Spray Nozzles are the perfect choice for fine mist and precise control, which is critical for dust suppression applications.

At first, they were skeptical about the size of the 1/8 NPT Air Atomizing Spray Nozzle. The liquid nozzle they were using was “about as large as a baseball” and was supplied with a 1/2″ pipe. Once installed, though, they were impressed with the fine mist in the broad, thin pattern that was easily – and widely – controllable by regulating the air & liquid supply pressures.

From Round Patterns (left), to Flat Fan Patterns (middle), to Hollow Circular Patterns (right), EXAIR has Spray Nozzles to suit your liquid spraying needs.

EXAIR Air Atomizing Spray Nozzles are THE ideal solution when you need low flow rates – whether it’s for conservation of expensive liquids, eliminating drips or runs when applying coatings, or preventing runoff like in this application. If you want to find out how EXAIR can help you get the most out of the liquid you’re spraying – and your compressed air usage – give me a call.

Russ Bowman, CCASS

Application Engineer
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ATEX Rated Cabinet Cooler Systems Now Available From EXAIR!

Published on by Russ BowmanLeave a comment

In 1815, Sir Humphrey Davy patented an oil lamp for use in coal mines, and coincidentally pioneered the movement to provide safe and reliable products for use in explosion-prone environments. In the days before electricity, miners used lamps that burned fuel oil for lighting. The problem with that was, deposits of underground coal are almost always accompanied by methane gas pockets which, when mixed with coal dust in proximity to an open flame, created terrible and deadly explosions. Davy’s design incorporated a brass net around the wick chamber that let the light out, and let oxygen (necessary for combustion of the fuel oil) in, but if methane entered the wick chamber, it’d extinguish the flame and prevent ignition of the gas outside the lamp.

Industrial growth and the proliferation of electricity that (literally) powered it introduced new hazards in a number of industries other than just mining…which grew exponentially through the 19th century, since coal was the main fuel in electric generating plants. As hazards were identified (usually, unfortunately, by a tragic accident), new and safer products were developed, and eventually, industry professionals implemented controls & standards to make sure these new and safer products were designed, manufactured, and used for the prevention of future tragic accidents.

In North America, the National Electrical Code’s (NEC) system of Classes and Divisions specifies requirements of electrical product testing & use to ensure safety in this regard. In 2014, the European Union created the ATEX Directive, which specifies similar (but not identical) requirements, also aimed at mitigating explosion risks in industrial environments. In 2019, EXAIR introduced our HazLoc Cabinet Cooler Systems, which comply with certain NEC requirements, and we just recently introduced ATEX Cabinet Cooler Systems to comply with that directive.

Both the HazLoc (left) and ATEX Cabinet Cooler Systems are available from stock in NEMA 4 and NEMA 4X ratings.

Like our HazLoc Cabinet Cooler Systems, their ATEX counterparts have been subject to stringent UL testing to ensure compliance with the ATEX Directive. They’re approved for use in areas defined by the Directive as:

  • Zone 2 (an atmosphere where a mixture of air and flammable substances in the form of gas, vapour or mist is not likely to occur in normal operation, but if it does occur, will persist for a short period only) and
  • Zone 22 (an atmosphere where a mixture of air and flammable substances in the form of powder or dust is not likely to occur in normal operation, but if it does occur, will persist for a short period only.)

This fall, EXAIR will celebrate 40 years of dedication to safety and efficiency in engineering & manufacturing compressed air products for a wide range of applications. If you’d like to find out how our Cabinet Cooler Systems – or any of our Intelligent Compressed Air Products – can increase safety and efficiency, and lower sound levels for your compressed air usage, give me a call.

Russ Bowman, CCASS

Application Engineer
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Compressed Air Use in the Construction Industry

Published on by John BallLeave a comment

EXAIR uses many different methods to connect with our customers.  We have our website, social media, blogs, publications etc. We like to share solutions for some of the most common pneumatic problems in the industry.  EXAIR generated a large collection of application information where EXAIR products have solved problems and improved processes.  We organized them by Application and by Industry.  In this blog, I will show you how to use the Application database; specifically, for the Construction Industry.

Compressed Air Systems are considered to be a fourth utility within industries because they use a large amount of energy.  Whether it is an air compressor using fuel for portable units or electricity, it is important to use the compressed air as efficiently as possible.  This would apply to the construction industry.  From blowing off sheets of lumber to cleaning sites with an EXAIR Industrial Vacuum to cooling hot melt on window frames, EXAIR has a library of different processes in which we already accomplished these improvements.  We like to use the expression, “Why re-invent the wheel” at EXAIR.  If you are in the construction industry, it would benefit you to take a peek at the implementations where we already improved, made safe, and saved money.

Here is how you can find this library.  First, you will have to sign into EXAIR.  Click here: Log In.  Once you fill in the proper information, you can then retrieve a great amount of resources about EXAIR products that we manufacture.   The Application Database is under the Knowledge Base tab.  (Reference photo below).

At the Application Search Library, we have over one thousand applications that we reference.  In the left selection pane, we organized then in alphabetical order under two categories, Applications and Industry.   (Reference photo below).

Scroll down in the selection pane until you come to the sub-category: Industry.  Under this Sub-category, you will find three selections that are related to this blog: Construction; Construction and Mining Equipment; and Construction, Lumber.  You will find many applications that EXAIR has already improved and documented.

Why is this important?  If you are a plant manager or owner, the value of the Application Database can improve your current processes with pre-qualified results.  Within the construction industry, simple solutions can be found to address those “nagging” issues that you encounter every day.  For crisis situations and shutdowns, EXAIR categorized these applications in a way to reference quickly and easily.  And since EXAIR has a high volume of stocked items, we can get the product to you very fast; minimizing downtime.

In today’s market, companies are always looking for ways to cut cost, increase productivity, and improve safety.  EXAIR can offer engineered products to do exactly that.  With the “been there and done that” solutions already described in the Application Database; you can have confidence in finding a way in solving pneumatic issues.  If you do not sign up at www.EXAIR.com and take advantage of these offerings, you will be missing out on a great tool in optimizing your compressed air system.

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

EXAIR’s High Power Cold Gun Keeps Saw Blade Cool in Mining Operation

Published on by Tyler DanielLeave a comment

Our distributor in Peru recently contacted me with an application they were working on with a customer of theirs that deals in the mining industry. They are one of the largest gold mining companies in South America and were looking for a means of keeping their saw blades cool without having to use any type of coolant or water.

In this specific application, they had been using water to maintain the temperature of the blade while cutting. While this did work, it created quite a mess and also resulted in product contamination. The water on the floor presented a slipping hazard and production would have to periodically be halted so that someone could come by and clean the mess off of the floor. So, not only were they creating a contamination issue, but also a safety concern as well as lost production time.

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Cold Guns installed

Our distributor introduced them to EXAIR and our line of Cold Gun Spot Cooling Products. By replacing the water cooling with (2) Model 5230 Cold Gun systems, they were able to maintain the temperature of the blade at 24°C (75°F), well within their specifications. This allowed them to completely eliminate the need for water as a cooling method, improving their worker safety as well as increasing production.

Efixo Demo Cold Gun.png1

EXAIR’s Cold Gun utilizes Vortex Tube technology to create two streams of air: one hot and one cold. The hot air is muffled and exhausted, while the cold air is also muffled and ducted to deliver a cold stream of air directly onto the material needing to be cooled. With only a supply of clean, dry compressed air required to operate, installation is quick and easy. Since the Cold Gun has no moving parts to wear out, there’s also no maintenance required so long as the Auto-Drain filter included in the kit is installed upstream of the Cold Gun.

If you’re tired of dealing with messy water-based cooling systems or equally messy coolants, give an Application Engineer a call today and try out a Cold Gun. With our Unconditional 30 Day Guarantee, there’s absolutely no risk to do so!

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