Super Air Knife Makes EVERYTHING Better

When we compare the EXAIR Super Air Knife to other methods of providing a curtain or sheet of air flow in terms of operating cost, efficiency, safety, and sound levels, the Super Air Knife is ALWAYS the clear choice.

The EXAIR Super Air Knife is the most efficient and quietest compressed air blow off product on the market today.

The Super Air Knives successfully replace these, and many other methods of providing a curtain or sheet of air flow all the time, while saving compressed air and decreasing noise.  The word “replace” oftentimes means “do the same job as.”

What you’re about to read is NOT one of those times.

A paper products manufacturer has a machine that treats a specialty product, and the process generates ozone (O3) at levels that would exceed personnel exposure limits, so they need to be contained.  They installed a long piece of drilled pipe to blow an air barrier, but they could only run the machine at about 65% of their desired capacity before the ozone level in the operators’ area exceeded their limits.

This company was familiar with several of our product lines already…they had several Cabinet Cooler Systems, a Reversible Drum Vac, and Super Air Knives in a variety of applications, so they knew how they worked.  Since the barrier needed to be 120″ long, though, this was going to be a much larger scale than they were used to.

Not only was the drilled pipe loud and inefficient, it was not particularly effective either.

Still, the installation of two Model 110060 60″ Aluminum Super Air Knives, coupled with our Model 110900 Air Knife Coupling Kit, was quick and easy.  Then came the good part: they found they were able to operate the machine at 100% capacity, while keeping the ozone at a safe level in the operators’ area.

EXAIR Super Air Knives provided a total solution: quiet, efficient, and most of all, EFFECTIVE.

Then came the better part:  The machine was pretty loud (we couldn’t do anything about that,) at 93dBA when it was running.  With the drilled pipe in operation, it was 94.5dBA.  When they took that out and installed the Super Air Knives, there was no net increase in noise level…it remained at 93dBA.

THEN came the even better part: Compressed air consumption was reduced to about 30% of what the drilled pipe was using.  Right in line with our table above.  Just another validation of the trustworthiness of our published data.  As EXAIR’s President is fond of saying, “Claims are easy, proof is hard.”

If you’re looking for a quiet, efficient – and effective – solution for a compressed air product application, give me a call.

Russ Bowman
Application Engineer
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FREE EXAIR Webinar – November 2nd, 2017 @ 2:00 PM EDT

On November 2, 2017 at 2 PM EDT, EXAIR Corporation will be hosting a FREE webinar titled “Optimizing Your Compressed Air System In 6 Simple Steps”.

During this short presentation, we will explain the average cost of compressed air and why it’s important to evaluate the current system. Compressed air can be expensive to produce and in many cases the compressor is the largest energy user in a plant, accounting for up to 1/3 of the total energy operating costs. In industrial settings, compressed air is often referred to as a “fourth utility” next to water, gas and electric.

Next we will show how artificial demand, through operating pressure and leaks, can account for roughly 30% of the air being lost in a system, negatively affecting a company’s bottom line. We will provide examples on how to estimate the amount of leakage in a system and ways to track the demand from point-of-use devices, to help identify areas where improvements can be made.

To close, we will demonstrate how following six simple steps can save you money by reducing compressed air use, increasing safety and making your process more efficient.

CLICK HERE TO REGISTER

Justin Nicholl
Application Engineer
justinnicholl@exair.com
@EXAIR_JN

Super Air Knife Plumbing Kit Allows Installation In Tight Quarters

I recently had the pleasure of helping a long-time user of our Super Air Knives with a challenging application. They already use quite a few of our Model 110012SS 12″ Stainless Steel Super Air Knives to clean & dry their nonwoven material as it’s being rolled for packaging. They like them because they’re quiet and efficient, but also because they’re durable…this particular product off-gasses a mildly corrosive vapor, which used to corrode other equipment in the area. Not only does the Stainless Steel Super Air Knife resist corrosion itself, the air flow keeps these vapors contained. Two birds, one stone.

They have a new product…same kind of material, but much wider…that needed to be blown off, and the identified the Model 110060SS 60″ Stainless Steel Super Air Knife as a “no-brainer” solution. Thing is, it had to be a pretty even air flow across the length, and a 60″ Super Air Knife has to get air to four ports across its length for optimal performance. And, they wanted to install it at a point where it would serve not only as a blow off, but as a vapor barrier, just like the 12″ Super Air Knives they’re already so fond of. The space was a little limited, though, so they opted for the Model 110060SSPKI 60″ Stainless Steel Super Air Knife with Plumbing Kit Installed, which allowed them to simply run an air supply line to both ends.

EXAIR SS Super Air Knives can be ordered with a Plumbing Kit installed, or you can easily install a Plumbing Kit on your existing Super Air Knife.

If you want to find out more about an engineered solution for your compressed air application – cleaning, drying, vapor barrier, or all of the above – give me a call.

Russ Bowman
Application Engineer
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Intelligent Compressed Air: How to Develop a Pressure Profile

An important part of operating and maintaining a compressed air system is taking accurate pressure measurements at various points in the compressed air distribution system, and establishing a baseline and monitoring with data logging.  A Pressure Profile is a useful tool to understand and analyze the compressed air system and how it is functioning.

Pressure Profile 1
Sample Pressure Profile

The profile is generated by taking pressure measurements at the various key locations in the system.  The graph begins with the compressor and its range of operating pressures, and continues through the system down to the regulated points of use, such as Air Knives or Safety Air Guns.  It is important to take the measurements simultaneously to get the most accurate data, and typically, the most valuable data is collected during peak usage periods.

By reviewing the Pressure Profile, the areas of greatest drop can be determined and the impact on any potential low pressure issues at the point of use.  As the above example shows, to get a reliable 75 PSIG supply pressure for a device or tool, 105-115 PSIG must be generated, (30-40 PSIG above the required point of use pressure.)  As a rule of thumb, for every 10 PSIG of compressed air generation increase the energy costs increase 5-7.5%

By developing a total understanding of the compressed air system, including the use of tools such as the Pressure Profile, steps to best maximize the performance while reducing costs can be performed.

If you have questions about getting the most from your compressed air system, or would like to talk about 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.

Brian Bergmann
Application Engineer

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The Old One-Two: Super Air Knives And Super Air Nozzles

The EXAIR Super Air Knife is THE ideal, efficient, and quiet solution for most any blow off application. We know this for a fact; we’ve been making them for years, folks all around the world have been buying them for years, and they keep coming back for more. They’re popular enough that over the years, we’ve introduced Mounting Systems and Plumbing Kits for ease of installation, and when Coupling Kits (to join multiple Super Air Knives together for greater lengths) became big sellers, we “upped our game” and started making Super Air Knives up to nine feet (108″) long. And certain applications (I’m looking at YOU, lumber and paper industries) order multiples of THOSE, and our Coupling Kits. Quite literally, there’s no job too big for EXAIR Super Air Knives.

EXAIR Super Air Knifes come in a wide variety of lengths to suit a wide range of applications.

No matter how long they are, though, the laminar, high velocity curtain of air they generate only moves in one direction. So, if there are significant geometric features (holes, bosses, recesses, “nooks & crannies,” etc.) to be blown off, we’ll have to look at something supplemental.

Enter the EXAIR Blowoff Systems…it doesn’t get any easier than this: an EXAIR engineered Super Air Nozzle, attached to a flexible, repositionable Stay Set Hose, mounted to a Magnetic Base.  Put a hard hitting, high velocity, pointed flow of air right where you want it.  If the next piece is different, that’s no problem – just bend the hose to re-aim the air flow.

Mag Bases come with one or two outlets. Stay Set Hoses come in lengths from 6″ to 36″.

No matter what the requirements of your blow off application are, we have an efficient, quiet, and safe solution.  If you’d like to find out more, give me a call.

Russ Bowman
Application Engineer
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Custom Air Amplifiers To Meet Most Any Requirement

When I think of “special” in regard to Air Amplifiers, I’m more inclined to think of the applications they can be used in. I mean, the Air Amplifier itself is about as straight-forward as an engineered compressed air product can be:

Air Amplifiers use the Coanda Effect to generate high flow with low consumption.

Considering the simplicity of the product itself, they can be used for a large variety of “typical” applications:

  • Cooling
  • Drying
  • Cleaning
  • Ventilation
  • Fume Exhausting
  • Dust Collection

There are no shortage of “special” applications either.  They’re used successfully in Air Operated Conveyance applications (when the stronger vacuum head of a Line Vac isn’t required) and we’ve even got a customer who uses one instead of an E-Vac Vacuum Generator for a “pick & place” operation…they’re picking up small, porous fiber discs (sort of like a coffee filter) one at a time, and the E-Vac wanted to pick up a good part of the whole stack, no matter how low they turned the pressure.  And of course, I can’t think of anything more special about Air Amplifiers than this:

You have to read it to believe it.  Follow the link and click on “Case Study: Roaring Banana Breath”

With fifteen distinct models to choose from in a range of sizes (3/4″ to 8″,) materials (aluminum or Stainless Steel) and even a High Temperature model that’s rated to 700°F (374°C), we’ve still made a fair number of Custom Air Amplifiers too…thirty-four, to be exact, as of this writing.

I won’t bore you with all the details – I can’t, actually, because some of them are proprietary* – but here are some “regular” examples of “special” accommodations:

  • Connections: EXAIR Air Amplifiers have smooth bores on the inlet & outlet plenums that you can hose clamp a hose (or round duct) to if you need to get air flow from, or to, one place or another.  Sometimes, though, they’re going in to an existing system, so we’ve made them with flanges (150#RF and Sanitary Tri-Clamp, for example) or threads (NPT or BSPP.)  If you want to use something other than a standard hose or duct line, we can help.
  • Material of construction: Our durable, lightweight aluminum Super & Adjustable Air Amplifiers are just fine an awful lot of the time.  Our type 303 Stainless Steel Adjustable Air Amplifiers will hold up to heat and corrosives.  We’ve also in PTFE (Teflon™) as well as a range of metal alloys to meet specific corrosion or wear conditions.  If your environment calls for a little something extra, we can help.
  • Assembly: Super Air Amplifiers are fitted with a stock shim that gives you published performance.  We’ve got other thicknesses, though, if you need more (or less) flow, though.  Adjustable Air Amplifiers are, well, adjustable…you just thread the plug in/out of the body until you get the results you want.  Sometimes the user knows what shim they want in a Super Air Amplifier, or what gap their Adjustable Air Amplifier needs to be set to, and we can assemble it accordingly.  If you have a ‘tried-and-true’ performance setting and want it met right out of the box, we can help.
  • Assembly, part 2: Good engineering practices call for lubrication on O-rings and threaded connections, and we use high quality, general purpose compounds when assembling our Air Amplifiers.  These are detrimental, however, in certain situations (silicone exclusion areas, I’m looking at you.) If certain chemicals or compounds are prohibited by your application, we can help.

*Let’s say you’ve done the “heavy lifting” to call out one (or more) of these special design features.  If we make a custom product (and that’s not just Air Amplifiers, by the way) using directions based on your time and labor, we’ll treat that product as proprietary to you, and you alone.

EXAIR has 208 catalog pages worth of Intelligent Compressed Air Products on the shelf…8 of those pages are our Air Amplifiers.  If you want to talk about customizing one to meet your needs, give me a call.

Russ Bowman
Application Engineer
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About Double Acting Reciprocating Air Compressors

My colleague, Lee Evans, wrote a blog “About Single Acting Reciprocating Compressors”, and I wanted to extend that conversation to a more efficient relative, the double acting reciprocating compressor.   As you see in the chart below, this type of compressor falls within the same family under the category of positive displacement compressors.

Compressor Types

Positive displacement compressors increase air pressure by reducing air volume within a confined space.  The reciprocating type of air compressor uses a motor that turns a crank which pushes a piston inside a cylinder; like the engine in your car.  In a basic cycle, an intake valve opens to allow the ambient air into the cylinder, the gas gets trapped, and once it is compressed by the piston, the exhaust valve opens to discharge the compressed volume into a tank.  This method of compression happens for both the single and double acting reciprocating compressors.  With a single acting compressor, the air is compressed only on the up-stroke of the piston inside the cylinder.  The double acting compressor compresses the air on both the up-stroke and the down-stroke of the piston, doubling the capacity of a given cylinder size.  This “double” compression cycle is what makes this type of air compressor very efficient.  A single acting compressor will have an operating efficiency between 22 – 24 kW/100 cfm of air while the double acting compressor has an operating efficiency between 15 – 16 kW/100 cfm.  Therefore, electricity cost is less with a double-acting reciprocating air compressor to make the same amount of compressed air.

To explore the internals a bit closer, the mechanical linkage used to move the piston is slightly different as well as the additional intake and exhaust valves.   Instead of the connecting rod being attached directly to the piston as seen inside a single acting compressor, a crosshead is added between the compression piston and the connecting rod (view picture below).  The rod that connects the crosshead to the compression piston can be sealed to keep the cylinder completely encapsulated.  For every rotation of the electric motor, the air is being compressed twice.  With the added heat of compression, the double acting compressors are generally water-cooled.  Also, with the added mechanism between the crank and the piston, the rotational speeds are typically less.  Because of the larger size, water jackets, and added parts, the initial cost is more expensive than the single acting compressor, but the efficiency is much higher.

Double Acting Reciprocating Air Compressor

Double acting compressors are generally designed for rugged 100% continuous operations.  Dubbed the work horse of the compressor family, they are also known for their long service life.  They are commonly used in high pressure services in multistage styles and can come in lubricated and non-lubricated configurations.   With the dual compression, slow speed and inter-cooling, it makes this type of air compressor very proficient in making compressed air.

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

 

Photos:  used from Compressed Air Challenge Handbook