Tag: pneumatics

Compressed Air Is Powering the Energy Transition — Not Just Manufacturing

Published on by Jordan T ShouseLeave a comment

A major breakthrough just hit the industry: researchers unveiled the world’s most powerful single-unit compressed air energy storage (CAES) compressor, rated at 101 MW.

  • Achieves ~88% efficiency at max discharge pressure
  • More than doubles the power of prior single-unit CAES compressors
  • Designed to store energy by compressing air for later electricity generation

This positions compressed air not just as a plant utility—but as a grid-scale energy storage solution.

From Shop Air to Grid Power

For decades, compressed air has been known as the “fourth utility” of manufacturing—powering tools, automation, conveying systems, and production lines across nearly every industrial sector.

But today, compressed air is stepping into a much larger role.

Recent breakthroughs in compressed air energy storage (CAES) technology are transforming compressed air from a plant-floor necessity into a grid-scale energy solution. Massive new compressor systems are now capable of storing surplus renewable energy and releasing it back into the electrical grid when demand spikes.

In other words, compressed air isn’t just powering production anymore—it’s helping power the future of energy.

What Is Compressed Air Energy Storage (CAES)?

Compressed Air Energy Storage is a method of storing energy for later use—similar in purpose to batteries, but very different in scale and operation.

Here’s how it works:

  1. Energy Capture
    Excess electricity—often from renewable sources like wind or solar—is used to power large compressors.
  2. Air Compression & Storage
    The compressed air is stored in underground caverns, tanks, or geological formations.
  3. Energy Release
    When electricity demand rises, the stored air is released, heated, and expanded through turbines to generate power.

Why CAES Matters

Renewable energy plays a critical role in the global shift toward sustainability, but it comes with a fundamental challenge: intermittency. Solar power only generates electricity during daylight hours, wind output fluctuates based on weather conditions, and grid demand changes constantly throughout the day. This mismatch between energy production and consumption creates reliability challenges for utilities. Compressed Air Energy Storage (CAES) helps solve this issue by capturing excess energy when supply is high and releasing it when demand spikes. The technology provides long-duration energy storage, supports grid stabilization, helps meet peak demand, and reduces reliance on fossil fuel peaker plants. While lithium-ion batteries currently dominate short-term storage solutions, compressed air stands out for its ability to store massive volumes of energy over longer periods—making it especially well suited for utility-scale applications.

A Breakthrough Moment for Compressed Air

Recent advancements in high-capacity compressors designed specifically for energy storage are pushing the boundaries of what compressed air technology can achieve. These next-generation systems deliver unprecedented compression power, achieve significantly higher efficiency levels, and are engineered to support renewable energy integration at grid scale. By reducing energy loss during compression and discharge cycles, they make large-scale air storage more practical and economically viable than ever before. This innovation marks a turning point for the industry: compressed air is no longer confined to manufacturing facilities—it is now being positioned as a core component of national energy infrastructure planning and the broader transition to renewable power.

Jordan Shouse, CCASS

Application Engineer / Sales Operations Engineer

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Schematic of the compressed air energy storage method courtesy of (Image: https://voltatechnique.com/technology/) Creative Commons License

Pneumatics: Top 10 Advantages of EXAIR Compressed Air Products

Published on by bdwagesLeave a comment

Pneumatics is a branch of engineering that makes use of gas or compressed air. The word pneumatic is derived from the Greek words πνεῦμα pneuma and means wind breath. With 9 out of 10 industries utilizing compressed air products and processes, we could say that pneumatics are the “breath” of industry. OK, I may be stretching here, but it it does flow well…

At EXAIR, we pride ourselves on using compressed air intelligently. Nearly all of our products utilize compressed air and maximize it’s efficiency. Let’s take a deep breath and look at some of the reasons why “wind breath”, and more importantly why the EXAIR products are so advantageous in industry.

REASONS TO USE COMPRESSED AIR

PNEUMATICS

  1. There is an infinite supply of air on this planet to be compressed and used. I know this seems obvious but what other energy source has an infinite supply?
  2. There are very low maintenance costs with pneumatic tools. Our products have minimal to no moving parts. There is no motor to repair, no oil to change, no bearings or fans.
  3. Our products are engineered to be easily installed and can be adjusted for performance. Most of the time you simply mount the product and add air. A simple pressure regulator provides a huge bandwidth of adjustment to dial in the force and performance.
  4. Air is very easy to transport. With your current compressor system, you can easily run pipe to the point of use and supply the products with their power source.
  5. Compressed air is compact, and usually takes up less space to install a compressed air product.
  6. Our products and tools are extremely reliable. Due to the precision engineering and production, our products produce a repeatable result every time they are turned on.
  7. EXAIR products all comply with OSHA standards for sound (29 CFR 1910-242 (b)) as well as dead end pressure 29 CFR-1910.95(a)).
  8. Initial purchase as well as installation costs are typically considerably lower than non pneumatic options. When you add in the upkeep and maintenance, EXAIR products are almost always less expensive than alternative products.
  9. Using compressed air as your power supply typically facilitates a cleaner, dryer, safer work environment.
  10. At EXAIR, you have a team of application engineers at your fingertips that will help you choose the best product for your specific application. Feel free to call or email at anytime.

Please let us know if there is anything we can do to he

Application Engineer
Brian Wages
EXAIR Corporation
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*Albert Einstein picture by Parent/rap Pixabay license *Top 10 picture by geralt Pixabay License

Compressed Air Pipe

Importance Of Proper Pneumatic Tube, Pipe, And Fittings

Published on by Russ BowmanLeave a comment

When it comes to engineered compressed products, the number one cause of less-than-optimal performance is improper supply line sizing.  This can mean one of two things:

  • The hose, pipe, or tubing running to the device is too small in diameter.
  • The hose, pipe or tubing is big enough in diameter, but too long.

The problem with either of these is line loss (follow that link if you want to do the math.)  Put simply, the air wants to move faster than it’s physically permitted to.  Any time fluid flows through a conduit of any sort, friction acts on it via contact with the inside surface of said conduit.

With smaller diameters, a larger percentage of the air flow is affected…no matter what diameter the line is, the air closest to the inner wall is affected by the friction generated.  When diameter increases, the thickness of this affected zone doesn’t increase proportionally, so larger diameters mean less of the air is affected by friction.  It also means there’s a lot more room (by a factor of the square of the radius, times pi…thanks, Archimedes!) for the air to flow through.

Likewise, with longer lengths, there’s more contact, which equals more friction.  Length, however, is often a non-negotiable.  You can’t just up and move a 100HP air compressor from one part of the plant to another.  So, when we’re talking about selecting proper supply lines, we’re going to start with the distance from the compressed air header to our device, and pick the diameter that will give us the flow we need through that length.  In fact, that’s exactly how to use the Recommended Infeed Pipe Size table in EXAIR’s Super Air Knife Installation & Maintenance Guide:

This table comes directly from the Installation & Operation Instructions for the Super Air Knife.

Once we have the correct line size (diameter,) let’s consider the fittings:

  • Tapered pipe threads (NPT or BSPT) are the best.  They offer no restriction in flow, and are readily commercially available.  If you’re using pipe, these are the standard threads for fittings.  If you want to use hose, a local hydraulic/pneumatic shop can usually make hoses with the fittings you need, at the service counter, while you wait.
  • If you need to frequently break and make the connection (e.g., a Chip Vac System that’s used throughout your facility,) quick connects are convenient and inexpensive.  Push-to-connect types are by far the most common, but a word of warning: they’re notoriously restrictive, as the inside diameter of the male end is markedly smaller than the line size.  If you use them, go up a size or two…a quick connect made for 1/2 NPT connections will work just fine for a 1/4″ line:
  • The nice thing about these quick connects is that you don’t have to depressurize the line to make or break the connection.  If you have the ability to depressurize the line, though, claw-type fittings (like the one shown on the right) provide the convenience of a quick connect, without the restriction in flow.

Proper air supply is key to performance of any compressed air product.  If you want to know, at a glance, if you’re supplying it properly, install a pressure gauge right at (or as close as practical) to the inlet.  Any difference in its reading and your header pressure indicates a restriction.  Here’s a video that clearly shows how this all works:

I want to make sure you get the most out of your compressed air system.  If you want that to, give me a call with any questions you might have.

Russ Bowman
Application Engineer
EXAIR Corporation
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