It is a very sad day for me at EXAIR… No, I’m not retiring or leaving the company, but today is my last day to write about Plant Engineering Product of the Year Awards …for this year. It has been quite an honor to write about four of our best innovations from the last year over the past weeks. In case you missed the entries, you can click on the these links to read more about our other 2013 award winners: 316 Stainless Steel Dual Cabinet Coolers, 1 Inch Flat Super Air Nozzle or the Heavy Duty HEPA Vac. Today’s post is about the No Drip External Mix Atomizing Nozzle, which the readers of the Plant Engineering magazine bestowed the gold award for fluid handling products. EXAIR’s Liquid Atomizing Nozzles combine the liquid of your choice with compressed air to create a mist of atomized liquid. The external mix nozzles have the highest liquid flow rate of any of EXAIR’s Liquid Atomizing Nozzles with flow rates up to 60 GPH. They are a great solution for applications where independent air and liquid control is required. Additionally, more viscous fluids can be used with the external mixing of the nozzle than either the internal mixing or siphon fed nozzles. External Mixing Nozzles can be used to atomize liquids up to 800 centipoise. In addition to the benefits of the external mix atomizing nozzle, this spray nozzle features a valve to positively stop liquid flow, when the compressed air drops below 30 psig. Any time you need to maintain a smooth finish or are spraying an expensive liquid, the no drip function can be invaluable to preventing rework, and ensuring a quality finish on each and every product. The EXAIR no drip function is patent pending and does not require an additional air line to control the no drip mechanism, simplifying installation and functionality.
Today, we are getting one of the larger snow storms for Cincinnati, OH. Compared to cities north of Dayton, OH, we don’t get very much snow, but once or twice a year we get 4-5 inches and the drivers in this city go crazy. You won’t see anyone on the freeways driving faster than 35 MPH, but you will see a few people spun out on the side of the road. It reminds me that winter is here. With the snow, winter also brings dry low-humidity air which increases the number of electrostatic discharge (ESD) occurrences. ESD is the proper term for a static electricity shock. At EXAIR, we have an entire line of products that are designed to neutralize static on a surface or a product. To neutralize the static, we use a 5kV power supply which supplies voltage through a sharp point (emitter point) on all of our products. This high voltage generates positive and negative ions, which we then deliver to the charged surface using compressed air to eliminate static on the surface. See this video for more information.
So why do we have more static electricity in the winter? Actually, we don’t. The same amount of static is generate year round. Here is a better question – Then why do we get shocked more often in the winter? It really all comes down to humidity. Water is a very conductive material. This allows the charges to spread out, around the surface area of the water and any conductive surfaces that are electrically linked with where the static charge was generated. The charges spread out across the surface are dissipated without any ESD (shock). For instance, a plastic sheet bolted to a metal plate. During the more humid summer the moisture in the air will electrically link the bolt, metal plate and the plastic sheet because of the thin microscopic layer of water across the plastic sheet. This combined surface allows the charge to dissipate by any ground that the metal plate may be attached or slowly dissipated into the air.
This week I had a customer who was looking to dissipate static in his entire facility. This would not be a typical solution for our electric static elimination product line but we were able to provide a different solution. The customer had an air recirculation system that they used to heat their building. The air would pass through a 24″ X 24″ square duct. With the knowledge of what causes static shock, the maintenance department called asking for a recommendation for an atomizing spray nozzle that would humidify the duct without leaving a large amount of moisture. The customer had two questions. First, which nozzle would cover a 24″ square area? Second, how to control the amount of moisture added to the ventilation system, so as not to create a hazard of standing water in the duct work. For the first question, I was able to recommend the Internal Mix Wide Angle AW1040SS. I recommend he use two nozzles to cover the entire duct. The second problem would need more work on the customer’s end. Any of the atomizing spray nozzles can come with a liquid adjustment knob, which would allow the customer to control the amount of liquid added to the duct, but the customer would need to determine how much moisture was needed in their system. The liquid adjustment could control the flow of liquid from zero flow up to maximum flow of 24.0 GPH.
Our customer manufactures roll formed profiles such as tube, pipe, angle, flat bar, metal deck, etc. All are produced in cold rolled steel, hot rolled steel and galvanized steel. When they contacted EXAIR, their roll-former line needed a couple of solutions from EXAIR.
The process of roll forming tubes and pipes generates high temperatures because of the welding to close the tube. Thus, a lot of water is used to cool the tube while welding and avoid over heating of machine and material. This water is causing the pipe and tube to rust within a couple hours of processing. The customer’s pipe size ranges in size from ½” up to 2-1/4” outside diameter. The line speed of the machine is about 40 ft./minute.
The customer knew what they needed to do which was to blow off the water and apply an anti-corrosion type fluid to the pipe. They just didn’t know where to find such solutions until they found EXAIR. After short discussion, I recommended they start with EXAIR Model 2404 (4” Super Air Wipe) to enable blow off of the outside of their pipes to get them dry. Then 2 pcs. Of Model SR1020SS (Siphon Fed Round output) Atomizing nozzles placed on either side of the pipe and adjusted to apply a thin film of atomized anti-corrosion fluid to the outside.
In all, adding these two components to their processing line eliminated the need for future media blasting to get rid of the rust and hand-sprayer application of the same anti-corrosion fluid.
This month I returned to EXAIR, after a three year hiatus. I had originally worked at EXAIR as a student, while I was attending the University of Cincinnati as part of a co-op program, so I thought I would be well versed in EXAIR’S products. EXAIR already had air knives, air nozzles, vortex tubes, Cabinet Cooler systems, Static Eliminators, vacuum generators, air operated conveyors, and so on. What else could they add to utilize compressed air?
Well, as our regular readers will be quick to point out, I was sorely mistaken – EXAIR has added and changed many things. Not only did they re-imagine, improve, or add to existing product lines with products such as the Heavy Duty HEPA Vac, Chip Shields, and the 1” Flat air nozzle but they have added whole new products lines like the Atomizing Spray Nozzle, which use liquid and compressed air to form a mist of liquid for precisely tuned applications. All models of nozzles are made from stainless steel for durability and corrosion resistance. The nozzles are completely adjustable by changing the ratio of air pressure and liquid pressure, or the liquid can be fed by gravity or siphoned using the compressed air. The nozzles use two different mixing methods: internal or external. There is also the choice of models which use a pressurized liquid source or siphon fed nozzles for a non-pressurized liquid. Each mixing methods supports several patterns and liquid flows rates. This wide range of products and adjustability give EXAIR the ability to help with thousands of applications, but I felt a little like Billy in the following clip.
Except my dad couldn’t drive me to school in the Lincoln Town Car. Our car always looked more like the O’Doyles.
Have a good weekend,
Have you ever been in a public place and noticed one of your company’s products in full view of everyone passing by? Those of you who work for car manufacturers, soda bottlers, or snack food makers (like my three friends that I had this conversation with recently do) may not think it’s a big deal (my friends indeed didn’t), so you’ll have to forgive those of us who work mainly in industrial or commercial markets when we get excited to see something that came from The Shop, while we’re walking around the County Fair.
Years ago, I worked for an industrial weighing equipment company. Every year, we were asked to provide a scale for the County Auditor’s booth at the fair – people could step on this scale, and get their weight automatically printed out on one of the Auditor’s business cards. It was a neat little setup, and my friends who recognized that it came from my employer would all crack wise about how obviously inaccurate this scale was. Since I was the one who calibrated the scale, using test weights that I was responsible for having certified by the state, I knew that the numbers on those printed cards said a lot more about the availability of deep fried candy bars on the midway, than the intrinsic accuracy of our precision instrument.
When I go to the fair this summer (and I will, and not just for the deep fried candy bars), I’m certain it’ll be hot that day…which means I’ll have my eye out for the cooling stations that are always set up along the midway, providing a fine mist of cooling water. In addition to a brief respite from the summer heat, I’ll also be looking for EXAIR Atomizing Spray Nozzles, as this would be an ideal application for our External Mix Atomizing Spray Nozzles. They provide independent control of the liquid flow rate – which will be determined solely by the liquid supply pressure – and the air used to atomize the spray: varying the air pressure won’t affect the amount of liquid; only the size/shape of the flow pattern.
Depending on what you need to spray, how much (or little) of it you need to disperse, and over what kind of area, we also have highly efficient Internal Mix designs, and, if your liquid isn’t able to be pressurized, we have Siphon Fed Spray Nozzles as well. We recently added No Drip options to all models as well, to conserve expensive solutions, and/or to prevent inadvertent stains, runs, etc.
They’re all available in a variety of narrow and wide angle, round and flat fan patterns. For more information, feel free to give us a call.
(800)923-9247 toll free