I have written blogs about laminar and turbulent flows as related to the Reynold’s number. Now, let’s demonstrate the difference between the two flows and the advantages of laminar flow from EXAIR’s engineered air nozzles; as demonstrated by our VariBlast Safety Air Gun.
Fluid mechanics is the field that studies the properties of fluids in various states. There are two main areas; fluid statics and fluid dynamics. Fluid dynamics studies the forces on a fluid, either as a liquid or a gas, during motion. Osborne Reynolds, an Irish innovator, popularized this dynamic with a dimensionless number, Re. This number determines the state in which the fluid is moving; either laminar flow, transitional flow, or turbulent flow. Equation 1 below shows the relationship between the inertial forces of the fluid as compared to the viscous forces.
Equation 1: Re = V * Dh/u
Re – Reynolds Number (no dimensions)
V – Velocity (feet/sec or meters/sec)
Dh – hydraulic diameter (feet or meters)
u – Kinematic Viscosity (feet^2/sec or meter^2/sec)
The value of Re will mark the region in which the fluid (liquid or gas) is moving. If the Reynolds number, Re, is below 2300, then it is considered to be laminar (streamline and predictable). If Re is greater than 4000, then it is considered to be turbulent (chaotic and violent). The area between these two numbers is the transitional area where you can have eddy currents and some non-linear velocities. To better show the differences between each state, I have a picture below that shows water flowing from a drain pipe into a channel. The water is loud and disorderly; traveling in different directions, even upstream. With the high velocity of water coming out of the drain pipe, the inertial forces are greater than the viscous forces of the water. This indicates turbulent flow with a Reynolds number larger than 4000. As the water flows into the mouth of the river, the waves transform from a disorderly mess into a more uniform stream. This is the transitional region. A bit further downstream, the stream becomes calm and quiet, flowing in the same direction. This is laminar flow. Air is also a fluid, and it will behave in a similar way depending on the Reynolds number.
Why is this important to know? In certain applications, one state may be better suited than the other. For mixing, suspension and heat transfer; turbulent flows are better. But, when it comes to effective blowing, lower pressure drops and reduced noise levels; laminar flows are better. In many compressed air applications, the laminar region is the best method to generate a strong force efficiently and quietly. EXAIR offers a large line of products, including the Super Air Knives, Super Air Amplifiers and Super Air Nozzles that utilizes that laminar flow for compressed air applications. If you would like to discuss further how laminar flows could benefit your process, an EXAIR Application Engineer will be happy to help you.
Laminar flow is an fundamental component of compressed air efficiency. Believe it or not, laminar flow is controlled exclusively by the airline used in a compressed air system. To fully understand the effects of laminar flow in a compressed air system, we need to explain exactly what it is.
Fluids & gases are unique in their ability to travel. Unlike solid molecules that remain stationary whose molecules tend to join others of the same kind; fluid molecules aren’t so picky. Fluid molecules, such as gases and liquids, partner with different molecules and are difficult to stop.
Laminar flow describes the ease with which these fluids travel; good laminar flow describes fluid travelling as straight as possible. On the contrary, when fluid is not travelling straight, the result is turbulent flow.
Turbulent air flow results in an inefficient compressed air system. This may not seem like a major concern; yet, it has huge impacts on compressor efficiency. Fluid molecules bounce and circle within their path, causing huge energy wastage. In compressed air systems, this turbulent airflow results in a pressure drop. How do you avoid this from happening? It all comes down to compressed air system design.
The design and material of the air pipe, as well as the positioning of elbows and joints, has a direct connection to laminar flow and pressure drop. To avoid high energy consumption of your compressed air system, reducing pressure drop is key.
If your system is experiencing high pressure drop, your compressor has to work overtime to provide the needed air pressure. When your compressor works overtime, it not only increases your maintenance costs, but also your energy bills.
To discuss your application and how an EXAIR Intelligent Compressed Air Product can help your process, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.
A drilled pipe has been used for many years to blow compressed air across a span for cleaning, cooling, and drying. They are a simple tool that was created from spare parts and many holes. The cost to make this type of product is not expensive, but to use this product in your application is very expensive. Similarly, an incandescent lightbulb is inexpensive to purchase, but it will cost you much more in electricity than a LED light bulb. Since 1983, EXAIR has been innovating safe and efficient products to be used in compressed air systems. In this blog, I will compare the drilled pipe with the Super Air Knife.
Even though you can find the components relatively easily to design your own drilled pipe, this blow-off design is very costly and stressful to your compressed air system. Typically, the holes along the pipe are in a row next to each other. As the airstream leaves from each hole, it will hit the airstream from the one next to it. This will cause turbulent air flows which has inconsistent forces and loud noises. Also, with turbulent air flows, the ability to entrain the surrounding ambient air is very small. We call this the amplification ratio. The higher the amplification ratio, the more efficient the blow-off device is. For a drilled pipe, the amplification ratio is near 3:1 (3 parts ambient air to 1 part compressed air).
A colleague, Brian Bergmann, wrote a blog about the amplification ratio of the EXAIR Super Air Knife. (Read it HERE.) This blog demonstrates how EXAIR was able to engineer an efficient way to blow air across a span. The unique design of the Super Air Knife creates an amplification ratio of 40:1 which is the highest in the market. Unlike the drilled pipe, the gap opening runs along the entire knife for precise blowing. This engineered gap allows for laminar air flow which has a low noise level, a consistent blowing force, and maximum amplification ratio. With these benefits, the Super Air Knife can reduce the amount of compressed air required, which will save you money and save your compressed air system.
In comparing the drilled pipe to the Super Air Knife, I will relate both products in a simple cooling application. Thermodynamics expresses the basics of cooling with an air temperature and an air mass. Since both products are represented in the same application, the air temperature will be the same. Thus, the comparison will be with the amount of air mass. In this example, the customer did some calculations, and they needed 450 Lbs. of air to cool the product to the desired temperature. At standard conditions, air has a density of 0.0749 lbs/ft3. To convert to a volume of air, we will divide the weight by the density:
450 lbs. / (0.0749 lbs./ft3) = 6,008 ft3 of air
To meet this requirement, reference Table 1 below. It shows the volume of air required by your compressed air system to meet this demand. As you can see, your compressor has to work 13X harder to cool the same product when using a drilled pipe. Just like the LED light bulbs, the Super Air Knife has more efficiency, more innovation, and uses less compressed air. In turn, the Super Air Knife will save you a lot of money in electrical costs. If you would like to see how much the Super Air Knife can save compared to the drilled pipe, we have that information in this blog. (Read it HERE.) For my reference, it will reduce the stress of your compressed air system.
if you would like to compare any of your current blow-off devices with an innovative EXAIR product, you can contact an Application Engineer. We can do an Efficiency Lab to shine an LED light on saving energy and money with your compressed air.