A simple solution to reduce costs and noise levels on compressed air blowoff operations is to use Exair air nozzles and jets. These nozzles and jets produce up to 25 times the air flow while using only a small amount of compressed air as the power source.
Air savings, compared to open copper tubes or pipe nipples commonly used for blowoff can be as high as 80%. Less compressed air means less noise. The typical noise reduction is 10 dBA. All nozzles and jets meet OSHA dead end requirements.
An open 6 mm copper tube, by contrast, ejects pure compressed air at up to 1,1 kilolitres per minute (the entire output of a 7,5 kW compressor). Annual energy costs can be exorbitant. Noise levels in excess of 100 dBA are commonly produced and when supply pressure exceeds 200 kPa, an open pipe, tube or drilled holes violate OSHA static pressure requirements.
The use of compressed air for blowoff in most facilities is a problem due to the energy costs, noise level and the potential danger to personnel who are exposed to high pressure air. Open air pipes, copper tubes and drilled pipes are a few of the common abusers. They consume tremendous amounts of energy and often produce noise levels over 100 dBA.
The best way to cut energy costs is through proper maintenance and use of the compressed air system. Leaks and dirty filters require maintenance on a regular basis. Energy savings can also be realised when replacing outdated compressor motors and controls with high efficiency models that often pay for themselves in a short period of time.
The most important factor to dramatically boost efficiency is proper use. Using engineered products like Exair's Super Air Nozzle can cut operating costs since it uses only a fraction of the compressed air of typical blowoffs. In addition, all of the air nozzles and jets can be cycled on and off with instantaneous response so compressed air is only used when needed.
High noise level is a common problem for many plants. Compressed air noise often exceeds 90 dBA resulting in hearing loss to those working in close proximity. Noisy blowoffs at 550 kPa that produce noise levels of 100 dBA can be reduced to only 74 dBA when using the Super Air Nozzles. At that pressure, it is still possible to obtain hard-hitting force without the high noise.
Air penetrating the skin
Air can be dangerous when the outlet pressure of a hole, hose or copper tube is higher than 200 kPa. In the event the opening is blocked by a hand or other body part, air may enter the blood stream through the skin, resulting in a serious injury. All of the air nozzles and jets manufactured by Exair have been designed for safety. All are safe to be supplied with higher pressure compressed air and meet OSHA standard CFR 1910.242(b).
Consider the following example where a Model 1102 Mini Super Air Nozzle replaces a 3,2 mm open pipe. The significant compressed air savings are easy to calculate. Payout for air nozzles and jets, including filter and installation cost is measured in weeks - not years as is the case for other cost reduction equipment.
Example
Existing blowoff is 3,2 mm open pipe at 550 kPa supply. Air consumption, from Table 1 is 1,98 kilolitres per minute.
Using a Model 1102 Mini Super Air Nozzle (also at 550 kPa supply), air consumption is 283 litres per minute. Therefore, air saved is 1,697 kilolitres per minute. For this example the blowoff is continuous. Further air savings can be achieved by cycling operation according to demand.
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