FANS & BLOWERS

Confederation of Indian Industry

FANS & BLOWERS

Machines to move gases/ gases mixed with small solid particles

Operation of fan similar to that of pumps

Axial flow fans

Centrifugal fans Efficiency of fans (40-70%)

Confederation of Indian Industry

Fans & Blowers - Major Energy Consumer Cement Paper Power Plants Sugar Energy Consumption - 10 to 25% - Depending on Type of Industry Substantial Energy Saving Potential Installing VSDs Upto 25% Confederation of Indian Industry

PUMPS/BLOWERS FORMULAE

Rpm Head

a Capacity a Rpm2

Power a Capacity x head Power a Rpm3

Confederation of Indian Industry

PUMPS/BLOWERS FORMULAE
If rpm is reduced what happens to

Capacity
Head Power

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Types of Control
Damper - Most Popular Variable Speed Drive
Recirculation

100

Damper VFC

Power

75 50 25 25

VFD Ideal

50

Flow

75

100

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FANS HOROSCOPE CHARACTERISTIC CURVE

DP

80% 76% 74% n1 rpm n2 rpm

Power consumption

Volumetric flow
Confederation of Indian Industry

FAN EFFICIENCY
QxP 102 x (m) x kW(I)

Q - Volume flow rate in m3/s

P- Pressure rise of the fan, mm WC
(m) - Motor

efficiency

kW(I) - Motor Input Power

Confederation of Indian Industry

FACTORS AFFECTING THE PERFORMANCE OF A FAN

RPM Diameter Density Temperature
Parameter Volumetric capacity Pressure rise Power consumption a a a Rpm n n2 n3 Diameter D3 D2 D5 Density r r Temperature 1/T 1/T

Confederation of Indian Industry

THROTTLING OF A FAN

Suction/Delivery

Why?

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THROTTLING - SUCTION
0 mm

-600 mm
-700 mm

Average pressure of fan = (10336 - 700) + 10336 2 = 9986 mmWg

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THROTTLING - DISCHARGE
+100 (120) mm -600 mm 0 mm

Average pressure of fan = (10336 - 600) + (10336 + 100) 2 = 10086 mmWg

Average density higher power consumption high

Confederation of Indian Industry

POWER CONSUMPTION OF AN OVER SIZED FAN

Fan designed 1,20,000 m3/hr 650 mmWg Actual requirement 90,000 m3/hr 510 mmWg
10 mmWg Damper 60%

-500 mmWg -720 mmWg

Confederation of Indian Industry

POWER CONSUMPTION OF A OVER SIZED FAN

Pressure rise = 10 - (-720) = 730 mmWg Power a 730 mm Wg x 90000 m3/hr

Consumes - 289 kW

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CORRECT SIZE FAN

+ 10 mmWg

-500 mm Wg

Pressure rise

= 10 - (-500) = 510 mmWg

Power a 510 mmWg x 90000 m3/hr Consumes - 202 kW

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Energy Loss in Damper Control..

P r e s s u r e

720

Loss Across Damper Required

510

N1 rpm

N2 rpm

Volume
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POTENTIAL IN OVER SIZE FAN

Energy saving potential in over sized fan

P across damper = Total pressure rise x Power consumption

220 = x 289 kW = 87 kW 730

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ENERGY AUDIT IN FANS & BLOWERS

Is the fan/blower really required?

Is it off the correct capacity/head?

How is the fan controlled? Damper throttling Guide vane control Speed control
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ENERGY AUDIT IN FANS & BLOWERS

Can the capacity/head be further fine tuned? What is the efficiency of fan?

Replacement by high h fan Can the blower be interlocked with process operation? Confederation of Indian Industry

Coal Mill Ventilation Fan Speed Reduction

BF

-360 mm

+ 5 mm
rpm of ventilation fan reduced by10%
Savings Rs 1.34 lakhs

-270 mm

50%

38 kW

Investment Rs 5000 Payback 1 month

Pressure drop = 90/365 = 24% Head required = 0.76 times present head Belt driven Confederation of Indian Industry

INSTALL A LOWER RPM MOTOR FOR VENTILATION FAN

+ 20 mmWg

P 130 mm wg
+ 50 mmWg

-50 mmWg -150 mmWg

38 kW

Pressure rise of the fan = 200 mmWg Net p across damper = 65%

Confederation of Indian Industry

INSTALL A LOWER RPM MOTOR FOR VENTILATION FAN (contd)

Power consumed by the 150 kW/ 1440 rpm motor = 100 kW

Replace with 75 kW/980 rpm motor

Power consumption by 75 kW/ 980 rpm motor = 50 kW
savings Rs.8.00 lakhs Investment Rs 2.00 lakhs

Payback

months

Confederation of Indian Industry

Install right size fan for ESP

Fan Design 1, 10, 000 m3/ hr, 200 mm Variable speed Plant originally rated for 300 TPD, operating at 450 TPD Present operation 1, 48, 000 m3/ hr, 110 mm WC 110 kW
Confederation of Indian Industry

CHARACTERISTIC CURVE
1000 rpm

200 Head (MM) 110

740 rpm

Des point Eff. - 78 %

Op point

Eff. - 44 %

110 148 Quantity km3/hr

Confederation of Indian Industry

Install right size fan for ESP

Install right size fan Capacity - 1, 50, 000 m3/ hr Pressure - 125 mm Annual Savings - Rs. 12.00 Lakhs Investment Rs. 10.0 Lakhs Payback - 10 Months
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INSTALL HIGH EFFICIENCY FAN FOR COOLER FAN #1

Temperature 32oC 80%
Temperature 55oC 550 mmWg

Fan inefficient = 54% Replaced with high efficiency fan

Savings

Rs 3.00 lakhs

Investment Rs 4.00 lakhs Payback 16 months

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Install VFD for Boiler ID Fans

PIC

ESP

VF D

30TPH
Boiler

-60mm -110mm
50% ID Fan 53kW VFD-29kW

Present Control Damper Based on Furnace Draught Energy Loss Across Damper
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Install VFD for Boiler ID Fans..

Install Variable Frequency Drive (VFD) Control by Varying Speed Damper - 100% Open Power with damper = 53 kW Power with VFD = 29 kW Savings = 24 kW
Annual Savings - Rs. 7.76 Lakhs Investment - Rs. 6.85 Lakhs Payback - 11 Months
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ID Fans Operation

ESP ID Fan

ID fan is operated with fluid coupling & IGV Control System studied in detail 135 m3/sec, 236 mmWg, 645 KW Overall efficiency 52%

Where to attack?
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ID Fans Operation ID fans power consumption

Fluid Power 52% 333 kW

Input Power 100% 645 kW

Motor
hLoss 6% 38.7 kW

VFC
hLoss 20.46% 129 kW

Fan
h Loss 21.54 % 144 kW

Motor losses, VFC and fan These need to be looked into

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ID Fans Operation
Loss in Variable fluid Coupling

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ID Fans Operation
% loss is highest at 66% speed For this fluid coupling few suppliers Loss estimated at 132 KW Calculated loss also 127 KW How to Avoid / Reduce this? Replace VFC with high efficient VSD Operate VFC with higher speed not possible
Confederation of Indian Industry

ID Fans Operation Based on ID fan characteristic curve Reduction in speed Doesnt affect operating efficiency much

Confederation of Indian Industry

ID Fans Operation How to proceed now? I Step

Reduce IGV Control and lower speed of fan & control through VFC Explore the option of putting VFC in closed loop with draught Discuss with suppliers & collect loss curves At 40% speed closed loop should be possible Replace with quick response actuator Operating in many cement plants for critical fan applications Soda recovery boilers in paper plant
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ID Fans Operation How to proceed now? II Step

Replace VFC with a 6.6 KV VFD Excellent long term option HT VFDs installed already

Chettinad cement 6 drives- recently

Tata power VFD for ID fan Operating for last 8 years China Recent years several HT VFDs installed
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ID Fans Operation

Option -1
Annual Saving Rs 30.2 Lakhs

Option -2 Annual Saving Investment Payback period Rs 198 Lakhs Rs 375 Lakhs 23 Months

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To Sum Up
Fans & Blowers Energy Savings

Industry Implement Benefit

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 Confederation of Indian Industry