Main Fans

by Daniel Brassel
(CTS - TPT)

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Main Fans

 Design and Efficiency of Impellers

 Fan Equations and Performance Curves

 Flow Control

 Reliability
 Build-ups
 Vibrations
 Erosion

 Fan Selection

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Main Fans in a Cement Plant

 Kiln ID Fan
 Raw Mill Fan energy

 Cooler Exhaust Gas Fan

 Kiln Dedusting Fan

Altogether these fans consume

between 30% and 50%
of the plant’s total electrical energy.

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Design and Efficiency of Impellers

Type Efficiency  Application

backward aerofoil for clean gas applications,

> 84 %
blades dust < 50 g/m3

backward curved for gas with a dust

up to 82 %
blades concentration < 100 g/m3

backward inclined for gas with a dustload

up to 80 %
blades up to 100 g/m3

for gas with a high dustload

radial straight blades 60 – 75 %
(dust > 100 g/m3)

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Power Requirement


3
V  p  10
N kW 


N Required Power [kW]

V Gas Flow [m3/s]
p Total increase of pressure in fan [Pa]
 Efficiency of the Impeller [-]

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Example: Effect of Fan Efficiency

3’000 t/d, 4-stage SP kiln, kiln ID fan

V = 115 m3/s at 350°C 1 = 0.75
p = 6000 Pa 2 = 0.85

V  p 115  6000  10 3
N1    920 kW
1 0.75

V  p 115  6000  10 3
N2    812 kW
2 0.85

Power saving = 108 kW 0.86 kWh/t cli

at 7’500 h/year, 0.05 USD/kWh yearly saving: 40’500 USD

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Fan Performance Curves I

 derived from laboratory data

 conditions at fan inlet

Definitions:
 Fan static pressure
 Fan power
 System resistance curve

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Fan Performance Curves III

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Fan Performance Curves IV

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Fan Performance Curve II

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Fan Equations at Variable Speed

 n2 
Volume Flow V2   V1
n1

2
 n2 
Static Pressure p St 2     p St 1
 n1 
3
 n2 
Power Requirement N2     N1
 n1 

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Influence of Density Changes

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Pressure / Density

The static pressure generated by the fan is

depending on the gas density,
i.e. type of gas and temperature.

p St 1 1 T2
 
p St 2 2 T1

T in degree Kelvin !

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Flow Regulation / Control

 Outlet damper

 Inlet box damper

 Radial inlet vane

 Speed control

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Design Possibilities for Fan Dampers

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Parallel Inlet Box Damper

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Radial Inlet Vane I

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Radial Inlet Vane II

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Cooler Undergrate Fan: Radial Inlet Vane

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Flow Regulation

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Flow Regulation by Outlet Damper

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Flow Regulation by Inlet Vane Damper

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Flow Regulation by Inlet Box Damper

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Flow Regulation by Speed Control

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Fan Capacity Adjustment

Fan capacity low:

 System changes
 eliminate false air
 reduce pressure drop

 Fan changes
 increase fan speed
 increase wheel diameter
 replace rotor

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Possible Problems with Fans

build-ups wear

vibrations

reliability
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Example of build-ups

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Possible Reasons for Material Build-ups

 Mineralogical Composition of Raw Mix

 Burning Conditions

 Duct / Fan Arrangement

 High Temperatures

 Inappropriate Blade Shape and Angles

 High Fan Speed

 Dew Point Problems

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Build-ups

Permanent remedy could be gained through:

 Change of duct / fan arrangement

 Change of fan speed or impeller diameter
 Modification of fan inlet or impeller blade shape
 Larger shaft diameter

If the above listed measures do not solve the

problem, regular cleaning has to be envisaged!

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Cleaning

 High pressure water spray

 Steam injection

 Compressed air injection

 Sand blasting

 Acoustic Resonance (ultrasonic)

 Dynamic balancing
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Acoustic Cleaning Devices

acoustic horn

acoustic horn

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Sand Cleaning Device

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Cleaning Devices

compressed air
water
steam

compressed air
water
steam

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Erosion / Wear (example)

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Erosion / Wear

Blade erosion

 varies in the second or third power of the speed of

a particle that hits the blade
 particle speed is proportional to the rotor speed

 is affected by the wheel inlet velocity

 fan flow divided by smallest inlet section

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Wear Protection

 Direct protection
 Increased thickness of wear parts
 Direct hard surfacing
 Glued-on ceramics

 Protection by wear plates

 Corners or mild steel plates
 Abrasion resistant steel plates
 Mild steel plates with hard surfacing

 Deflector plates
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Wear Protection by Particle Deflection

without with

Deflector

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Example of deflector plates

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Fan Selection

 Continuous operation
 vibrations
 build-ups
 wear

 Fan efficiency
 mechanical design
 type of regulation

 Equipment cost

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Questions / Remarks ?

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Have a nice evening !

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