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Energy Efficiency Guide for Fans & Blowers
1.
1 Training Session on
Energy Equipment Fans & Blowers Presentation from the “Energy Efficiency Guide for Industry in Asia” www.energyefficiencyasia.org © UNEP 2006
2.
2 © UNEP 2006 Training
Agenda: Fans & Blowers Introduction Types of fans and blowers Assessment of fans and blowers Energy efficiency opportunities
3.
3 Introduction © UNEP 2006 1.
Fan components 2. System resistance 3. Fan curve 4. Operating point 5. Fan laws
4.
4 Introduction Fan Components Outlet Diffusers Baffles Heat Exchanger Turning Vanes (typically
used on short radius elbows) Variable Frequency Drive Motor Centrifugal Fan Inlet Vanes Filter Belt Drive Motor Controller © UNEP 2006 (US DOE, 1989) Provide air for ventilation and industrial processes that need air flow
5.
5 Introduction System Resistance © UNEP
2006 • Sum of static pressure losses in system • Configuration of ducts, pickups, elbows • Pressure drop across equipment • Increases with square of air volume • Long narrow ducts, many bends: more resistance • Large ducts, few bends: less resistance
6.
6 Introduction System Resistance © UNEP
2006 System resistance curve for various flows (US DOE, 1989) calculated Actual with system resistance
7.
7 Introduction Fan Curve © UNEP
2006 Performance curve of fan under specific conditions • Fan volume • System static pressure • Fan speed • Brake horsepower (US DOE, 1989)
8.
8 Introduction Operating Point © UNEP
2006 Fan curve and system curve intersect Flow Q1 at pressure P1 and fan speed N1 Move to flow Q2 by reducing fan speed Move to flow Q2 by closing damper (increase system resistance) (BEE India, 2004)
9.
9 Introduction Fan Laws © UNEP
2006 (BEE India, 2004)
10.
10 © UNEP 2006 Training
Agenda: Fans & Blowers Introduction Types of fans and blowers Assessment of fans and blowers Energy efficiency opportunities
11.
11 © UNEP 2006 Types
of Fans & Blowers Types of fans • Centrifugal • Axial Types of blowers • Centrifugal • Positive displacement
12.
12 © UNEP 2006 Types
of Fans & Blowers • Rotating impeller increases air velocity • Air speed is converted to pressure • High pressures for harsh conditions • High temperatures • Moist/dirty air streams • Material handling • Categorized by blade shapes • Radial • Forward curved • Backward inclined Centrifugal Fans
13.
13 © UNEP 2006 Types
of Fans & Blowers Centrifugal Fans – Radial fans • Advantages • High pressure and temp • Simple design • High durability • Efficiency up to 75% • Large running clearances • Disadvantages • Suited for low/medium airflow rates only (Canadian Blower)
14.
14 © UNEP 2006 Types
of Fans & Blowers Centrifugal Fans – Forward curved •Advantages • Large air volumes against low pressure • Relative small size • Low noise level •Disadvantages • Not high pressure / harsh service • Difficult to adjust fan output • Careful driver selection • Low energy efficiency 55-65% ( Canadian Blower)
15.
15 © UNEP 2006 Types
of Fans & Blowers Centrifugal Fans - Backward-inclined • Advantages • Operates with changing static pressure • Suited for high flow and forced draft services • Efficiency >85% • Disadvantages • Not suited for dirty airstreams • Instability and erosion risk ( Canadian Blower)
16.
16 © UNEP 2006 Types
of Fans & Blowers • Work like airplane propeller: • Blades create aerodynamic lift • Air is pressurized • Air moves along fan axis • Popular with industry: compact, low cost and light weight • Applications • Ventilation (requires reverse airflow) • Exhausts (dust, smoke, steam) Axial Fans
17.
17 © UNEP 2006 Types
of Fans & Blowers Axial Fans – Propeller fans • Advantages • High airflow at low pressure • Little ductwork • Inexpensive • Suited for rooftop ventilation • Reverse flow • Disadvantages • Low energy efficiency • Noisy (Fan air Company)
18.
18 © UNEP 2006 Types
of Fans & Blowers Axial Fans – Tube axial fans (Canadian Blower) • Advantages • High pressures to overcome duct losses • Suited for medium-pressure, high airflow rates • Quick acceleration • Space efficient • Disadvantages • Expensive • Moderate noise • Low energy efficiency 65%
19.
19 © UNEP 2006 Types
of Fans & Blowers Axial Fans – Vane axial fans (Canadian Blower) • Advantages • Suited for medium/high pressures • Quick acceleration • Suited for direct motor shaft connection • Most energy efficient 85% • Disadvantages • Expensive
20.
20 © UNEP 2006 Types
of Fans & Blowers Blowers • Difference with fans • Much higher pressures <1.20 kg/cm2 • Used to produce negative pressures for industrial vacuum systems • Types • Centrifugal blower • Positive displacement
21.
21 © UNEP 2006 Types
of Fans & Blowers Centrifugal Blowers • Gear-driven impeller that accelerates air • Single and multi-stage blowers • Operate at 0.35-0.70 kg/cm2 pressure • Airflow drops if system pressure rises (Fan air Company)
22.
22 © UNEP 2006 Types
of Fans & Blowers Positive Displacement Blowers • Rotors trap air and push it through housing • Constant air volume regardless of system pressure • Suited for applications prone to clogging • Turn slower than centrifugal blowers • Belt-driven for speed changes
23.
23 © UNEP 2006 Training
Agenda: Fans & Blowers Introduction Types of fans and blowers Assessment of fans and blowers Energy efficiency opportunities
24.
24 © UNEP 2006 Assessment
of fans and blowers • Fan efficiency: • Ratio of the power conveyed to air stream and power delivered by the motor to the fan • Depends on type of fan and impeller • Fan performance curve • Graph of different pressures and corresponding required power • Supplier by manufacturers Fan Efficiency and Performance
25.
25 © UNEP 2005 Assessment
of fans and blowers Peak efficiency or Best Efficiency Point (BEP) © UNEP 2006 (BEE India, 2004) Airfoil Tubular Forward Efficiency Flow rate Backward Radial Airfoil Tubular Forward Efficiency Flow rate Backward Radial Type of Fan Peak Efficiency Range Centrifugal fans: Airfoil, Backward curved/inclined 79-83 Modified radial 72-79 Radial 69-75 Pressure blower 58-68 Forward curved 60-65 Axial fans: Vane axial 78-85 Tube axial 67-72 Propeller 45-50
26.
26 © UNEP 2006 Assessment
of fans and blowers Before calculating fan efficiency • Measure operating parameters • Air velocity, pressure head, air stream temp, electrical motor input • Ensure that • Fan is operating at rated speed • Operations are at stable condition Methodology – fan efficiency
27.
27 © UNEP 2006 Assessment
of fans and blowers Step 1: Calculate air/gas density Step 2: Measure air velocity and calculate average Step 3: Calculate the volumetric flow in the duct Methodology – fan efficiency t = Temperature of air/gas at site condition Cp = Pitot tube constant, 0.85 (or) as given by the manufacturer p = Average differential pressure γ = Density of air or gas at test condition
28.
28 © UNEP 2006 Assessment
of fans and blowers Step 4: Measure the power drive of the motor Step 5: Calculate fan efficiency • Fan mechanical efficiency • Fan static efficiency Methodology – fan efficiency
29.
29 © UNEP 2006 Assessment
of fans and blowers • Non-availability of fan specification data • Difficulty in velocity measurement • Improper calibration of instruments • Variation of process parameters during tests Difficulties in Performance Assessment
30.
30 © UNEP 2006 Training
Agenda: Fans & Blowers Introduction Types of fans and blowers Assessment of fans and blowers Energy efficiency opportunities
31.
31 © UNEP 2006 Energy
Efficiency Opportunities 1. Choose the right fan 2. Reduce the system resistance 3. Operate close to BEP 4. Maintain fans regularly 5. Control the fan air flow
32.
32 © UNEP 2006 Energy
Efficiency Opportunities • Considerations for fan selection • Noise • Rotational speed • Air stream characteristics • Temperature range • Variations in operating conditions • Space constraints and system layout • Purchase/operating costs and operating life • “Systems approach” most important! 1. Choose the Right Fan
33.
33 © UNEP 2006 Energy
Efficiency Opportunities • Avoid buying oversized fans • Do not operate at Best Efficiency Point • Risk of unstable operation • Excess flow energy • High airflow noise • Stress on fan and system 1. Choose the Right Fan
34.
34 © UNEP 2006 Energy
Efficiency Opportunities • Increased system resistance reduces fan efficiency 2. Reduce the System Resistance • Check periodically • Check after system modifications • Reduce where possible (BEE India, 2004)
35.
35 © UNEP 2006 Energy
Efficiency Opportunities • Best Efficiency Point = maximum efficiency • Normally close to rated fan capacity • Deviation from BEP results in inefficiency and energy loss 3. Operate Close to BEP
36.
36 © UNEP 2006 Energy
Efficiency Opportunities • Periodic inspection of all system components • Bearing lubrication and replacement • Belt tightening and replacement • Motor repair or replacement • Fan cleaning 4. Maintain Fans Regularly
37.
37 © UNEP 2006 Energy
Efficiency Opportunities a) Pulley change b) Dampers c) Inlet guide vanes d) Variable pitch fans e) Variable speed drives (VSD) f) Multiple speed drive g) Disc throttle h) Operating fans in parallel i) Operating fans in series 5. Control the Fan Air flow
38.
38 © UNEP 2006 Energy
Efficiency Opportunities a) Pulley change: reduce motor/drive pulley size • Advantages • Permanent speed decrease • Real energy reduction • Disadvantages • Fan must handle capacity change • Only applicable if V-belt system or motor 5. Control the Fan Air flow (BEE India, 2004)
39.
39 © UNEP 2006 Energy
Efficiency Opportunities b) Dampers: reduce flow and increase upstream pressure • Advantages • Inexpensive • Easy to install • Disadvantages • Limited adjustment • Reduce flow but not energy consumption • Higher operating and maintenance costs 5. Control the Fan Air flow
40.
40 © UNEP 2006 Energy
Efficiency Opportunities c) Inlet guide vanes • Create swirls in fan direction • Reduce angle air and fan blades • Lowering fan load, pressure, air flow • Advantages • Improve efficiency: reduced load and airflow • Cost effective at 80-100% of full air flow • Disadvantage • Less efficient at <80% of full air flow 5. Control the Fan Air flow
41.
41 © UNEP 2006 Energy
Efficiency Opportunities d) Variable pitch fans: changes angle incoming airflow and blades • Advantages • High efficiency at range of operating conditions • No resonance problems • No stall problems at different flows • Disadvantages • Applicable to axial fans only • Risk of fouling problems • Reduced efficiency at low loads 5. Control the Fan Air flow
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Efficiency Opportunities e) Variable speed drives (VSDs): reduce fan speed and air flow • Two types • Mechanical VSDs • Electrical VSDs (including VFDs) • Advantages • Most improved and efficient speed control • Speed adjustments over continuous range • Disadvantage: high costs 5. Control the Fan Air flow
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Efficiency Opportunities e) Variable frequency drives • Change motor’s rotational speed by adjusting electrical frequency of power • Advantages • Effective and easy flow control • Improved efficiency over wide operating range • Can be retrofitted to existing motors • Compactness • No fouling problems • Reduced energy losses and costs 5. Control the Fan Air flow
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44 © UNEP 2006 Energy
Efficiency Opportunities f) Multiple speed drive • Changes fan speed from one speed to other speed • Advantages • Efficient control of flow • Suitable if only 2 speeds required • Disadvantages • Need to jump from speed to speed • High investment costs 5. Control the Fan Air flow
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45 © UNEP 2006 Energy
Efficiency Opportunities g) Disc throttle: Sliding throttle that changes width of impeller exposed to air stream • Advantages • Simple design • Disadvantages • Feasible in some applications only 5. Control the Fan Air flow
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46 © UNEP 2006 Energy
Efficiency Opportunities h) Operate more fans in parallel (instead of one large fan) • Advantages • High efficiencies at varying demand • Risk of downtime avoided • Less expensive and better performance than one large fan • Can be equipped with other flow controls • Disadvantages • Only suited for low resistance system 5. Control the Fan Air flow
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Efficiency Opportunities i) Operate fans in series • Advantages • Lower average duct pressure • Less noise • Lower structural / electrical support required • Disadvantages • Not suited for low resistance systems 5. Control the Fan Air flow
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Efficiency Opportunities 5. Controlling the Fan Air Flow Comparing Fans in Parallel and Series (BEE India, 2004)
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Efficiency Opportunities (BEE India, 2004) 5. Controlling the Fan Air Flow Comparing the impact of different types of flow control on power use
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50 Training Session on
Energy Equipment Fans & Blowers THANK YOU FOR YOUR ATTENTION © UNEP 2006
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51 © UNEP 2006 Disclaimer
and References • This PowerPoint training session was prepared as part of the project “Greenhouse Gas Emission Reduction from Industry in Asia and the Pacific” (GERIAP). While reasonable efforts have been made to ensure that the contents of this publication are factually correct and properly referenced, UNEP does not accept responsibility for the accuracy or completeness of the contents, and shall not be liable for any loss or damage that may be occasioned directly or indirectly through the use of, or reliance on, the contents of this publication. © UNEP, 2006. • The GERIAP project was funded by the Swedish International Development Cooperation Agency (Sida) • Full references are included in the textbook chapter that is available on www.energyefficiencyasia.org
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