Fan Efficiency

SE Asia Fan Efficiency TT

Sergio García Gallardo, CM-EPT

© 2013 Holcim Ltd

Agenda

1. What is Efficiency? 3
2. Impacts on Fan Efficiency 14
3. False Air: An Enemy to be Defeated 29

© 2013 Holcim Ltd 2

What is Efficiency?
• Efficiency in general, describes the extent to which time, effort
or cost is well used for the intended task or purpose
• Electrical Efficiency: useful power output per electrical power
consumed

𝑃𝑜𝑜𝑜
𝜂=
𝑃𝑖𝑖

(Source: Wikipedia)

© 2013 Holcim Ltd 3

What is fan Efficiency?

𝑉̇ ∙ ∆𝑝
𝜂=
𝑃𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

© 2013 Holcim Ltd 4

Power consumption – some definitions
• Shaft power (as calculated process-wise)

∆p⋅V
Pshaft = η fan
• Total power (as measured electrically)

Ptot =
Pshaft
ηtrans ⋅η motor

© 2013 Holcim Ltd

Power Consumption of Fan System

© 2013 Holcim Ltd 6

Calculation of Shaft Power Requirement

∆p Typical values:
P
ηTransformer = 99.0%
PPshaft ≠ PMeasured ηVSD = 97.5%
ηCable = 99.5%
∆p
ηMotor = 96.5%
ηCoupling = 100%

V V

© 2013 Holcim Ltd 7

Fan Efficiency

𝛥𝑝 ∙ 𝑉̇
𝜂𝑖𝑖𝑖 =
10 ∙ 𝑃𝑠𝑠𝑠𝑠𝑠

ηimp impeller efficiency [-]

𝑉̇ fan inlet gas flow [m3/s]
∆p total increase of static pressure by fan [mbar]
Pshaft required power at fan shaft [kW]

⇒ in case of significant dust load additional shaft power to be considered

⇒ for detailed calculation application of HGRS fan tools recommended; ask for support

© 2013 Holcim Ltd 8

Location of pressure measurement planes for site testing

Holcim specifies conditions at

(4) and (8)
dynamic differences are ignored
because of same/similar gas velocities
in ducts

1a
Supplier typically specifies
conditions at (1)/(1a) and (2)/(2a)
2a and sometimes ignores losses from (4) to
(1a) and from (2a) to (8)
(1a = impeller inlet)
(2a = fan outlet)
Source of drawing: ISO 5802

© 2013 Holcim Ltd 9

Fan system efficiency definition

∆p static , 4−8 ⋅ V4
η system =
10 ⋅ Pshaft ,nodust

4
8

Source of drawing: VDI 2044

© 2013 Holcim Ltd 10

System efficiency compared to impeller efficiency
• Substituting no dust shaft power with impeller efficiency equation
∆pstatic , 4−8 ⋅ V4 ∆pstatic , 4−8 ⋅ V4
η system = = ⋅ηimpeller
Pshaft ,nodust ∆ptot ,1a − 2 a ⋅ V1a

• Special case: no false air and no gas recirculation through impeller

clearance (V1a=V4), no difference in dynamic pressures

∆pstatic ,1a − 2 a − ∆pdesign _ related _ losses

η system = ⋅ηimpeller
∆pstatic ,1a − 2 a

• Example: static impeller pressure diff. = 100 mbar and system pressure
diff. = 95 mbar  5 mbar losses in inlet nozzle, flanges, diffusors etc. are
resulting in 5% efficiency loss.
Assuming 84% impeller efficiency  80% system efficiency.

© 2013 Holcim Ltd

Impacts on Fan Efficiency

© 2013 Holcim Ltd 12

Volume Conversion
𝑝∙𝑉 =𝑛∙𝑅∙𝑇

𝑛 ∙ 𝑅 ∙ 𝑇1
𝑉1 = 𝑛 ∙ 𝑅 ∙ 𝑇2
𝑝1
𝑉2 𝑝2
= (n, R  Constants)
𝑛 ∙ 𝑅 ∙ 𝑇2 𝑉1 𝑛 ∙ 𝑅 ∙ 𝑇1
𝑉2 = 𝑝1
𝑝2

𝑝1 𝑇2
𝑉2 = 𝑉1 ∙ ∙
𝑝2 𝑇1

V = Volume [m3]
p = Pressure [mbar]
T = Temperature [K]
n = Number of moles [mol]
R = Ideal gases constant [0.083 m3∙mbar ∙ K-1 ∙ mol-1]

© 2013 Holcim Ltd 13

Gas Density Impact (1/2)
∆p  The fan curve is a result of the fan
geometry, at a given gas density
and fan speed
 ρreference ≠ ρactual ∆𝒑𝟐 = ∆𝒑𝟏 ∙
𝝆𝟐
𝝆𝟏

Fan characteristic
Design point

ρactual < ρreference

∆pD  fan capacity reduction

∆pD,real
Same fan speed
real
fan capacity

VD V
© 2013 Holcim Ltd
Gas Density Impact (2/2)
P
 The power curve depends also
on the gas density
𝝆𝟐
𝑷𝟐 = 𝑷𝟏 ∙
𝝆𝟏

Design point
fan characteristic

PD

PD,real

VD
V
© 2013 Holcim Ltd
Density Conversion
𝑝∙𝑉 =𝑛∙𝑅∙𝑇

𝑛 𝑝1
𝜌1 ≡ = 𝑝2
𝑉1 𝑅 ∙ 𝑇1
𝜌2 𝑅 ∙ 𝑇2
= 𝑝 (n, R  Constants)
𝑛 𝑝2 𝜌1 1
𝜌2 ≡ = 𝑅 ∙ 𝑇1
𝑉2 𝑅 ∙ 𝑇2

𝑝2 𝑇1
𝜌2 = 𝜌1 ∙ ∙
𝑝1 𝑇2

V = Volume [m3]
p = Pressure [mbar]
T = Temperature [K]
n = Number of moles [mol]
R = Ideal gases constant [0.083 m3∙mbar ∙ K-1 ∙ mol-1]

© 2013 Holcim Ltd 16

Fan Efficiency with Dust Impact

𝛥𝑝∙𝑉̇ 𝜌𝑑𝑑𝑑𝑑
𝜂𝑖𝑖𝑖 = ∙ 1+
10∙𝑃𝑠𝑠𝑠𝑠𝑠 𝜌𝑔𝑔𝑔

ηimp impeller efficiency [-]

𝑉̇ fan inlet gas flow [m3/s]
∆p total increase of static pressure by fan [mbar]
Pshaft required power at fan shaft [kW]
ρdust dust load [g/m3]
ρgas gas density (dust free) [g/m3]

© 2013 Holcim Ltd 17

Fan Speed Impact (VSD)

n2
volume flow v2 = × v1
n1
2
 n2 
static pressure pst 2 =   × pst1
 n1 
3
 n2 
power requirement P2 =   × P1
 n1 
⇒ first approach, as equations do not consider changes in density, compressibility and efficiency

© 2013 Holcim Ltd 18

Control Method: Efficiency Field
∆p  The fan efficiency η is typically at
the optimum near design point
 With VFD the efficiency field moves
with shifting the fan characteristic,
such the fan efficiency is high in a
wide operating range
design point
ηmax
pD
operating point
0,8
η=
fan characteristic
pO η=0
,7reduced
fan speed 100% fan speed

η=0,6

VO VD
V
© 2013 Holcim Ltd 19
Control Methods: VSD vs. Fixed Speed

Cement Manufacturing Course Spring 2013, 2013-04-17 © 2013 Holcim Ltd 20

Impeller Type

© 2013 Holcim Ltd 21

Impeller Types, Efficiency and Dust Load

Preheater ID Fan
400°C normal operation
Aerofoil design
Result:
<1 year impeller life time
© 2013 Holcim Ltd 22
Impeller Type: Efficiency vs. Build-Up Risk
steep blades (large β1, β2) flat blades (small β1, β2)
• higher c2 / pdynamic: lower efficiency • lower c2 / pdynamic: higher efficiency
• lower F / higher FS : lower build-up risk • higher F / lower FS : higher build-up risk

β1
β1

β2 β2

© 2013 Holcim Ltd 23

The right Fan Design is crucial for fan performance
 Consider p, V and P reserves on expected operating points
− e.g. kiln ID fan (new line): 30% flow, 30% pressure, 10% power
− choose appropriate fan accuracy class
 Consider the right gas temperature and density
− consider peak operating temperatures: lifetime, interlock
− design gas density: dust, T, O2, CO2, H2O
 Choose the appropriate fan blade design
− consider dust, build-up risk, efficiency
− use aerofoil blades only for clean gas applications
 Use VSD with direct connection of motor and fan
 Prefer larger impeller diameter, lower max fan speed
− < 1‘000 rpm for large fans; < 3‘600 rpm for e.g. clinker cooler cooling air fans
 1st critical fan speed minimum 150% of max fan speed
 Check fan curve (surge, motor and speed limits)
 Do workshop inspection
© 2013 Holcim Ltd 24
Have you ever heard…
• My fan is too small / I need a bigger fan…

• The speed of the fan is at the limit…

• The fan must be replaced…

• The fan capacity is not enough…

© 2013 Holcim Ltd 25

Before saying any of these sentences…

© 2013 Holcim Ltd 26

False Air: An Enemy to be Defeated

© 2013 Holcim Ltd 27

False Air Definition
• Undesired “extra” flow coming from outside of the duct
False Air
Gasin 20 % Gasout
100 % 120 %
• Impacts:
 Process:
− Cools down the gases
− Increases dust recirculation
− Increases thermal energy consumption
− …
 Fans:
− “Eats up” fan reserves
− May lead to wrong measurements
− Increases electrical energy consumption

© 2013 Holcim Ltd 28

A Little Exercise…
• Process gas flow:
 700’000 m3/h  103.5 mbar  3044 kW

+ 96 kW
• +10% False Air: 365 days
 770’000 m3/h  105.4 mbar  3140 kW 85% oper. Hours

+ 715’000 kWh/year

+ 71’500 $/year

© 2013 Holcim Ltd 29

How do I find it?
• By noise False Air
20 %
Gasin Gasout
• Visually 100 % 120 %

• Measuring flow or:

 O2 %O2,in %O2,out
Tgas,in Tgas,out
 %O2,out − %O2,in 
FA[%] =   ⋅ 100

 21 − %O2,out 

 T
TGas ,in − TGas ,out − Tloss
FA[%] ≈ ⋅ 100
TGas ,out − Tair %O2,in/out = measured O2 concentration (dry) before / after intake (%)
Tgas,in/out = measured temperature before / after intake (°C)
TLoss = assumed temperature (heat) loss over surface (°C)
TAir = temperature of inleakage air ≈ Ambient temperature (°C)
 Opening Area A = open Area (m2)
ρAir,N = air density at normal conditions (=1.29 kg/Nm3)
ρAir = air density at ambient condition (kg/m3)
0.75 A
VFA intake ≈ 2 ⋅ ∆p ⋅ ρair Δp = pressure difference over aperture (Pa)
ρair,N

© 2013 Holcim Ltd 30

Typical values

Location False Air

(% of flow before intake)

Bag filter <5

Electrostatic precipitator < 10
Conditioning tower <5
Expansion joint 0!
Fan <2

Damper (butterfly, jalousie, guillotine) <2

Preheater cyclone <2

Kiln inlet seal <1

Source: PPE guide

© 2013 Holcim Ltd 31

Target values of a 4 Stage Preheater (Exercise)

TGas Press 𝑂2,𝑂𝑂𝑂 − 𝑂2,𝐼𝐼

SP4 O2
[mbar] 𝐹𝐹𝐹𝐹𝐹 𝐴𝐴𝐴 % =
[°C] [%] 21 − 𝑂2,𝑂𝑂𝑂

Stage 1 350 3.4% - 45

Kiln Inlet to Stage 1:

Stage 2 545 3.0% - 31 3.4 − 2.5

𝐹𝐹𝐹𝐹𝐹 𝐴𝐴𝐴 % =
21 − 3.4
Stage 3 690 2.6% - 23

𝐹𝐹𝐹𝐹𝐹 𝐴𝐴𝐴 = 5%
Stage 4 800 2.4% - 16

°C 2.5% - 9

Cement Manufacturing Course Spring 2013, 2013-03-15 © 2013 Holcim Ltd 32

Target values of a 5 Stage Preheater with PC (Exercise)

TGas ηsep O2 Press 𝑂2,𝑂𝑂𝑂 − 𝑂2,𝐼𝐼

PC5 𝐹𝐹𝐹𝐹𝐹 𝐴𝐴𝐴 % =
[°C] [%] [%] [mbar] 21 − 𝑂2,𝑂𝑂𝑂

Stage 1 320 ~93 3.6% - 55

PC Exit to Stage 1:

Stage 2 520 ~85 3.1% - 43 3.6 − 2.0

𝐹𝐹𝐹𝐹𝐹 𝐴𝐴𝐴 % =
21 − 3.6

Stage 3 660 ~80 2.6% - 36

780 ~70 2.3% - 29 𝐹𝐹𝐹𝐹𝐹 𝐴𝐴𝐴 = 9%

Stage 4

Stage 5 880 ~60 2.0% - 22

2.5% - 5
1100°C

Cement Manufacturing Course Spring 2013, 2013-03-15 © 2013 Holcim Ltd 33

Summary
• Fan Efficiency

𝛥𝑝∙𝑉̇ 𝜌𝑑𝑑𝑑𝑑
𝜂𝑖𝑖𝑖 = ∙ 1+
10∙𝑃𝑠𝑠𝑠𝑠𝑠 𝜌𝑔𝑔𝑔

• 𝜂𝑖𝑖𝑖𝑒𝑒𝑒𝑒𝑒 ≠ 𝜂𝑠𝑠𝑠𝑠𝑠𝑠
• Consider:
 Right measuring place
 Dust concentration
 False Air

© 2013 Holcim Ltd 34

Questions????

© 2013 Holcim Ltd 35