FAN TECHNOLOGY

I Optimise fan performance

by Allen L Ray
Process Equipment
Barron Industries, USA

ystem losses, other than those of

the kiln and ancillary equipment
of the kiln, are normally a result of
the total pressure losses from friction in
the ductwork, elbows, changes in duct
cross-sectional area and losses associated
with emissions control equipment. A
certain amount of loss is unavoidable;
however, losses may be reduced many
times by simple and relatively inexpensive
modifications such as turning vanes,
well developed and longer sections for
diverging and converging flows, redesign
of compound elbows and aerodynamically
enhancing or removing obstructions in the
flow path.
The losses in total pressure as a result of
flow through a system are caused by two
factors: friction losses due to the viscosity
as the air flows along the surface of the
ducts and system equipment and dynamic
losses due to the turbulent wake caused
by changes in direction and separation of
flow around obstructions.
The total pressure (Pt) in a system is
comprised of two components, static
pressure (Ps) and velocity pressure (Pv). Pt
is the summation of Ps and Pv [Pt = Ps +
Pv]. Ps is that component of pressure that
exists by virtue of compression only and
Pv is that component that exists due to
motion only. These pressure components
will change as the cross-sectional area
changes. By conservation of energy, the
56 ICR AUGUST 2005

The mechanical draft fans that provide combustion air and then exhaust
the gases through the air pollution control system are some of the largest
parasitic loads required in the operation of a kiln. These fans include
cooler vent fans, cooler forced draft fans, kiln induced draft fans, and bag
house induced draft fans. More often than not, these fans do not operate
at peak efficiency. Given todays competitive climate, evaluating the
operation of these fans and their systems to adjust their capacity to match
the system and its resistance as well as examining possibilities to improve
efficiencies is a smart business decision.

sum of Ps and Pv at any point in the flow

system is equal to the sum of Ps and Pv
at any other point in the system, plus any
losses in pressure occurring between the
two points. With each conversion there is
a loss of total pressure. The more abrupt
the change in cross-sectional area, the
greater the loss. Minimising the number of
times the cross-sectional area changes will
reduce the system losses. Also, recognising
that changes will have to occur, the more
gentle the change or the lower the angle
of divergence or convergence in the
transition section, the lower the losses
will be. If possible, maintain an angle of
convergence of 30 or less total and an
angle of divergence of 15 or less total.
There are losses associated with turns
in direction of flow or duct elbows. Again,
they are necessary but the number should
be reduced as much as possible. The gas
velocity should be limited and the aspect
ratio should be limited to no less than 1:1
and no more than 4:1.
Turning vanes installed in the elbow
can help reduce the loss as well as guide
the flow and keep the velocity profile
as uniform as possible. Also, the greater
the angle of turn, the more the loss. If
possible, combine elbows. For example,
if a duct is making a change in elevation,
use two 45 elbows if possible instead of
two 90 elbows. Also, try to maintain a
reasonable turning radius on the elbow.
Generally, the smaller the radius, the
greater the loss.
If there are any unnecessary
obstructions in the duct system or any
unused equipment, it would be wise
to evaluate losses and consider their
removal. Taking a simple total pressure
reading upstream and downstream of the

obstruction or equipment will define the

losses and their operational costs.
Poorly operating mechanical draft fans
can be a major contributor to excessive
parasitic loss in a kiln. Mechanical draft
fans have a peak efficiency point on their
fan curve normally located just to the right
of the peak of the capacity curve. A fan
manufacturer will normally size and design
the fan such that the performance curve
and the system resistance curve intersect
at an efficient point. However, this point
of operation is often not achieved because
of the over accumulation of safety factors
in the specification by the owner, the
architect/engineer and ultimately the fan
manufacturer.
Fans need to be right sized.
Oversized fans will often require
considerable inlet dampering which in
itself is inefficient. The fear of many
designers is that the fan will be too small
and will become a limiting factor in the
high demand times of operation so larger
than needed safety factors are applied.
If the volumetric flow rate is overstated,
the fan will be selected too wide and then
the fan will operate closer to its peak
and there will be opportunity for unstable
operation.
If the pressure is overstated, the fan
will require excessive dampering to reach
its point of operation. Design for too
little flow rate or pressure will leave the
fan short and unable to provide the draft
requirements at peak loads. Therefore,
as stated before, it is imperative that the
designer have a good understanding of
the volumetric flow rate needed for the
process and the pressure requirements of
the system for that flow rate so that the
draft fans can be properly sized. _______I