At the heart of perfect systems
PERFORMANCE OF
FANS
AFTER
RETROFITTING
AT VARIOUS PLANTS
At the heart of perfect systems
Example :
Application : Cooler
ESP Fan in Cement Plant
Client : Manikgarh
Cement
Saving in, power consumed for a period of one year,
considering at Rs. 4.50 per kW for 7000 operating hours.
(252-165) x 7000 x 4.50 = Rs. 27,40,500/Therefore average saving in power for one month
=
=
Rs. 27,40,500.00 / 12
Rs. 2,28,375.00
Return on investment = 10,00,000/2,28,375 = 4.37 Months.
At the heart of perfect systems
Client :
Manikgarh Cement
Application :
Cooler ESP Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
Existing Fan Make
: ABB
Before Retrofitting
Design
Operating
After Retrofitting
Flow
420,120 m3/Hr
441,360 m3/Hr
500,040 m3/Hr
Static Pressure
180 mm WG
45 mm WG
85 mm WG
Power
402 kW
252 kW
165 kW
Fan Speed
740 rpm
469 rpm
472 rpm
Efficiency
51.2 %
21.5 %
70.1 %
At the heart of perfect systems
Client :
India Cements Ltd..
Application :
VRM Exhaust Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
Existing Fan Make
: Hamada Blower Co.
Before Retrofitting
After Retrofitting
Flow
6,30,000 m3/Hr
6,30,000 m3/Hr
Static Pressure
950 mm WG
1000 mm WG
Power
2100 kW
2016 kW
Fan Speed
980 rpm
971 rpm
Efficiency
77.6 %
85 %
At the heart of perfect systems
Client :
Raasi Cement Ltd.
Application :
Waste Gas Fan
Components replaced : Impeller, Casing &
Inlet Cone
Reason for retrofitting : Improving Efficiency
Existing Fan Make
: Andrew Yule
Before Retrofitting
After Retrofitting
Flow
414,000m3/Hr
414,000 m3/Hr
Static Pressure
900 mm WG
900 mm WG
Power
1463 kW
1424 kW
Fan Speed
950 rpm
950 rpm
Efficiency
69.4 %
77.26 %
At the heart of perfect systems
Client :
Orient Cements
Application :
Pre Heater Fan
Components replaced : Impeller, Casing &
Inlet Cone
Reason for retrofitting : Improving Capacity &
Increasing Efficiency
Existing Fan Make
: KHD HUMBOLDT
Before Retrofitting
After Retrofitting
Flow
384,240m3/Hr
432,000 m3/Hr
Static Pressure
800 mm WG
750 mm WG
Power
1186 kW
1086 kW
Fan Speed
990 rpm
880 rpm
Efficiency
70.6 %
81.3 %
At the heart of perfect systems
Client :
ACC - Wadi
Application :
K3 Waste Gas Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Power Saving and
Increasing Capacity
Existing Fan Make
: ABB
Before Retrofitting
After Retrofitting
Flow
293,400 m3/Hr
332,800 m3/Hr
Static Pressure
900 mm WG
975 mm WG
Power
1060 kW
1065 kW
Fan Speed
980 rpm
989 rpm
Efficiency
67.8 %
78.2 %
At the heart of perfect systems
Client :
Larsen & Toubro - Awarpur
Application :
Kiln ESP Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency,
power saving and
increasing capacity
Existing Fan Make
: FLS
Before Retrofitting
After Retrofitting
Flow
6,50,000 m3/Hr
738,000 m3/Hr
Static Pressure
140 mm WG
250 mm WG
Power
413 kW
646 kW
Fan speed
300 rpm
365 rpm
Efficiency
60 %
82 %
At the heart of perfect systems
Client :
ACC - Wadi
Application :
K1 & K2 Waste Gas Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Power Saving and
Increasing Capacity
Existing Fan Make
: ABB
Before Retrofitting
After Retrofitting
Flow
189,360m3/Hr
189,360 m3/Hr
Static Pressure
960 mm WG
960 mm WG
Power
660 kW
586.5 kW
Fan Speed
980 rpm
992 rpm
Efficiency
75 %
84.5 %
At the heart of perfect systems
Client :
Larsen & Toubro - Awarpur
Application :
Cooler ESP
Fan
Components replaced : Impeller, Casing &
Inlet Cone
Reason for retrofitting : Power Saving and
Increasing Capacity
Existing Fan Make
: FLS
Before Retrofitting
After Retrofitting
Flow
780,000m3/Hr
780,000 m3/Hr
Static Pressure
150 mm WG
180 mm WG
Power
501 kW
474 kW
Fan Speed
500 rpm
509 rpm
Efficiency
63.5 %
80.7 %
At the heart of perfect systems
Client :
Raasi Cement Ltd.
Application :
Cooler ESP Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
Existing Fan Make
: Batliboi
Before Retrofitting
Design
Operating
After Retrofitting
Flow
681,840 m3/Hr
591,000 m3/Hr
732,960 m3/Hr
Static Pressure
165 mm WG
80 mm WG
150 mm WG
Power
381 kW
390 kW
428 kW
Fan Speed
590 rpm
600 rpm
678 rpm
Efficiency
81.5 %
33.0 %
70.0 %
At the heart of perfect systems
Client :
Zuari Cement
Application :
Raw Mill Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Power Saving and
Improving Efficiency
Existing Fan Make
Before Retrofitting
After Retrofitting
Flow
180,000 m3/Hr
180,000 m3/Hr
Static Pressure
615 mm WG
615 mm WG
Power
520 kW
365 kW
Efficiency
58 %
82.6 %
At the heart of perfect systems
Client :
ACC - Lakheri
Application :
Bag House Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
& Increasing Capacity
Existing Fan Make
: ABB
Before Retrofitting
After Retrofitting
Flow
300,000 m3/Hr
330,000 m3/Hr
Static Pressure
300 mm WG
270 mm WG
Power
298 kW
309 kW
Fan Speed
945 rpm
980 rpm
Efficiency
54.8 %
78.5 %
At the heart of perfect systems
Client :
JK Corp - Lakshmi Cements
Application :
Cooler Vent
Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
& Increasing Capacity
Existing Fan Make
: Andrew Yule
Before Retrofitting
After Retrofitting
Flow
2,45,000 m3/Hr
4,66,000 m3/Hr
Static Pressure
330 mm WG
172 mm WG
Power
367 kW
297 kW
Fan Speed
985 rpm
980 rpm
Efficiency
60 %
73 %
At the heart of perfect systems
Client :
Madras Cements Ltd.
Application :
Pre Heater Fan
Components replaced : Impeller, Casing &
Inlet Cone
Reason for retrofitting : Increasing Capacity
Existing Fan Make
: Andrew Yule
Before Retrofitting
After Retrofitting
Flow
72,000 m3/Hr
85,000 m3/Hr
Static Pressure
650 mm WG
750 mm WG
Power
164 kW
193 kW
Fan Speed
985 rpm
980 rpm
Efficiency
78.0 %
79.6 %
At the heart of perfect systems
Client :
Orient Cement
Application :
Cooler ESP Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
Existing Fan Make
: Andrew Yule
Before Retrofitting
Design
Operating
After Retrofitting
Flow
405,000 m3/Hr
294,000 m3/Hr
390,000 m3/Hr
Static Pressure
125 mm WG
70 mm WG
100 mm WG
Power
187 kW
190 kW
135 kW
Fan Speed
745 rpm
710 rpm
745 rpm
Efficiency
73.7 %
29.5 %
78.7 %
At the heart of perfect systems
Client :
ACC - Chanda Cement Works
Application :
Fan
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
& Increasing Capacity
Existing Fan Make
: Kilburn
Before Retrofitting
After Retrofitting
Flow
2,00,000 m3/Hr
2,00,000 m3/Hr
Static Pressure
130 mm WG
130 mm WG
Power
120 kW
95 kW
Fan Speed
980 rpm
971 rpm
Efficiency
59 %
75 %
Kiln ESP
At the heart of perfect systems
IMPROVEMENT OF EFFICIENCY BY INSERTING HIGH EFFICIENCY IMPELLER
IN THE EXISTING CASING OF LOW EFFICIENCY CENTRIFUGAL FANS
A) DESIGN PARAMETERS
OF EXISTING FAN :
Application
Flow rate, m3/Hr:
B) REVISED PARAMETERS,
IF ANY :
: ....
C) Overall dimensions of existing Fan Casing, as marked `? ;
: ..
: ..
Static Pressure, mm WG
: ...
: ..
Temperature, oC
: ...
: ..
Inlet Density, Kg/m 3
: ..
Fan Speed, RPM
: ..
Dust Load, Kg/m3
: ..
Fan Shaft Power, kW
: ...
: ..
Arrangement of Fan
: ...
: ..
Drive Arrangement
: ...
: ..
Make of the Fan
: . .
Model No. of the Fan
: ...
: ..
Motor connected-kw&rpm
: ...
: ..
D) Overall dimensions of existing Fan arrangement, as marked `? ;
: ..
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