THE DESIGN AND CONSTRUCTION OF INDUSTRIAL BLOWER

BY

NWASA IFEANYICHUKWU BENEDICT ENG/2141960394

LONGE GREAT EMIEJOMO ENG/2141960111
OSARIEMEN DAHLIN OSAKPOLOR ENG/2141950108
OFANGBON ISAAC ENG/2141840512

A PROJECT WORK PRESENTED TO THE DEPARMENT OF

MECHANICAL ENGINEERING TECHNOLOGY,
SCHOOL OF ENGINEERING, AUCHI POLYTECHNIC,
AUCHI.

IN PARTIAL FULFILMENT OF THE REQUIREMENT

FOR THE AWARD OF HIGHER NATIONAL DIPLOMA
IN MECHANICAL ENGINEERING TECHNOLOGY

MARCH 2021
 CERTIFICATION

This is to certify that the project entitled “DESIGN AND

CONSTRUCTION OF INDUSTRIAL BLOWER” has been carried out by

NWASA IFEANYICHUKWU BENEDICT, LONGE GREAT EMIEJOMO,

OSARIEMEN DAHLIN OSAKPOLOR, OFANGBON ISAAC, in partial

fulfillment of the requirement for the award of Higher National Diploma

in Mechanical Engineering Technology, Auchi Polytechnic, Auchi during

the academic year 2020-2021.

___________________
MR AREWA DATE
Project Supervisor

___________________
ENGR DR.IZAH L.A DATE
Project Supervisor

___________________
ENGR ANSLEM. A DATE
Head of Department

II
 DEDICATION

This project work is dedicated to God Almighty, the author and

finisher of our faith, for his mercies, protection, and guidance toward the

successful completion of our project and also to our lovely parents for

their love and support.

III
 ACKNOWLEGEMENT

To God be the glory and honor, the Author and Finisher of our faith.

With Him all things are possible indeed.

Our appreciation goes to our supervisors, Engr. Dr. Izah L.A. and

Engr. Arewa who ensured that this Project Report was successful with

useful and brilliant ideas.

More so, our appreciation goes to our Parents and Relatives for

their financial support and immense prayer for us.

IV
 ABSTRACT

Poor performance of a furnace cannot be unassociated to failure

in the design of the industrial blower among other components, this
project dissertate the design of a centrifugal blower for a furnace which
will give the required manometric efficiency that will aid adequate
combustion as needed. The blower was designed to convert ‘driver’
energy to kinetic energy in the fluid by accelerating it to the outer rim of
the revolving device centrifugally casting the fluid away from the impeller
vane tips. The amount of energy given to the fluid corresponds to the
velocity at the edge or vane tip of impeller. The two main components of
a centrifugal blower are the impeller and the casing. The impeller is a
rotating component while the casing is a stationary component; air
enters axially through the impeller eyes and air exists radially. The
blower volute casing is to direct the air to the impeller and lead it away at
a high pressure. In this project, the air flow rate is 11.22m3/min and the
motor speed is 2730 rpm. The shaft diameter is 20mm; impeller inlet
diameter and outlet diameter are 207mm and 371mm.

Keyword: Impeller, Centrifugal blower, Manometric Efficiency, Volute

Casing and Flow Rate.

V
 TABLE OF CONTENT
Title page - - - - - - - - - - I
Certification - - - - - - - - -
II
Dedication - - - - - - - - -
III
Acknowledgement - - - - - - - - IV
Table of Contents - - - - - - - -
V
Abstract - - - - - - - - - - VI

CHAPTER ONE
1.0 Introduction . . . . . . . . . 1
1.1 Background of Study . . . . . . .
2
1.2 Statement of Problem . . . . . . .
3
1.3 Aims and Objectives of Study . . . . . . 4
1.4 Motivation of Study . . . . . . . 4
1.5 Significance of the Study . . . . . . . 4
1.6 Scope of Study . . . . . . . .
5
1.7 Limitation of Study . . . . . . . . 6
1.8 General Description of the Work and its Working Principles .
7
1.8.1 Centrifugal Blower . . . . . . .
7
1.8.2 Schematic diagram of Centrifugal Blower . . . .
8
1.8.3 Classification of Centrifugal Blower . . . .
8
1.8.4 Component of the Centrifugal Blower . . . .
9
1.8.5 Industrial Blower Application . . . . . . 11
1.8.5.1 Air Handling . . . . . . . . 11
1.8.5.2 Dust loading . . . . . . . . 11
1.8.5.3 Fumes Extraction . . . . . . . .
12

VI
1.8.5.4 Material Handling . . . . . . . 12
1.8.5.5 Exhausting . . . . . . . .
13
1.8.5.6 Cooling . . . . . . . . . 13

CHAPTER TWO
2.0 Literature Review . . . . . . . . 14
2.1 Brief History of Centrifugal Blower . . . . . 15
2.2 Current Review of Centrifugal Blower . . . . 15
2.3 Summary of Review . . . . . . .
19
2.4 Review of the Types of Industrial . . . . .
21
2.4.1 Types of Industrial Blower . . . . . . 21
2.4.1.1 Positive Displacement Blower . . . . .
21
2.4.1.2 Centrifugal Industrial Blower . . . . .
21
2.4.1.3 High Speed Industrial Blower . . . . .
22
2.4.1.4 Helical Screw Industrial Blower . . . . . 22
2.4.1.5 Axial Industrial Blower . . . . . .
23
2.4.1.6 Vapor Recovery Industrial Blower . . . . 23

CHAPTER THREE
3.0 Materials and Method . . . . . . . 24
3.1 Design Methology . . . . . . . . 24
3.1.1 Design Specification/Consideration . . . . .
24
3.1.2 Design Analysis . . . . . . . . 24
3.1.3 Design calculation . . . . . . .
25
3.1.3.1 Design of Blower Impeller . . . . . . 25
3.1.3.2 Analysis of various Velocities of the Impeller Blades . .
29
3.1.3.3 Design of Volute Casing of the Blower . . . . 32
3.1.3.4 Determination of the Horse Power required by the Electric Motor
33
3.1.3.5 Determination of pressure through the Impeller . .
34
3.1.3.6 Determination of Efficiency of the Blower . . .
34
VII
3.1.3.7 Determination Shaft diameter of Impeller . . .
35
3.2 Material selection . . . . . . . . 36
3.3 process selection/ Manufacturing process . . . . 36

CHAPTER FOUR
4.0 Performance Evaluation . . . . . . . 39
4.1 Presentation of Result . . . . . . . 39
4.2 Analysis of Result . . . . . . . 41
4.3 Bill of Engineering Measurement and Evaluation . . . 42

CHAPTER FIVE
5.0 Summary, Conclusion and Recommendation . . . 43
5.1 Summary . . . . . . . . . 43
5.2 Conclusion . . . . . . . . . 43
5.3 Recommendation . . . . . . . . 44

REFERENCES . . . . . . . . . 45

LIST OF FIGURES
Fig 1.8.2: Schematic diagram of Centrifugal Blower . . . 8
Fig 3.1.2: Velocity diagram of the Impeller Blade . . .
29

LIST OF TABLES
Table 1: Radius of volute at different angles . . . .
33
Table 2: Physical Characteristics and Performance Parameters . .
39

VIII
 CHAPTER ONE

1.0 INTRODUCTION

In decades past, the productions of an engineering component to

an optimal standard have been of optimum importance. Also, the

separation of materials using air (generation of hot or cold air) for

manufacturing purpose in order to meet industrial requirement has been

a problem in the past since the invention of industrial blower. Blowers

are used in many manufacturing, process installations and many

equipment and machinery.

In engineering today, industrial blowers are the workhorses of the

process industries because they are used for various applications

including supplying high air flows for various applications including

factory and mine ventilation, air conditioning, cooling, and combustion.

Common types of blowers are axial blower and centrifugal blower. A

centrifugal blower consists of an impeller, electric motor, a vacuum

through which air enters through the air inlet pipe before being

accelerated by the impeller to where it is required through the delivery

port.

An industrial blower is used in the forcing of air into an apparatus

for example, on the furnace where air is needed to atomize the fuel on
1
the nozzle before combustion can take place; the blower is used to

achieve this atomization by providing the forced air. In this project,

emphasis is made on that which is used in supplying air to the furnace

(i.e. pit furnace).

More so, industrial blower is designed to meet the most critical

application requirements and features. The impeller and casing are

mostly manufactured from aluminum alloy in order to ensure maximum

strengths, reduce weight and increase corrosion resistance. The blower

and motor are constructed as a mechanical unit; simplicity and

maximum structural integrity. The elimination of clutches and gears,

belts and sliding blades has reduced periodic maintenance requirements,

and in turn increases reliability.

1.1 BACKGROUND OF STUDY

Blowers are machines widely used in present industrial and

domestic life. It is important to recognize that the design of such turbo

machine is an interdisciplinary process, involving aerodynamics,

thermodynamics, fluid dynamics, stress analysis, vibration analysis, the

selection of materials, and the requirements for manufacturing (Bleier,

2016). The principles involved in the design of a blower is similar to that

of a centrifugal pump except for the fact that the term “centrifugal pump”

2
is often associated with liquid as its working fluid while, the blower is

meant to work on air. The blower can therefore be described as a device,

which converts "driver energy" to kinetic energy in a fluid by accelerating

it to the outer rim of a revolving device known as an impeller. The

impeller, driven by the blower shaft adds the velocity component to the

fluid by centrifugally casting the fluid away from the impeller vane tips

(Abubakar et al., 2018). Impeller is the most important part of the blower

components because of the fact that its performance inadvertently

determines the blower’s performance. An impeller is essentially a disk-

shaped structure with vanes that create the actual suction in a blower.

The impeller is always placed directly onto the shaft of the electric

motor so that it spins at a very high speed. The effects of centrifugal

force acting upon the spinning air within the impeller create the suction.

In this study, the aim is to characterize the performance of

industrial blowers to determine typical energy consumption, how

performance differs between standard laboratory rating conditions and

real life applications, what attributes of blowers contribute significantly

to their performance, and to use this information to evaluate proposed

performance testing.

1.2 STATEMENT OF PROBLEM

3
 Concerned industry manufactures blowers and supplies it to

foundry industry. It is found that they are facing many problems

regarding centrifugal blower. They use centrifugal blower for air supply

purpose and also to maintain the temperature of furnace. The present

centrifugal blower is made up of mild steel material, here corrosion is a

major problem, weight of the present blower is high, strength of impeller

is less and also the noise produced during operation of blower is higher.

1.3 AIMS AND OBJECTIVES OF STUDY

The aim of the study is to design and construct an industrial

blower for the furnace to maintain a steady efficiency of heat. The

specific objectives in the design and construction of an industrial blower

are as follows:

1. To design and fabricate a centrifugal blower for the supply of

compressed air to aid combustion.

2. To optimize the load of the industrial blower impeller

1.4 MOTIVATION OF STUDY

The low level of technology in Nigeria has been a matter of great

concern to the industrial sector and its expenses. This low technological

state is a motivating factor which has led to the manufacturing of the

product (industrial blower), with the locally available materials.

4
1.5 SIGNIFICANCE OF THE STUDY

The study is a major step toward developing indigenous

technology for local foundry workshops.

The study is significant in the following ways:

1. It will provide the relevant geometrical parameters and

performance characteristics for the manufacturing of blowers.

2. It will gear up the process industries by providing accurate flow of

air or gas needed for exhausting, cooling, ventilating, conveying

and combusting.

3. The study contributes to the numbers of literature available for

research purpose.

1.6 SCOPE OF STUDY

This Project presents the design and development of a centrifugal

industrial blower for a low capacity air supply purpose. While designing

the blower, the most important impeller design parameters to be

determined were grouped into three categories and used in the

construction. The groups are: Geometrical Parameters (Tip diameter,

hub diameter, and tip width), Operating conditions (Inlet total pressure,

inlet total temperature, and fluid density), and Performance

5
characteristics (mass flow parameter, pressure ratio, and specific speed)

which will be used to obtain blower efficiency and performance. This

includes identifying suitable performance metrics and target

performance levels for use in standards. The blower and residential

furnaces were tested for air moving performance. It was tested in two

different furnace cabinets. During testing, the blower and furnace

combination was operated over a range of air flows and pressure

differences to determine air flow performance, power consumption and

efficiency. Additional tests varied the clearance between the blower

housing and the furnace cabinet, and the routing of air flow into the

blower cabinet.

1.7 LIMITATION OF STUDY

The study provides important insight regarding the design and

construction of a centrifugal to supply air for combustion purpose. But

still the study has some limitations which were mentioned below:

1. The study is chiefly concentrated only on centrifugal blower.

Hence it becomes difficult to ascertain the design characteristics

and performance evaluation of other types of industrial blower.

2. The outcome of the study cannot be generalized because the

study is only based on radial type impeller blade thereby

6
 neglecting forward and backward type impeller blade.

3. For the study only few factors have been taken into consideration

to measure the manometric efficiency of the blower. Industrial

blower is a vast thesis and there are many other factors which can

be considered for the study.

4. Time factor was a major challenge because the study was time

bound so it becomes difficult to collect information from

numerous literatures.

5. Late availability of funds in financing the project work, both the

research work and materials for production.

1.8 GENERAL DESCRIPTION OF THE WORK AND ITS WORKING

PRINCIPLES

1.8.1 Centrifugal Blower

Centrifugal blowers are constant volume devices that are designed

with high speed impellers or blades typically rotating at about 15,000

rpm. The speed of the air stream entering into the blower is increased by

the impeller or blades, where it gains kinetic energy and accelerates with

higher pressure through outlet in radial direction. Like Centrifugal fan

systems, these blowers also have different drive mechanisms such as

belt, variable and direct driven. To adjust the air flow rates, centrifugal

7
blowers are fitted with dampers & louvers, ducts and other similar

airflow resistant components.

A centrifugal blower can be single and multi-stage unit and can

have different blade orientations such as radial, forward curved and

backward curved. Often, single stage centrifugal blower is used when a

uniform airflow is required whereas multi-stage blower is useful when

there is a requirement for varying flow of air at a fixed pressure.

Centrifugal blowers are basically classified into three types based

on their ability to generate pressure during operation. They are low

pressure, medium pressure and high pressure centrifugal blowers.

Fig.1.8.2 Illustrates a cross section of the blower designed. Fluid enters

the inlet port at the center of the rotating impeller, or the suction eye. As

the impeller spins in a counterclockwise direction, it thrusts the fluid

outward radially, causing centrifugal acceleration. As it does this, it

creates a vacuum in its wake, drawing even more fluid into the inlet.

Centrifugal acceleration creates energy proportional to the speed of the

impeller. The faster the impeller rotates, the faster the fluid movement

and the stronger its force. Impellers are the rotating blades that actually

move the fluid. They are connected to the drive shaft that rotates within

the blower casing. The impeller is designed to impart a whirling motion

8
to the air in the blower.

1.8.2 Schematic Diagram of Centrifugal Blower

FIG. 1.8.2 (Abubakar et al., 2018)

1.8.3 Classification of Centifugal Blower

On the basis of characteristic features, the centrifugal blowers are

classified as:

1. Type of casing

2. Working heads

3. Liquid handled

4. Number of impellers per shaft

5. Number of entrance to the impeller

6. Relative direction of flow through impeller

1.8.4 Components of the Centrifugal Blower

9
1. Impeller: An impeller is a wheel (or rotor) with a series of backward

curved blades. It is mounted on a shaft which is usually coupled to an

electric motor. Each type of configuration serves a specific purpose

for airflow. Radial blades are for high pressure applications with

medium airflow. Forward curved blades are for medium pressure

applications while backward curved are for high pressure

applications.

a. Closed Impeller: In this type of impeller, vanes are provided

with metal cover plates and shrouds on both the sides. It

provides better guidance for the fluid. This type of impeller

is chosen in this design.

b. Semi-open impeller: In this type, the vanes have only the

base plate and no crown plate. It can be used with fluids

that contain debris.

c. Open-impeller: this type of impellers has neither the crown

plate nor the bottom plate. They are employed to blow the

air that contains suspended solids.

2. Casing: The casing is an air tight-chamber surrounding the blower

impeller. It contains suction and discharge arrangements, supporting

bearings, and facilities to house the rotor assembly and protects

leakages. There are also three types of casing.

a. Volute Casing: In this casing type, the area of flow

10
 gradually, increase from impeller outlet to the delivery pipe

so as to reduce the velocity of flow. Thus the increase in

pressure occurs in volute casing.

b. Vortex Casing: If a circular chamber is provided between

the impeller and the volute chamber, the casing is known

as vortex casing. The circular chamber is known as vortex

or whirlpool chamber. The vortex chamber converts some

of the kinetic energy to pressure energy. So it has more

efficiency than simple involutes casing.

3. Suction inlet: This is the pipe or opening that connects the centre of

the impeller to sump from which fluid is to be lifted.

4. Delivery outlet (Nozzle): This is the outlet of the blower; its main

function is to help in giving higher velocity to the air at the expense of

pressure drop in it.

1.8.5 Industrial Blower Applications

Industrial blowers are used in operations and applications where

the flow of gas or air is necessary such as conveying systems,

ventilation, cooling, aspiration, and exhaust systems. The many types

and varieties of blowers are designed to perform important and unique

functions that are required by specific applications. This can be seen in

the difference between blowers that is used for ventilating a

11
manufacturing plant from one used to provide air circulation for a

nursery. (http//iqsdirectory.com)

The differentiation between blowers is determined by the type of

blower, flow capacity, dimensions, operating pressure, design, and

electrical rating. The many types of blowers are used for cooling, drying,

dust control, and fluid bed aerators.

1.8.5.1 Air Handling

Industrial blowers provide high and even airflow through the

ductwork of a building. Air movement is achieved by large angle blades

connected to the hub of the blower.

1.8.5.2 Dust Loading

Dust loading industrial blowers collect dust to improve air quality.

For some industries, dust collection is an essential part of their

operations as well as being a legal requirement under Environmental

Protection Agency (EPA) regulations. Air quality regulations are for the

protection of workers since air particulates can lead to a variety of

health conditions. Industrial dust loading units moves air and

contaminants through a system that captures, collects, and removes

dangerous particles. Included in the system are hoods, air filtration

systems, and collectors such as bag houses, traps, and ductwork.

12
1.8.5.3 Fumes Extraction

A wide variety of industrial processes produce fumes, smoke, and

chemicals that have to be removed from the air. The fumes and other

contaminants are removed by scrubbers or points of emission. This is

normally achieved through the use of a system of blowers and fans.

Fume remover industrial blowers are a part of a whole system that is

designed with a large capacity filtration system. The 99% efficiency of

the system guarantees that all harmful odors, contaminants, and gas

fumes are being removed.

1.8.5.4 Material Handling

The material handling industry uses pneumatic pressure systems

to move granular and powder materials to production. Industries

such as the pharmaceuticals, food processing, Agriculture, chemical,

and cement producers requires industrial blowers to remove fine

particulates from the air. Though normal fans can remove average

particles, heavier materials have to be handled by abrasion resistant,

heavy duty industrial blowers that are specifically designed to

withstand the wear of such materials. Blowers for these types of

operations are made of exceptionally sturdy materials and are

capable of enduring the severe abuse from removing the chips,

13
 particles, and granular residue.

1.8.5.5 Exhausting

In small and enclosed workspaces where paint and vapors

accumulate, industrial blowers serve the purpose of removing and

filtering the fumes and vapors to keep the air clean. Since some of the

chemicals in these applications can be combustible, exhaust industrial

blowers have to be spark resistant. A buildup of paint, lacquer, and

varnish has the potential of being volatile and explosive. The spark

resistant blowers for these conditions are normally made with specially

fabricated aluminum impellers.

1.8.5.6 Cooling

Cooling industrial fans are referred to as fluid displacers due to the

fact that they displace air in one location to move it to another location

through the use of rotating blades. The purpose of cooling fans is to

blow in cold air and drive out hot air, which gives them the name of

industrial cooling blowers.

14
 CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 BRIEF HISTORY OF CENTRIFUGAL BLOWER

The earliest mention of centrifugal fans was in 1556 by Georg

Pawer (Latin: Georgius Agricola) in his book De Re Metallica, where he

shows how such fans were used to ventilate mines. Thereafter,

centrifugal fans gradually fell into disuse. It wasn't until the early

decades of the nineteenth century that interest in centrifugal fans

revived. In 1815 the Marquis de Chabannes advocated the use of a

centrifugal fan and took out a British patent in the same year. In 1827,

Edwin A. Stevens of Bordentown, New Jersey, installed a fan for blowing

air into the boilers of the steamship North America. Similarly, in 1832,

the Swedish-American engineer John Ericsson used a centrifugal fan as

blower on the steamship Corsair. A centrifugal fan was invented by

Russian military engineer Alexander Sablukov in 1832, and was used

both in the Russian light industry (such as sugar making) and abroad.

(“Centrifugal fan,”2016)

In 1862, British Guyana Bell centrifugal fan invention, the impeller,

housing for the concentric type, the rear housing with brick, wood to the

straight blade impeller, the efficiency is only about 40%, mainly for mine

15
ventilation. In 1880, it devised volute casing for exhaust air of the mine,

and backward curved blade centrifugal fan structure has been more

perfect. 1892 France developed into a cross-flow fan. In 1898, the Irish

people designed centrifugal fan blades and are widely used in various

countries; and have been used in mine ventilation.

One of the most important developments for the mining industry

was the Guibal fan, which was patented in Belgium in 1862 by the

French engineer Theophile Guibal. The Guibal fan had a spiral case

surrounding the fan blades, as well as a flexible shutter to control the

escape velocity, which made it far superior to previous open-fan designs

and led to the possibility of mining at great depths. Such fans were used

extensively for mine ventilation throughout Britain. (Dicheng, 2018)

2.2 CURRENT REVIEW OF INDUSTRIAL BLOWER

Many researchers have focused on the fan noise in the context of

reducing the noise generated from the fan. But, only a few researches

have been carried out on the noise prediction because of the difficulty in

obtaining detailed information of flow-field and implementing scattering

effects by the casing.

(Morris G.K, 2012) conducted a research that details the modeling,

design optimization, and experimental verification approaches used to

16
optimize blower housing designs for variable speed drives with the

assertation that the design of the blower housing is just as important as

the blower selection and by modifying the housing dimensions, the

shape and quantity of flow exiting the housing can be controlled.

(Atre P. C, and Thundil Karuppa R.R, 2012) looked into how the

numerical design and parametric optimization of centrifugal fans with

airfoil blade impellers would help to increase blade efficiency and weight.

(Jeon.W, 2014) developed a new method to predict the noise from

a centrifugal fan and the sound characteristics of a splitter impeller were

analyzed. The objective of the study was to calculate the effects of

splitter vanes that are attached to an original impeller on acoustic

signature. A Discrete Vortex Method (DVM) was used to describe the

flow-field of the centrifugal fan. Lawson’s equation was used to predict

the acoustic far-field pressure. In the paper, four impeller types were

considered: original impeller, an impeller that has twice number of blade,

a splitter impeller, and a splitter impeller that has twice number of

splitter blade.

The study reveals that the splitter modifies the flow-field near the

impeller tip more uniformly. The splitter impeller influences the acoustic

characteristics as well as the performance. The splitter impeller, which

17
has the splitter to be placed in a jet region, is found to improve the

acoustic characteristics, and therefore reducing noise.

(Epple. P, et al 2014) Tested centrifugal blower with volute casing

with large tongue clearance and concluded that at design point, the ratio

of circulating flow rate to total flow rate at the volute end is about 45%,

and the pressure recovery in the volute is about 45%, As the remaining

55% of the pressure recovery in the casing is recovered in the Section

between volute and exit duct and also casing acts as a high-

performance diffuser. The centrifugal force produced by the secondary

flow and boundary layer suction, are the main causes of large pressure

recovery.

A combined analytical and numerical method for designing of BC

blower was presented, suited to design high-efficiency radial impellers.

The torque-speed characteristic of the motor without the need of a

previous impeller series or knowledge of experimental data, allowing

optimizing efficiency in the design stage, the blade shapes were

computed using an inverse method. An efficiency increase of 13% and a

maximum flow rate increase of 11%. The design point was also met. It

was concluded that β2 less than 16° will not increase efficiency further,

rather induce more losses.

18
 (A. Amladimanesh, el at. 2015) used numerical analysis and

experimental data to determine the effect of blade numbers on the

performance of a centrifugal fan, both flow rate and power consumption,

the blower were tested at three different speed using five fabricated

impellers with 4 to 8 blades respectively, it was found that, for all the

three selected blower speed, air flow rate increase by about 19% by

increasing the number of impeller blades from 4 to 8. It was concluded

that when space is a constraint, increase in the number of blades or

blower speed can be respectively applied to increase air flow depending

on the magnitude of the increase required.

(Zhang. J, el at, 2016) reviewed the numerical simulation and

analysis of a backward curve centrifugal blower, and the results from

numerical simulations and measurements were compared to verify the

validity of numerical simulation, and the effects of blade angle, blade

number, tongue length, and scroll contour were numerically studied.

Some favored parameter changes were determined and utilized to

redesign one of the blowers.

(Sunil R, el at. 2018) focused on the effect of volute tongue

clearance variation on the performance of backward curved blades

centrifugal blower. The four types of casings of the centrifugal blower

with different volute tongue clearance of 6%, 8%, 10% and 12.5% of
19
impeller diameter were used for numerical and experimental analysis

and the performance characteristics such as total pressure, efficiency

and flow rate of the blower were calculated. The result shows that the

volute tongue clearance has a significant effect on the performance of

centrifugal blower and the parameter increase with decrease in volute

tongue clearances.

(Yogesh R.P, el at. 2020) carried out numerical analysis to

understand the flow characteristics for different impeller configuration

of a single stage centrifugal blower. The volute design was based on

constant velocity method and four different impeller configurations were

selected for the analysis. The result suggested that for the same

configuration of centrifugal blower, as we change geometrical

parameter of the impeller, the flow inside the blower get affected.

(More K.C et al. 2020) conducted an experimental and numerical

analysis to study the effect of impeller blade thickness and rotating

speed on the performance of the impeller, different blade thickness

were been considered with different rotating speed and a modal analysis

was done for the numerical study using ANSY workbench software. The

numerical result was validated with the experimental result found on

test; the result shows that, the blade with 1.5 mm thickness has a

reduced noise and vibration with maximum rotating speed

20
2.3 SUMMARY OF REVIEW

The present literature survey highlights research work in multiple

dimensions with respect to Blower casing. Literature survey is done as

per effect of geometry of casing such as volute casing shape and width,

in which only theoretical work is done; but to verify in medium range

blower experiment is required. Later survey is done for the experimental

work done by the various researchers. It is observed that experimental

work is done in compressor only, not in medium range blower. Recent

development in the field of flow analysis in blower shows that various

researchers have used latest technology of flow measurement such as

PIV and CFD analysis in compressor, but not in blower.

After the Literature review it is found that still there is a lack of

information available in the medium size blower. Literature survey has

enhanced the problem formation of investigation of the flow in blower

volute casing. In the scope of investigation of flow in blower volute

casing is divided in three parts experimental work, design, and

optimization. Detail experimental work is required, to validate the

optimization regarding the flow. Many factors must be considered in its

practical design because the flow generated in the blower is quite

complicated with three dimensionality and unsteadiness.

21
 The fundamental blower performance is primarily determined by

the impeller of the blower and is also affected by the casing. However,

the theoretically estimation of the effect of the casing on the

performance has not been well established. In order to estimate the

casing effect on the blower performance, detailed design analysis in the

casing is necessary. Survey has encouraged the developing of uniform

design methodology for blower casing by considering various constraint.

Optimal design has become a matter of interest in the blower design

with the rapid development of a computational power. Optimized design

with various constraints is built up for overcoming the uniform

methodology for the design of volute casing.

2.4 REVIEW OF TYPES OF INDUSTRIAL BLOWER

Industrial blowers are an essential part of any type of production

or manufacturing operation to increase airflow and create positive air

pressure. Present day industrial blowers were developed in the middle of

the first industrial revolution as an air pump for internal combustion

engines. The simple design of these initial designs included a motor,

shaft, and impeller blades. The first industrial blowers have progressed

and advanced into a wide variety of types, uses, designs, and

applications to assist in the performance of industrial jobs and help in

making work faster, easier, and safer. The modern industrial blower is
22
used in processes to create a steady and strong flow of air or gas.

2.4.1 Types of Industrial Blower

2.4.1.1 Positive Displacement Industrial Blower

Positive displacement industrial blowers, also known as lobe

blowers, release air at a specific time, pressure, velocity, and direction,

using a safety valve. The name lobe blower comes from two propellers

in the mechanism that counter rotate. Air enters a chamber of the

blower and exits through an outlet.

This design allows the blower to maintain constant air flow and

pressure.

2.4.1.2 Centrifugal Industrial Blower

Centrifugal industrial blowers are the most frequently used type of

industrial blower found in ventilation systems due to its capacity to

continuously transfer gas and air as well as block air pollutants. The air

stream goes through a set of rotating impellers where the speed and

volume of the air is steadily increased.

The fan wheel shifts in direction and accelerates as the amount of

air passing through increases. As more air enters, the kinetic energy of

the blower increases.

23
2.4.1.3 High Speed Industrial Blower

A high speed industrial blower operates at very high speed

creating high pressure and rapid airflow. It has an electric motor and

impellers placed around the shaft of the blower to increase the volume

of air being taken in. The construction of a high speed blower consists

of a valve to release the air and a compression unit to control blower

speed. Each of these factors is easily adjustable to fit the needs of the

operation.

2.4.1.4 Helical Screw Industrial Blower

A helical screw industrial blower has a main rotor with two lobes

and a second rotor. The main rotor is placed in the flute of the second

rotor. The design of helical screw industrial blowers is more intricate but

is extremely efficient in producing higher pressure. The two rotors turn

in a helical pattern, which is carefully timed to avoid contact.

2.4.1.5 Axial Industrial Blower

Axial industrial blowers create positive and negative pressure

around their blades, which creates airflow. The fan blades are positioned

vertically and tilted to allow for atmospheric pressure changes. In an

axial blower, the air is forced to move in an axial parallel direction to the

shaft where the blades rotate. This design is what creates the air
24
pressure difference causing the continuous airflow.

The performance of an axial fan is determined by its number of

blades and their shape.

2.4.1.6 Vapor Recovery Industrial Blower

Vapor recovery industrial blowers are a special type of centrifugal

blower designed to collect vapors of gas and fuels such that they do not

escape into the atmosphere. Under certain conditions, this type of

industrial blower is required by law in cases where there are noxious,

explosive, and flammable fumes.

Pressure builds up in fuel storage tanks as they get filled. The

vapors from the pressure are removed by vapor recovery industrial

blowers that send it on to become natural gas or burned off.

CHAPTER THREE

3.0 MATERIALS AND METHODS

3.1 DESIGN METHODOLOGY

25
 Proper sizing of blowers involves the determination of many

system factors and prioritizing them into different requirement versus

preferences. Some of these factors were the static pressure that the

blower must overcome, the required average air flow volume, the shape

and direction of the desired air flow, space limitation, audible noise

allowances, available power, efficiency, air density, and cost. Along with

available power considerations which are generally the most critical for

blower designs.

3.1.1 DESIGN SPECIFICATION/ CONSIDERATION

This blower is expected to have the following ratings:

Q = 11.22 m3/min

P = 2 – 15Kpa

Where Q = volumetric flow rate

P = pressure developed

3.1.2 DESIGN ANALYSIS

This design is made based on the following assumptions for

maximum efficiency.

I. Air enters the impeller eye in radial direction which makes the

whirls component at inlet zero.

II. No loss due to shock at entry base on the above mentioned

26
 assumptions the design parameters are fairly estimated, these are:

 Blade inlet and outlet diameter

 Blade width

 Number of blades

 Number of blade revolutions per minute

 Manometric head

 Analysis of the various velocities during the blades

operation

 The Motor horse power required

 The pressure rise across the impeller

 The overall efficiency and power developed by the blower.

3.1.3 DESIGN CALCULATION

3.1.3.1 Design of Blower Impeller

DETERMINATION OF IMPELLER DIAMETERS

From the optimum performance specification, it is stated that the

ratio of the internal diameter to the external diameter is to fall between

0.4 – 0.7. As stated in the ASME code.

D1
That is. 0.4 < < 0.7, for this design . . . . (3.1)
D2

27
 D1
The ratio = 0.55 is taken;
D2

If D1 = 204 mm

D1 204
D2 = = = 371 mm
0.55 0.55

Therefore, D1 = 204 mm, D2 =371 mm

DETERMINATION OF NUMBERS OF IMPELLER BLADES

From ASME code, for optimum performance the number of blades

is given by

8.5 sinβ2
C= .. . . . . . . . (3.2)
D
1 - 1
D2

Where β2 is the outlet vane angle which has a range of 200< β2<900

0 D1
For this design β2 = 41 and = 0.55
D2

8.5 sin41
C=
1 - 0.55

C = 12 Blades

28
DETERMINATION OF IMPELLER BLADES WIDTH

The numbers of blades in a centrifugal blower can vary from 2 to

64 depending upon the application, type, and size. Too few blades are

unable to fully impose their geometry on the flow, whereas too many of

them restrict the flow passage and lead to higher losses. Most of the

effort to determine the optimum numbers of blades has resulted in only

empirical relation given from ASME code specification that, the blade

width is given by the formula. [Sani M, el at. (2016).]

W=6
( 2) .
D1
. . . . . . . . (3.3)
C+ 1

Where C is the numbers of blades

W=6
(0.204
2 )
= 47mm
12 + 1

NUMBER OF REVOLUTION PER MINUTE OF IMPELLER

For a centrifugal blower to deliver an air, the centrifugal head must

be equal to the total head.

U22-U21
Thus, = Hman. . . . . . . . (3.4)
2g

29
Where U1 and U2, are the respective mean impeller velocities at inlet and

outlet

πD1N πD2N
U1 = and U2 = . . . . . (3.5)
60 60

So,

U22 - U21 = 2gHman

Where Hman is the Manometric head

[ ] [ ]
πD2N 2 πD1N 2
60
-
60
= 2 × 9.81 ×10

[ 60 ] [
π ×0.371 × N 2 π ×0.204× N 2
-
60
= 196 ]
3.77× 10-5 N2 – 1.14×10-5 N2 = 196

N = 2730 rev / min

DETERMINATION OF THE MANOMETRIC HEAD OF THE BLOWER

This is the head which the blower needs to overcome before it

delivers and it is given as

U22-U21
Hman = . . . . . . . . (3.6)
2g

30
 πD1N π ×0.204 ×2730
U1 = = = 29 m / s
60 60

πD2N π ×0.371 ×2730

U2 = = = 53 m / s
60 60

Therefore, the manometric head of the blower is

512-282
Hman = = 10 m
2 ×9.8

3.1.3.2 Analysis of The Various Velocities of The Impeller Blades

Fig 3.1.2: illustrates the velocity diagram of the impeller blades

Outlet Vw2
Velocity
Triangle

U2

α2

Vr2

V2

Rotation

Inlet
velocity
Triangle Vr1 V1 = Vf1
Vw1 = 0

β1 α1

U1

31
 Fig 3.1.2

V2 = Absolute velocity of the fluid at outlet to impeller

Vr2 = Relative velocity of the fluid at outlet

Vf2 = Velocity of flow at outlet of the Blade

Vw2 = Whirl velocity at outlet of the Blade

U2 = Mean velocity of the blades at outlet

β2 = Outlet vane angle to the impeller blade

The corresponding inlet parameters are:

V1, Vr1, Vf1, Vw1, U1 and β1

DETERMINATION OF VELOCITIES OF FLOW AT OUTLET AND INLET OF

THE BLADES

From the continuity equation

Discharge = Area × Velocity

Q = A× V . . . . . . . . (3.7)

Q= D2 W Vf2 = D1 W Vf1 . . . . . (3.8)

Q = 0.187 m3/ s

32
 Q 0.187
Vf2 = = = 3.4 m / s
π D2W π × 0.371 × 0.047

Q 0.187
Vf1 = = = 6.2 m /s
π D1 W π × 0.204× 0.047

These are the velocities of flow at outlet and inlet of impeller blade.

DETERMINATION OF ABSOLUTE VELOCITIES OF FLOW AT OUTLET

AND INLET OF BLADES

For the absolute velocities of the flow V1 and V2 from the velocity

diagram

Also in this design ∅ =300, β1=120, β2=410

v1
Where, tan β1= . . . . . . . .
U1

(3.9)

6.2
tanβ1 = = tan-1(0.214) = 120
29

vf2
v2 = . . . . . . . . . (3.10)
sin ∅

And V1 = Vf1 (from initial assumption)

This are taken from the range optimum performance from ASME code

33
 3.4
v2 = = 6.8 m / s
sin 300

V1 = Vf1 by assuming radial flow at inlet

DETERMINATION OF WHIRL VELOCITIES AT INLET AND OUTLET OF

THE BLADES

The whirl velocities at inlet and outlet are estimated from

Vw1 = 0. From initial assumption

Vw2 = V22- V2f2 . . . . . . . . . . (3.11)

Vw2 = 6.82-3.42 = 5.9 m / s

34
DETERMINATION OF RELATIVE VELOCITIES AT OUTLET AND INLET

OF THE BLADES

The relative velocity Vr1 and Vr2 at the inlet and outlet are

given from the velocity diagram.

Vf2
Vr2 = . . . . . . . .
sin β2

(3.12)

3.4
Vr2 = = 5.2 m / s
sin 410

Vf1
Vr1 = . . . . . . (3.13)
sin β1

6.2
Vr1 = = 29.8 m / s
sin 120

3.1.3.3 Design of Volute Casing of The Blower

DETERMINATION OF THE WIDTH OF THE VOLUTE CASING

The width of the volute casing is normally 2 to 3times the impeller

inlet blade width(c). [Vibhakhar, (2012)]

For this design 2.5 times was used. Therefore,

Wv = 2.5(W) = 2.5 × 47

35
The width of the volute casing is

Wv = 118 mm

THE VOLUTE RADII AT DIFFERENT VOLUTE ANGLES

Table 1: Radius of Volute at different angles taking a volute tongue

clearance of 8% of the impeller diameter

Ѳ in degrees Volute radius (r) in m

0 0.216

60 0.246

120 0.276

180 0.306

240 0.336

300 0.366

360 0.396

3.1.3.4 Determination of the Horse Power Required by the Electric

Motor

The horsepower (hp) is the rate at which work is done, usually in

reference to the output of the electric motor.

This is given by the formula

36
 Q γ Hman
Php = . . . . . . (3.14)
550

Where, Q = Volumetric flow rate of air

γ = ρg

Where,

g = Force of gravity which is given as 9.81 m/s2

ρ = Density 0f air Kg/m3 which is also given as 1.002 kg/m3

11.22 ×1.002 ×9.8 ×10

Php
550

Php = 2.0 hp

The horsepower required by the electric motor is 2.0 hp

3.1.3.5 Determination of The Pressure Through The Impeller

By applying the energy, equation from the entrance to exit of the

impeller including the energy head.

P2- P2 V22- V21

= Hman - . . . . . . (3.15)
γ 2g

[
P2 - P1 = γ Hman-
V22- V21
2g ]
37
 [
p2 - p1 = 9.8 ×1.002 10-
6.82-6.22
2 ×9.8 ]
p2 - p1 = 94Pa

Therefore, the pressure through the Impeller = 94Pa

3.1.3.6 Determination of Efficiency of The Blower

The efficiency of the blower is given by

manometric head
ηman = . . . .
head imparted by impeller to fluid

(3.16)

Hman =10 m

Vw2 U2
Head imparted by impeller = . . . .
g

(3.17)

2.8 ×53
Head imparted by impeller = = 15.1 m
9.8

10
ηman = = 66.2%
15.1

This is the manometric efficiency developed by impeller.

3.1.3.7 Determination of Shaft Diameter of Impeller

38
 The shaft diameter d is calculated from

3 16T
Ds = . . . . . . . (3.18)
πSs

Where, T = Torque in N-m bhp = Brake horsepower

Ss = Allowable shear stress is 300 psi ≈ (6900×300)

N/m2

60×bhp
T= . . . . . . . (3.19)
2πN

Motor horsepower (Php)

bhp = . . . . (3.20)
Manometric efficiency (ηman)

[(Aye M.T, el at 2019)]

2.0
bhp = = 3.02 hp ≈ 2252.8 Nm/s
0.662

60×2252.8
T= = 7.88 N-m
2×π×2730

3 16×7.88
Ds = = 0.02 m ≈ 20.3 mm
π×6900×300

For the shaft, a 20 mm diameter mild steel rod was selected to

accommodate the torsional and bending loads the shaft may be

subjected to as a result of high speed rotation and weight of the blower

39
impeller.

3.2 MATERIAL SELECTION

The major material that was used in the production of the

industrial blower is mild steel because it inexpensive and have the

advantages of compactness, ductility low cost and light weight. More so,

it is relatively wieldable due to its low carbon content and also its ability

to withstand vibration.

3.3 PROCESS SELECTION/MANUFACTURING PROCESSES

In the manufacturing of the industrial blower, the various part of

the blower was measured out in the right dimension and also during the

course of measurement cautious should be taken to avoid error due to

parallax and marking out before cutting, bending and folding into the

required shapes and sizes. The casing must be in volute profile to

guarantee uniform speed build up in the casing. The casing was

balanced to avoid vibration as it is expected to operate at high speed.

Also, the vanes should have a smooth curvature and should open into

the inlet at 900, this reduce shock at entry and ensures maximum flow

losses.

The materials used for the construction of the blower are Mild

steel gauge 16 (0.9 mm) sheet, an angle iron of dimensions (25 mm x 3

40
mm) and a 2.0 HP, 2800 rpm electric motor obtained in the market that

can give the required power output to the blower.

The blower casing was made of mild steel (400 mm x 400 mm x 2

pieces) on which the volute radius were marked out, drawn, and cut to

form the volute casing, and drilled a hole of 204 mm and 371 mm

diameters respectively. A strip of width 118 mm mild steel was

measured and cut to form the circumference of the casing. On the other

circular plate, four holes of 8mm diameter were drilled at a square of 90

mm.

An 80 mm diameter round pipe mild steel was measured and cut

to a length of 100 mm. An angle bar was cut to the required dimension,

welded to form the electric motor stand.

A circular sheet mild steel of 371mm diameter was cut, marked,

divided into 12equal parts and drilled a hole of 20 mm diameter at the

center. A strip of 47 mm width x 167 mm long was cut and welded to the

circular sheet which formed the blades.

Finally, the components were assembled and coupled to the 2.0

HP, 2800 rpm electric motor.

The tools and equipment used for the fabrication of the blower

impeller and its housing were hacksaw, bench, hammer, divider, center
41
punch, steel rule, chisel, hand shear, hand files, scriber, mallet, work

bench V-block, drilling machine, welding machine and a bench vice.

42
 CHAPTER FOUR

4.0 PERFORMANCE EVALUATION

The blower was run and tested for flow rate using an open

gate flow meter and a mercury manometer to estimate the head of the

blower and the following result were obtained.

Discharge (flow rate) = 9.82 m3/min

Head = 8.53 m

4.1 PRESENTATION OF RESULTS

Table 2: Physical Characteristics and Performance

Parameters of the Designed Blower

SN Design Parameters Nomenclature Value

1
Impeller inlet diameter D1 204 mm

2 Impeller outlet diameter D2 371 mm

3 Impeller blade width W 47 mm

4 Numbers of blade C 12

5 No of revolution per minute N 2730

rpm
43
6 Mean velocity at the inlet U1 23 mm

7 Mean velocity at the outlet U2 53 mm

8 Inlet vane angle to impeller β1 120

9 Outlet vane angle to impeller β2 410

10 Absolute velocity at inlet to V1 6.2 m/s

impeller

11 Absolute velocity at outlet to V¬2 6.8 m/s

impeller

12 Relative velocity at inlet to impeller Vr1 29.8 m/s

13 Relative velocity at outlet to Vr2 5.2 m/s

impeller

14 Velocity of flow at inlet to impeller Vf1 3.4 m/s

15 Velocity of flow at outlet to Vf2 6.2 m/s

impeller

16 Whirl velocity at outlet to impeller Vw2 5.9 m/s

17 Width of volute casing Wv 118 mm

44
 18 Power of motor selected Php 2.0 hp

19 Pressure through the impeller ∆P 94 pa

20 Manometric head Hman 10 m

21 Manometric efficiency ηman 66.2%

22 Shaft diameter of impeller Ds 20 mm

4.2 ANALYSIS OF RESULTS

It was observed that the calculated (theoretical) flow rate and

head is 11.22m3/min and 10m respectively while the actual flow rate
3
and head from the test evaluated is 9.82 m /min and 8.53m respectively.

These differences in actual and calculated values can attributed to

losses in the following forms:

1. Slip losses: This occur due to improper contact between the fluid

and the impeller blades.

2. Shock losses: This occurs at air entry into the impeller and it is

usually occasioned to guide the impeller blades especially when

operating outside the design calculation. This is usually a factor of

the volumetric flow rate of the blower, dependent on the blower

efficiency. As it will have a value of zero when the calculated

45
 efficiency of the system is equal to the ideal efficiency.

3. Friction losses: This is brought about by the contact of the fluid

with solid boundaries such as the casing and blades.

When the blower operates at its efficiency, the main attributable

causes of the difference in the calculated and actual value of

performance of the blower will be the friction losses for head difference

and the slip losses for the drop in flow rate.

However, the blowers are generally associated with some

problems such as vibration, lack of performances, excessive noise and

premature component failure. These limit the speed of the blower. An

addition of adequate balls bearings on the shaft was done to reduce the

noise and the use of vibration absorber or dampers to hold the electric

motor rigidly in the middle of the stand in order to absorb the vibration

caused by the rotating impeller.

4.3 BILL OF ENGINEERING MEASUREMENTS AND EVALUATION.

S/N ITEM MATERIAL QUATITY SIZE PRICE (N)

1 Impeller disc Mild steel Half sheet 24,000

2 Hack saw blade 2 2000

3 Filing disc 1 2500

4 Angle bar Mild steel 2 length 1mm 12,000

5 Electrodes gauge 12 1 pack 4500

46
6 Casing 1 sheet 36,000

7 Electric motor 1 25,000

8 Hose 500

9 Base Flat bar 1 2mm 5000

10 Cutting disc 1 2500

11 Miscellaneous 5000

Total N114,000

CHAPTER FIVE

5.0 SUMMARY, CONCLUSION AND RECOMMENDATION

5.1 SUMMARY

Modern blower has a wide variety of application, e.g. refrigeration

and air conditioning systems, pipeline transport of Natural Gas,

petroleum refineries, gas turbine systems, farm machinery, and in many

various industrial, manufacturing and building processes. Blower can

vary in size from a few feet to tens of feet in diameter, depending on

their application. In this project, the centrifugal blower is designed for

11.22 m2/min of flow rate and 15Kpa (absolute) pressure. The rotational

speed is 2730 rpm. The calculated impeller design has inlet diameter of

204mm and impeller outside diameter of 371mm. The design volute is

calculated by depending on the impeller outlet diameter.

47
5.2 CONCLUSION

For optimum performance the ratio of the internal diameter to

external diameter falls between 0.4 - 0.7(ASME). The diameter of the

blade is a design parameter which others depend upon. If the speed

(rpm) of the impeller remain the same then the larger the impeller

diameter, the larger the generated head. As the diameter of the impeller

increases, the tip speed at the outlet edge of the impeller increases

commensurately. However, the total energy imparted to the fluid as the

diameter increases goes up by the square of the diameter increase. This

can be understood by the fact that the fluid energy is a function of its

velocity and the velocity accelerates as the passes through the impeller.

The blower was specifically designed for a furnace operation but it can

equally be adapted for use in operations that needed air supply system

for its smooth running, most especially in combustion-related

operations.

5.3 RECOMMENDATION

The following suggestions were recommended for further

modification of the blower;

1. A variable speed motor drive can be used to vary the rate of flow

of air from the blower.

48
2. The blade can be made of thermal resistant plastic materials to

reduce noise and vibration.

3. A guided vane can be mounted with the impeller to increase

blower efficiency.

4. The motor can be protected from moisture and dust by casing it

thereby reducing corrosion attack.

49
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51