AM 308: DESIGN OF AGRO-

PROCESSING MACHINERY

CHAPTER 4
FANS AND BLOWERS
4.1 Introduction
Fans and blowers provide air for ventilation
and industrial process requirements.
In agro-processing, fans and blowers are used in
material-waste separation and materials
handling.
Fans generate pressure to move air (or gases)
against resistance caused by ducts, dampers, or
other components and materials in a fan system.
The fan rotor receives energy from a rotating
shaft and transmits it to the air.
4.1 Introduction
Any device that produces a current of air by the
movement of broad surfaces can be called a fan.
Fans fall under the general classification of
turbomachinery and have a rotating impeller
encased in a stationary housing.
Fans are similar in many respects to pumps. Both
are turbomachines that transfer energy to a
flowing fluid. Pumps handle liquids; fans
handle gases.
Broadly speaking, the function of a fan is to
propel, displace, or move air or gas.
4.1 Introduction
Difference between Fans, Blowers and Compressors
Fans, blowers and compressors are differentiated by the method used
to move the air, and by the system pressure they must operate against.
As per American Society of Mechanical Engineers (ASME) the
specific ratio, i.e. the ratio of the discharge pressure over the suction
pressure, is used for defining the fans, blowers and compressors.


4.1 Introduction
Table 5.1: Differences between Fans,
Blowers and Compressors

Note: Fans and blowers will be discussed further

under the name “FAN” to mean both.
4.2 Fan Types

Fans fall into two general categories: centrifugal flow and axial flow.

In centrifugal flow, airflow changes direction twice – once when

entering and second when leaving, Figure 4.1(a)&(b).

In axial flow, air enters and leaves the fan with no change in direction,
Figure 4.2.


4.2 Fan Types

Figure 4.1(a): Centrifugal Fan

4.2 Fan Type

Figure 4.1(b): Centrifugal Fan (Uses a rotating

wheel/impeller enclosed in a scroll shaped housing)
4.2 Fan Types

Figure 4.2: Axial Fan (Uses propeller with two or

more blades)
4.2 Fan Types
a) Centrifugal Fans (C/Fans)
C/Fans use a rotating impeller to move air first
radially by centrifugal action, and then
tangentially away from the blade tips.
C/Fans are capable of generating relatively high
pressures with high efficiencies.
They are frequently used in dirty airstreams
(high moisture and particulate content), in
materials handling applications and in systems
operated under high temperatures.
4.2 Fan Types
a) Centrifugal Fans (cont…)
C/Fans are the most commonly used types
of industrial fans.
C/Fans have several types of blade shapes
including: Backward-inclined curved
blade; backward-inclined airfoil blade;
backward inclined flat blade; forward
curved blade; radial blade and radial tip
(Figures 4.3-4.5).
Radial blade c/fans are capable of serving
widely varying industrial conditions.
 4.2 Fan Types
a) Centrifugal Fan Types (cont…)

Figure 4.3
Forward-curved
Centrifugal Fan
 4.2 Fan Types
a) Centrifugal Fan Types (cont…)

Figure 4.4
Radial-blade and
Radial-tip
Centrifugal fans
 4.2 Fan Types
a) Centrifugal Fan Types (cont…)

Figure 4.5
Backward-
inclined
Centrifugal fans
4.2 Fan Types
b) Axial Fans
A/Fans use propeller, having two or more
blades, to move air in an axial direction
through a cylindrical housing or formed
orifice panel.
Axial airflow fans have a number of
advantages over other types including
compactness, lightweight, and low cost.
4.2 Fan Types
b) Axial Fans (cont…)
The usual applications of A/fans include:
 Exhausting contaminated air or
supplying fresh air;
 Unidirectional or reversible air flow
applications;
 Exhaust applications where airborne
particulate size is small, such as dust
streams, smoke and steam.
4.2 Fan Types
b) Axial Fans (cont…)
Disadvantages of A/Fans include:
 A stall region in lower airflow range that
makes them unsuitable for systems
operating under widely varying air flow
conditions.
Anti-stall devices can be installed to alter
airflow patterns around the fan blades and
eliminate the stall problem – but this means
more expenditure!
4.2 Fan Types
b) Axial Fans (cont…)
Disadvantages of A/Fans (cont…)
 To achieve the same airflow capacity as
centrifugal fans, axial fans must rotate at
a higher speed. For this reason, axial
fans are generally noisier than
comparable centrifugal fans.
 4.2 Fan Types
b) Axial Fan Types

Figure 4.6
Propeller Fan
 4.2 Fan Types
b) Axial Fan Types (cont…)

Figure 4.7
Tubeaxial Fan
 4.2 Fan Types
b) Axial Fan Types (cont…)

Figure 4.8 Vane

axial Fan
4.2 Fan Types:
Fan Efficiencies
Peak Efficiency
Type of fan
Range
Centrifugal Fan
Airfoil, backward
79-83
curved/inclined
Modified radial (tip) 72-79
Radial 69-75
Forward curved 60-65
Axial fan
Vane axial 78-85
Tube axial 67-72
Propeller 45-50
Characteristics and Typical Applications of Centrifugal Fans

Typical
Type Characteristics
Applications
High pressure, medium flow, Various industrial
Radial efficiency close to tube-axial fans, applications, suitable for
power increases continuously dust laden, moist air/gases

Forward Medium pressure, high flow, dip in Low pressure HVAC,

pressure curve, efficiency higher packaged units, suitable
curved than radial fans, power rises for clean and dust laden
blades continuously air/gases

Backward High pressure, high flow, high

HVAC, various industrial
efficiency, power reduces as flow
curved increases beyond point of highest
applications, forced draft
blades fans, etc.
efficiency
Same as backward curved,
Same as backward curved type,
Airfoil type highest efficiency
but for clean air
applications
 Characteristics and Typical Applications of Axial .

Fans
Type Characteristics Typical Applications
Propeller Low pressure, high flow, low Air circulation,
efficiency, peak efficiency ventilation,
close to point of free air exhaust
delivery (zero static pressure)

Tube Axial Medium pressure, high flow, HVAC,

higher efficiency than drying ovens,
propeller type, dip in pressure exhaust systems
flow curve before peak
pressure point
Vane Axial High pressure, medium flow, High pressure
dip in pressure-flow curve, applications including
use of guide vanes improves HVAC systems
efficiency exhausts
. . 24
4.3 Blower Types
Blowers can achieve much higher pressures than
fans, as high as 1.20 kg/cm2.
They are also used to produce negative
pressures for industrial vacuum systems.
Major types are; centrifugal blower and
positive-displacement blower.
Centrifugal blowers typically operate against
pressures of 0.35 to 0.70 kg/cm2, but can
achieve much higher pressures.
The impeller can rotate as fast as 15,000 rpm.
 4.3 Blower Types (cont…)
 One characteristic of centrifugal blower is that airflow tends to drop drastically as
system pressure increases, which can be a disadvantage in material conveying
systems that depend on a
steady air volume.
 Positive-displacement blowers have rotors, which "trap" air and push it through
housing.
 Positive-displacement blowers provide a constant volume of air even if the
system pressure varies. They are especially suitable for applications prone to
clogging.
 They turn much slower than centrifugal blowers (e.g. 3,600 rpm), and are
often belt driven to facilitate speed changes.
4.4 Belt drive versus Direct drive
Belt Drive Direct Drive
Flexibility in operating speeds.Lower number of
components resulting in lower
The air stream passing over the costs.
motor cools it. Requires no regular checkups
for adjustment of belt.
Large size fans can be operated Higher fan efficiency since
at low speeds while motor is no slippage due to belt drive.
operated at higher speeds
resulting in economical Results in more flow since
operation. motor does not obstruct flow.
Performance flexibility can be
obtained by adjustable pitch of
blades and increasing number of
blades.
4.5 Fan Laws
The fans operate under a predictable set
of laws concerning speed, power and
pressure.
A change in speed (RPM) of any fan will
predictably change the pressure rise and
power necessary to operate it at the new
RPM.
4.5 Fan Laws (cont…)
a) Airflow rates vary in direct proportion to the
rotational speed of the fan
 4.5 Fan Laws (cont…)
b) Pressure built up by the fan varies as the square of
rotational speed of the fan

SP = static pressure
 4.5 Fan Laws (cont…)
c) Power required by the fan varies with the cube power
of the rotational speed of the fan
 4.6 Fan Selection Criteria

 Precise determination of air-flow and required outlet pressure are most

important in proper selection of fan type and size.
 The air-flow required depends on the process requirements such as heat
transfer rates, combustion air, flue gas quantity etc.
 Detailed analysis should be carried out to determine pressure drop across
the length, bends, contractions and expansions in the ducting system,
pressure drop across filters etc.
 These pressure drops should be added to any fixed pressure required by
the process in order to determine the total fan capability.


4.6 Fan Selection Criteria
Frequently, a very conservative approach is adopted, i.e.
allocating large safety margins, resulting in over-sized fans
which operate at flow rates much below their design values and,
consequently, at very poor efficiency.
Once the system flow and pressure requirements are
determined, the fan and impeller type are then selected. For best
results, one may seek advice of the manufacturer.


4.6 Fan Selection Criteria
For a given fan type, the selection
of the appropriate impeller depends
additionally on rotational speed.
High speed small units are generally
more economical because of their
higher efficiency and relatively low
cost. However, at low pressure ratios,
large, low-speed units are preferable.
4.7 Fan Performance and Efficiency
Typical static pressures and power requirement
curves for different types of fans are shown in
the Figure 4.9 and Figure 4.10 shows efficiency.

Power

Figure 4.9 Static Pressure and Power Requirements for

Different Fans
 4.7 Fan Performance and Efficiency

Figure 4.10 Fan

efficiency curves
 4.7 Fan Performance and Efficiency
System Effecting Factors
Apart from fan type, fan performance is dependent on:
Fan enclosure and duct design: Spiral housing designs with inducers and diffusers
are more efficient than square housings.
Density of inlet air: affects both volume flow-rate and capacity of the fan to develop
pressure.
Inlet and outlet conditions (whirl and turbulence created by grills, dampers, etc.)
can significantly alter fan performance curves from that provided by the
manufacturer.
Bends and elbows in the inlet or outlet ducting can change the velocity of air,
thereby changing fan characteristics.
4.7 Fan Performance and Efficiency

 Allthe above factors, termed as System

Effect Factors, should, therefore, be
carefully assessed during fan selection or
design since they would modify the fan
performance curve.
4.7 Fan Performance and Efficiency
Economics of Application - guidelines
 Centrifugal fans are suitable for low to moderate flow at high pressures.
 Axial-flow fans are suitable for low to high flows at low pressures.
 Centrifugal fans are generally more expensive than axial fans.
 Fan prices vary widely based on the impeller type and the mounting (direct-or
belt-coupled, wall-or-duct-mounted).
 Among centrifugal fans, airfoil and backward-curved blade designs tend to be
somewhat more expensive than forward-curved blade designs.
But they provide more favourable economics on a lifecycle basis.


4.7 Fan Performance and Efficiency

Economics of Application - summary

Careful technical and economic
evaluation of available options is
important in identifying the fan that will
minimize lifecycle costs in any specific
application.
4.7 Fan Performance and Efficiency
Installation of Fan
The installation of fan and its mechanical
maintenance also play a critical role in the
efficiency of the fan.
Specified mechanical clearances among parts
should be maintained.
Required maintenance practices of the fan
should be carried out properly.
 4.7 Fan Performance and Efficiency
System Resistance Change
 The system resistance has a major role in determining the performance and efficiency of a fan.
 The system resistance changes depending on the process, e.g. formation of coatings or erosion of
the lining in the ducts etc. changes the system resistance marginally.

 Change of equipment in the system, e.g. change of cyclone, duct modifications etc, can drastically
shift the operating point, resulting in lower efficiency! In such cases, to maintain the efficiency as
before, the fan has to be changed.
 Hence, the system resistance has to be periodically checked, more so when modifications are
introduced and action taken accordingly, for efficient operation of the fan.


 4.8 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Some conventional terms that describe
fan performance
The static pressure (Ps) required to send
air through a system is proportional to the
square of the quantity (cfm) delivered.
Static pressure α (cfm)2
The air travelling at a given velocity V
(ft/min) will create a velocity pressure Pv
(in. wg) = (V/4005)2 .
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Some conventional terms that describe
fan performance
Pv is always positive and is always
exerted in the direction of airflow.
The energy transferred to the air by the
impeller results in an increase in static and
velocity pressure. The total pressure is the
sum of both static and velocity pressures:
Pt = Ps + Pv
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Some conventional terms that describe
fan performance
For a given system, the efficiency does
not change with speed; however, capacity,
total pressure, and power all depend on
the speed: Refer to Fan Laws.
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Concepts of Fan Pressures
The flow of air through a system requires
energy to overcome any static pressure at
the entry or outlet of the system. The fan
provides this energy by the increase in total
pressure from the fan’s inlet to the fan’s
outlet.
Fan velocity pressure is the pressure
corresponding to the average velocity of
travelling air at the fan outlet.
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Velocity pressure,
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Fan Static Pressure is the difference between the
fan total pressure and the fan velocity pressure.
Ps = Pt - Pv

Ps is derived from the method of testing fans,

where it is equal to gauge static pressure at the fan
discharge when the fan draws air from surrounding
atmosphere through a well shaped inlet.
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Overall Size Design
Choose an operational speed (rpm).
Determine minimum hub diameter from

where: d is in inches, Ps is in (in.wg)

Depending on the operation range of the static

pressure, medium to high, the hub diameter can
vary from 30 to 80% of the blade outside
diameter.
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
The hub/tip ratio is defined as
Where,

dt
dH
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Number of Blades
 The optimum number of blades nb can be approximately determined from the
hub and tip radii by:

 The static pressure produced is proportional to the number of blades n b times

the blade width L.
Thus, doubling the number of blades and reducing
their width to one-half, for example, cannot change the fan performance, at least in terms
of air volume and static pressure.


 FAN DESIGN EXAMPLE
Axial Flow Fan Development
 The turbulence and noise are mostly produced by the leading and trailing
edges of the blades and not their surface.
Therefore, fewer and wider blades will result in a better fan efficiency and a lower noise
level.
However, if the number of blades becomes too small and the blade width, therefore, too
large, the fan hub becomes too wide axially and thus heavy, bulky, expensive, and hard to
balance.
 In general, as a compromise between efficiency and cost, five to twelve
blades are good practical solutions.
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Solidity of Blades
 The solidity of the blades, as indicated by the
ratio of the chord length to the blade spacing
(also called pitch-chord ratio) i.e. xc/xp - more or
less determines the flow rate per revolution for a
given blade angle.

Chord and pitch lengths

 FAN DESIGN EXAMPLE
Axial Flow Fan Development
xp which is the blade spacing or pitch, is the circumference at a particular
radius 2πR divided by the number of blades nb.
 Therefore,

xc which is the chord length of the blade, is the distance between the
leading and trailing edges at same radius R.

It is suggested to use an almost constant chord over the entire blade length.


 FAN DESIGN EXAMPLE
Axial Flow Fan Development
A pitch-chord ratio of 4:1 or higher can
provide good efficiencies, however, it is
common to use a pitch-chord ratio near unity.
rm : which is the mean effective radius of an
axial-flow fan, is that radius, which divides
the flow into two equal parts.
Thus, assuming a uniform axial velocity, the
mean radius, in terms of tip and hub radii r t
and rH is:
 FAN DESIGN EXAMPLE
Axial Flow Fan Development
Blade Width
 Width of blades is measured along the intersection of a cylindrical surface
with the blades.
 At the hub, blades must be non-overlapping in order not to choke the
airflow.
 To avoid blade overlapping, make the blade width L

where d is the hub diameter and nb is the number of blades.

AXIAL FLOW FAN IMAGES
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AXIAL FLOW FAN IMAGES