Industrial fans systems are essential for the furnace industry, but why? In these environments, industrial fan systems are used to regulate temperature, improve ventilation, and enhance combustion processes.
Furnaces generate extreme temperatures, therefore having a fan system which is efficient can drastically improve productivity, reduce energy consumption and increase business profitability.
In this blog, we’ll look at the key features and benefits of industrial fans for these extreme environments, as well as the importance of regular maintenance.
Why should furnaces have energy efficient industrial fans?
Efficiency is critical when it comes to industrial fans for furnace facilities, and this is something we’re particular about at Industrial Fan Services. An efficient industrial fan is designed to move large volumes of air while consuming less energy which in turn, reduces operational costs. We know this first hand – one of our customers in the glass manufacturing industry was able to reduce their energy consumption by a staggering 40% with an energy efficient fan system from Industrial Fan Services (we share more about this later in this blog). Upgrading your system to something more efficient means you can reduce carbon emissions, which is also important in helping meet Government targets for the country’s carbon footprint.
What are the key features of industrial fans for the furnace industry?
The specific type of industrial fan used in a furnace will depend on a variety of factors, including the size of the furnace, the type of fuel being used, and the desired output temperature. In general, larger furnaces will require larger fans to ensure adequate air flow, while higher temperature applications may require specialised fans that are designed to withstand extreme heat.
Because temperatures inside a furnace can reach over 1000°c, the industrial fans must be very durable and heavy construction to withstand these very harsh conditions. Paddle Blade (PB) or Backward Lamina (BL) fans are best suited to withstand these conditions, as well as inconel, a versatile and resistant metal alloy which can withstand very high temperatures.
The size of the furnace determines the amount of airflow required. The industrial fan must keep the air distributed at a regular temperature to avoid hot spots to aid safety and production efficiency.
Generally, the background noise of furnaces can be quite high due to the burners. However, industrial fans for furnaces are low pressure, meaning they don’t create excessive additional noise.
Require regular maintenance
Due to the temperatures and harsh environment they are operating in, regular maintenance of industrial fans is critical to their performance and longevity. Regular cleaning and inspection can help prevent buildup of dust and debris that can impede airflow, and replacement of worn or damaged components can help ensure that the fan operates at peak efficiency. Industrial fans are often positioned on top of the furnace near the heat source, so it’s important to inspect and grease bearings regularly. If issues are left undetected, it can result in breakdown and interrupted production.
What are the main benefits of using industrial fans in the furnace industry?
Furnaces generate a vast amount of heat and exhaust, and industrial fans can help to ensure that these byproducts are safely vented away from the furnace and the surrounding environment.
Industrial fans provide a consistent and powerful flow of air, which is necessary for effective heating and cooling processes in furnaces.
Reduced energy bills
Industrial fans can help reduce the energy consumption of furnace systems by circulating hot air throughout the furnace more efficiently.
The ability to maintain a constant temperature within the furnace allows for improvements in productivity by ensuring that the furnace is operating at optimal conditions.
Furnaces generate a lot of heat and exhaust. Industrial fans can help to ensure that these byproducts are safely vented away from the furnace and the surrounding environment. This also helps to work towards the Government’s net zero strategy.
Why is vibration monitoring important for industrial fans in furnace environments?
Industrial fan systems operate at high speeds, typically between 900 and 3600 RPM (depending on their specific application, design, and size) which in turn means the system is subject to high stress levels. By carrying out regular vibration monitoring, the levels of vibration in the fan can be analysed to detect any abnormal patterns or trends which can indicate a range of issues such as worn bearings, unbalanced blades, misalignment, or mechanical looseness.
What are the benefits of vibration monitoring for industrial fans?
Early detection of faults
Effective vibration analysis is essential to maximising machinery uptime, and regular monitoring can ensure this by detecting issues in good time before they potentially have catastrophic consequences. Unexpected downtime from industrial fan failure or breakdown can have severe impacts on business operations and competitive edge.
Informs maintenance schedules
Regular vibration monitoring can help inform your maintenance schedule for your critical rotating machinery proactively rather than retrospectively. Vibration monitoring in conjunction with machine condition monitoring will allow you to predict potential issues with your industrial fan and plan maintenance in advance. Be sure to monitor excessive or unusual vibration, heat and noise, as well as bearing health checks for wear and tear.
Worn bearings can result in excessive noise, heat, increased energy consumption and more critically, premature catastrophic machine failure. Therefore, regular vibration monitoring and a proactive maintenance schedule will ensure your industrial fan is operating smoothly and reliably, increasing efficiency and productivity.
How can Industrial Fan Services help?
We have worked extensively designing and manufacturing industrial fans for furnace applications, supplying BC (Backward Curved), BL (Backward Lamina) and PB (Paddle Blade) fans to customers in the furnace industry as they are more robust and suitable for these high temperatures. We design and manufacture these fans in mild steel up to 400°c, stainless steel up to 650°c, incoloy up to 800°c and alloy 330 up to 1000° depending on the requirements.
Our track record: power savings of 40%
We achieved substantial energy savings for a glass manufacturer in Bulgaria.The glass cooling fans on the furnace on site in Bulgaria could not meet the pressure requirements that were needed at the present time. We attended site, measured the airflow and pressure of the existing units that were running at 3000rpm.
We supplied 4 new 500kW fans to produce 20% at its peak point of pressure if required for future processes. When running at normal operating pressure, considerable power will be saved.
As a result, the company was able to:
- Expand the range of glass produced with the additional pressure provided
- Save circa 40% in electricity cost per annum due to the efficiency gain for normal processes
- Fans were amortized within 12-18 months
Discover our large range of designs across all types of industry from heating and ventilation to the most arduous petrochemical applications.
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Do you want to learn more about why maintenance and efficiency is important for industrial fan systems in the furnace industry? Visit WDB to learn more.