Author: Ryan Preis, Application engineering, AirStream Systems Inc.

Co‐Autor:Peter WindmoellerSales custom fan upgrades

Fan upgradetechnology for thecement industry

Process improvement is a necessary cost to improve plant operation:

Environmental equipment modifications

Increased use of alternative fuels

Kiln upgrades

Raw mill upgrades

Duct modifications

Efficiency improvements

Introduction

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Process Fan Requirements

• Baghouse ID Fans

• Kiln ID Fans

• Raw Mill Fans

• Finish Mill Fans

• Cooler Vent Fans

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Initial capital investment

Ongoing maintenance costs

Operating costs

Process Fan Costs

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Fan Upgrades  Capital Cost Savings

• Minimized equipment costs (reuse fan housing, motor, bearings, etc.)

• Reduced installation costs (no foundation changes)

• Reduced installation time (shorter shutdown required)

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Fan Upgrades  Reduced Maintenance Costs

• Maintenance cost reduced up to 50%(reduced dust impingement, improved design technology)

• 2x to 4x longer wear life (longer replacement cycles, reduced replacement costs)

• Reduced dust build‐up(gas velocities, engineered blade design)

Year  3After Minor Repairs

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Fan Upgrades  Operating Cost Benefits

• Electrical cost reduced 10% to 30%(AirStream high efficiency rotors)

• Performance increased up to 25%(within existing fan housing, existing motor)

• Fast payback, typically 1‐2 years

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Case Study#1 2700kW Kiln ID Fan Upgrade

Canadian cement plant with: Calciner 4‐stage preheater

Process improvements to increase production included modification of: Preheater Firing systems Clinker cooler line

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Case Study#1 2700kW Kiln ID Fan Upgrade

Conditions found at site:

Plant production was fan limited

Fan total efficiency was ~50%

Wear related maintenance caused production stoppages

Annual impeller replacement due to rapid wear rates

Complete fan replacement was seen as only solution

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Case Study#1 2700kW Kiln ID Fan Upgrade

AirStream upgrade achieve the following results: Plant production increase of 7% Power consumption reduced by 

over 36% = 1235kW No noticeable wear after 2 years During annual maintenance no 

repairs were required.

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Case Study#2 4500kW Raw Mill Fan Upgrade

New 1.8Mt/y cement plant in Southern US: Previous project with this 

customer resulted in 1804kW  power savings

Original process fans had light  construction

AirStream invited to evaluate  Raw Mill ID Fan

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Case Study#2 4500kW Raw Mill Fan Upgrade

Conditions found at site:

Uneven material loss due to insufficient wear protection and light  construction

Heavy maintenance required after  first  year of operation

Fan pressure was only 82% of design  value at full speed 

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Case Study#2 4500kW Raw Mill Fan Upgrade

AirStream upgrade achieved the following results:

Restored full design performance

Reduced power use by 804kW

Increased wear life by more than 4  times

Significantly reduced maintenance  requirements

Economical project cost13

Summary

New technology by AirStream improves process fan operation:

Electrical cost reduced by 10% to 30%

Maintenance cost lower by up to 50%

Dust build-up reduced

Impeller wear life increased by 2x to 4x

Performance increased by up to 25%

Fast payback

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Conclusion

Still No Wear!!

Peter Windmoellerp.windmoeller@airstreaminc.ca+1 (514) 887-7172

AirStream Systems is a full service supplier of largeprocess fans to cement plants throughoutNorth America, Central America and the Caribbean.

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