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Energy Efficiency Fan
Energy Efficiency Fan
Technical Know-how
• Scientists from Aerospace Engineering have been involved in the Aerodynamic design development of our FRP Fans
• National Aeronautical Laboratory & Hindustan Aeronautical Laboratory were involved in structural design of the FRP blades
• Prof. Mr. A.K. Rao Technical consultant to Lockheed of U.S.A. With his group from Indian Institute of Science Bangalore is behind the success of FRP Fans
Design Criteria
Performance : By Optimizing Fan dia. & no. of Blades
Efficiency : By Lower H.P.
ղ = Q x TP1,000 x KW
Q = Airflow (M3 / Second)
TP = Total pressure (Pascal)
ղ = Fan efficiency
E & C Resistance : Selection of High-Grade FRP
UV Degradation (Epoxy Resin) Composites
Vibration : Higher dampening property
Noise : Lower level (< 85 dbA)
Analysis of Power Consumption in Axial Flow Fans
KW at Fan Shaft = Q x TP = FKW
3.68 x 105 x ղf
Q = Airflow (M3/Hr.)
TP = Total pressure (Pascal)
ղ = Fan efficiency
If ղT = Transmission efficiency
KW at Motor Shaft = FKW/ ղT = MKW
If ղM = Motor efficiency
MKW to Motor = MKW/ ղM
Factors Affecting Fan Performance
Design of BladeAirfoil sectionProfile of blade at difference radii & staggeringChord length at difference radiiThickness and CamberBlade twistAngle of attack
Design of HubMinimum Air Cycling loss
No. of BladesAir volume & Pressure requirement
Fan RPMFor tip speed along with Noise & Vibration Criteria
Factors Affecting Fan Performance
1) Fans Design
2) Deteriorated Factor
3) Friction Loss
4) Weight of Fans
: 70 %
: 15 %
: 10 %
: 5 %
• Reduction of that surface while maintaining the shape and effect of an Airfoil was investigated. The solution was found in an Airfoil shaped extra surface available to trim at the blade tip, which follows the spherical line of the profile as shown in figure.
• The change in the pressure distribution by the modification with the Aerospan is remarkable. The pulse caused by the surface velocity pressure of the blade tip has been minimized.
Aerospan
Pressure Zone on the Airfoil
• Faster airflow causes a decrease in air pressure.
• Air Flowing over the curved upper surface if wing speeds up
• Increase in speed reduced pressure above the wing and produces the upward lifting force
Performance Curve
Criteria for Material Selection
• Corrosion resistance
• Higher Efficiency due to improved
• Aerodynamics characteristics
• Structural Integrity
• High strength to Weight ratio
• General adaptability to complex Geometries
Choice of Resins
• Epoxy Resin
• Superior mechanical strength• Greater chemical resistance• Lower water absorption• Higher heat resistance• High dynamic strength• High fatigue strength• Better surface finish
• Polyester (GRP)
• Cheaper quality standard• Weak resin structure• High Water absorption
EKOSMART
Selection
Properties Comparison of EKOSMART FRP with Epoxy Blades & Steel Blades
Properties Unit ENCON FRP with
Epoxy Fans Blades
Steel Blades
Ultimate Tensile Strength Kg/cm2 4,000 – 8,000 2,038
Tensile Modulus Kg/cm2 2.5 – 4.8 x 105 21.4 x 105
Flexural Strength Kg/cm2 2,500 – 10,000 1,940
Flexural Modulus Kg/cm2 3 – 5 x 105 21.4 x 105
Compressive Strength Kg/cm2 2,500 – 5,000 1,900
Specific Gravity - 1.8 - 2 7.8
EKOSMART Product Range
Fan diameter 2 ft – 50 ft
No. of Blades 2 – 22
Air Flow Up to 1,800 M3/sec
Pressure Up to 1,400 Pascal
Speed 81 – 3,000 RPM
Power rating 0.5 – 270 HP
Operating
temperature
-10 0C – 230 0C
Standard Material of Construction
Material of Construction
Blades
Fibre Glass Reinforced Plastic
with High Grade Epoxy Resin
Hub Assemblies
CS HDG/CI Alloy
Aluminium Alloy LM-4/LM-6
SS 304
SS 316
SS 316L
Fan Materials1) FRP (Vetrotex)
2) Epoxy (Huntsman)
3) Anti-Corrosion Epoxy Paint
4) Extra Coating (Erosion & UV
preventing)
Productionby Pressure Bag Molding
Application Areas of EKOSMART
1) Cooling Tower
2) Air Cooled Heat Exchanger
3) Air Cooled Condensers
4) Humidifier
5) Air Washer
6) Mines & Ventilation
1) Radiator Engines
2) Dryers
3) Kiln Shell
4) Industrial Ventilation & Exhaust
5) Man Cooler
Application Areas of EKOSMART
Factories
Petroleum Refining
Petrochemical
Power Generation
Gas Processing
Textile
Cement
Pulp & Paper
Steel & Metal
Foods
Chemicals Etc.
Building
High Rise Building
Hotel
Hospital
Department Store
Application : Cooling TowerFan Dia. : 1 ft. – 50 ft.
No. of Blades : 4 - 12
Air Flow Range : 10 m3/sec – 1,200 m3/sec
Total Pressure : 50 – 250 Pascal
Efficiency : 84% - 90%
RPM : 54 – 540 RPM
Application : Air Cooled CondenserFan Dia. : 1 ft – 40 ft.
No. of Blades : 4 - 12
Air Flow Range : 10 m3/sec – 1,200 m3/sec
Total Pressure : 50 – 250 Pascals
Efficiency : 84% - 90%
RPM : 54 – 540 RPM
Application : MinesFan Dia. : 2 ft. – 16ft.
No. of Blades : 4 – 24 (Even)
Air Flow Range : 5 – 500 m3/sec
Total Pressure : 5 – 1400 Pascal
Efficiency : 81% - 90%
RPM : 300 – 3000 RPM
Application : Withering ThroughFan Dia. : 2 ft. – 6 ft.
No. of Blades : 4 - 8
Air Flow Range : 3 m3/sec – 30 m3/sec
Total Pressure : 50 – 250 Pascal
Efficiency : 81% - 90%
RPM : 1000 – 1500 RPM
Application : Air WasherFan Dia. : 1 ft. – 7 ft.
No. of Blades : 4 - 12
Air Flow Range : 5 m3/sec – 50 m3/sec
Total Pressure : 50 – 900 Pascal
Efficiency : 81% - 90%
RPM : 550 – 3000 RPM
Distinctive Benefits
Guaranteed max. efficiency
Greater Economy
Aerodynamic designed
Higher lift to drag ratio
Negligible skin friction
Short Pay back period
Low noise level
Trouble freeMaintenance free
And many more
Tuflite & Sturdy
Superior duty condition
Difference between EKOSMART FRP Fans & Aluminium
No Items E- Glass Epoxy ENCON Fans Aluminum/GRP/FRP
1 Efficiency 81% - 90% 56% – 65%
2 Design Aerodynamic High Profile Old conventional
3 Material High Grade Epoxy (CIBA -USA)
laminated with FRP (Vetrotex -
France)
Aluminium Casting
4 Blade Hollow Blade (Less Weight) Solid Blade (More Weight)
5 Axial Low Axial thrust on Gear Box High Axial thrust on Gear Box
6 Energy Saving
Guarantee
20% + for Energy Saving
Guarantee
Energy Saving is Nil
7 Endurance Life > 10 years Aging effect after 2 - 3 years
Difference between EKOSMART FRP Fans & Aluminium
No Items E- Glass Epoxy ENCON Fans Aluminum/GRP/FRP
8 Skin Friction Negligible skin friction More Drag losses due to rough
surface
9 Heat Distortion
Resistance
High , due to Epoxy Base Material N.A.
10 Maintenance Cost Zero Maintenance prone
11 Leading Edge
Protection
Provided with extra re-inforcement
of Epoxy resin
High deteriorates
12 Degradation Protected from Erosion, Corrosion,
UV degradation & Abrasion
resistance
High
13 Fan replacement Only individual blade to be replaced Discarding Pair of blade
EKOSMART Fans Advantages
ENERGY SAVING :
- Lower H.P. motor can be used after installation of EKOSMART fan.
REDUCTION IN THRUST LOAD :
- The thrust load of EKOSMART fan is less than Aluminum blade
- Increase life of Gear Box bearings.
EFFICIENCY :
- Design to achieve minimum 86% efficiency
EASE OF MAINTENANCE:
- EKOSMART Fans are designed for long-free service
- Reduce down time or maintenance power requirement and maintenance cost
BALANCING & VIBRATIONS
- Balance as per ISO standard 1940 (grade 6.3)
- Residual unbalance below 80 mm x gms / kg (micron).
ENVIRONMENT FRIENDLY
- Negligible skin friction due to glossy surface finish
- Fan achieves a low noise level due to Airfoil profile of blades
- More suitable for better ecological peaceful surroundings.
Fan Testing Facilities
EKOSMART Wind Tunnel Test Bench
Electronic Moment Balancing Machine
Dynamic Balancing Machine
Hardness Tester
Cantilever Test Fixture
Coin Tapping Test
Universal Testing Machine
Pendulum Impact Tester
Heat Distortion Test
Muffle Furnace
Anemometer
Sound Level meter
Power Analyzer
EKOSMART Products Testing
Dynamic Balance
Machine
EKOSMART Products Testing
Dynamic Balance
Machine
EKOSMART Products Testing
Static Balance Machine
EKOSMART Products Testing
Loading Testing
Quality Assurance
The Aerodynamic performance of FRP Fan can be evaluated in Wind Test Bench as per AMCA 210-8 Standard
Raw material are selected out of stringent quality as per ISO/ASTM Standard followed 100% in house process inspection
Guaranteed life of EKOSMART design FRP Fan are normally above 9-14 years operation without any wear & tear and lose of performance
EKOSMART Products Certificate
• Fans : Static Balance Certificate
• Hubs : Dynamics Balance Certificate
• Products Guarantee Certificate
PERFORMANCE TEST :
OUR ENGINEER WILL BE CONDUCTING THE ‘ PERFORMANCE TEST’ OF YOUR EXISTING
ALUMINIUM AND OUR FRP FANS IN PRESENCE OF YOUR OFFICIALS AND SHALL BE
MEASURING THE FOLLOWING PARAMETERS :
AIR FLOW
POWER CONSUMPTION AT MOTOR TERMINALS.
BEFORE AFTER
CTI Code CTI Member
Performance Testing Report
Customer Ref. 1
Customer Ref. 2
Customer Ref. 3
We shall provide“Performance Test” of your Existing and
EKOSMART FRP Fans
Return On Investment (ROI)
No Description Aluminum Fan ENCON
Fan
Power
Saving (%)
Increase
Airflow (%)
1 Airflow (CFM) 3,358,783 4,999,023 - 48.83
2 Power (KW) 1,007.4 624.2 38.03 -
Company : Jong Stit Co.,Ltd.,Thailand (Textile)
Application : Air Washer Plant
Q’ty : 114 units
Saving/Year = 3,383.2 KW x 24 Hrs x 360 days= 3,310 MW / Year
No Description Aluminum Fan ENCON
Fan
Power
Saving (%)
Increase
Airflow (%)
1 Airflow (CFM) 533,186 593,940 - 7
2 Power (KW) 27.26 16.2 40.57 -
Company : TATA Power Co.,Ltd. (Power Plant)
Application : Cooling Tower
Saving/Year = 11.06 KW x 24 Hrs x 360 days
= 95,558.40 KW / Year
Pay Back Period = 2.98 Months
Return On Investment (ROI)
No Description Aluminum Fan ENCON
Fan
Power
Saving (%)
Increase
Airflow (%)
1 Airflow (CFM) 70,726 84,466 - 19.42
2 Power (KW) 7.1 5.0 29.57 -
Company : Honda Automobiles Co., Ltd. (Automotive)
Application : Cooling Tower
Saving/Year = 2.1 KW x 24 Hrs x 350 days= 17,640 KW Units
Pay Back Period = 7.47 Months
Return On Investment (ROI)
No Description Aluminum
Fan
ENCON
Fan
Power
Saving (%)
Increase
Airflow (%)
1 Airflow (M3/sec) 836.97 1,024.03 - 22.34
2 Power (KW) 2,219.93 1,408.98 36.53 -
Company : Reliance Industries Co.,Ltd.,(Petrochemical)
Application : Air Fin Coolers
Saving/Year = 810.95 KW x 24 Hrs x 360 days= 7,006,608 KW Units
Pay Back Period = 2.31 Months
Return On Investment (ROI)
No Description Aluminum Fan ENCON Fan Power
Saving (%)
Increase
Airflow (%)
1 Airflow (CFM) 13,610 14,816 - 8.86
2 Power (KW) 75.39 50.26 33.3 -
Company : Bayer Thai Co.,Ltd., (Polymer)
Application : Cooling Tower
Saving/Year = 25.13 KW x 24 Hrs x 350 days= 211,092 KW Units = 211 MW/year
Pay Back Period = 8.4 Months
Return On Investment (ROI)
No Description Aluminium
Fan
ENCON
Fan
Power
Saving (%)
Increase
Airflow (%)
1 Airflow (CFM) 81,383 86,278 - 6.01
2 Power (KW) 8.74 6.20 28.14 -
Company : Thai Textile Industry PCL. (Textile)
Application : Cooling Tower
Saving/Year = 2.54 KW x 24 Hrs x 360 days= 21,945 KW Units
Return On Investment (ROI)
Reference CustomerCustomer Name Application Energy Saving (%)
Alkyl Amines Chemicals Limited Cooling Tower 30%
Amines & Plasticizers Limited Cooling Tower 22%
Balasore Alloys Limited Cooling Tower 37.89%
Ballarpur Industries Cooling Tower 25%
Banswapa Syntex Limited Humidification 25%
BASF India Limited Cooling Tower 18% - 20%
Bayer (India) Limited Cooling Tower 20%
Central India Polyesters Ltd. Air Washer 20% - 25%
Century Rayon Cooling Tower 33%
Chennai Petroleum Corporation Ltd. Cooling Tower 25%
Citurgia Biochemicals Limited Cooling Tower 28.31%
DLF Power Limited Cooling Tower approx. 18%
Electrosteel Casting Limited Cooling Tower > 25%
German Remedies Ltd. Cooling Tower 25%
Ginni Filaments Limited Humidification 25%
Gontermann - Peipers (India) Ltd. Air Washer > 15%
GR Grasim Cooling Tower 30%
Grasim Aditya birla Group LTG Plant 18%
GSL (India) Limited Humidification 25%
Gujarat State Fertilizers Co.,Ltd. Cooling Tower 15% - 20%
HEG Limited Humidification 20% - 30%
Hindalco Industries Limited Cooling Tower 30%
Customer Name Application Energy Saving (%)
Indian Petrochemicals Corporation Ltd. Cooling Tower 30%
Indian Rayon and Industries Ltd. Cooling Tower 15% - 20%
Indifil Chemicals Company Cooling Tower 26%
Indo Gulf Fertilisers Ltd. Cooling Tower 25%
Indo Rama Synthetics (I) Ltd. Cooling Tower 27.6%
ITC Limited Air Washer 23.7%
JBF Industries Limited Cooling Tower 25% - 30%
Kanoria Chemicals & Industries Ltd. Cooling Tower 35.5%
Kribhco Shyam Fertilizers Ltd. Air Cooler 25%
Maiher Cement Cooling Tower 25% - 30%
Maruti Udyog Ltd. Air Cooler 25%
Modipon Fibres Company Cooling Tower > 30%
MRF Limited Cooling Tower 25%
Nirion Ltd. Cooling Tower 25%
NSIC Technical Services Center Cooling Tower 20.65%
Orissa Power Generation Corporation Ltd. Cooling Tower 25% - 30%
Pan-Century Edible Oils Sdn. Bhd. Cooling Tower > 25%
Pan Century Oleochemicals Sdn. Bhd Cooling Tower 20% - 25%
Petro Araldite Pvt. Ltd. Cooling Tower 35%
Polychem Limited Cooling Tower 30%
Praxair India Private Ltd. Cooling Tower 30%
P.T. Indo-Bharat Rayon Cooling Tower 30%
Rajashree Syntex Humidification 25% - 38%
Customer Name Application Energy Saving (%)
Renusagar Power Co.,Ltd. Cooling Tower 25%
Sansam Spinners Humidification 30%
Sarabhai M Chemicals Cooling Tower 30%
SATNA Cement Works Cooling Tower 20% - 22%
Shetkari Sahakari Soot Girni Ltd. Cooling Tower 20% - 25%
Shree Digvijay Cement Co.,Ltd. Air Cooler Radiator 33%
Shree Synthetics Limited Cooling Tower 20%
Shruti Synthetics limited Humidification 30%
Standard Mills Co.,Ltd. Humidification 30%
TATA Engineering & Locomotive Co.,Ltd. Cooling Tower 38.8%
TATA Steel Co.,Ltd. Cooling Tower > 30%
Thai Acrylic Fibre Co.,Ltd. Cooling Tower 35%
The Associated Cement Co.,Ltd. Cooling Tower 25%
The Bombay Dyeing & Manufacturing Co.,Ltd. Cooling Tower 20%
The Dawn Mills Co.,Ltd. Humidification > 35%
The Madras Aluminium Co.,Ltd. Cooling Tower 25%
The Ruby Mills Ltd. Air Conditioning 25%
The Mysore Paper Mills Limited Cooling Tower 25% - 35%
Zenith Spinners Ltd. Humidification 20% - 25%
Curves
Required Information for Fans offer
Fan Material & Fan diameter
Fan RPM
Motor power (HP/KW)
Air Flow
Actual power consumption (KW or Amps)
% Energy Saving Guarantee Pay-Back Period Technical Details
EKOSMART will offer
Easy Maintenance
Daily Maintenance
• Check for any unusual noise or vibration
• Check Ammeter for undue fluctuation in the current.
Monthly Maintenance
• Stop the fan & check the fan blades
• Check motor for overheating
• Check all hardware for security/perfect tightening
• Ensure that hole at the blades tip from blockage
• To touch up with suitable paint, whatever required to all exposed parts of steel. Any abnormal condition noticed during the above inspection, the corrosive should be taken up immediately, as required.
Aluminum Fans Dismantling
Aluminum Fans Dismantling
Aluminum Fans Dismantling
Fans Installation
Fans Installation
Fans Installation
Fans Installation
HONDA Installation
HONDA Installation
HONDA Installation
HONDA Installation
HONDA Installation
HONDA Installation
HONDA Installation
HONDA Installation
HONDA Installation
HONDA Installation
HONDA Installation
FANS OPERATION
Installation in Cooling Tower
Installation in Cooling Tower
Before
FRP Fan
After
Aluminium Fan
TORAY FIBER (THAILAND)
