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DESIGN AND CONSTRUCTION OF CENTRIFUGAL FAN FOR A FLUIDIZED BED

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Nigerian Journal of Tropical Engineering
Vol. 8 No. 1 & 2 | ISSN: 1595-5397 | Dec. 2015

DESIGN AND CONSTRUCTION OF CENTRIFUGAL FAN

FOR A FLUIDIZED BED COMBUSTOR
I. I. Ozigis*, H. Dandakouta** and G. Egbo**
Email: [email protected], [email protected]; [email protected]
*Department of Mechanical Engineering, University of Abuja
**Department of Mechanical/Production Engineering ,
The Abubakar Tafawa Balewa University, Bauchi.

Abstract
The design, construction and performance evaluation of centrifugal fan for a fluidized bed combustor was
carried out. The local construction of machines including centrifugal fan uses less of design calculations
resulting in substandard output. In addition, the lack of balancing equipment for centrifugal fan and little
knowledge in use of computational fluid dynamics are challengers to fan fabricators in Nigeria. Empirical
correlations and basic turbo machinery equations were used to design the components parts of the
centrifugal fan. The centrifugal fan was constructed with mild steel, plates and rods. The impeller with
rotor, hub and blades were balanced on a shaft before assemblage and testing of the centrifugal fan. The
centrifugal fan has air capacity of 0.121 m3/s (256 CFM), total pressure of 5,017.5 N/m2 and fan output
power of 1.61 kW at air outlet velocity of 6.88 m/s. As the speed of impeller varies from 750 rpm to 1500
rpm, the dynamic pressure arises from 100 N/m2 to 280 N/m2. The static and dynamic pressures of about
5,000 N/m2 enhance motion of particles in fluidization processes. The detailed design will aid generation
of program code to compute some aspects of centrifugal fan and in centrifugal fan performance
evaluation.

Keywords: blade, centrifugal, fan, fluidized, impeller, pressure.

1. Introduction from rotor to volute scroll casing. The parts of

Centrifugal fan is a device with rotating centrifugal fan include impeller, casing, shaft, hub,
blades, which circulate and move current of air. The bearings, coupling and electric motor [2].
balance of air and fuel are required for combustion Centrifugal fan supplies air to a test furnace that
processes and proper operation of solid fuel-fired produced 80 kg/hr airflow rate to burn coal at rate of
fluidized bed combustor. Adequate air and pressure 50 kg/hr, which produced steam at 14 kg/hr [3]. In
are also required to keep the bed fluidize. addition, 70 kW fluidized bed gasifier had air at
Centrifugal fans can operate continuously for long 62.42 kg/hr to fire rice husk and solid waste at rates
period up to one year or more; so, the fans must be of 33.02 kg/hr and 7.26 kg/hr, respectively to
well designed, ruggedly constructed, well balanced produce gas flow of 88.2 kg/hr [4].
and efficient over a wide range of output for a
power plant [1]. Centrifugal fan for fluidized bed combustor
has its own specific requirements to meet its
Fans provide air for industrial process intended design purpose. Among the requirements
requirements. Centrifugal fans discharge its air is high static pressure and low dynamic pressure to
perpendicular to the axis of impeller rotation. overcome pressure drop due to heat transfer
Centrifugal fan operates by combination of surfaces and increased ability to push upward,
deflection of blades and centrifugal force exerted transportation of solid and gas particles in the
on air rotating with blades and thereby moving fluidized bed combustor. Centrifugal fan for
outward in a radial direction. The pressure energy fluidized bed combustor has small ratio difference
of air increases with help of centrifugal action by between inlet and outlet, short transition pipe and
lifting air and particles from lower level to higher low pressure in which air enters through air
level. The produced vortex also causes a reduction distributor to fluidize bed materials. Centrifugal fan
of pressure at the centre of the impeller resulting in for fluidized bed combustor are mainly constructed
o
rush of air through the inlet hole. In centrifugal fan, of steel that can withstand up to 800 C as drying
air is accelerated radially through impeller blades processes for fuel starts before combustion. The

1
 Design and Construction of Centrifugal Fan for a Fluidized Bed Combustor
elevated temperature of up to 800oC minimize available for overcoming resistance of fluidized
clogging of feed pipe and air distributor as well as bed combustor (air distributor, bed, heat
increases fluidization quality and reduces energy exchangers) and is exerted in all directions. 5000
consumption of the centrifugal fan. N/m2 (20.07 in H2O) for a simple centrifugal fan
was obtained [14]. An electric motor of maximum
The local manufacturers of centrifugal fans speed of 2880 rpm was selected for this work based
build for specific need without formulas and on its availability.
balancing which often result in excessive
vibrations and none yet for fluidized bed I. Impeller and fan diameters.
combustor in Nigeria. Some of the local fabricators
The impeller diameter in inches was based on
designed a centrifugal pump test rig for school
empirical relation [15]:
laboratory but there were no design calculations for
the components [5]. Furthermore, blower unit for
cowpea thresher and paddy rice dryer were (1)
constructed without design calculations [6, 7]. A
group of researchers summarized in their study that where;
majority of (agricultural) fabrications in Ekiti and
PS is static pressure = 20.07 in H2O [14].
Ondo States of Nigeria are substandard [8].
Internationally, design and manufacturing of
Impeller diameter was found as:
centrifugal fan has advanced into use of
computational fluid dynamics to evaluate their
performances [9, 10, 11]. The lack of laboratory in
Nigeria for centrifugal fan testing as approved by
Air Movement and Conditioning Association The best fan machine has D1/D2 ratio of 0.6-0.7
(AMCA) standard 210 [12], made generation of [16]. Using ratio 0.7, the fan diameter is
performance curves impossible. Available
centrifugal fans supply air to combustors such as D2=
rotary kiln, coke oven plant, cupola and crucible
furnaces are without design data. Design data may
Hence D1 and D2 are impeller and fan diameters
be used to design a new fan, maintain and to
of width 0.5 m and 0.7 m, respectively.
produce an exact scaled copy of the original fan.
The aim of this research is to design a
centrifugal fan using empirical correlations and to this value is within standard
construct the centrifugal fan for a fluidized bed design ratio [16].
combustor. i. Fan blade length and width.
The blade length (L) and width (W) are in
2. Design of Centrifugal fan range stated below for forward and backward
Centrifugal fan design is a complex curved fans with guide vanes [16]:
processes that starts with basic knowledge of
system operating conditions, air properties, air L = (0.084 - 0.16) D2 … (2)
flow rate, pressure and system layout. Other factors
includes number of blades, front and rear casing W = (0.084 - 0.16) D2 … (3)
and impeller diameters, inlet and outlet areas and The absence of guide vane in the present fan and to
drive speed. Empirical formulas were used to match the capacity, require range outside the
design the centrifugal fan without performance above. Therefore, the ranges selected were:
curve and then the actual performance was … (4)
measured after assembly. L = 0.25 D2
… (5)
W = 0.2 D2
2.1 Centrifugal fan dimensions
Forward-curved blades radial fan was The radial blade length is determined as in the
designed and constructed from mild steel sheet of 3 relation:
mm thickness. The air needed was estimated to be L = 0.25 ´ 700 = 175 mm
3
0.121 m /s (256.4CFM) for a square duct 0.3 3 m by
0.33 m by 1.63 m fluidized bed combustor [13]. The radial blade width is found as:
Static pressure is the useful working pressure W = 0.2 ´ 700 = 140 mm

2
 I. I. Ozigis, H. Dandakouta and G. Egbo
For maximum capacity and balancing, radial fan
with eight blades were selected.
… (10)
i. Fan inlet and outlet diameters.
Fan minimum inlet diameter in inches was where;
given as [15]: N is speed of electric motor. Substituting the values
of D2 = 0.7 m into eqn (10), gives U2 as:

… (6)

Substituting the values, the fan inlet diameter is

found as: The velocity of flow at outlet (vf2) is defined as [2]:

256.4
d1 = 113 = 4.91 in » 4.91´ 25.4 = 124.7 mm … (11)
2880
The centrifugal fan is a low duty fan; the air inlet Radius 1 Cut off point Radius3
diameter (d1) was approximated to 150 mm.
The air exit diameter from centrifugal fan is
determined as in relation [16]:
d 2 = d1 … (7)
d 2 = 0.15 = 150 mm
i. Fan width.
Clearance fit for running blades and
impeller, requires maximum allowance [17].
Therefore, the fan width, WF, was obtained as
follows:
WF = 0.24 D2 … (8) Offset 1 Offset 2 Radius 2
WF = 0.24 ´ 0.7 = 168 é 170 mm
Fig. 6. Development of Scroll Casing and Impeller of the
i. Scroll fan casing
Centrifugal Fan
Scroll was found by three radii, offsets and
cut off point as follows [15]: Substituting for values into the above equation, Vf2
R1 = 0.5 D1 = 0.5 ´ 0.5 = 0.25 m was found as:
R2 = 0.7 D1 = 0.7 ´ 0.5 = 0.35 m
R3 = 0.9 D1 = 0.9 ´ 0.5 = 0.45 m
Off set = 0.1D1 = 0.1´ 0.5 = 0.05 m The tangential velocity of impeller at inlet, (U1)
Cut off po int = 0.05D1 = 0.05´ 0.5 = 0.025 m … (9)
is given as [2]:
The offsets are placed on the horizontal line but at … (12)
both sides of the vertical line.
These offsets serve as radii 1 and 2 respectively, to
obtain the volute shape of scroll casing. Radius 3 The U1 is also tip speed at outside edge of
originates from offset 1 on the left side of vertical impeller, thus found as:
line as shown in Fig.1.

2.2 Velocity triangles of centrifugal fan

The tangential velocity of impeller at outlet
(U2) is given by [16]:

3
 Design and Construction of Centrifugal Fan for a Fluidized Bed Combustor

The velocity of flow at intlet (Vf1) was found 2.2Torque, Power, Shaft Diameter, Pressure
from the relation [2]: and Air Velocity of Centrifugal Fan
i. Torque due to air
Fav … (13) The torque exerted by blades on air, may
Vf1 = D1d1 be expressed as follows [2]:
p

.
Substituting for values into eqn. (13), the Vf1 w F a Vw 2 R2 … (17)
Tq =
g
was determined to be:
where;
V f 1 = 0.121 = 0.514 m / s
p ´ 0.5 ´ 0.15 w = r1 g = 1.2 ´ 9.81 = 11 .772 N / m 3
The velocity triangles illustrate velocity of fluid
flow exerted on the blades. o 3
1ris air density at 30 C and 1 atm=1.2 kg/m
From velocity triangle (see Fig.2), we have
g is acceleration due to gravity = 9.81 m/s2.
velocity of whirl at inlet (Vw1) as:
R2 is radius of impeller width (D2) = 0.70/2= 0.35

Vf1
Vw1 = U1 - … (14) Substituting the values in above equation, the
tan q
torque was calculated to be:
The blade tip angle was taken as q = 30o [2].
Substituting for values into the above equation,
the whirl velocity was therefore calculated: Tq = 11 .772 x0.121x104.96 x0.35 = 5.334 Nm
9.81

Vw1 = 75.4 - 0.514 = 74.51 m / s

0.577
Absolute tangential velocity at outlet (Vw) was
found [2]:

Vf 2
Vw 2 = U 2 - … (15)
tan q

The VW2 is thus found as:

Vw 2 = 105.6 - 0.367 = 104.96 m / s

0.577

The absolute peripheral velocity of air leaving

blade at outlet (V2) was found as:

V2 = V f22 + Vw22 … (16)

The V2 is thus found as:

V2 = 0.367 2 + 104.96 2 = 104.96 m / s

Fig.2: Centrifugal fan and its velocity triangles

4
 I. I. Ozigis, H. Dandakouta and G. Egbo

ii Fan output power 5500 ´ 60

The fan output power is given as [2]: Tq = = 25 Nm = 2500 Ncm
2 ´ 3.142 ´ 2100

2pNTq
Pair = … (18) v. Coupling shaft diameter
60

The fan output power is thus found as: The diameter of the coupling shaft to

2 ´ p ´ 5.334 ´ 2880 electric motor is given as [19]:

Pair = = 1609 W é 1.6 kW
60
Tq 16
iii Brake horse power (Shaft power) d =3 … (23)
The power required to drive the centrifugal pg
fan (pm) is given as [18]:
where;
Pm = 2pNT … (19) g is the allowable torsional stress = 1.2 kN/cm2[19].
h 60 Substituting the values into above equation, the shaft
where; diameter was calculated to be:

h is efficiency of the centrifugal fan = 0.4[16] 2500 ´16

The shaft power is thus calculated as: d =3 = 2.2 cm é 30 mm
3.142 ´1200
\ Pm = 2 ´ 3.142 ´ 2880 ´ 5.334 = 4022 W é 4 kW
0.4 ´ 60
vi. Hub diameter
iv Torque due to coupled drive
Centrifugal fan shaft torque subjected to The hub diameter may be found [19]:
torsion by electric motor and partly to self-
induced transverse forces of gravity and d hb = 1.4d … (24)
centrifugal forces caused by impeller misbalance.
The torque is given as [18]: The hub diameter is thus found as:

Pm 60 … (20) d hb = 1.4 ´ 30 é 40 mm
Td =
2pN
vii Air velocity from centrifugal fan to plenum
Since the efficiency of the fan drive is 0.73 [19],
of the fluidized bed combustor
then, adjusted speed of drive becomes:
Air velocity (Va) supplied by the fan into
Nd = N ´ m … (21) fluidized bed steam generator was found as:
Fav
Substituting the values into above equation, Nd is: Va = … (25)
Ad 2
N d = 2880 ´ 0.73 = 2100 rpm
Ad2 is the cross-sectional area of transition duct
The required power for the drive becomes [19]:
pipe and d2 = 0.15 m
P … (22)
Pd = m Substituting the value of d2 to find the area, Ad2
m
The required power was found by substitution of becomes:

Pm and m into eqn (22):

p 0.152
Ad 2 = = 0.018 m 2
4022 4
Pd = = 5500 W
0.73 Substituting the values of Fav and Ad2 into eqn.
The drive torque obtained by substitution of
(25), the air velocity was calculated to be:
adjusted speed and shaft power values was:

5
 Design and Construction of Centrifugal Fan for a Fluidized Bed Combustor
0.124
Va = = 6.88 m s
0.018 2
é 6.88 ´196.8 ù
viii Total pressure of the centrifugal fan PV = ê ú = 0.724 5 in H 2O
Total pressure is sum of static and dynamic ë 4 009 û
pressures of fan as given by [1]:
Dynamic pressure converted into S.I. unit:
PT = PS + PV … (26) PV = 0.724 5 ´ 249.1 @ 17.5 N m 2
where;
PS is static pressure = 5 000 N/m2 (adopted for Substituting for value of Pv into eqn. (26), the
simple centrifugal fan [14]
PV is dynamic pressure (in H2O) given as [20]: total pressure was obtained as:

2 PT = 5 000 + 17.5 = 5 017.5 N m 2

é V ù
PV = ê a ½ … (27)
ë 4 009 û
Substituting the value of Va, converted into feet
2.1 Construction of Centrifugal fan
per minute (see eqn. 27): The centrifugal fan, which was constructed
from 3 mm thick steel plate, has eight blades,
impeller and casing as shown in Fig. 3. The
impeller has a diameter of 0.5 m, cut

30mm shaft
‫ ▓ ▓ ﮭ ﮭ ﯾ‬źĂ■ 18x30x50mm Bearing
Electric motor 40mm Hub
Impeller
Blade

Impeller
Isometric view section A - A

- All dimension in mm
Fig. 3: Centrifugal Fan
from 3 mm thick plate of dimensions 1.22 m by vertical lines were scribe using the centre point
2.44 m using angle-cutting machine. A circular and punched. The offset to the right and left of the
pipe of 40 mm outside diameter and 5 mm vertical line which were used to scribe the radii 1, 2
thickness forms the hub. Protractor was used to and 3 to form involute casing as shown in Fig. 2.
scribe 45o on the impeller for locations of the eight The shape was cut out using angle cutting
blades. The 8 pieces blades of 140 mm width by machine. A 170 mm by 2,400 mm strip plate was
175 mm length were cut from the same plate and cut and flange made on its edge and round the fan
welded on a 500 mm diameter impeller. Scroll fan width using a flat bar. The casing and 170 mm by
casing was constructed using offset and three radii 2.4 m plate were welded to each other, while the
obtained in flanged at ends were joined with bolts and nuts.
The air inlet and outlet pipe diameters of 150 mm
design. Fan involute shape was made on a plate each were made on the casing and fan width,
with the help of a tape rule, marker and centre point. respectively. Air delivery pipe was welded to
The centres of the casings were centre punch to rectangular opening of 170 mm by 150 mm on the
scribe casing diameter of 700 mm. Horizontal and fan casing. Air regulator was placed at 450 mm
equidistant from both the fan and the plenum. The

6
 I. I. Ozigis, H. Dandakouta and G. Egbo
damper was made from 6 mm thick plate and was 4 Results and Discussion
cut to form 150 mm diameter circular plate with This section presents results and discussion on
threaded rod at both ends. The rod passes through specifications and performance evaluation of the
an air transition pipe and enters a nut welded at the centrifugal fan. The centrifugal fan design
bottom of circular plate thus forming the knob for
specifications are as shown in Table 1. The direct
opening. A stepped solid shaft of 40 mm diameter
drive speed of 2880 rpm and total pressure of 5307
and 450 mm long was made hollow by drilling 100
mm deep and 30 mm diameter; and was coupled to N/m 2 in this work are similar to some
5.5 kW electric motor rotor shaft via pulley and V- researchers'work, which obtained air flow rate of
belt system. The shaft was made from 50 mm steel about 200-300 m3/hr, at a speed of 2825 rpm with
rod using lathe machine. A hole of 10 mm was pressure of 4.5 kPa and driven by 3 kW electric
drilled across hollow part of the shaft and a 10 mm motor for a fluidized bed combustor [14]. Facts
blind hole was made on the shaft for coupling with inbedded in this design by incorporation of speed
electric motor shaft. A roller bearing of 40 mm variation was to avoid poor centrifugal fan design
inner diameter, 62 mm outer diameter and 22 mm that can results in a fan that is too large or a fan that
width was selected and placed on a housing welded will run at a higher speed than necessary for a
to the casing. The electric motor and fan's vibration fluidized bed combustor [21, 22, 23]. The design
were damped with plywood board on floor and an calculation in this work makes it easy for local
angle iron was used for installation of the electric designers of centrifugal fan for fluidized bed
motor. Body filler were used to fill rough spots and combustor to generate program code for
dents to reduce air leaks which also provided good computation in design before production.
finish on painting.
The control valve in this centrifugal fan is
3 Experimental Procedure only for start and stop air flow into combustion
The barometric pressure in mm Hg and chamber as any reduction in air flow also results in
room temperature were noted. The control valve loss of static and dynamic pressures losses to
on the transition pipe was closed and the electric fluidize solid fuels. In cupola furnace, control
motor was started, which rotates the impeller shaft. valve has more usefulness to control air at
When the impeller has attained normal speed, the different stages of burning fuel and melting metal
control valve on transition pipe was opened and [15, 22]. The dynamic pressure in centrifual fan
readings were taken. To adjust the delivery for fluidized bed combustor is higher than
pressure, the control valve on transition pipe was
centrifugal fan for cupola
adjusted. The speed of impeller was measured by
Table 1: Specifications of the centrifugal fan
tachometer while period of experimental run was
by stop watch. The barometric pressure was noted
by measurement of initial height in U-tube
manometer for both at the inlet and at transition
pipe. The dyed water in U-tube manometer rose as
the electric motor was started. A knob was used to
adjust control valve installed on the transition tube.
There were three different pulleys in addition to
direct couple to vary the speed of the impeller. The
second diameter pulley was changed and the above
processes were repeated. Similarly, the third
diameter pulley was replaced and observations
were noted.

The pressure was calculated as follows:

p = rgH … (7)

Where r is water density in manometer = 1000

3 2
kg/m .gis acceleration due to gravity = 9.81 m/s .
H is mean height of readings from manometer
tube.

7
 Design and Construction of Centrifugal Fan for a Fluidized Bed Combustor
furnace since the former needs to lift up particles capacity of 0.121 m3/s (256.4 CFM) at total
while the latter is just to provide air for combustion pressure of 5307 N/m2.
of coke [22], even though both uses centrifugal fan ii. At speed of 1500 rpm, the generated
for high temperature environment. The fan inlet dynamic pressure was 220 N/m2.
and out let diameters for this design was iii. The detailed design will aid generation of
determined to be 150 mm each as against an inlet program code to compute some aspects of
diameter of 221 mm and oulet diameter of 425 mm, centrifugal fan and in centrifugal fan
which will also give different performances due to performance evaluation
different ratios of fan inlet and outlet diameters iv. The centrifugal fan has air torque of 5.33
[24]. The performance of the centrifugal fan is Nm, fan output power of 1.61 kW and
described by a profile plotting the pressure over a outlet velocity of 6.85 m/s.
range of speed of impeller as shown in Fig.4. The v. Impeller and fan diameters of the centrifugal
pressure profile in this work agrees well with fan are 500 mm and 700 mm respectively
characteristics of most centrifugal fan [16]. while inlet and outlet were 150 mm each.
Incorrect positioning of impeller and impeller vi. Radial blade centrifugal fan is simple to
blades inside the centrifugal fan affects the design, construct and ease to maintain.
aerodynamics performances and influences vii. The absence of fan test rig made generation of
impeller axial thrust loads resulting in unknown the performance curve impossible.
characteristics [21]. The tip clearance adopted in References
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