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As an essential component of a kiln, kiln fans are mainly divided into supply fans, extraction fans and mixed flow fans. The following are some details about them.
Supply fans
Also known as primary air blowers, supply fans are located at the inlet of the kiln. Their main job is to facilitate the flow of external fresh/primary air into the kiln to aid fuel combustion and drying of materials. By doing this, they play a critical role in regulating temperature and enhancing the quality of the finished products. In some kilns (like cement rotary kilns), supply fans are designed to produce a strong axial air flow that can conveniently sweep through a vast amount of material.
Extraction fans
Extraction fans, also referred to as secondary air blowers, are positioned at the outlet of the kiln. Unlike supply fans that blow air into the kiln, extraction fans are designed to suck out the residual air (including the burnt gases) from the kiln. This process creates negative pressure within the kiln that helps to draw more primary air into the zone of burning (via the supply fan). Consequently, the processes of combustion and material drying are improved. Apart from improving the quality of material processing, extraction fans also have the benefit of recycling the heat from the clinker to the pre-heater. This enhances the overall energy efficiency of the plant.
Mixed flow fans
As the name implies, mixed flow fans are designed to incorporate the features of axial flow fans and centrifugal fans. It, therefore, comes as no surprise that mixed flow fans are widely used in various industries application scenarios. In many modern kilns, mixed flow fans are used for material transportation, dust removal and gas extraction. They are frequently utilized in the cement industry. In terms of energy consumption, mixed flow fans surpass centrifugal fans but are lower than axial flow fans.
Fan flow
Kiln fan flow measures the volume of air a fan can move. It depends on the fan's design, size, speed, and the power of the driving motor.
Static pressure
This is the resistance of air that the fan can overcome. It is the measure of the static pressure of a kiln fan, which is an essential factor in determining its ability to move air through different levels of resistance, such as ductwork and apertures. Matching the static pressure to a system's needs can boost efficiency and guarantee suitable airflow delivery.
Operating temperature:
A kiln fan's typical working temperatures vary greatly depending on its design and application, ranging from -40 to +60 degrees Celsius. Nonetheless, for the longevity and reliability of the equipment, extreme temperatures should be avoided and acceptable operating temperatures should be maintained.
Fan speed
The rotational speed of a kiln fan influences the amount of airflow generated. It is usually expressed in revolutions per minute (RPM). The fan speed must be adjusted correctly to meet specific requirements without sacrificing safety.
Regular inspection and maintenance
A professional engineer or qualified technician should routinely inspect the kiln fan to check for any performance problems. Moreover, maintenance of the fan should be scheduled frequently to make sure it stays in good condition and to catch any likely issue before it becomes serious.
Lubrication
Lubricating the moving parts of a kiln fan, such as the bearings and motor, allows for smooth operation while reducing the risk of friction-related malfunctions. Buyers or users should remember to select the right lubricating oil for their fan model.
Cleaning
Cleaning the fan on a regular basis is a crucial maintenance procedure that users should not overlook. Cleaning eliminates dust accumulation, dirt, and other obstructions that affect performance and provides fresh air circulation. Remember to use non-toxic cleaning solutions for both the environment and user safety during the cleanup operation.
Replacement of parts
Replacement of damaged or worn parts of the kiln fan is necessary to maintain optimal performance. After conducting regular inspections, if any damaged components are discovered, buyers are advised to replace them immediately to avoid fan failure and prolonged downtime.
Pilot Scale Industries
Due to the limited scale of production, many small-scale industries cannot justify the cost of investing in heavy-duty kiln fans. Nonetheless, the effective air circulation and heat distribution provided by fans are still essential for the quality of products in kilns and dryers. Therefore, small-scale industries often opt for affordable, entry-level kiln fans that can meet their basic requirements.
Growth Stage Industries
Many mid-sized manufacturing industries are currently in the growth stage of their business and are experiencing increased production capacity. As a result, these industries have a greater need for more efficient and durable equipment. Heavy-duty kiln fans, which can withstand prolonged use and higher airflow rates, are essential to meeting the equipment needs of these industries during this stage of development.
Furnace Type Industries
Industries that use different types of furnaces also have distinct requirements for kiln fans. For instance, high-temperature resistance fan blades that can withstand the scorching heat are essential in industries such as ceramic and refractory material production. On the other hand, fans with a higher airflow rate and lower noise level are preferred in the food processing industry to ensure the quality and safety of food products.
Cement Manufacturing Factories
The primary application of kiln fans in cement manufacturing factories is to facilitate the drying of raw materials and the calcination process in the cement rotary kiln. During the calcination process, a significant amount of thermal energy is released, and the proper circulation of air within the kiln is crucial for maintaining consistent temperatures and promoting the chemical reactions necessary for cement production. As a result, cement manufacturing factories typically use axial-flow fans or high-temperature centrifugal fans as their primary type of kiln fan.
Timber Drying Plants
In timber drying plants, the primary function of kiln fans is to expedite the drying process of timber. This helps to reduce the moisture content of the wood and improve its stability and durability. Centrifugal fans are the preferred choice for timber drying plants due to their ability to provide the necessary airflow and achieve efficient timber drying.
Glass Production Factories
Glass production factories have different types of fans used in their production lines. While cement manufacturing factories primarily use axial-flow fans, glass production factories may employ cubic fans or inline fans. The specific design and airflow performance of each type of fan are suitable for meeting the particular requirements of different production processes in the factory.
Several factors need to be considered when purchasing kiln drying fans for sale.
Airflow :
The airflow generated by a kiln fan is measured in cubic feet per minute (CFM). It indicates the volume of air the fan moves. To assess the required airflow for a kiln, one must consider the dimension and layout of the drying room, the volume of the lumber being dried, and the desired drying rate. Once these factors have been assessed, it is essential to look for fans that can provide the recommended CFM to ensure an effective drying process.
Fan Type :
There are various types of kiln fans, such as axial flow fans, backward-curved fans, radial fans, etc. Each possesses its own unique characteristics and applications. Researching and understanding the features of each fan type can help to choose a fan that will suit a specific application.
Size :
When it comes to the performance of a kiln drying fan, the size of the fan plays a crucial role. Larger fans tend to move more air but take up more space and use more power. On the other hand, smaller fans use less space and power but may not provide sufficient airflow. To find a balanced solution, it is essential to consider the application and the space constraint.
Noise Level :
The amount of sound that a kiln fan produces during operation is referred to as its noise level. Selecting a fan with a noise level is helpful, especially when the drying room is located near residences, workplaces, or other sensitive areas. Choosing a fan with a low noise level can minimize the impact of noise on the surrounding environment, thereby creating a more peaceful and comfortable space for everyone.
Cost :
From the initial cost of purchasing the kiln fan to installation and maintenance expenses, as well as the fan's energy efficiency and performance, are all factors that should be taken into consideration. When it comes to choosing the kiln dryer fan, it's important to weigh the overall life cycle cost and find a balance between performance and expense.
Q: How big is the fan business?
A: The global industrial fan market is expected to reach $4.1 billion by 2030.
Q: What is the growth driving?
A: The growth is likely because industrial fans perform the critical functions of supplying and exhausting air in industrial facilities. With the expected growth of the industrial machinery sector globally, kiln fan growth is also likely.
Q: What are the trends?
A: The market is moving towards energy-efficient products. Hence, businesses use EV kiln fans for their furnaces. The use of intelligent technologies that enable remote monitoring and predictive maintenance is also a trend. More industrial facilities are using industrial fans with low noise levels because they want to create a conducive work environment.
Q: What are the dominant fan types in terms of revenue?
A: The axial segment dominated the market in 2021 due to its widespread applications across various industries. However, the centrifugal segment is likely to grow at a rapid pace because it is suitable for high-pressure operations.
