Mixed flow fan

Exploring the Growth of the Mixed Flow Fan Market

Market Overview: The mixed flow fan market is a significant segment within the broader industrial and commercial fans and blowers industry, which saw an increase from USD 10.3 billion in 2023 to an estimated USD 14.9 billion by 2030, reflecting a solid CAGR of 5.4% during this period, according to Global Industry Analysts, Inc. This growth is driven by the rising demand for efficient ventilation solutions across various sectors, including manufacturing, food and beverage, and wastewater treatment. In particular, the U.S. market was valued at approximately USD 2.7 billion in 2023, with China expected to outpace many regions, growing at an impressive CAGR of 8.2% to reach USD 3.3 billion by 2030. These statistics indicate a robust market environment for mixed flow fans as industries increasingly prioritize energy efficiency and operational performance.

Industry Insights: The demand for mixed flow fans is bolstered by their versatility and efficiency in handling air movement in low to medium-pressure applications. This trend aligns with the broader industrial focus on enhancing air quality and optimizing processes, especially in sectors like wastewater treatment, where aeration systems consume significant energy. Additionally, as industries face stringent environmental regulations, the adoption of energy-efficient technologies, including mixed flow fans, becomes paramount. Major players in the market, including established companies like Ingersoll Rand and Atlas Copco, are investing in innovative solutions to capture market share. As consumer behavior shifts toward sustainability and efficiency, the mixed flow fan segment is well-positioned for continued expansion, reflecting the industry's ongoing commitment to meeting modern operational challenges.

Types of mixed flow fans

A mixed flow fan, also known as a mixture directional flow impeller, is a fan that can produce air that moves in a mixture of axial and radial directions. Moreover, it is a hybrid fan combining centrifugal and axial flow fans. Mixed flow fans work by drawing air or gas from the vicinity of the fan hub and displacing it parallel to the fan shaft. Next, the air or gas is moved outward in a circular motion around the periphery of the impeller. The principal flow direction in a mixed flow fan lies between axial and centrifugal radial directions. Fans of this kind can be found in jet engines, HVAC systems, and water pumping industries.

Depending on the mixture construction and design, there are two types of mixed flow fans.

• Cased

Cased mixed-flow fans have a casing that directs the airflow. Additionally, this type of mixed flow fan provides an airflow pattern similar to axial fans but with higher pressure and efficiency comparable to centrifugal fans. The housing also aids in noise reduction and boosts safety in the area around the fan.

• Uncased

Uncased mixed flow fans do not have a case. As a result, the air from the hub disperses in all directions perpendicular to the hub, like an explosion. This fan's configuration boosts the velocity and flow rates of air or gases. In addition, an uncased mixed flow fan allows installation in tight spaces, as it does not take up much room due to the lack of casing. However, the presence of the casing provides protection for the impeller from any potential harm to the device in the environment where it works or operates. Also, the open design allows for easy maintenance and cleaning.

Specification and Maintenance of Mixed Flow Fan

The specifications of a mixed flow fan will vary depending on the particular application. However, the following are some typical specifications to expect:

• Dimension: A mixed flow fan's dimension refers to the overall length, breadth, and height of the fan. Dimensions vary depending on installation requirements or available space. Common dimension ranges are 200~500mm for diameter, 500~1500mm for length, and 200~600mm for height.
• Airflow Volume: A mixed flow fan's airflow volume refers to the amount of air the fan is capable of moving within a given time. It is usually measured in cubic meters per hour (m3/h) or liters per minute (lpm). A typical small electro-mixed fow fan will have an airflow volume of around 100~500m3/h, while large industrial mixed flow fans will have an airflow volume of around 1,000~5,000m3/h or higher.
• Speed: Speed refers to the rotating speed of the mixed flow fan and is usually measured in revolutions per minute (RPM). Smaller mixed flow fans have a speed of around 2,000~3,600RPM, while larger fans have a speed of around 1,000~1,800RPM. Low speed means less noise and more efficiency, while high speed means more airflow.
• Power Consumption: It refers to the amount of power the mixed flow fan consumes during operation. It is normally measured in watts(W) or kilowatts (kW). The power consumption of small mixed flow fans might range from 50 to 200W, while larger, more powerful industrial fans would use 500W to 2,000W or more.
• Pressure: A mixed flow fan generates static pressure to overcome resistance in the air handling system, thus moving air. Mixed flow fans produce normal static pressure of 100mm to 500mm. Higher static pressure indicates the ability of the fan to overcome air resistance.
• Function: Some mixed flow fans are made to ventilate and extract to/from the environment, while others are designed to circulate air within a space. Some fans are designed to operate under normal atmospheric conditions, while others are made for explosion-proof or anti-corrosion applications.

Maintenance

• Regular Inspection: A mixed flow fan should be visually inspected frequently to look for indications of damage, looseness, wear, or leak.
• Clean: Ensure that nothing is in the way of the air inlet or outlet to prevent clogging. Use vacuum cleaners or air compressors to blow away any dust, debris, or obstructions that may be present within the fan.
• Lubricate: If the mixed flow fan has any lubrication parts, be sure to apply lubrication oil regularly to keep it well-lubricated and functioning smoothly.
• Fasten Components: Check the fastening condition of components like screws and clips over time to ensure safety and operational reliability. Replace or repair the part if it is forever loose.
• Check for Noise: If there's any abnormal noise, such as rattling or grinding. Look and see if there's any obstruction in the way. Try to locate and remove the obstruction. If the noise persists, have a qualified technician check the fan.

Scenarios

Mix flow fans are used in various industries and applications. Some of the common usage scenarios include the following.

• HVAC systems

  The fans are primarily used as duct fans in air conditioning and heating ventilation systems. They are used to provide fresh air into a room or space, exhaust stale air, and control and regulate room temperature.

• Industrial ventilation

  Mix flow fans are used to provide ventilation in different manufacturing and industrial settings. The ventilation may be for workers' comfort or to dilute or remove harmful and toxic fumes, dust, smoke, and gases to maintain air quality.

• Boiler units

  The fans are commonly used in boiler units to provide the necessary combustion air. They can be used with different types of boilers, including gas, oil, and coal boilers.

• Firefighting

  In firefighting applications, mixed flow axial fans are used to control smoke and improve the visibility of people in buildings during a fire. The fans are used to create a clear and safe passage for evacuating people and firefighters within the building.

• Tunnel ventilation

  Mix flow fans are used to provide ventilation in transport tunnels, such as road and rail tunnels. They are used to dilute and remove smoke and fumes from vehicles and ensure the safety and comfort of tunnel users.

• Cold storage facilities

  Cold rooms or storage facilities also employ the use of mixed flow fans. They are used to provide the necessary refrigeration and maintain the desired temperature to prolong the shelf life of perishable goods and prevent spoilage.

• Dust collection

  Industries and manufacturing facilities that produce a large amount of dust and particulate matter must install dust collection systems to maintain high air quality. Those systems may use a mixed flow fan to collect and filter circulating air.

How to choose a mixed flow fan

When selecting a mixed flow fan for any application, it's essential to consider several critical factors to ensure the performance, efficiency, and suitability of the chosen fan. Focusing on these factors will help users choose a fan that performs well, operates efficiently, and meets the application's specific airflow and pressure requirements.

• Airflow and pressure requirements:

  Determine the required airflow (usually measured in cubic feet per minute, CFM) and static pressure (usually measured in inches of water gauge, WG) for the application. Airflow refers to the volume of air moved by the fan, while static pressure refers to the resistance against which the fan must operate. Mixed flow fans are designed to handle specific combinations of airflow and static pressure, so it's essential to choose a fan that matches the application's requirements.

• fan size:

  Consider the physical dimensions of the application and any installation constraints. Mixed flow fans are available in various sizes, so it's essential to choose a fan that fits within the available space. Additionally, consider the orientation and mounting configuration of the fan to ensure it can be appropriately installed in the application.

• Motor and drive options:

  Mixed flow fans use different motor and drive options, such as direct-drive or belt-drive configurations. Direct-drive fans have the motor mounted directly on the fan impeller shaft, resulting in a compact design with fewer moving parts. On the other hand, belt-drive fans use a belt-driven transmission system to separate the motor from the fan, providing flexibility in the motor's location and the fan's speed. Consider the advantages and disadvantages of each configuration and choose the one that suits the application's needs.

• construction materials:

  Mixed flow fans are made from various materials, such as plastic, galvanized sheet metal, stainless steel, and aluminum. The construction material of the fan affects its durability, strength, and resistance to environmental conditions. For example, heavy-gauge galvanized steel is suitable for exterior applications exposed to harsh weather conditions because it provides excellent resistance to corrosion and other environmental elements. As a result, selecting the appropriate construction material for the fan ensures its long-term durability and performance in the intended application.

Q&A

Q1: How do mixed flow fans work?

A1: Mixed flow fans work by drawing in air parallel to the fan's axis and then discharging it perpendicularly by employing a unique blend of axial and radial flow processes. The technique involves a rotor with blades that accelerate the air after which it is circulated via the system by a fixed housing.

Q2: Are mixed flow fans energy efficient?

A2: While the exact level of efficiency will depend on particular model and usage factors, in general, mixed flow fans are known to have better energy efficiency than traditional centrifugal or axial fans. This is because they can provide high pressure at low power consumption.

Q3: Can a mixed flow fan handle particulate matter?

A3: Unlike some other types of fans, mixed flow fans have close tolerances between the wheel and housing which can allow them to handle a certain level of particulate matter. However, if the housing is particularly tight then this could cause a build-up of dust inside the system. In this case, it might be better to use a centrifugal fan. Always consult the manufacturer's guidelines to determine the correct mixed flow fan for use with dust or particulate matter.

Q4: What type of motor is used in mixed flow fans?

A4: In most cases mixed flow fans will have an energy-efficient external rotor motor. However, the exact type of motor may vary according to the model and manufacturer. Usually the choice will be made in order to achieve optimal performance and energy efficiency.

Q5: What comes after the mixed flow fan in the system?

A5: Usually a high speed centrifugal fan will come after a mixed flow fan in a ventilation system. This is because centrifugal fans are well suited to handling high pressure and pushing air through filtration elements. However, always analyze the requirements of the system to ensure the best possible fans are used.