Design Optimization and Field Validation of Industrial Fans with CFD for Cement Production: Performance, Energy Savings, and Environmental Benefits

Abstract

This study presents a computational-experimental assessment of two industrial centrifugal fans used in cement production, focusing on aerodynamic optimization and energy efficiency validation. The first case concerns a Farin Kiln Filter Fan initially constrained by existing inlet duct geometry, which caused vortex formation, flow asymmetry, and a pressure loss exceeding 15%. CFD analyses identified major inlet vortices and asymmetric splitter loading, guiding a redesigned configuration with an expanded fan body (1982-2520 mm), an increased outlet width (1808-1858 mm), and a vortex breaker to stabilize inlet flow. CFD simulations indicated a flow rate of 601,241 m3/h, static pressure of 2200 Pa, and total pressure of 2580 Pa, achieving an 83% efficiency. Field validation confirmed a 34.4% reduction in shaft power, 30% decrease in torque, and 4% gain in efficiency, corresponding to 449 MWh/year energy savings and 180 t CO2/year emission reduction, assuming 8000 operational hours. The second case involves an Induced Draft (ID) Fan designed for 441,643 m3/h flow at 990 rpm. Transient CFD simulations using the SST k-omega model captured rotor-stator interaction and confirmed the effectiveness of the design revisions in suppressing swirl and flow separation. The optimized design achieved 8653 Pa static pressure, 9203 Pa total pressure, and 83% efficiency under design conditions. Field measurements showed a 26.2% drop in shaft power and 19.6% improvement in efficiency, yielding 2527 MWh/year energy savings and an estimated 1011 t CO2/year emission reduction. Overall, the CFD-guided redesign framework demonstrated strong alignment between simulations and field measurements, highlighting the method's practical relevance for improving fan performance and energy sustainability in industrial systems.