SELECTING THE RIGHT PREHEATER FAN AND DRIVE

By:
Victor J. Turnell, P.E.
Process Engineer
Penta Engineering Corporation

ABSTRACT

The preheater fan is a key piece of equipment in any cement plant. In many cases, this fan limits clinker
production by limiting the gas flow through the preheater. It consumes about 10 percent of the total
power used at a plant. Large gas flows, high gas temperatures, high static pressures, and the potential for
material abrasion and buildup on the impeller makes the fan design for this application complex.
Selecting the optimum fan and drive requires careful consideration of each application and of all design
options available.
Preheater fans proposed by vendors vary significantly. For example, some vendors propose single width,
single inlet type fans, while others propose double width, double inlet type fans. Some vendors propose
radial blade fans while others propose backward curved or airfoil fans. The degree of wear protection
differs significantly from one vendor to another.
This paper discusses various topics that are important when selecting a fan and drive for this application.
Topics discussed are: the process requirements and conditions, the options available for fans and drives,
the advantages and disadvantages of fans and drives available, and the impacts of each fan and drive on
capital and operating costs.

INTRODUCTION

The tendency today is to build cement plants with larger production capacities to minimize capital and
operating costs. Such plants are typically designed to use preheater exhaust gases in a vertical roller mill
for raw material drying. Preheater fans in these applications are designed for large gas volumes at high
gas temperatures and static pressures. Several variables must be considered while selecting a fan for
this application: wear caused by the dust loading in the preheater gases, material buildups on the fan
impeller, drive starting characteristics, drive power factor, and drive efficiency.

OPERATING CONDITIONS

Typically, preheater exhaust gases pass through a gas-conditioning tower before entering the preheater
fan. From there the gases go to either the roller mill or directly to the main dust collector before being
vented to the atmosphere. The preheater fan creates the induced draft that pulls gases through the
preheater and conditioning tower. During times when the raw mill is not operating, water is sprayed in the
conditioning tower to cool the gases to less than 200C (400F). During times when the roller mill is
operating, little or no water is sprayed in the conditioning tower. At this point, the gas temperature
entering the preheater fan ranges from 300 to 425C (570 to 800 F). Preheater fans are required to
generate static pressures in the range of 500 to 1000 mm WG (20 to 40 in WG) with large gas flows. The
3
3
dust concentration entrained in the preheater exit gases ranges from 20 to 60 g/m (9 to 18 grains/ft ) of
gas and will impact the recommended fan design.

4
4.1

GENERAL DESIGN PRACTICE

Process Considerations

The first step in selecting a preheater fan is to determine the expected operating conditions such as the
gas flow rates, temperatures, static pressures, and dust loading. These operating conditions are usually
determined using mass and energy balances, empirical equations, and assumptions based on past
experiences.
To ensure that the preheater fan does not limit the pyroprocess system to a level below the design
capacity, it is prudent to design the fan with a safety factor. One of the more commonly applied safety
2
factors is 115 percent of the expected gas flow at 132 percent (1.15 ) of the expected static pressure
requirement.

4.2

Mechanical Considerations

The design must minimize maintenance requirements caused by abrasion and material buildup on the
impeller. Several technical papers are available that provide potential solutions to buildup problems. One
paper, Cement Plant Preheater Fan Build-up Control, (Gutzwiller 1991) published in the IEEE
Transactions On Industry Applications provided recommendations which are summarized below.

Reduce the gas operating temperature to below 250C (482F).

Design the impeller for the smoothest possible flow lines to reduce the impact energy as dust
particles strike the fan blades. Smooth flow lines are best achieved by using backward curve and
airfoil shaped impellers.

Design the fan to minimize the gas and dust particle velocity at the inlet of the fan impeller. This can
be achieved by selecting double inlet fans instead of single inlet fans, and selecting larger diameter
and lower speed fans instead of smaller diameter and higher speed fans. If possible, the peripheral
speed at the impeller inlet opening should be limited to 76 m/s (15,000 ft/min), and the inlet velocity
should not be in excess of 38 m/s (7500 ft/min).

Oversize the impeller shaft, bearings, and supports to reduce the sensitivity to unbalance.

In general, the gas temperature entering the preheater fan is dictated by the roller mill requirements for
raw material drying; therefore, lowering the gas temperature to below 250C may not be possible.

4.3

Example of Fan Selection Process Specifications

The examples used throughout this paper are based on a preheater fan designed for a 4500 mt/d clinker
pyroprocessing system with a modern 5-stage preheater and an inline vertical roller mill for raw grinding.
The preheater fan is assumed to be located after the preheater conditioning tower.
Table 1 contains both expected and designed gas flow conditions for the example of the preheater fan
with the raw mill operating and not operating. The fan design conditions are based on 115 percent of the
expected gas mass flow at 132 percent of the expected static pressure requirement. In all cases, the
fans are designed with double widths, double inlets, and a maximum speed of 900 rpm.

Table 1

Description
Raw Mill Operating
Inlet gas flow
Inlet static pressure
Temperature
Inlet Density
Power at 100% fan
and drive efficiency
Raw Mill Not
Operating
Inlet gas flow
Inlet static pressure
Temperature
Inlet density
Power at 100% fan
and drive efficiency

5
5.1

Preheater Fan Operating Parameters

Metric Units
U.S. Customary Units
Units
Expected
Design
Units
Expected
Design
m /h
mm WG
C
3
kg/m
kW

700,000
-790
310
0.61
1508

830,000
-1040
310
0.59
2357

acfm
in WG
F
3
lb/ft
hp

410,000
-31
590
0.038
2021

488,000
-41
590
0.037
3160

630,000
-790
210
0.72
1346

740,000
-1040
210
0.70
2104

acfm
in WG
F
3
lb/ft
hp

370,000
-31
410
0.045
1800

435,000
-41
410
0.044
2820

m /h
mm WG
C
3
kg/m
kW

FANS
Fan Impeller Design Options

Six basic types of centrifugal fans are available which are distinguished by their impeller configurations:
radial blade, radial tip, backward incline, backward curved, forward curved and airfoil. Forward curved
impeller designs are not considered for the preheater fan because of its potential for material buildup;
therefore, it will not be considered further in this paper. Figure 1 shows the different impeller designs.
Each impeller type is generally more suitable than the other types for a particular application. There are
examples of preheater fans with each of the above impeller types that operate successfully.
Radial blade and radial tip fans are used primarily for gases heavily laden with dust applications because
they are simple to repair in the field (AMCA publication 201-90). These fans are considered the best in
resisting material buildup; however, in preheater fan applications backward curved and airfoil type
impellers are recommended. (Gutzwiller 1991)
Backward inclined and backward curved fans are used where airfoil blade designs are not acceptable
because of a corrosive or erosive environment. (AMCA publication 201-90)
Airfoil fans are used primarily for clean gas applications. (AMCA publication 201-90) The problem
commonly associated with airfoil fans in dust-entrained gas applications is the potential for material to
enter the inside of the airfoil and create vibration problems. This potential problem can be minimized in
the design, fabrication, and maintenance of the fan. It is important to note that several cement plants do
have airfoil fans operating successfully in preheater applications.

Figure 1 Fan Impeller Types

Table 2 provides some general information about the different fan impeller types.
Table 2
Description
Efficiency
Peak efficiency

5.2

Radial
Blade
Lowest
72%

Fan Impeller Types

Radial Tip
Backward
Incline
Lower
Good
75%
80%

Backward
Curved
Higher
84%

Airfoil
Highest
90%

Example of Fans

The Table 3 below compares some general data and capital costs for fans with different impeller types.
The data and costs are based on operating conditions of the example in Section 4.3. Following the table,
Graph 1 compares the fan performance of each fan type for the design condition with the raw mill
operating. At different flow and pressure combinations, the relative performance may be different. For
example, the efficiency of the airfoil fan may be higher than shown in Table 3.

Table 3
Description
Maximum efficiency
Wheel diameter
Wheel inertia
Fan cost

Fan General Design Data and Costs

Units
Radial Blade/
Backward
Radial Tip
Incline
76
73
%
3,460
3,510
mm
2
7,500
10,800
kg-m
US$
332,000
329,000

Backward
Curved
80
3,650
8,700
331,000

Airfoil
83
3,640
10,700
343,000

The difference in costs between the various types of fan impellers is not substantial; therefore, the
recommended fan impeller types for typical preheater fan applications are backward curved or airfoil type
fans.

Graph 1, Comparison of Fan Performance

1,400

Pressure (mm wg)

1,200
Work
Point

1,000
800

Backward
Inclined

600
Backward
Curved

400

Radial
Tip

200
Airfoil
Point

0
0

500,000

1,000,000

1,500,000
3

2,000,000

Volume (m /h)

2,500,000

3,000,000

6
6.1

FLOW CONTROL
Flow Control Options

Two options are available for flow control. One option uses a fixed speed fan with a damper in the
system while the other adjusts the fan speed. Figure 2 shows the different dampers and their locations in
the fan system.
Dampers provide control of gas flow by adjusting the systems static pressure loss. Parallel-blade inlet
box dampers, variable inlet vanes, and radial inlet dampers provide an advantage as compared to the
other damper types available. As the parallel-blade inlet box damper, variable inlet vane, and radial inlet
dampers are closed, they pre-spin the gases entering the fan resulting in a more efficient fan performance
curve. Variable inlet vanes and radial inlet dampers are not used in preheater fan applications because of
the potential for material buildup on them.
Outlet dampers cost about the same as inlet dampers; however, outlet dampers are not as efficient. For
this reason, outlet dampers are usually not considered for preheater fan applications.
Opposed-blade inlet box damper, parallel-blade inlet box damper, and variable speed control are the flow
control options typically considered for preheater fans.

Figure 2 Fan Damper Control Options (Air Movement And Control Association, Publication 201-90, Figure
10-1)

6.2

Example of Different Flow Control Methods

Table 4 provides the static efficiencies for the different operating conditions described in the example of
Section 5.2.
Table 4
Description
Airfoil
Raw mill on-design
Raw mill on-expected
Raw mill off-design
Raw mill off-expected
Backward Curved
Raw mill on-design
Raw mill on-expected
Raw mill off-design
Raw mill off-expected
Backward Incline
Raw mill on-design
Raw mill on-expected
Raw mill off-design
Raw mill off-expected
Radial Blade/Radial Tip
Raw mill on-design
Raw mill on-expected
Raw mill off-design
Raw mill off-expected

Fan Static Efficiency (%)

Opposed Blade Inlet
Parallel Blade Inlet
Box Damper
Box Damper

Variable Speed
Control

82.7
69.1
58.3
47.7

82.7
72.3
63.6
53.6

82.7
83.1
83.0
83.1

80.4
66.7
56.2
45.9

80.4
71.4
62.1
51.4

80.4
80.7
80.6
80.7

75.7
62.6
52.5
42.5

75.7
67.5
59.6
50.3

75.7
75.3
75.5
75.2

72.6
61.6
51.8
42.0

72.6
62.5
54.2
46.6

72.6
72.4
72.6
72.5

The most energy efficient method is variable speed control, followed by the parallel-blade inlet box
damper, and then by the opposed-blade inlet box damper.
There is little or no cost difference between the parallel and opposed blade dampers; therefore, if
selecting a fixed speed fan, the recommended damper for typical preheater fan applications is a parallel
blade damper.

7
7.1

FAN DRIVES
Fan Drive Options

Several options exist for fixed speed fans: AC squirrel cage induction motors, synchronous motors,
wound rotor motors, and synchronous induction motors. The options for variable speed fans include the
following: AC squirrel cage induction motor with a fluid coupling, DC motor and drive, and AC variable
frequency drive with an AC squirrel cage induction motor.
When selecting a preheater fan drive system, several factors must be considered such as the available
starting torque and inertia, the effect of the motor current inrush on the plants electrical system, the drive
efficiency, and the capital and maintenance costs.
Designing an AC squirrel cage induction motor capable of starting large inertia loads typical of preheater
fans can be difficult or impossible. Starting currents for these motors are between six and seven times the
normal full load current. This inrush of current causes severe heating of the stator and rotor. Excessive
heat can damage the motor windings, which would result in premature motor failure. Care must be taken
not to exceed the thermal limit of the motor. An AC squirrel cage induction motor can be customized by
adjusting the rotor resistance to allow starting with loads greater than NEMA moment of inertia minimums.
The resistance of the rotor of a synchronous motor, unlike the rotor of an AC squirrel cage induction
motor, cannot be changed significantly to allow the starting of large inertia loads. This limitation often
prevents a standard synchronous motor from being used on a large fan application.
A wound rotor motor is an AC induction motor with a wound rotor that is connected to a variable
resistance. In the past, wound rotors had received criticism because of the banks of wound wire resistors
that were used as rotor resistance. These banks were subject to frequent failures and choppy starts as
the different values of resistance were sequenced during start. A modern wound rotor motor uses a liquid
rheostat, which provides continuous instead of stepped rotor resistance changes. The liquid rheostat is
also more reliable than stepped rotor resistances.
During the startup of a wound rotor motor, an electrolytic salt solution is pumped out of a tank that
contains the motor rotor electrodes.
The low level of electrolytic salt solution between the rotor
electrodes creates a high resistance that results in high starting torque for low starting current. In the
starting sequence of the motor, electrolytic salt solution is returned to the tank, raising the level of
electrolytic salt solution between the rotor electrodes and reducing resistance. Once the starting
sequence is completed, the rotor electrodes are shorted-out by a shorting contactor that reduces rotor
resistance to a minimum.
This motor has the best starting and operating characteristics from a rotor resistance standpoint. During
startup, the resistance is high resulting in lower current flow per unit torque supplied. During normal
operating conditions, the resistance is low resulting in better efficiency than during the startup.
Recently, the synchronous induction motor hybrid has been reintroduced as a fan drive option. This
motor starts as an AC induction wound rotor motor connected to an external rotor resistance. When
approaching synchronous speed, the external resistance is removed and a DC field is supplied to the
rotor causing the motor to operate as a synchronous motor. This motor can start large inertia loads and
then operate as a synchronous motor.
AC squirrel cage induction motors with fluid couplings were a common choice for fans in the past;
however, today they are not considered for variable speed fans because other methods to vary fan speed
exist that are more efficient at transferring power.
DC motors and drives were also common choice for fans in the past; however, they are difficult to
implement on large motor power applications. The commutating action of the armature limits the
armature voltage and results in a large current rating requirement. The losses associated with this large

current make the DC drive a poor choice for todays preheater fans. The DC drive has an efficiency profile
that is about the same as an AC variable frequency drive (VFD). The DC drive requires more
maintenance because of the brushes and commutator.
Table 5 provides typical operating limitations of motors.

Table 5
Description

Starting current
(percent of full
load current)
Power factor

Note:

AC Squirrel
Cage
Induction
Motor
600%

0.80 to 0.85
lag

Typical Operation Limits

Synchronous Wound Rotor
Motor
Motor

Synchronous
Induction
Motor

650%

150 to 200%

150 to 200%

1.00 to 0.80
lead

0.73 to 0.78
lag

1.00 to 0.80
lead

AC Variable
Frequency
Drive and
Motor
See the note
below
0.95 lag

Starting current is programmable and typically limited to the capacity of drive and motor.

Table 6 provides benefits of using a variable speed drive compared to using a fixed speed drive (ABB
Fan Group North America, November 2000).
Table 6
Benefits Of Using A Variable Speed Drive Versus a Fixed Speed Drive
Feature
Benefit
High efficiency
Reduced energy cost
Soft starting
Reduced stress on fan, motor, and coupling, resulting in
extended equipment lifetime
Reduced impact on the electrical supply network (low voltage
drop due to starting)
Elimination of problems with starting high inertia loads
Unlimited number of starts per hour
Lower audible noise
Improved working environment
Low fan erosion at lower speeds
Extended fan lifetime
Reduced maintenance costs
Ability to select a fan with maximum
Flexibility in design
efficiency at speeds other than
synchronous speed

7.2

Example Of Drives

For purposes of comparing the power transmission efficiency and capital cost of the different drives, the
fan from the example of Section 6.2 was selected.
Table 7 provides the expected efficiencies for different drive systems based on the fan systems in the
example of Section 6.2. This table does not consider power factor correction and the losses associated
with that correction. Table 8 provides an estimated cost of the different drives. This table does not
consider harmonic filtering that may be needed with the AC variable frequency drive.

Table 7
Typical Motor And Drive Efficiency At Full Load
Description
Units
Efficiency
Fixed Speed Motor efficiencies
AC squirrel cage Induction
%
96.6 (see the note below)
Wound Rotor
%
96.3
Synchronous Induction (1.0 power factor)
%
96.5
AC Variable Frequency Drive and AC Squirrel
Cage Induction Motor
99.0
%
Transformer efficiency
98.1
%
Drive efficiency
96.6
%
Motor efficiency
Effective efficiency
%
93.8
Note:

The efficiency of the AC squirrel cage induction motor depends on the rotor resistance of the
selected motor.

There is little difference in efficiency between three different fixed speed drives; therefore, the
recommended drive should be the one that has the lowest cost with the ability to start the fan while
satisfying the plants technical needs.

Table 8
Description

Transformer cost
Drive cost
Motor cost
Total cost

AC Squirrel
Cage
Induction
Motor
160,000
160,000

Drive Systems Costs (US$)

Synchronous Wound Rotor
Motor
Motor

247,000
247,000

240,000
240,000

Synchronous
Induction
Motor
435,000
435,000

AC Variable
Frequency
Drive and
Motor
78,000
235,000
145,000
458,000

VARIABLE SPEED VERSUS FIXED SPEED FANS

The following is a comparison of a variable speed drive and a fixed speed drive based on the fan systems
used in the example of Section 7.2.
8.1

Capital Costs

Table 9 provides the capital cost comparison between installing a fixed speed fan and damper versus
installing a variable speed fan with a variable frequency drive.
Table 9

Description
Fan
Damper
Transformer cost
Drive cost
Motor cost
Drive installation cost
Total cost
Cost difference
8.2

Variable Speed and Fixed Speed Fans

Capital Costs (US$)
Fixed Speed Fan and Damper
Variable Speed Fan with a
Variable Frequency Drive
331,000
331,000
not required
23,000
78,000
not required
235,000
not required
145,000
160,000
60,000
25,000
539,000
849,000
310,000

Power Consumption

Table 10 provides the power consumption comparison between installing a fixed speed fan and damper
versus installing a variable speed fan with a variable frequency drive.
Table 10
Power Consumption
Fixed Speed Fan and Damper Versus
Variable Speed Fan with a Variable Frequency Drive
Raw mill
Description
Units
Raw mill
Raw mill
off-design
on-design
onexpected
Power at 100% fan and drive
kW
2357
1508
2104
efficiency
Fixed speed fan with
damper
Total input power (kW)
kW
2823
2346
2853
Specific power consumption
kWh/mt
15.0
12.4
15.1
Variable speed fan with
variable frequency drive
Total input power
kW
2907
1855
2606
Specific power consumption
kWh/mt
15.4
9.8
13.8
Difference between the
power consumption of the
two fan controls
-84
491
247
Total input power
kW
-0.4
2.6
1.3
Specific power consumption
kWh/mt

Raw mill
offexpected
1346

2573
13.7

1677
8.9

896
4.8

8.3

Fan Operating Scenarios

Two operating scenarios will be considered. Scenario One assumes the preheater fan operates under the
expected conditions as shown in Table 10. This operating scenario occurs when the preheater fan is
not the bottleneck of the pyroprocess system. Scenario Two assumes the preheater fan operates under
the design condition as shown in Table 10. This operating scenario occurs when plant personnel
operate their kilns at the maximum possible capacity, which usually results in the preheater fan being the
bottleneck of the pyroprocess system.
For the cost analysis of the two scenarios, the following assumptions were made:

the kiln operates 8000 hours per year, equivalent to about 91 percent uptime
the raw mill operates 7200 hours per year, equivalent to about 90 percent of the time that the
preheater operates
the average power cost is US$0.05 per kWh consumed

In Scenario One, the power savings obtained by installing a variable speed instead of the fixed speed fan
is 491 kW when the raw mill is operating, and 896 kW when the raw mill is not operating. This results in a
potential annual savings in power costs of US$213,000, US$177,000 per year with the raw mill operating,
and US$36,000 per year with the raw mill not operating. The payback time for the additional capital cost
of installing the variable speed fan instead of the fixed speed fan is 1.5 years.
In Scenario Two, the power savings obtained by installing a variable speed instead of the fixed speed fan
is -84 kW when the raw mill is operating, and 247 kW when the raw mill is not operating. This results in a
potential annual loss in power costs of US$20,000, US$30,000 per year with the raw mill operating, and US$10,000 per year when with the raw mill not operating. The additional capital cost of the variable
speed fan versus the fixed speed fan is not justified in this operating scenario.
9

CONCLUSIONS

The difference in costs between the various types of fan impellers is not substantial; therefore, the
recommended fan impeller types for typical preheater fan applications are backward curved or airfoil type
fans.
There is little or no cost difference between the parallel and opposed blade dampers; therefore, if
selecting a fixed speed fan, the recommended damper for typical preheater fan applications is a parallel
blade damper.
There is little efficiency difference between the various fixed speed drives; therefore, the recommended
drive should be the one with the lowest cost and the ability to start the fan while satisfying the plants
other technical needs.
When purchasing a preheater fan, consideration should be given to the expected operation of the fan
and the safety factor applied to the fan design. As shown above, if the fan operates near its design
capacity, a variable speed-drive is not financially justifiable; however, if the fan operates significantly
below its design capacity, then a variable speed-drive is financially justifiable.

ACKNOWLEDGEMENTS
Mr. Jason R. Stoklosa at ABB Fan Group, Inc for providing information used to develop this paper.
ABB Motor Group for providing information used to develop this paper.

REFERENCES
Les Gutzwiller, Chief Engineer Robinson Industries, Inc.; H. Daniel Banyay, Manager Research Robinson
Industries, Inc.; Sidney M. Cohen, Director of Research and Development Fuller Company, Cement
Plant Preheater Fan Build-up Control, Published in the IEEE Transactions on Industry Applications, vol.
27, No. 3 May/June 1991.
ABB Fan Group North America, SCR Retrofits Provide Opportunity for Variable Speed Fans, published
in Power Engineering, November 2000, pages 82-86.
Air Movement And Control Association, Publication 201-90, Figure 10-1