Reitz India Ltd.

,Hyderabad, India

5/31/2019
 Reitz India-20 years of German partnership

Reitz India Limited was established in 1998 as an Indo-German joint venture Company
with technical and financial collaboration of M/S Konrad Reitz Ventilatoren GmbH
Germany, leader in centrifugal technology in Europe. Since, its inception, Reitz India
has remained as a progressive organization offering tailor made solutions to its
customers thus earning its name as a leading fan company in India and abroad.
Reitz India’s Overseas companies

Reitz India Limited

Hyderabad., India

Reitz Middle East Reitz South East Asia

Dubai-Sharjah, UAE Singapore
 Fan Production facilities in India
Reitz India’s own facility –Area 9000 sq.m
Work force 180

Turbovent - Area 4,000 sq.m

Work force 120
Inside view of Reitz workshop

5/31/2019
CNC Spinning and Flanging Machine

5/31/2019
Manual Spinning Machine

5/31/2019
Flanging
Belmouth
Shroud Forming
Why Fans need wear protection?

Sulfur and other acidic

Solids like silica and Ceramic compounds like
traces and moisture
quartz in the form of alumina or corundum
make the surfaces
cement clinkers, fly-ash which are extremely
vulnerable for oxidation
or dust hard and abrasive.
and corrosion.

Results in

Accelerated Replacement
wear /downing of Parts
Frequent Repair
of the fan
Wear Protection

Fans designed by Reitz, manufactured by Reitz India

or the parent company Reitz, Germany, are tailored to
withstand wear and tear challenges of the Iron and
Steel industry

We carefully select materials and treatment for

optimum abrasion resistance

The surfaces likely to be affected by abrasion and

corrosion are reinforced adequately with wear
resistive coatings or liners or both.
 Wear and Tear of Industrial Fans

Abrasion and corrosion damage occur in process equipment like fans, conveyors and ducts

The degree of abrasion is decided by the type of particulates present and their relative
direction and magnitude of impingement.

The rotating parts of the impeller like the eye, the front and back plates and the blade
surfaces, as well as the static components like the casing surfaces and the duct walls are
thus damaged to a large extent.

Corrosion occurs when metal surfaces react with oxygen in the presence of acidic
moisture to form oxide layers.

These layers are then removed by physical erosion through the abrasive action of the
turbulent fluids along with the entrained solid particles, exposing the metal to fresh
corrosion
Reitz approach for resistance to wear and tear

The velocity of impingement is kept to as low a value as possible through

appropriate fan size and blade angle selection

Adequate coverage is given on these abrasion prone surfaces like the leading
edge zone where the relative velocities are the highest, the driving face as well as
on the back plate.

The coating material, usually an alloy of Chromium, Nickel, with addition of

Molybdenum, Vanadium and Manganese whenever required

A severely abrasive environment is protected by the use of partial wear liners and
requires resistant materials such as ceramic, Chromium carbide or Tungsten
carbide to protect the surfaces
 Retrofitting or the up-gradation of
equipment
Retrofit is a word used frequently in cement industries for
up - gradation of its equipment or plant. During
Retrofitting, we look at the past performance of the fan
and then upgrade the equipment with the help of various
techniques to achieve best performance.

Improving efficiency is the main criteria for retrofit and up

gradation of fans in countries like India, Asian countries,
Middle East, CIS countries, as well as North & South
American countries. We always look at minimal shut
down period, For example, only the change of impeller will
need around five days of shut down; whereas change of
complete fan takes longer days may be 15 to 30. Since
the working fan is an earning fan, this short shutdown
alongwith retrofit period is another way cost - effective
solution to repair machinery and ensure its longevity.
 Retrofitting at Reitz India

Situation 1: The existing fan is not an efficient one

perhaps due to difference between design and actual
parameters. Retrofitting helps with little modification
in impeller, by trimming or by tipping, that gap can
be closed with minimum expenditure.

Situation 2: If solution 1 doesn’t suffice then to meet

the expected requirement of flow and pressure, the
old impeller is replaced with a new one. This way, the
investment required and the payback period will be
minimum.

Situation 3: If changing of just the impeller is not

enough, we will retrofit it with a completely new fan by
mounting the same on existing foundation.
 TRIMMING OR TIPPING OF
IMPELLER
Techniques using the method of trimming or tipping of impeller to change the
performance of fan are widely used.

• Due to trimming of impeller blades or increasing the impeller effective diameter by

tipping the blades, disturbs the geometrical similitude and that’s why, fan laws or affinity
laws are not applicable for recalculation of parameters when this method is employed.

• With trimming or tipping the impeller, change in flow, pressure and power, generally,
follow the same proportions, which are applicable for change in speed. That means,
relation between change in impeller diameter and that of flow, pressure and power will
be

– Change in flow is directly proportional to change in impeller diameter.

– Change in pressure is directly proportional to (change in impeller diameter) 2
– Change in power will be directly proportional to (change in impeller diameter) 3
 TRIMMING OR TIPPING OF
IMPELLER

• If the change in impeller diameter is restricted to smaller extent, then

change in efficiency may be considered as negligible.

• Since the fan is a low speed machine, trimming or tipping can be done to a
greater extent to avail appreciable change in flow and pressure, without
appreciable loss in efficiency. As a thumb rule, we can always consider that
10% change in impeller diameter is always possible.
 TRIMMING OR TIPPING OF
IMPELLER

There is a relation with

specific speed and
change in impeller
diameter and graphical
presentation of the
same is furnished
hereunder.
TRIMMING OR TIPPING OF
IMPELLER
Specific speed calculation

Specific speed Ns = 3.65 N X √Q /(H)3/4

Where
N = fan rpm
Q = flow rate m3/s
H = fan head in meters at 1.2 Kg/m3 density.

Various fan types have following Ns values:

Centrifugal : 40-300
Axial : 600-1200
 REPLACEMENT OF OLD IMPELLER
WITH A NEW ONE

1. It is well understood that the design of impeller is main criteria for performance of fan.
The role of fan casing is to carry the flow to the required destination. That’s why,
while replacing the old impeller, we follow the following procedures.

a. To collect the required performance of the existing fan viz.,

• Actual flow rate.

• Actual system resistance at fan inlet and outlet.
• Gas temperature at fan inlet.
• Gas density at fan inlet.
• Site altitude.
 REPLACEMENT OF OLD IMPELLER
WITH A NEW ONE

Based on the above parameters, we are designing the impeller from the proven design,
keeping the impeller diameter near to the existing fan impeller size, so that impeller can
be inserted in the existing fan casing without any modification. If, for any reason, the
designed diameter of the retrofitted impeller is bigger and if it is difficult to place the
impeller in existing fan casing, then we opt for modification of the existing fan casing at
its throat portion, keeping the cut off clearance at required level. With our past
experience, we have found that cut off clearance (cut off clearance means, minimum
clearance between fan impeller and casing – please refer the enclosed sketch) may vary
between 4.5% and 21% depending on flow and pressure combination.
 REPLACEMENT OF OLD IMPELLER
WITH A NEW ONE
2. The role of inlet cone is also very important for fan performance. That’s why, all the
retrofitted impellers will accompany the matching inlet cone.

3. To keep the expenditure as well as down time minimum, it is our endeavour to keep all
the existing components unchanged to maximum possible extent. That’s why, for this
technique, we look for change of impeller, inlet cone and shaft only, whereas other
components will remain unchanged, until and unless, the new impeller is demanding
bigger bearings or coupling.

4. Again, while retrofitting, we look for use of existing coupling and motor also, provided
the required parameters permit to use them. In India and also in Middle East and South
East Asian countries, we have carried out retrofit of several fans in cement / steel
industries in similar fashion i.e. by replacing the old impeller with a new one with
matching inlet cone and shaft and our success rate is 100%. For your reference, we are
furnishing the performance data of various fans in India, Indonesia, Malaysia and Brazil.
 REPLACEMENT OF OLD FAN WITH A NEW ONE ON
EXISTING FOUNDATION

1. This is the costliest proposal for retrofit and generally, it is the last option to be chosen.

2. In cement industries, up - gradation of various equipments as well as enhancement of

plant capacity is order of the day. If someone is quite optimistic and plans to upgrade the
plant capacity to maximum possible extent, then the change of fan may be a necessity.
Also, in some cases, due to change in process requirement, change of design of
impeller is also necessary to ascertain trouble free mechanical operation. In above
cases, complete change in fan may be required and one has to opt for the same.

3. As per our past experience, some fans in cement industries need a special care while
designing the impellers.
 REPLACEMENT OF OLD FAN WITH A NEW ONE ON
EXISTING FOUNDATION

4. For example, following cares are needed while selecting the fans in cement
industries.
– Cooler compartment fans: Since these fans are handling atmospheric air and
now-a-days, cement manufacturers are able to keep the cooler region dust free, any
design of impeller will be suitable for this application. However, with our past
experience, we avoid using aerofoil bladed impellers.

– Cooler ESP Fan: Though this fan is handling hot gases and with clinker dust, still
any design of impeller (except aerofoil) will be suitable for this application. In this
case, to get better life from impeller, it is necessary to armour the impeller on wear
prone areas.
 REPLACEMENT OF OLD FAN WITH A NEW ONE ON
EXISTING FOUNDATION

– Preheater Fan: The design of this impeller and fan is little tricky one. Though dust
handled by this fan is mild in nature, still behaviour of dust varies from plant to plant.
That’s why, depending on the feed back from our customer, we design the impeller
with/without armouring.

But since the fan is handling lot of dust, one has to design the impeller in such a
way that accumulation of dust on impeller blades is avoided. This can be done by
keeping the blade angle above 40 degrees. For your information, more the blade
outlet angle means impeller is having better property to clean its blades on its own.
But, increase in blade angle also means surrendering the efficiency to some extent.
Being big fan, optimization is needed.
 REPLACEMENT OF OLD FAN WITH A NEW ONE ON
EXISTING FOUNDATION

We have feedback from various customers that preheater fan is prone to

vibration, due to uneven accumulation of solid dust layer on impeller blades as
well as on other components of the impeller and in turn, the impeller rotates with
higher unbalance. After investigation, it was found that this type of accumulation
is due to some chemical reaction and not avoidable. This may be minimized by
reducing the velocity of dust inside the impeller. That means, designing the
impeller at lower speed will be better option to minimize the problem.

– Raw mill fan / Raw mill exhaust fan : In this case, blade outlet angle is the prime
criteria while designing the impeller. Again, since raw mill fan is handling lot of
dust and the dust may be abrasive, it is necessary to protect the impeller against
wear and tear and a suitable liner has to be selected for its protection. We are
using various options as protection against wear and tear.
Advantages of Retrofitting using
Reitz Fans
Increase reliability

Save cost

Better performance

Improve fuel efficiency

Reduce emissions

Replace obsolete internals

Increase productivity of the plant

Help the Environment

Retrofitting Projects – Few Examples
Raw Mill Fan - Star Cement Co. LLC, RAK –
U.A.E

Components replaced : Impeller, Shaft & Inlet Cone

Reason for retrofitting : Improving Efficiency & Increasing Capacity
Existing Fan Make: Flakt

Before Retrofitting After Retrofitting

Flow 646,322 m3/Hr 660,960 m3/Hr

Static Pressure 1280 mm WG 1204 mm WG

Power 2907 kW 2520 kW

Fan Speed 980 rpm 980 rpm

Efficiency 77.5% 86.0%
Kiln ESP Fan - Ultratech Cement

5/31/2019
 Kiln ESP Fan - Ultratech Cement
Components replaced : Impeller, Shaft & Inlet Cone
Reason for retrofitting : Improving Efficiency, power saving increasing capacity
Existing Fan Make : FLS

Before Retrofitting After Retrofitting

Flow 6,50,000 m3/Hr 738,000 m3/Hr

Static Pressure 140 mm WG 250 mm WG

Power 413 kW 646 kW

Fan Speed 300 rpm 365 rpm

Efficiency 60 % 77.8 %
Bag House Fan - Holcim Lakheri

5/31/2019
 Bag House Fan – Holcim Lakheri

Components replaced : Impeller, Shaft & Inlet Cone

Reason for retrofitting : Improving Efficiency & Increasing Capacity
Existing Fan Make : ABB

Before Retrofitting After Retrofitting

Flow 300,000 m3/Hr 330,000 m3/Hr

Static Pressure 300 mm WG 270 mm WG

Power 448kW 309 kW

Fan Speed 945 rpm 980 rpm

Efficiency 54.8 % 78.5 %

Cooler Vent Fan - JK Lakshmi
 Cooler Vent Fan JK Lakshmi
Components replaced : Impeller, Shaft & Inlet Cone
Reason for retrofitting : Improving Efficiency & Increasing Capacity
Existing Fan Make: Andrew Yule

Before Retrofitting After Retrofitting

Flow 2,45,000 m3/Hr 4,66,000 m3/Hr

Static Pressure 330 mm WG 172 mm WG

Power 367 kW 297 kW

Fan Speed 985 rpm 980 rpm

Efficiency 60 % 73 %
Cooler ESP Fan- Ultratech Cement

Components replaced : Impeller, Casing & Inlet Cone

Reason for retrofitting : Power Saving and Increasing Capacity
Existing Fan Make : FLS

Before Retrofitting After Retrofitting

Flow 780,000m3/Hr 780,000 m3/Hr

Static Pressure 150 mm WG 180 mm WG

Power 501 kW 474 kW

Fan Speed 500 rpm 509 rpm

Efficiency 63.5 % 80.7 %
Waste Gas Fan - India Cement Ltd

Components replaced : Impeller, Casing & Inlet Cone

Reason for retrofitting : Improving Efficiency
Existing Fan Make : Andrew Yule

Before Retrofitting After Retrofitting

Flow 414,000m3/Hr 414,000 m3/Hr

Static Pressure 900 mm WG 900 mm WG

Power 1463 kW 1424 kW

Fan Speed 950 rpm 950 rpm

Efficiency 69.4 % 77.26 %
Cooler ESP Fan - India Cement Ltd.,
Cooler ESP Fan- India Cement Ltd.,

Components replaced : Impeller, Shaft & Inlet Cone

Reason for retrofitting : Improving Efficiency
Existing Fan Make : Batliboi

Before Retrofitting After Retrofitting

Flow 591,000 m3/Hr 732,960 m3/Hr

Static Pressure 80 mm WG 150 mm WG

Power 390 kW 428 kW

Fan Speed 600 rpm 678 rpm

Efficiency 33.0 % 70.0 %
Cooler ESP Fan - Orient Cement
Cooler ESP Fan - Orient Cement

Components replaced : Impeller, Shaft & Inlet Cone

Reason for retrofitting : Improving Efficiency
Existing Fan Make : Andrew Yule

Before Retrofitting After Retrofitting

Flow 294,000 m3/Hr 390,000 m3/Hr

Static Pressure 70 mm WG 100 mm WG

Power 190 kW 135 kW

Fan Speed 710 rpm 745 rpm

Efficiency 29.5 % 78.7 %
Retrofit Projects - Testimonials

5/31/2019
5/31/2019
5/31/2019
Reitz India Fans – Few Testimonials

5/31/2019
5/31/2019
5/31/2019
5/31/2019
5/31/2019
5/31/2019
 The picture can't be display ed.

5/31/2019
5/31/2019
 Thank you

5/31/2019