Fan Systems

Fan systems are widely used in industry for a variety of purposes – including material handling, ventilation, heating and cooling, and flue gas treatment. High dependence of plant production on the performance of the fan systems, often lead to fan systems being designed conservatively, with more capacity than what is needed. This increases operating costs of the system, and in fact negatively impact reliability.

The cost-effective operation and maintenance of a fan system requires attention not only to the needs of the individual pieces of equipment, but also to the system as a whole. An analysis of both the supply and demand sides of the system and their interaction with one another is necessary – essentially shifting the focus from individual components to total system performance.

Fan SystemsSchematic

Fan SystemsTechnologies & Measures

Technology or MeasureEnergy Savings PotentialCO2 Emission Reduction Potential Based on LiteratureCostsDevelopment Status
Correct Fan Size/Type to Increase Efficiency

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 18% for low efficiency base cases;
• 11% for medium efficiency bas cases;
• %2 for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010):

  Final (GWh/y)  Primary (TJ/y)
US 2418 26550
Canada 444 5528
EU 1705 16026
Thailand 180 1810
Vietnam 82 1176
brazil 347 3873

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 1458
Canada 221
EU 743
Thailand 93
Vietnam 41
brazil 51

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $8000  for S < 37 kW;
• US $15000 for 37 kW < S < 75 kW;
• US $25000 for 75 kW < S < 150 kW;
• US $50000 for 150 kW < S < 375 kW;
• US $100000 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 81.9
Canada 79.9
EU 89.8
Thailand 56.4
Vietnam 56.5
brazil 53.9

Commercial
Use of Efficient Drives

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 4.5% for low efficiency base cases;
• 2.5% for medium efficiency bas cases;
• 0.5% for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010):

  Final (GWh/y) Primary (TJ/y)
US 812 8913
Canada 149 1856
EU 573 5380
Thailand 84 844
Vietnam 38 548
brazil 153 1712

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 490
Canada 74
EU 249
Thailand 43
Vietnam 19
brazil 22

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $200  for S < 37 kW;
• US $750 for 37 kW < S < 75 kW;
• US $1000 for 75 kW < S < 150 kW;
• US $N/A for 150 kW < S < 375 kW;
• US $N/A for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 52.9
Canada 52.7
EU 49.6
Thailand 7.6
Vietnam 7.8
brazil 13.2

Commercial
Remove Scale/Sediment from System Surfaces

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 2.5% for low efficiency base cases;
• 1.5% for medium efficiency bas cases;
• 0.5% for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010):

  Final (GWh/y) Primary (TJ/y)
US 520 5711
Canada 95 1189
EU 367 3448
Thailand 51 516
Vietnam 23 334
brazil 94 1046

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 313
Canada 48
EU 160
Thailand 26
Vietnam 11
brazil 14

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $100  for S < 37 kW;
• US $110 for 37 kW < S < 75 kW;
• US $135 for 75 kW < S < 150 kW;
• US $580 for 150 kW < S < 375 kW;
• US $1090 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 22.5
Canada 22.2
EU 25.8
Thailand 6.1
Vietnam 6.1
brazil 7.4

Commercial
Isolate Flow Paths to Non-essential or Non-operating Equipment

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 12%for low efficiency base cases;
• 8% for medium efficiency bas cases;
• 2% for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010):

  Final (GWh/y) Primary (TJ/y)
US 3291 36145
Canada 604 7526
EU 2322 21817
Thailand 356 3576
Vietnam 163 2323
brazil 595 6640

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 1984
Canada 300
EU 1012
Thailand 184
Vietnam 80
brazil 87

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $1150  for S < 37 kW;
• US $2250 for 37 kW < S < 75 kW;
• US $2625 for 75 kW < S < 150 kW;
• US $3550 for 150 kW < S < 375 kW;
• US $4700 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 11.3
Canada 10.8
EU 13
Thailand 3.1
Vietnam 3.1
brazil 4.0

Commercial
High Efficiency Motors for Fan Systems

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 5% for low efficiency base cases;
• 3% for medium efficiency bas cases;
• 1% for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010):

  Final (GWh/y) Primary (TJ/y)
US  601 6604
Canada 110 1375
EU 425 3986
Thailand 56 569
Vietnam 26 369
brazil 85 952

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 362
Canada 55
EU 185
Thailand 30
Vietnam 12
brazil 12

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $2200  for S < 37 kW;
• US $4500 for 37 kW < S < 75 kW;
• US $8000 for 75 kW < S < 150 kW;
• US $21000 for 150 kW < S < 375 kW;
• US $35000 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 104.9
Canada 102.9
EU 112.5
Thailand 56
Vietnam 56
brazil 64.6

Commercial
Correcting Damper Problems

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 5% for low efficiency base cases;
• 3% for medium efficiency bas cases;
• 1% for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010): 

  Final (GWh/y) Primary (TJ/y)
US 1448 15902
Canada 266 3311
EU 963 9055
Thailand 127 1283
Vietnam 58 833
brazil 288 3215

 

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010):

US 873
Canada 132
EU 421
Thailand 66
Vietnam 28
brazil 42

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $200  for S < 37 kW;
• US $250 for 37 kW < S < 75 kW;
• US $300 for 75 kW < S < 150 kW;
• US $400 for 150 kW < S < 375 kW;
• US $450 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 9.5
Canada 9.0
EU 11.6
Thailand 4.2
Vietnam 4.1
brazil 3.7

Commercial
Efficient Flow Regulation- Variable Speed Drives for Fan Systems

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 35% for low efficiency base cases;
• 20% for medium efficiency bas cases;
• 8% for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010):

  Final (GWh/y) Primary (TJ/y)
US 5487 60245
Canada 1007 12543
EU 3870 36363
Thailand 507 5098
Vietnam 232 3311
brazil 927 10341

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 3306
Canada 501
EU 1688
Thailand 263
Vietnam 114
brazil 135

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $8000  for S < 37 kW;
• US $15000 for 37 kW < S < 75 kW;
• US $30000 for 75 kW < S < 150 kW;
• US $80000 for 150 kW < S < 375 kW;
• US $150000 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 65.6
Canada 64.8
EU 69.7
Thailand 35.3
Vietnam 35.3
brazil 37.2

Commercial
Predictive Maintenance Program

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 3% for low efficiency base cases;
• 2% for medium efficiency bas cases;
• 1%for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010):

  Final (GWh/y) Primary (TJ/y)
US 674 7398
Canada 124 1540
EU 475 4465
Thailand 59 593
Vietnam 27 386
brazil 108 1204

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 406
Canada 61
EU 207
Thailand 31
Vietnam 13 
brazil 16

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $260  for S < 37 kW;
• US $260 for 37 kW < S < 75 kW;
• US $1000 for 75 kW < S < 150 kW;
• US $2000 for 150 kW < S < 375 kW;
• US $5000 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 26.9
Canada 26.6
EU 28.2
Thailand 7.0
Vietnam 6.9
brazil 9.5

Commercial
Improve Airflow at Fan Inlets & Outlets

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 10% for low efficiency base cases;
• 5% for medium efficiency bas cases;
• 1%for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010):

  Final (GWh/y) Primary (TJ/y)
US 1833 20122
Canada 336 4190
EU 1293 12146
Thailand 226 2273
Vietnam 104 1477
brazil 413 4611

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 1105
Canada 167
EU 564
Thailand 118
Vietnam 51
brazil 60

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $1000  for S < 37 kW;
• US $2000 for 37 kW < S < 75 kW;
• US $3000 for 75 kW < S < 150 kW;
• US $5000 for 150 kW < S < 375 kW;
• US $10000 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 16.7
Canada 16.2
EU 18.5
Thailand 5.4
Vietnam 5.4
brazil 5.9

Commercial
Fixing Leaks and Damaged Seals

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 5% for low efficiency base cases;
• 3% for medium efficiency bas cases;
• 2% for high efficiency base cases.

Electrical and primary energy savings potential of this technology for different countries is estimated as following (UNIDO, 2010):

  Final (GWh/y) Primary (TJ/y)
US 1367 15002
Canada 251 3123
EU 1022 9598
Thailand 173 1743
Vietnam 79 1132
brazil 317 3536

Total emission reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 823
Canada 125
EU 445
Thailand 90
Vietnam 39
brazil 46

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $175  for S < 37 kW;
• US $325 for 37 kW < S < 75 kW;
• US $600 for 75 kW < S < 150 kW;
• US $1375 for 150 kW < S < 375 kW;
• US $2650 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following (UNIDO, 2010):

US 10.6
Canada 10.4
EU 11.2
Thailand 2.9
Vietnam 2.9
brazil 3.5

Commercial

Fan Systems Publications

Improving the Energy Efficiency of Industrial Equipment

This Discussion Paper sets out ideas for improving the energy efficiency of new industrial equipment such as motor-driven systems, that is, electric motors connected to equipment such as pumps and fans, and gas fuelled equipment such as boilers. The document is prepared by a a joint initiative of Australian, State and Territory and New Zealand Governments, titled Equipment Energy Efficiency Program

Page Number: 

25-32

Fan Systems Tools

Fan System Assessment Tool

The Fan System Assessment Tool (FSAT) is a free online software tool that helps industrial users quantify energy use and savings opportunities in industrial fan systems. Use FSAT to understand how well your fan systems are operating, determine the economic benefit of system modifications, and establish which options are most economically viable when multiple opportunities exist for system modification (US DOE Advanced Manufacturing Office, 2012).