The mathematics for properly designing ventilation and emission control systems have been around for quite awhile, but studies of hundreds of systems show that many are wasting energy, while still lacking capacity to meet applicable codes and process objectives.
There's a lot of money on the table in operating costs for these systems. More than 40% of the energy consumed in most manufacturing plants is used to power fans, pumps and ventilators. In some cases, the annual operating costs of a system may actually exceed the initial capital cost within two years of installation. This represents a large part of the plant's operating costs in a year and can have a significant effect on profits. Opportunities for improvement reside in the air power equation. It is a simple mathematical representation of the flow through ventilation systems (measured in CFM or cubic feet per minute) and the resistance that these systems must overcome due to lengths of duct, number of elbows and air control devices like scrubbers or baghouses). The latter is measured in units of pressure and normally "w.g. or "H2O (inches water gauge).
Reasoning within the equation can be a tool to review where the savings can be found as can be seen below.
Power required for an air handling system is computed with the following factors:
1) Volumetric Flow Rate "Q", stated in ft3/min (cubic feet per minute)
2) Total Pressure (resistance due to friction in ducts, hoods and ΔP of control device, etc.) "TP' stated in inches of water ("H20)
3) Density factor of the gas being collected "df" (dimensionless),
4) Efficiency of the fan, "η" (dimensionless),
These are combined into the Air Power Equation:
Power (horsepower) = (Q) (TP) (df) over (n) (6356)
Small reductions in the numerator can have a significant cost impact. For example, a typical 20,000 CFM baghouse requires 60 or more horsepower for operation. A reduction of 1000 CFM with improved hood design, or reduction of 1 inch static pressure with an improved duct or baghouse system, can save as much as $4000 per year.
There are always limits on what can be done, however. The process may require acertain airflow or hooding arrangement, and that will dictate air volume. Adjustments to system pressure and fan efficiency may be better places to effect reductions.
System pressure is usually affected by two factors:
1) Hood and duct resistance as a function of velocities in the system and the inefficiencies of flow (poorly designed hoods, short radius elbows, branch entry angles greater than 45°, abrupt contractions, and elbows and other interferences at fan inlets and outlets ' called Fan System Effects, etc.)
2) Resistance across the emission control device. A baghouse that operates at a pressure drop of 8 inches H2O will require twice the power of a collector operating at 4 inches H20. However, the lower pressure drop collector may not provide the capture efficiency of the baghouse with higher pressure drop. Of course you can lower the pressure drop in a baghouse by adding filter area, but this means a larger housing. More important, baghouses often perform best at high pressure drops. The key is to minimize pressure drop while still meeting emission requirements. Excess static pressure just wastes power.
Here are some tips to help find that narrow range of safe and efficient operation.
1. Minimize Flow
Systems directly connected to a process source are inherently volume-limited, whereas systems that capture emissions with enclosures or hoods need to be optimized during the design process. Total enclosure of an emission source minimizes air flow and worker exposure. However, such enclosures can restrict visual observation of the process and hinder maintenance access.
Hoods that cannot be designed for total enclosure should be located as close to the source as possible. A side draft hood located twice the distance from the source can require as much as four times the exhaust volumetric flow rate as a total enclosure. Capture hoods for high-velocity emissions (from grinding, sawing, etc.) must be located so the opening is in the direct path of the dust, fume or mist. The American Conference of Governmental Industrial Hygienists publication Industrial Ventilation ' A Manual of Recommended Practice provides guidelines for good design of hoods, duct and similar equipment.
Other factors such as explosive limits for the gas being collected, moisture content (dew point) and heat content may influence the air volumetric flow rate requirements so there may be limits to the optimization.
2. Minimize Pressure
Pressure offers greater opportunities to reduce energy costs. A system with good airflow characteristics (duct velocities and sizes optimized), matched with the proper control device, pressure monitors and variable frequency drives, can help manage system pressure. Most bag houses or other collection devices will have varying pressure drops over the life of the system. Bags are generally more efficient at higher pressure drop, but then use more energy. Scrubbers, oxidizers and electrostatic precipitators tend to operate at more constant resistance. A good pressure monitoring system that controls system volumetric flow rate can save thousands of dollars every year on the operation of even medium sized systems. As variable frequency drives become less expensive they are now being found on many installations, especially systems of over 10,000 CFM.
Be mindful of duct inefficiencies and Fan System Effects (elbows at inlets and outlets, etc.). These shortcuts increase static pressure and operating costs for the life of the system. Short-radius elbows and system effects could add thousands of dollars per year in wasted power.
3. Control Density
Temperature, moisture, molecular weight, elevation and the absolute pressure in the duct or vessel affect the density of the transporting gas. A density change may affect the hardware requirements for the system. Evaporative cooling, for example, reduces volume, but the higher density air requires more power. This may be more than offset by reduced costs for smaller ducts, control devices and fans (as well as lower the value for volumetric flow rate in the equation). Cooler temperatures may also allow use of less expensive collectors, fans and peripheral devices.
4. Fan Efficiency
The design of the fan and its blade type can greatly affect efficiency and power requirements. Laboratory-measured peak fan efficiency may not be the most stable point of operation. If peak efficiency coincides with the peak of the pressure curve then there may be operational problems as volumetric flow rates vary with small changes in system pressure. The designer must consider both curves when selecting the best fan and operating point to optimize reliability and power usage. And fan type may dictate proper selection. Airfoil wheels, while more efficient, may not be a good choice when handling particulate-laden air.
The key to any design is proper fan selection. The figure by #2 above illustrates the importance of matching the fan to the system, as calculated. Any of the three improper matches waste power and produce unsatisfactory system performance.
Summary
The power equation identifies four main areas ' volumetric flow rate, pressure, density and fan efficiency ' that affect energy consumption. The challenge for industry is to operate in the narrow functional range that guarantees system effectiveness with minimum energy consumption. Attention to the Air Power Equation can help meet those goals.
The author of this piece, Gerry Lanham P.E., is president of KBD/Technic, Inc. based in Cincinnati, Ohio and part of the CECO family of companies. Known as "The Air Engineering Company," KBD specializes in industrial ventilation engineering, providing the latest and most advanced systems in air pollution control and ventilation technology. Services are offered through three specialized divisions: Design Engineering, Systems Analysis and Stack/Emissions Testing. For more information about the company visit http://www.cecoenviro.com/Technic or call 513-351-6200.
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