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

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 m 3 /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 CO 2 /year emission reduction, assuming 8000 operational hours. The second case involves an Induced Draft (ID) Fan designed for 441,643 m 3 /h flow at 990 rpm. Transient CFD simulations using the SST k–ω 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 CO 2 /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.