Technical White Paper: Research on Centrifugal Fan Selection and Cost-Efficiency Optimization in the Chemical Industry
—A Case Study on the Application of Yutong FRP Anti-Corrosion Fans in New Energy Chemical Projects
Introduction
With the rapid development of the chemical industry and new energy composite materials, the emission of intermediate chemical gases has become a significant challenge. These complex environments are characterized by high temperatures, high pressures, and strong corrosiveness. Developing gas purification machinery capable of withstanding these specialized conditions is now a key focus for heavy-duty fan manufacturers.
Fiberglass-reinforced plastic (FRP) fans offer exceptional resistance to corrosion, acids, and alkalis. They provide the most effective anti-corrosion performance among all fan types. However, some enterprises hesitate to select them due to their higher initial costs compared to traditional carbon steel fans. This paper examines a project undertaken by Xinxiang Yutong Environmental Protection Blower Co., Ltd. (hereinafter referred to as “Yutong Blower”) for a leading new energy chemical enterprise. We explore strategies for fan selection and cost-efficiency optimization within the chemical industry.
Centrifugal Fan Selection for Extreme Operating Conditions
Lithium hexafluorophosphate is a crucial component for electrolytes in lithium-ion batteries. Its synthesis involves extreme conditions, including high/low temperatures and strong corrosiveness. Consequently, tail-gas fans require exceptional reliability for exhaust operations.
During the initial selection phase, technical debates emerged. Some on-site engineers argued that standard carbon steel fans were cost-effective enough to meet basic requirements. In contrast, Yutong Blower’s technical team—drawing on years of expertise in fluid dynamics and materials science—pointed out a major flaw. In highly corrosive environments containing HF (hydrofluoric acid) and HCl (hydrochloric acid), carbon steel fans suffer total corrosion within months, making long-term, stable operation impossible. To substantiate this position, Yutong Blower collaborated with the chemical enterprise to conduct comparative field tests. The project’s operating conditions were as follows:
- Conveyed medium: Corrosive gas mixture containing air, HF (hydrofluoric acid), and HCl (hydrochloric acid)
- Medium temperature: 10°C – 50°C
- Inlet airflow: 15,000 m³/h (CMH)
- Total pressure requirement: 5,000 Pa (maximum static pressure test reached 5,650 Pa)
Test Environment and Core Performance Comparison
To ensure accuracy, Yutong Blower provided two units for side-by-side comparison: a carbon steel fan and a Yutong FRP fan. Both shared matching external dimensions and aerodynamic parameters. Both units utilized motors with the following specifications: 37 kW, 380 V, and 50 Hz. Yutong recorded detailed data regarding airflow output, shaft power, current, and vibration:
Airflow Output and Aerodynamic Efficiency
As static pressure increased, the carbon steel fan delivered significantly lower effective airflow. Because the heavier carbon steel impeller is prone to rust, it creates resistance within the flow channels. Conversely, the Yutong FRP fan utilized smooth, resin-molded flow channels, which minimized fluid separation and maintained higher volumetric efficiency.
Shaft Power and Energy Consumption (Energy Efficiency)
At the same static pressure output, the Yutong FRP fan required less shaft power. This is primarily because the lighter FRP material reduces the moment of inertia, resulting in a lower operating current for the motor. Over long-term operation, this low power consumption demonstrates remarkable energy-saving advantages.
Vibration and Operational Stability (Yutong’s Core Advantage)
Standard industry requirements (JB/T) mandate unit vibration within 4.5 mm/s. However, Yutong implemented internal quality standards far stricter than national requirements. We controlled the dynamic balance of the FRP impellers to a level of ≤G3.0. This ensured that our FRP fans maintained minimal vibration levels during high-load operation, effectively eliminating bearing failures caused by mechanical fatigue.
Results: Cost Reduction and Efficiency Gains Across the Lifecycle
The production environment for this new energy project was extremely harsh, featuring high humidity and temperature extremes ranging from a high of 40.9°C to a low of -22.8°C.
Based on test results, the enterprise ultimately adopted Yutong Blower’s custom-designed FRP combustion-support fans, induced-draft fans, and exhaust fans. Through aerodynamic optimization and the use of premium anti-corrosion materials, the Yutong team guaranteed a design service life of 10 years and a continuous, trouble-free operating time well exceeding 8,000 hours.
A subsequent lifecycle cost analysis covering the period from 2011 to 2017 yielded a remarkable conclusion: compared to the previous carbon steel fan setup—which required frequent shutdowns and replacements due to corrosion damage—the Total Cost of Ownership (TCO) for Yutong’s FRP fans was reduced by a substantial 44.22%.
Conclusion
In highly corrosive chemical projects, focusing solely on initial procurement costs is a serious strategic error. Empirical data from Yutong Blower demonstrates that our FRP anti-corrosion fans not only offer overwhelming advantages in corrosion resistance but also comprehensively outperform traditional carbon steel fans in airflow volume, energy consumption, and reliability. Scientific selection can directly enable chemical enterprises to achieve cost reductions exceeding 40%. As a dedicated provider of industrial ventilation solutions, Yutong Blower will continue to leverage precision manufacturing and advanced materials science to safeguard green and energy-efficient operations across the global chemical industry.
