Here is everything you need to know about industrial blowers on the internet.
You will learn:
- What is an Industrial Blower?
- Types of Industrial Blowers
- How Industrial Blowers are Used
- How Industrial Blowers are Made
- And much more…
Chapter One – What is an Industrial Blower?
An industrial blower is a device that enhances the air flow in a workspace effectively and efficiently using an electric motor, impeller, and airfoils. The purpose and function of industrial blowers is to be a permanent addition to a workspace to increase airflow and remove contaminants, dust, dirt, and particulate matter. These highly technical devices are designed to produce higher pressure than a fan at a ratio of 1.11 to 1.2, which places them somewhere between a fan and a compressor.
Industrial blowers can be either centrifugal, axial, or positive displacement. Centrifugal blowers have a gear system and can have a single or multiple stage construction. Axial industrial blower models are simpler to household fans with a central shaft that has blades attached while positive displacement blowers have a rotor geometry.
Chapter Two – Types of Industrial Blowers
Industrial blowers are an essential part of any type of production or manufacturing operation to increase airflow and create positive air pressure. Present day industrial blowers were developed in the middle of the first industrial revolution as an air pump for internal combustion engines. The simple design of these initial designs included a motor, shaft, and impeller blades.
The first industrial blowers have progressed and advanced into a wide variety of types, uses, designs, and applications to assist in the performance of industrial jobs and help in making work faster, easier, and safer. The modern industrial blower is used in processes to create a steady and strong flow of air or gas.
Types of Industrial Blowers
Though there is a wide assortment of types of industrial blowers, there are a few that are commonly used because of their endurance, reliability, and are flexible enough to adapt to a variety of conditions. They make it possible for large scale production work to be completed efficiently, reliably, quickly, and effectively.
Positive Displacement Industrial Blowers
Positive displacement industrial blowers, also known as lobe blowers, release air at a specific time, pressure, velocity, and direction, using a safety valve. The name lobe blower comes from two propellers in the mechanism that counter rotate. Air enters a chamber of the blower and exits through an outlet. This design allows the blower to maintain constant air flow and pressure.
Centrifugal Industrial Blower
Centrifugal industrial blowers are the most frequently used type of industrial blower found in ventilation systems due to its capacity to continuously transfer gas and air as well as block air pollutants. The air stream goes through a set of rotating impellers where the speed and volume of the air is steadily increased. The fan wheel shifts in direction and accelerates as the amount of air passing through increases. As more air enters, the kinetic energy of the blower increases.
Regenerative industrial blowers are known as high flow low pressure compressed air blowers. They produce a rapid flow of compressed air with low pressure or a vacuum. Air circulating in the housing is compressed, which generates pressure. This type of blower can be single or two stages, where the air circulates once in a single stage blower and twice in a two stage. The two stage type of regenerative blower creates higher pressure.
High Speed Industrial Blower
A high speed industrial blower operates at very high speed creating high pressure and rapid airflow. It has an electric motor and impellers placed around the shaft of the blower to increase the volume of air being taken in. The construction of a high speed blower consists of a valve to release the air and a compression unit to control blower speed. Each of these factors is easily adjustable to fit the needs of the operation.
Helical Screw Industrial Blower
A helical screw industrial blower has a main rotor with two lobes and a second rotor. The main rotor is placed in the flute of the second rotor. The design of helical screw industrial blowers is more intricate but is extremely efficient in producing higher pressure. The two rotors turn in a helical pattern, which is carefully timed to avoid contact.
Axial Industrial Blower
Axial industrial blowers create positive and negative pressure around their blades, which creates airflow. The fan blades are positioned vertically and tilted to allow for atmospheric pressure changes. In an axial blower, the air is forced to move in an axial parallel direction to the shaft where the blades rotate. This design is what creates the air pressure difference causing the continuous airflow. The performance of an axial fan is determined by its number of blades and their shape.
Vapor Recovery Industrial Blower
Vapor recovery industrial blowers are a special type of centrifugal blower designed to collect vapors of gas and fuels such that they do not escape into the atmosphere. Under certain conditions, this type of industrial blower is required by law in cases where there are noxious, explosive, and flammable fumes. Pressure builds up in fuel storage tanks as they get filled. The vapors from the pressure are removed by vapor recovery industrial blowers that send it on to become natural gas or burned off.
Chapter Three – Industrial Blower Applications
Industrial blowers are used in operations and applications where the flow of gas or air is necessary such as conveying systems, ventilation, cooling, aspiration, and exhaust systems. The many types and varieties of blowers are designed to perform important and unique functions that are required by specific applications. This can be seen in the difference between a blower that is used for ventilating a manufacturing plant from one used to provide air circulation for a nursery.
The differentiation between blowers is determined by the type of blower, flow capacity, dimensions, operating pressure, design, and electrical rating. The many types of blowers are used for cooling, drying, dust control, and fluid bed aerators.
Industrial Blower Applications
Air Handling:Industrial blowers provide high and even airflow through the ductwork of a building. Air movement is achieved by large angle blades connected to the hub of the blower.
Dust Loading:Dust loading industrial blowers collect dust to improve air quality. For some industries, dust collection is an essential part of their operations as well as being a legal requirement under Environmental Protection Agency (EPA) regulations. Air quality regulations are for the protection of workers since air particulates can lead to a variety of health conditions.
Industrial dust loading units move air and contaminants through a system that captures, collects, and removes dangerous particles. Included in the system are hoods, air filtration systems, and collectors such as baghouses, traps, and ductwork.
Fume Extraction:A wide variety of industrial processes produce fumes, smoke, and chemicals that have to be removed from the air. The fumes and other contaminants are removed by scrubbers or points of emission. This is normally achieved through the use of a system of blowers and fans.
Fume remover industrial blowers are a part of a whole system that is designed with a large capacity filtration system. The 99% efficiency of the system guarantees that all harmful odors, contaminants, and gas fumes have been removed.
Material Handling:The material handling industry uses pneumatic pressure systems to move granular and powder materials to production. Industries such as the pharmaceuticals, food processing, agriculture, chemical, and cement producers require industrial blowers to remove fine particulates from the air.
Though normal fans can remove average particles, heavier materials have to be handled by abrasion resistant, heavy duty industrial blowers that are specifically designed to withstand the wear of such materials. Blowers for these types of operations are made of exceptionally sturdy materials and are capable of enduring the severe abuse from removing the chips, particles, and granular residue.
Saturated Air:Saturated air contains moisture or gases. The term saturated air refers to when the humidity in the air is at its highest possible point in regard to the pressure and temperature. Above the established point, condensation occurs. The danger of such concentration is damage to equipment from corrosion and rust, which requires the air to be removed and cleaned.
To produce the needed results of removing saturated air, customized industrial blowers are made that are corrosion and rust resistant, which means the use of stainless steel or metals coated in a moisture resistant epoxy. The manufacture of saturated air industrial blowers requires custom designed blower blades that can perform in wet environments.
Exhausting:In small and enclosed workspaces where paint and vapors accumulate, industrial blowers serve the purpose of removing and filtering the fumes and vapors to keep the air clean. Since some of the chemicals in these applications can be combustible, exhaust industrial blowers have to be spark resistant.
A buildup of paint, lacquer, and varnish has the potential of being volatile and explosive. The spark resistant blowers for these conditions are normally made with specially fabricated aluminum impellers.
Cooling:Cooling industrial fans are referred to as fluid displacers due to the fact that they displace air in one location to move it to another location through the use of rotating blades. The purpose of cooling fans is to blow in cold air and drive out hot air, which gives them the name of industrial cooling blowers.
To accomplish the multiple operations of pulling in cool air and driving out hot air, requires a specially designed blower. Cooling fans have a larger diameter, which allows them to move large volumes of air at low pressure. Though this single feature distinguishes cooling industrial blowers, their other components, such as the motor, rotor shaft, impellers, casing, and mountings, are the same as other units.
Blow-Off:In the manufacturing process, parts that need to be painted normally go through some form of cooling and cleaning process that can involve water, specs of dust, granules, or other forms of abrasive materials. Before the parts can be painted, the particulate matter has to be removed by the forceful application of streams of air, which is provided by an industrial blower.
Industrial blowers provide a sufficient amount of force and power to remove water vapor from cooling operations or matter that accumulates on parts prior to their being painted. Pressure blowers for this purpose are made of materials to create the necessary pressure and drive to eliminate and clean parts.
High Pressure:Certain air flow systems have an increased resistance to airflow and require blowers that have greater force and power to be durable enough to provide the necessary energy. They are normally installed where there is high static pressure and can be used for equipment cooling, material conveying, drying, ventilation, or exhausting. High pressure blowers come with open drip proof motors to help maintain clean environments and enclosed ones for dusty and dirty conditions.
Due to the nature of the use of high pressure industrial blowers, they are flexible enough to be used in high temperature conditions and can be spark and corrosion resistant. For the best results, housings are welded using high gauge steel.
Material Conveying:Material conveying industrial blowers move air in a confined space to transfer and move various forms of granular and powder materials. Their main function is to generate air flow in a tube by creating a vacuum to pull granular, paper, powder, and pellet materials. The special nature of this type of blower requires that they be enclosed in a confined system to be able to perform pneumatic conveying. The type of material transport is considered to be the most efficient method for moving raw materials.
Chapter Four – How Industrial Blowers are Made
The chief requirement for any industrial blower is durability and endurance. Unlike the traditional fan, industrial blowers create a great deal of pressure and force, which necessitates them to be manufactured from high strength and sturdy materials.
Industrial blowers provide a large volume of air and gas to a wide variety of buildings, manufacturing units, and various other structures. The method for achieving proper airflow is by the rotation of a number of blades that are connected to a hub and shaft driven by a turbine or motor. The displacement of air from these devices ranges from 200 cubic feet to 2,000,000 cubic feet per minute.
How Industrial Fans are Made
Before making the determination of what type of blower you will need, it is important to know the cubic feet per minute, which is the measure of the airflow. All blowers handle the same volume of air and gas no matter what the density is. The actual cubic feet per minute is the value that should be used when selecting an industrial blower.
The flow rate for conveying material in an enclosed feeder line or pipe requires an understanding of the necessary velocity that will be sufficient to carry or transport the material through the line and not collect or settle.
Static pressure is the resistance to airflow caused by air moving through ducting, pipes, filters, or hoses. Pressure can be influenced by altitude and temperature, which has an effect on the performance of an industrial blower. This particular issue has to be discussed regardless of the location of your facility since they can dramatically determine the quality of air and gas movement of an industrial blower
The central part of an industrial blower is its motor, which supplies the electric power to turn the blades of the blower. When choosing a blower, it is important to examine the environment where the blower will be placed since there are a wide variety of motors available. Blower motors can be completely enclosed where it is not exposed to the elements.
The next consideration is the brake horsepower, which is the force needed to brake the motor. When purchasing a blower, the horsepower should be slightly higher than the brake horsepower.
Motors for blowers can be direct drive or belt drive. For a direct drive blower, the motor has to have the correct rpms for the application. Belt driven motors have to be chosen according to the brake horsepower and the amount of loss on the belt.
There are several forms of motors that can be used in blowers, which include brushed, switched reluctance, brushless, and induction. Of this group, induction motors are the most commonly used motors for industrial blowers since they can power high horsepower blowers.
An impeller is the central part of a centrifugal blower. It has a strong resemblance to the wheels found in a hamster cage. The rotation of the impeller pulls air into the blower, increases its movement, and changes its direction at 90o. The turning of the impeller creates constant air flow.
The blades for the fan portion of the impeller can be in four different forms, which are radial, forward curved, backward curved, or airfoil. Each type of configuration serves a specific purpose for airflow. Radial blades are for high pressure applications with medium airflow. Forward curved blades are for medium pressure applications while backward curved are for high pressure applications. The airfoil design is the most common and provides the greatest efficiency.
Fan Blades or Airfoils
An axial fan has fan blades or airfoils that are attached to a hub or impeller that is placed on the motor. The number of blades can vary from two or three up to as many as thirteen. They can be made from a wide variety of materials from steel and aluminum to different types of polymers. The key factor to the fan blades is their pitch, which can be fixed, propeller, or adjustable, depending on the type of fan.
The wing tip of the blade is similar to the tip of the propeller blades of an airplane. It serves the purpose of stopping air from moving from the positive side of the blade to the negative, which reduces turbulence and significantly reduces noise.
There are ten basic mounting configurations for belt or direct drive industrial blowers, which include top, bottom, or side mounts, and close mounted or coupled configurations. The variety and types of mountings are customized to fit the conditions with conveyance industrial fans being mounted on the conveyor line to create the correct pressure.
The port design for an industrial blower is related to how the blower may be attached to an existing duct, pipe, tube, vent, or line pattern. For an industrial blower to smoothly fit into an existing system, its in and outlet ports have to be chosen to match the existing configuration. This does not apply to all industrial blowers since several varieties may be mounted in the ceiling, on the floor, or hung from a wall.
The most important type of consideration for an industrial blower installation is for designs that require the blower to be attached to a conveying system since a tight and secure seal as well as exact fit is a necessity to maintain proper pressure for conveyance.
A central part of an industrial blower is the types of bearings used since they are an aspect of the device that need to be monitored and maintained. The higher the speed of the blower, the more likely the bearings will become a problem. The selection of the type of bearings can diminish the amount of time spent on maintenance and the need to swap out bearings.
There are a wide variety of configurations for bears with some being enclosed and sealed, which makes changing them easier. The main concern is that the bearings be well lubricated and have low friction between surfaces. Magnetic bears avoid friction by not making contact with moving parts by being levitated from rotating shafts.
Chapter Five – Industries that use industrial blowers
As pressure is rising for methods to remove odors and fumes as well as keep air clean, the use of industrial blowers has been rapidly growing for several years. Producers and manufacturers are constantly designing and engineering new innovative methods for airflow and air movement to meet the increasing demand.
Nearly every industry requires a ventilation system, air transfer, or air cleaning method. In the case of product handling and transport, industrial blowers have been a central part of their operation since their inception. Industrial blowers play a vital part in several industries as a means of creating safe conditions and removing unwanted substances.
Industries that use Industrial Blowers
The purpose of industrial blowers for wastewater treatment is for tank aeration, which has to be maintained round the clock. The types of industrial blowers have to be highly reliable and be low maintenance. Another aspect of wastewater treatment is the potential for methane gas and other types of gases, which can be dissipated with industrial blowers..
The food industry makes special use of industrial blowers above and beyond the need for clean air. Any equipment for the food industry has to meet the demanding requirements of the Federal Food and Drug Administration (FDA) and must be completely sanitary to comply with industry regulations. Though clean airflow is a necessity for food production, there are several other functions that industrial blowers perform.
Prior to production, fruits and vegetables have to be cleaned of contaminants by being scrubbed. Before being placed into production, any residual water or possible contaminants have to be removed, which is done by an industrial blower. This is also true for bottles and cans used for packaging food products.
Soil Vapor Extraction
As industrial operations progress and businesses fail, there is a constant need for a means to ensure that soil is free of any lingering gases or toxins. Industrial blower exhausters are used to remove any possible toxins from soil to provide for safe environmental conditions.
Soil vapor extraction blowers are connected to wells and apply negative pressure to the subsurface to remove contaminants. The removed vapors are treated at the surface to guarantee total removal. The main parts of the system are the blower, its motor, and a moisture separator.
Of all of the different industries that rely on industrial blowers, the mining industry has the most obvious use as a ventilation system for underground mining. The harsh and demanding conditions of the mining industry requires that industrial blowers be robust and resilient. It is essential that they provide longevity, durability, and be maintenance free.
A concern for industrial blowers for mining operations is the dust, dirt, and particulates that can be damaging to blowers at mining operations. These hazards require that the blowers be specially designed with collection units or filtration systems.
In the dry method of cement production, raw materials are crushed, pulverized to be reduced to granules or powder. The crushed materials are then mixed together in a kiln to form cement. The cooking process of the kiln produces gases that have to be removed while the mixture is blended into a powder to form concrete for mixing and building.
Blowers are used as part of the pneumatic system to transport the raw materials to various parts of the system such as into the kiln and bagging the finished product. They are also used for aeration, feeding oxygen, and part of cooling systems.
In the production of seafood, hatcheries play a vital part in the growing and cultivating of fresh and saltwater animals. Blowers are used to generate oxygen to help guarantee water quality and the freshness of food products. They are also used for feeding systems and the creation of bubble curtains. The main importance of air blowers for the aquaculture industry is the constant supply of fresh clean oxygen to ensure the life of the densely populated tanks.
Oxygen is a vital part of the survival of water animals, which makes aeration an important part of the production process. The aeration process maintains oxygen levels, provides constant oxygen levels, keeps water circulating, and offers protection against extreme temperature variations.
Pneumatic conveying systems offer a means of safely feeding the water organisms with pellets and powders. Industrial blowers ensure the smooth operation of pneumatic feeding systems. The versatility of industrial blowers makes them adaptable to any form of installation regardless of its location.
Low pressure industrial blowers are a central part of conveying petroleum materials for product production. Part of the refining process is the production of toxic hydrogen sulfide. Thermal incinerators are used to oxidize the sulfur by cleaning it. Blowers enhance the combustion process to assist in further cleaning of the gases.
In the production of carbon, that is used to produce plastics, paints, and ink, combustion is used to produce the material. Blowers supply high volumes of air to the furnaces and assists in injecting natural gas, which allows thermal decomposition to occur.
Chapter Six – Benefits of Industrial Blowers
Air and gas movement, filtration, and cleaning and removal have become a vital part of a wide array of industries as a central part of their production processes. Industrial blowers have become a vital and necessary part of these operations and have been found to perform above and beyond their expected functions.
All manufacturers that use industrial blowers have found them to be resilient and reliable pieces of equipment. Their well designed motors, fans, and mountings have more than proven their value and importance.
Benefits of Industrial Blowers
The elimination of air pollution, smoke, and unpleasant smells by industrial blowers produce a healthy and pleasant work environment. Industrial blowers minimize heat and humidity and come in a variety of functionalities and styles.
Power Usage:Industrial blowers offer a variety of outputs due to their various structures and innovations while having a very low use of input power. Since industrial blowers are used in offices, industrial operations, manufacturing, and technical production, it is essential that they be a cost effective part of the operation. All industrial blowers are designed for economical use of power to provide control of electrical costs. Construction, proper installation, and insulation materials are all used to keep costs down and efficiency up.
Adaptability:Industrial blowers are available to fit any form of air and gas movement operations. They come in different styles, designs, sizes, and configurations or can be custom built to fit unique applications. Regardless of the size of the space or the requirements of the application, an industrial blower can meet the requirements. A factor that adds to the adaptability of industrial blowers is the variety of configurations of fan blades, which makes them flexible enough to fit any airflow and pressure conditions.
Meet Occupational and Safety Health Administration (OSHA) Requirements:There is an ever growing need for the creation of work environments that have the central concern for the health and well being of workers. Many of the requirements come from OSHA and its set of standards. In an effort to comply with the regulations, manufacturers have requested for assistance in airflow purification and control from industrial blower producers, who produce fans and blowers that are specifically designed to meet OSHA standards.
Durability:One of the reasons for the popularity of industrial blowers is their ability to withstand the harsh and hazardous conditions that require their use. Hardcore and stressful industries have found that using industrial blowers improves working conditions and productivity while being able to endure the severe nature of the work environment.
Ventilation:A major issue in any workplace is the ventilation system. For harsh conditions, ventilation provides needed airflow to keep conditions cool. In the electronics industry, ventilation is necessary to avoid contaminants on delicate and intricate parts. In either type of environment, air movement and ventilation create a healthier and more pleasant work atmosphere. The advanced ventilation methods provided by industrial blowers remove dust, fumes, smoke, and contaminants to create a safe workplace. Industrial blowers stir up the air in enclosed areas, replacing stale and contaminated air with fresh air.
Regulation of Fumes and Smoke:There are several industrial operations that produce toxic fumes or lung damaging smoke, which has to be removed and exhausted. Under the present environmental restrictions, releasing such contaminants into the air can lead to serious difficulties with environmental agencies. Industrial blowers assist in the alleviation of the problem by using various methods for dissipating dangerous fumes and smoke.
The Air Movement and Control Association (AMCA):Industrial blower manufacturers comply with standards set by the AMCA, which has developed classes to identify the various types of industrial blowers. The AMCA classification method identifies the types and styles of blowers from ones that can be set on the floor of a factory to highly technical ones used for conveying and the control of dangerous fumes.
Healthy Work Conditions:Industrial blowers provide protection against respiratory diseases. The fans, impellers, and blades are designed to vent and cool large spaces. They keep humidity down to keep spaces cool and comfortable. A major health benefit of industrial blowers is the removal of dust, particulates, and contaminants from the air to create a clean air workspace. The removal of these harmful materials prevents respiratory diseases and other health issues.
Humidity Control:Dampness in a room leads to foul smells and bad odors. The nature of industrial blowers is to maintain constant airflow, which prevents the accumulation of unpleasant odors that can lead to non-hygienic conditions.
Dust Collection:The size and volume of air that an industrial blower moves requires some form of collection system. Depending on the operation, that system can involve a receptacle, bag, filter, or some other type of collection device. The simple fact that industrial blowers stir up the air makes it a necessity to have some form of collection method to protect workers. The type and size of the collection is dependent on the size of the industrial blower and the space to which it is directed.
Pressure:Industrial blowers operate at high speeds to move large volumes of air. This results in low to medium static pressure from the radial direction of air movement.
Safety:The motors for industrial blowers have high horsepower and operate at high speeds. This necessitates that the motors be exceptionally durable and reliable, which leads to less overloads and motor damage. The sophisticated nature of industrial blower motors makes them one of the most dependable pieces of equipment a manufacturer or producer can buy. This simple fact makes industrial blowers a very productive and safe investment.
- An industrial blower is a device that enhances the air flow in a workspace effectively and efficiently using an electric motor, impellers, and airfoils.
- Industrial blowers are either centrifugal, axial, or positive displacement.
- Industrial blowers are an essential part of any type of production or manufacturing operation to increase airflow and create a certain level of air pressure.
- Industrial blowers are used in operations and applications where the flow of gas or air is necessary such as conveying systems, ventilation, cooling, aspiration, and exhaust systems.
- Unlike the traditional fan, industrial blowers create a great deal of pressure and force, which necessitates them to be manufactured from high strength and sturdy materials.