Enhancing Industrial Fan Performance: A Data-driven Framework for Energy Savings and Cost Reduction

• P.K. Ngongo Department of Electrical, Electronic and Computer Engineering, Cape Peninsula University of Technology, Cape Town, South Africa https://orcid.org/0000-0001-8542-3907
• A.M.A. Almaktoof Department of Electrical, Electronic and Computer Engineering, Cape Peninsula University of Technology, Cape Town, South Africa https://orcid.org/0000-0002-1134-5587
• M.T.E. Kahn Department of Electrical, Electronic and Computer Engineering, Cape Peninsula University of Technology, Cape Town, South Africa https://orcid.org/0000-0002-3999-6322

DOI:

https://doi.org/10.7166/37-1-3245

Abstract

South Africa faces the challenge of balancing energy demand with sustainable development goals. Heating, ventilation, and air conditioning (HVAC) systems consume about 40.6 billion kWh of energy annually, which accounts for 20% of the country’s overall energy consumption, according to the Eskom Energy Management Information Pack from July 2015. Many fans used in these systems operate inefficiently, leading to increased energy and maintenance costs. Often, these fans are selected on the basis of standard sizes rather than being custom designed, resulting in oversizing and higher operational expenses. Optimising the entire system could lead to greater energy savings than simply optimising individual components. To assist in this effort, the US Department of Energy’s Office of Energy Efficiency and Renewable Energy has developed a free online fan system assessment tool (FSAT). This tool helps manufacturers, end-users, and engineers of industrial fan systems to identify and capitalise on energy optimisation opportunities. This paper outlines the basic features and functions of the FSAT, emphasising its role in promoting the sustainable development of facilities and addressing energy-efficiency gaps. The FSAT evaluates the efficiency, potential energy savings, and cost-effectiveness of a fan system by examining the energy consumption framework of a sample facility. It analyses operational parameters and energy usage patterns, providing detailed options for improving energy consumption. According to the findings, using an energy-efficient motor along with an optimised fan could lead to an estimated annual energy savings of 24.84% compared with the selected fans, and savings of 1.49% when compared with the overall facility energy usage.