Efficiency limits of fans

The purpose of this work is to identify upper efficiency limits of industrial fans such as axial rotor-only fans, axial with guide vanes, centrifugal rotor-only and centrifugal with volute. The efficiency limit is always a function of the class, the design point within the class and the definition of efficiency (total-to-static and total-to-total). The characteristic Reynolds number is another relevant parameter. First, based on analytical and empirical loss models, a theoretical efficiency limit is estimated. A set of idealizing assumptions in the loss models yields efficiencies which are assumed to be an insuperable limit but may be unrealistically high. Second, more realistic efficiency limits are estimated using a computational fluid dynamics-based optimization scheme, seeking for the best designs and hence the maximum achievable efficiencies in all classes. Given the self-imposed constraints in the geometrical parameter space considered, the thus-obtained practical efficiency limits can only be exceeded by admitting more complex geometries of the fans.