Retrofit of production hall ventilation
NOVENCO Building & Industry retrofitted the production hall ventilation in the foundry of a German car manufacturer together with contractor T&S Klimatechnik und Montagebau GmbH.
The previous system from 2012 used seven large axial fans. Each fan delivered 240,000 m3/h and was driven by a 160 kW motor via an inlet-side intermediate shaft. Failures caused long downtimes, and repairs were difficult due to the fan sizes. Replacement was impossible, and the system had high maintenance needs because of its design and many wear parts.
Fan arrays in modular design
The outdated system was replaced with modular NOVENCO fan arrays originally developed for large data centres. Special double diffusers were adapted to the existing interfaces so the system could use the available dynamic pressure.
Efficient motors and modern converter control now achieve system efficiencies above 80%. The modular fan arrays enable quick replacement using compact pallet trucks in a plug-and-play process. The low weight also allowed installation via existing doors and lifts.
A plug-in disc on the fan outlet stops backflow in case of failures and provides almost 90% redundancy.
A total of 28 NOVENCO ZerAx AZL900 axial fans were installed. Each fan delivers 60,000 m3/h at 1,600 Pa. With a total air volume of 1.68 million m3/h and more than 50% lower energy consumption, demand-controlled operation saves 4.9 million kWh per year.
Retrofit of seven large axial fans
- Contractor: T&S Klimatechnik & Montagebau GmbH
- Foundry in the German automotive industry
- 28 NOVENCO ZerAx fans, each 60,000 m3/h, in seven fan arrays
- Air volume capacity: 1,680,000 m3/h
- Energy savings up to 50%
- Weight savings up to 40%
- Total energy savings approx. 4.9 million kWh/year
- Redundant fan arrays as plug-and-play
