Simulation-based Design Tool for Centrifugal Fan

Centrifugal fans play a significant role in global energy consumption, making efficiency improvements essential for reducing operational costs and environmental impact. Even minor enhancements in fan performance can lead to considerable energy savings and reduced carbon emissions. This study introduces a design tool that integrates one-dimensional analytical equations with computational fluid dynamics (CFD) simulations to optimize the complete centrifugal fan, including the rotor and volute. By combining empirical correlations with advanced numerical modeling, the tool explores various design parameter combinations to enhance overall aerodynamic performance. The process begins by selecting initial design candidates based on fundamental equations, followed by defining a design space with upper and lower limits for key parameters. CFD simulates and then evaluates multiple configurations within this space to identify the most efficient design while satisfying performance criteria. A low-specific speed centrifugal fan with a backward-curved rotor and a well-matched volute is used as a case study. The optimized design is then manufactured and experimentally tested to validate the numerical simulations. Performance measurements confirm that the final prototype meets the required specifications and achieves higher efficiency than conventional designs, demonstrating the effectiveness of the proposed design approach.