In systems that process abrasive materials or corrosive gases, the industrial process fans are susceptible to fatigue and erosion from abrasive particles in the airstream. Improper application or inadequate maintenance increase that vulnerability. Customizing a fan design with high-density, durable materials results in higher efficiency, less downtime for repairs and continued productivity. Utilizing the most wear resistant material produces a longer-lasting machine. AirPro builds high-integrity, longer-lasting industrial fans with available alloy construction for any abrasive airstream.
Industries Susceptible to Abrasive Wear
- Frac Sand
- Mineral Processing
Materials Used to Protect Equipment
In applications where high blade-wear is expected, specific fan types and materials should be considered. AirPro engineers and fabricators are experienced in using many different alloys and steels for abrasive environments, including:
- Titanium – Used for a wide variety of industrial purposes, titanium typically has more favorable density than nickel-based or ferrous metals, and forms a strong surface oxide layer which acts as an exceptional corrosion inhibitor. Used in chemical processing, salt, and power generation applications.
- HASTELLOY® C22 – A nickel-chromium-molybdenum material well-known for its resistance to stress corrosion cracking, pitting and crevice attack, the HASTELLOY® C-22® alloy provides exceptional corrosion protection, and is widely used in FGD systems and pharmaceutical reaction vessels.
- Monel® — This group of nickel-copper alloys feature high strength and toughness in a wide range of corrosive mediums, including alkalies, hydrofluoric and sulphuric acids, and seawater. Especially appropriate for marine environments, chemical processing equipment, and more.
- AR400 – With added carbon and manganese, this quenched and tempered alloyed steel offers durability and high abrasion- and impact- resistance. Typically used in applications where materials such as gravel, earth, grains, or coal are handled.
Wear-resistant linings can also improve protection from heat and corrosion, dramatically improving the life and quality of industrial fan parts. Some of the top materials used for industrial fans include:
- Chromium carbide – Notable for its particular resistance to extreme heat (approximately 1,000F to 1,500F), chromium carbide coatings with a nickel/chrome binder chemistry also provide excellent oxide resistance under corrosive or oxidizing conditions.
- Tungsten carbide – Made of a carefully processed combination of tungsten and cobalt powders. Offers superior surface protection and resistance to extremely high temperatures.
- Ceramic tile – Lightweight, impact-resistant, and very hard, ceramic tiles have a long wear life and are especially useful for conveying materials such as coal dust or abrasive liquids.
Rebuilds, Repairs and Replacements
Maintenance and repair of abrasive resistant fans involve the typical PM steps such as regular greasing, wheel and connection inspections, and vibration analysis. Application specific considerations are wear-plate replacement, housing refurbishment, and complete wheel rebuild. AirPro has repaired and rebuilt fans originally manufactured by NYB, TCF, Garden City, IGE, and other US fan manufacturers. Visit our Parts & Service page for examples.