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How Aerotech's IDF-600 eliminated unplanned shutdowns and recovered ₹1.8 crore in annual energy savings at a major cement facility.
A 5,000 TPD cement plant in Rajasthan was experiencing chronic underperformance from its aging induced draft fans. Impeller erosion from abrasive clinker dust had reduced fan efficiency from 78% to 64% over three years of operation.
The plant was experiencing 4–6 unplanned shutdowns per year due to fan failures, each costing approximately ₹80 lakh in lost production. Maintenance costs had escalated to ₹45 lakh annually for impeller repairs and bearing replacements.
Aerotech's engineering team conducted a full performance audit, including site measurements of actual flow, pressure, and power consumption. The audit revealed that the existing fans were also undersized for the plant's expanded production rate.
Four Aerotech IDF-600 units were installed with Ni-Hard wear-resistant impellers, water-cooled bearing housings, and VFD control. The installation was phased to maintain production continuity.
Results after 12 months: fan efficiency improved to 84%, zero unplanned shutdowns, annual energy savings of ₹1.8 crore, and impeller wear rate reduced by 60%. The project achieved full payback in 14 months.
