As lithium battery manufacturing continues to expand, production facilities are placing increasing demands on ventilation systems.But when manufacturers look for ways to reduce HVAC and ventilation energy consumption, the first step should not always be replacing equipment.

It should be understanding how the existing system is actually operating.

Recently, Beijing Hengrui conducted a fan assessment for a high-tech manufacturer specializing in the R&D, production, and sales of lithium-ion cells, batteries, and power batteries.

The objective was to evaluate whether the existing ventilation fans could be upgraded to more efficient EC fan solutions.

Step 1: Measure the Real Operating Conditions

The existing systems were equipped with IE3 motors and had been in operation since 2022.

Pic.1 Old AHU nameplate before renovation

Pic.2 Old IE3 motors

Instead of relying solely on nameplate data, our team collected actual operating parameters, including:

The measurements revealed that actual operating points differed across production areas.

For example, one 40,000 m³/h system was measured at 38,880 m³/h and 825 Pa, with an actual power consumption of approximately 19.7 kW. Another 30,000 m³/h system operated at approximately 29,000 m³/h and 920 Pa, consuming around 16.6 kW.

Step 2: Select the Fan Based on the Operating Point

This is where engineering-based fan selection becomes important.

Rather than simply replacing the existing fan with an equivalent model, we matched EC fan models to the measured airflow and pressure requirements.

The proposed solution included R3G560 and K3G450/K3G560 EC fans, with different fan quantities selected according to each system's operating point and installation space.

Pic.3 Proposed solution by using ebm-papst fans

The assessment indicates an expected 30–43% reduction in fan operating power, depending on the individual application and operating point.

The Engineering Takeaway

For energy-intensive battery manufacturing facilities, ventilation is a continuous operating cost.

But improving efficiency does not necessarily require replacing the entire ventilation system.

Accurate field measurements + correct operating-point analysis + appropriate EC fan selection can identify significant energy-saving opportunities while keeping the retrofit focused on the components that matter most.

At Beijing Hengrui, we work with battery manufacturers, industrial HVAC contractors, facility engineers, and system integrators to identify fan retrofit opportunities through on-site assessment, operating-point analysis, EC fan selection, and system optimization.

Planning an HVAC or ventilation retrofit? Share your existing fan data or operating conditions with us—we can help evaluate the potential for a more efficient solution.

The right retrofit doesn't start with choosing a fan. It starts with understanding the system.