Iowa Energy Efficiency Statewide Technical Reference Manual—3.1.16 Grain Bin Fan Aeration Controls
Vol.3 Nonresidential Measures July 22, 2020 FINAL Page 48 of 410
3.1.16. Grain Bin Fan Aeration Controls
DESCRIPTION
A large portion of the corn produced every year has to be dried and stored in order to preserve for use in the future.
When wet grain comes in from the field, it goes through a grain dryer to remove moisture and to prepare the grain
for storage. Without the removal of moisture, stored grain can spoil or become moldy. For example, corn is typically
stored with a moisture content of 15% or below. During the drying process, the corn is heated up and often goes
into storage at temperatures at or above outdoor air temperatures.
Grain storage bins come in a variety of shapes and sizes. Some have capacities of a few thousand bushels and some
have capacities of hundreds of thousands of bushels. When grain is stored in these large bins, the grain on the outer
edges acts as an insulator for the grain in the middle. Because of this, as the outdoor air temperature drops, the
grain, and surrounding air on the outside of the bin, cools down while the interior grain and air stays warm. As the
warm air rises and the cool air sinks, convection currents of moving air transfer moisture to pockets within the grain.
These pockets of moisture cause the grain to start rotting, which leads to spoilage, insect infestations, or other
issues.
To prevent these moisture issues, grain storage bins are equipped with aeration fans that force air through the grain
to keep the temperature gradients minimal and prevent convection currents from forming. Depending on the size
(and especially height) of the bin, the fans often have significant horsepower to meet the CFM and static pressure
requirements. Larger bins can easily require fan systems with four to six, 40-60hp fans, or larger.
Most grain bin aeration systems are manually controlled and there is quite a bit of guesswork involved with when
to run the fans and for how long. The operation can be based on random grain samples, weather, or the operator's
general judgement. Most of the time, this leads to erring on the side of caution and running the fans more than
necessary. With the large fan motor horsepower involved, this leads to a lot of wasted energy.
Grain bin aeration fan controls use integrated moisture and temperature sensors embedded in the grain bin along
with weather data to sense where and when issues may be occurring within the grain, and when the best times to
dry the grain are. This removes a lot of the guesswork from the aeration fan system operation and results in a
significant reduction in the hours of operation.
Savings are achieved by replacing existing manual controls on grain storage bin aeration fans with controls that use
temperature and moisture sensors to modulate fan operation automatically. Electric savings are achieved in retrofit
projects by reducing the aeration fan run hours. With manual controls, the fans are run more frequently and for
longer than needed. The controls include moisture and temperature sensors which run the fans only when needed.
Grain bins using heating grain drying are not eligible for participation in this measure. The reported height of the
grain bin must be the eave height and not the height of the peak. Bins larger than 105 ft. in diameter or 100 ft. in
eave height must go through the custom program.
This measure was developed to be applicable to the following program types: RF, TOS, NC.
If applied to other program types, the measure savings should be verified.
DEFINITION OF EFFICIENT EQUIPMENT
The efficient condition is grain bin aeration fans with automatic controls based on integrated temperature and/or
moisture sensors.