We rigged it up so its flowing out the duct i was talking about so its blowing straight outside now... Much to my surprise, the noise is still there (albeit slightly quieter) so now i am not sure whether the noise of the air flowing out of the duct was even the problem. I made the noise even quiter by putting the fan in the very back corner - away from the walls near the lounge.
My plan is to seal the fan as best as i can inside the room (we're going to build a small insulated box to house the fan) to reduce its noise. Once i've done that, ill have another go a placing the duct back inside and i'll update with how noisy that is. If its still noisy, ill go for larger ducting.
1) Unlike other electrical devices, a closed centrifugal fan - as far as my logic goes - would be fine to cover in insulation, because the device is cooled and gets all its airflow from the air moving though it. Right? The fan housing never gets hot, so it wont matter if its covered in insulation will it?
2) Will adding a carbon filter significantly reduce the fan speed?