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Exhaust Gas Heat Recovery System

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Efficient Energy Recovery · Lower Operating Costs · Sustainable Operation

In many industrial processes such as drying, pelletizing, textile finishing, food processing, and material treatment, large volumes of high-temperature exhaust gas are continuously discharged to the atmosphere. These exhaust gases contain a significant amount of recoverable sensible heat, which is often wasted, leading to high energy consumption and increased operating costs.

The Exhaust Gas Heat Recovery System is designed to capture and reuse this wasted thermal energy, improving overall system efficiency while reducing fuel and electricity consumption.

Working Principle

The system is based on a plate-type air-to-air heat exchanger core. High-temperature exhaust gas and fresh intake air flow through separate, fully isolated channels inside the heat exchanger. Heat is transferred through the exchanger plates without any mixing of air streams, ensuring clean, safe, and odor-free operation.

Recovered heat is used to preheat fresh air supplied back to the process, such as drying chambers, pellet coolers, or ventilation systems. As a result, the load on heaters, burners, or steam systems is significantly reduced.

Key Advantages

  • High Heat Recovery Efficiency
    The plate heat exchanger core provides a large heat transfer surface, allowing effective recovery of sensible heat from exhaust gas.

  • No Air Mixing, No Contamination
    Exhaust air and fresh air are completely separated, preventing odor return, moisture carryover, or product contamination.

  • Energy Saving and Cost Reduction
    By reusing exhaust heat, fuel and electricity consumption are reduced, leading to fast return on investment.

  • Moisture Reduction and Temperature Control
    The system helps lower exhaust gas temperature and humidity, reducing downstream cooling or dehumidification requirements.

  • Low Operating Cost
    No additional heating or cooling energy is required. The system operates with minimal power consumption, mainly for fans.

  • Modular and Flexible Design
    The system can be customized according to air volume, temperature, and process requirements, suitable for both new installations and retrofit projects.

Typical Applications

  • Feed pellet drying and cooling systems

  • Industrial drying and deodorization equipment

  • Textile stenters and finishing machines

  • Nonwoven and leather processing lines

  • Industrial ventilation and exhaust air treatment systems

Sustainable and Reliable Solution

By converting waste heat into usable energy, the Exhaust Gas Heat Recovery System supports energy-efficient production and sustainable industrial development. It not only reduces operational costs but also contributes to lower carbon emissions and improved working environments.

This system is an ideal solution for industries seeking reliable, low-maintenance, and environmentally responsible heat recovery technology.

Waste Heat Recovery from Livestock Manure Fermentation Exhaust

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Equipment: BXB600-595-4-H Air-to-Air Plate Heat Exchanger
Working Conditions: 4500 m³/h airflow per unit; exhaust temperature 50–60°C; contains ammonia, moisture, and corrosive components

Application Background

During livestock manure fermentation, large volumes of warm and humid exhaust air containing ammonia are continuously discharged. A significant amount of heat is lost during this process. By using an air-to-air heat recovery exchanger to preheat fresh air, the system can reduce energy consumption for heating, improve ventilation efficiency, and decrease visible white plume from exhaust discharge.

Heat Exchanger Selection

The BXB600-595-4-H is a cross-flow aluminum plate heat exchanger, suitable for fermentation exhaust, composting exhaust, and other moderate-corrosive gas conditions.

• High efficiency: Cross-flow structure with strong temperature difference driving force; sensible heat recovery efficiency can reach 50–65%.
• Low pressure drop: Optimized flow channels, well-matched with the 4500 m³/h airflow requirement.
• Corrosion resistance: Optional surface passivation or epoxy coating for enhanced protection against ammonia and acidic condensate.
• Zero energy consumption: No water or steam required; heat recovery is achieved solely through the temperature difference between exhaust and fresh air.

Functional Benefits and Energy Savings

  1. Fresh Air Preheating
    Exhaust air at 50–60°C can effectively preheat cold fresh air during winter, reducing the heating load for livestock houses, composting systems, and fermentation equipment.

  2. Reduced Exhaust Humidity and White Plume
    After heat extraction, the exhaust temperature drops, reducing visible white vapor during outdoor discharge and improving environmental perception.

  3. Lower Corrosion Risks
    Exhaust and fresh air remain completely separated. Tail gas channels can be coated for extended service life when handling corrosive components.

  4. Energy Savings
    Compared with electric heaters or steam heating, the system can reduce energy consumption by 20–60%, depending on temperature conditions and fresh air load.

Installation & Maintenance Notes

• Install filters on the exhaust side to block dust and particulates.
• Ensure proper condensate drainage to prevent corrosion from acidic liquids.
• Select fans with sufficient static pressure to maintain airflow under varying humidity.
• Optional bypass system to stabilize fresh-air temperature during exhaust fluctuations.

Mine Exhaust Waste Heat Recovery System

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The mine exhaust waste heat recovery system captures heat from mine ventilation exhausts to provide heating for surface facilities or pre-warm incoming air.

Benefits

  • Energy Recovery: Recovers up to 60% of waste heat from exhausts.

  • Cost Efficiency: Reduces heating costs in cold climates.

  • Safety: Improves working conditions by managing underground heat.

Implementation

In a mining operation, exhaust air from deep shafts is passed through heat recovery units to warm surface buildings, enhancing energy use in remote locations.

Case Study

A mine in a cold region reduced heating costs by 25% using this system, improving operational sustainability.

Wind Turbine Nacelle Cooling System

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The wind turbine nacelle cooling system is designed to manage the temperature within wind turbine nacelles, ensuring optimal performance of electrical components in varying weather conditions.

Benefits

  • Equipment Longevity: Prevents overheating, extending component life.

  • Efficiency: Maintains peak performance of turbines.

  • Energy Recovery: Recovers heat for potential reuse.

Implementation

The system uses heat exchangers to dissipate heat from the nacelle's internal components, with recovered heat potentially used for nearby heating needs. This is critical in offshore wind farms.

Case Study

An offshore wind farm reported a 20% increase in turbine efficiency after installing this cooling system.

Indirect Evaporative Cooling System

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The indirect evaporative cooling system provides an energy-efficient cooling solution for data centers and commercial buildings, utilizing the evaporation of water without direct air humidification.

Benefits

  • Energy Savings: Reduces cooling energy use by up to 50% compared to traditional systems.

  • Environmental Friendliness: Uses no harmful refrigerants.

  • Comfort: Maintains low humidity levels, ideal for sensitive equipment.

Implementation

In a data center, the system uses a heat exchanger to cool incoming air with evaporative cooling, ensuring stable temperatures for servers without increasing indoor humidity.

Case Study

A data center reduced its cooling costs by 35% using this system, demonstrating its effectiveness in high-heat environments.

Smoke Whitening Environmental Protection System

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The smoke whitening environmental protection system is used in industrial settings to reduce visible smoke emissions, improving air quality and complying with environmental regulations.

Benefits

  • Air Quality Improvement: Eliminates visible smoke, reducing particulate matter.

  • Regulatory Compliance: Meets stringent emission standards.

  • Energy Efficiency: Recovers heat from flue gases for reuse.

Implementation

This system employs heat exchangers and condensers to cool flue gases below their dew point, causing water vapor to condense and reducing visible plumes. In a coal-fired plant, this technology reduced smoke visibility by 90%.

Case Study

A chemical plant implementing this system achieved a 95% reduction in visible emissions, aligning with local environmental goals.

Industrial Heat Emission Recovery and Reuse System

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The industrial heat emission recovery and reuse system is employed in factories and power plants to capture waste heat from industrial processes and repurpose it for heating or power generation.

Benefits

  • Energy Reuse: Recovers up to 70% of waste heat, enhancing overall efficiency.

  • Cost Reduction: Lowers fuel consumption and operational expenses.

  • Environmental Benefit: Reduces greenhouse gas emissions.

Implementation

In a power plant, heat from exhaust gases is captured using heat exchangers and redirected to preheat boiler feedwater or generate additional electricity. This closed-loop system minimizes energy loss.

Case Study

A steel manufacturing plant reduced its energy costs by 18% after installing this system, showcasing its potential in heavy industry.

Air Conditioning and Ventilation System for Large-Scale Scientific Breeding

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This system is tailored for large-scale scientific breeding facilities, such as greenhouses and aquaculture farms, where precise environmental control is necessary for optimal growth and health of plants and animals.

Benefits

  • Controlled Environment: Maintains ideal temperature, humidity, and CO2 levels for breeding.

  • Energy Efficiency: Recovers up to 65% of energy, reducing operational costs.

  • Sustainability: Supports eco-friendly farming practices.

Implementation

The system integrates ventilation units with heat recovery modules in greenhouses. For instance, exhaust air from a hydroponic farm is used to preheat incoming air, ensuring stable conditions for plant growth while minimizing energy input.

Case Study

A large hydroponic farm utilizing this system achieved a 25% increase in yield and a 15% reduction in energy costs, proving its efficacy in controlled agriculture.

Clean Air Conditioning Fresh Air System

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The clean air conditioning fresh air system is designed for environments requiring sterile conditions, such as hospitals and operating rooms. This system combines air conditioning with advanced filtration to maintain a contaminant-free atmosphere while recovering energy from exhaust air.

Benefits

  • Sterility: Provides a high level of air purification, essential for surgical environments.

  • Energy Recovery: Recovers up to 60-70% of energy, reducing operational costs.

  • Health Safety: Minimizes the risk of airborne infections.

Implementation

In an operating room, the system uses HEPA filters and energy recovery ventilators to circulate clean air. Exhaust air from the room is passed through a heat exchanger, preconditioning incoming fresh air to maintain stable temperatures and humidity levels, critical for patient safety.

Case Study

A hospital implementing this system reported a 20% reduction in energy use and improved infection control rates, highlighting its dual benefits.

Energy Recovery of Heat Pump Drying System

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The energy recovery of heat pump drying system is an advanced technology used in industries such as agriculture and food processing to dry products like tea, fruits, and grains efficiently. This system utilizes heat pumps to recover and reuse thermal energy, enhancing drying processes while minimizing energy waste.

Benefits

  • Energy Conservation: Recovers up to 75% of waste heat, reducing energy costs significantly.

  • Product Quality: Maintains optimal drying conditions, preserving the quality and nutritional value of products.

  • Environmental Impact: Lowers carbon footprint by reducing reliance on fossil fuels.

Implementation

The system operates by extracting heat from the drying chamber's exhaust air using a heat pump. This heat is then reused to warm the incoming air, creating a closed-loop cycle. For example, in tea processing, the system ensures even drying at controlled temperatures, improving yield and quality.

Case Study

In a tea processing plant, the adoption of this system reduced drying energy consumption by 30%, demonstrating its effectiveness in resource-intensive industries.

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