1. Maintain reaction temperature: Many chemical reactions require specific temperature ranges to ensure reaction rate and product quality. The heat pump heat exchanger can adjust the temperature inside the reaction vessel to timely remove or supplement the required heat generated by the reaction, so that the reaction can proceed under stable temperature conditions. For example, in the polyester synthesis reaction, it is necessary to strictly control the reaction temperature at around 200-250 ℃. The heat pump heat exchanger can accurately adjust the temperature of the reaction kettle to ensure the smooth progress of the reaction.
2. Recycling reaction waste heat: Some chemical reactions are exothermic reactions, and if the large amount of waste heat generated is not utilized, it will not only cause energy waste, but also may cause thermal pollution to the environment. Heat pump heat exchangers can recover the heat from high-temperature hot water or steam discharged from the reaction kettle, raise it to a higher temperature level, and use it for other processes that require heat, such as preheating reactants, heating process water, etc., thereby improving the energy utilization efficiency of the entire chemical production process.
What industrial fields are heat pump heat exchangers used in?
Process heating in industrial production: In some industrial production processes that do not require particularly high temperature but require a large amount of heat energy, such as food processing, textile printing and dyeing, wood drying, etc., heat pump heat exchangers can use industrial waste heat or environmental heat energy to provide the required heat for the production process, achieving energy recovery and energy conservation and emission reduction.
Industrial wastewater waste heat recovery: Many industrial production processes generate a large amount of wastewater, which often contains a certain amount of heat. Heat pump heat exchangers can extract heat from wastewater and use it to preheat production water or other processes that require thermal energy, reducing energy consumption and production costs for enterprises.
Dryer Exhaust Heat Recovery Exchanger Technical Overview
1. Exchanger Types
-
Plate Heat Exchanger
Compact structure with high heat transfer efficiency, suitable for low-temperature exhaust (<200°C) with minimal corrosiveness. Easy to clean, ideal for small to medium-sized dryers. -
Rotary Wheel Exchanger
Transfers heat via a rotating wheel, suitable for high-flow, low-temperature-difference exhaust recovery. High efficiency, best for large-scale drying systems, but requires more space.
2. Design Considerations
-
Exhaust Characteristics
Evaluate exhaust temperature (typically 80–200°C), flow rate, humidity, and dust content. Corrosive gases require resistant materials (e.g., stainless steel). -
Heat Recovery Efficiency
Efficiency ranges from 50%–80%, depending on temperature difference and heat transfer area. Balance efficiency with pressure drop to maintain exhaust performance. -
Maintenance and Cost
Plate exchangers are easy to disassemble and clean, with low maintenance costs. Rotary wheel exchangers suit continuous operation but have higher initial costs.
3. Application Scenarios
-
Plate Heat Exchanger: Used in small to medium dryers, such as in food or textile industries, for recovering low-temperature exhaust to preheat fresh air.
-
Rotary Wheel Exchanger: Applied in large industrial dryers, like paper or chemical material drying, for handling high-flow exhaust.
The research and development prospects of new technologies for waste heat recovery
Efficient heat exchanger technology: Developing heat exchangers with higher heat transfer efficiency, lower resistance, and smaller volume, such as plate heat exchangers and heat pipe heat exchangers designed with new materials and optimized structures, to improve the efficiency and economy of industrial heat recovery.
Intelligent control system: Develop an intelligent industrial heat recovery control system using technologies such as the Internet of Things, big data, and artificial intelligence. By monitoring and analyzing the thermal parameters in the production process in real-time, automatically adjusting the operating status of the heat recovery equipment, optimizing the control of heat recovery, and improving the stability and energy utilization efficiency of the system.
New energy storage technology: Research and apply new energy storage technologies such as phase change energy storage materials and thermochemical energy storage to solve the problems of industrial waste heat discontinuity and instability. By storing heat during the generation of waste heat and releasing it when needed, flexible utilization of waste heat can be achieved, improving the overall performance of the heat recovery system.
New application areas of waste heat recovery
Data center heat recovery: With the rapid development of data centers, their energy consumption and heat dissipation issues are becoming increasingly prominent. Recovering the waste heat generated by data center servers and other equipment for heating, hot water supply, or preheating of other industrial processes in surrounding buildings, achieving green and energy-saving operation of data centers.
Thermal management of electric vehicle batteries: During the charging and discharging process of electric vehicle batteries, a large amount of heat is generated. Developing an efficient battery thermal management system to recover the waste heat generated by the battery for energy supply to in car heating or other auxiliary equipment can not only improve the performance and lifespan of the battery, but also enhance the overall energy utilization efficiency of electric vehicles.
Industrial waste heat driven refrigeration system: Utilizing industrial waste heat to drive absorption refrigeration, adsorption refrigeration and other systems, providing cooling capacity for the cooling needs in industrial production processes. This method can reduce the energy consumption of traditional electric refrigeration systems, achieve cascade utilization of waste heat, and improve the comprehensive utilization efficiency of energy.
Several schemes for recovering waste heat from drying of shaping machine
During the working process of the molding machine, a large amount of high-temperature exhaust gas is generated during the drying stage, which carries a large amount of heat energy and is the main source of waste heat recovery. Generally speaking, the exhaust gas temperature emitted by the shaping machine is around 150 ℃ -200 ℃, which has high recycling value.
Several schemes for recovering waste heat from drying of shaping machine
Heat exchanger recovery: This is the most common method of waste heat recovery. By installing a heat exchanger, high-temperature exhaust gas can exchange heat with cold air or cold water, which can be reused in the drying process of the molding machine or other places that require heat energy. The plate heat exchanger we produce has the advantages of high heat transfer efficiency and compact structure, which can effectively transfer the heat in the exhaust gas to the medium that needs to be heated.
Heat pipe recycling: Heat pipes are efficient heat transfer components. In the waste heat recovery of the shaping machine, one end of the heat pipe is placed in the high-temperature exhaust gas to absorb the heat of the exhaust gas, and the other end is placed in the medium that needs to be heated to release the heat. Heat pipe recovery technology has the characteristics of fast heat transfer speed and low heat loss, which can achieve long-distance heat energy transmission and recovery.
Heat pump recycling: Heat pump technology can convert low-temperature heat energy into high-temperature heat energy for heating needs in production or daily life. In the waste heat recovery of the shaping machine, the heat pump can extract the low-temperature heat energy from the exhaust gas, and through compression, condensation and other processes, raise the heat energy to a higher temperature, and then use it for drying, heating water and other purposes. The advantage of heat pump recycling technology is that it can effectively utilize low-grade heat energy and achieve significant energy-saving effects.
indirect adiabatic cooling systems for the data centers use.
Indirect adiabatic cooling systems for data centers use a combination of evaporative cooling and heat exchange to efficiently manage heat loads while minimizing water use and maintaining air quality. Below is an explanation of how these systems work and their application in data centers:
Principle of Operation
Indirect adiabatic cooling leverages the natural cooling effect of water evaporation without directly introducing moisture into the data center’s internal air stream. The process involves two separate airflows and a heat exchanger:
- Primary Airflow (Data Center Air):
- Warm air from the data center (generated by servers and IT equipment) circulates through one side of a heat exchanger in a closed loop.
- This air is cooled by transferring its heat to the secondary airflow without mixing.
- Secondary Airflow (Outdoor Air):
- Outdoor air (scavenger air) is drawn into the system and passed over wetted media or sprayed with fine water droplets.
- As the water evaporates, it absorbs heat from the outdoor air, lowering its temperature (approaching the wet-bulb temperature).
- This cooled outdoor air then flows through the other side of the heat exchanger, absorbing heat from the primary airflow.
- Heat Exchange:
- The heat exchanger (typically plate-type or tube-based) facilitates the transfer of heat from the warm data center air to the cooled outdoor air.
- The cooled primary air is then returned to the data center, while the warmed secondary air is exhausted outside.
- Adiabatic Enhancement:
- The evaporative cooling of the secondary airflow enhances the system’s ability to handle higher ambient temperatures, extending the range of conditions under which free cooling (using outdoor air) is effective.
Key Features
- No Humidity Increase in Data Center: Unlike direct evaporative cooling, indirect systems keep the data center air dry, avoiding risks to sensitive IT equipment from excess moisture.
- Energy Efficiency: By using evaporation to pre-cool outdoor air, these systems reduce reliance on mechanical refrigeration (e.g., DX or chilled water systems), lowering energy consumption.
- Water Use: Water is only used for evaporation in the secondary airflow, and many systems operate in "dry mode" (no water) during cooler conditions, conserving water compared to traditional cooling towers.
Operational Modes
Indirect adiabatic cooling systems in data centers often operate in multiple modes to optimize efficiency:
- Dry Mode (Free Cooling):
- When outdoor temperatures are low (e.g., below 20°C), the system uses ambient air alone to cool the heat exchanger without water evaporation.
- Fans modulate airflow to meet cooling demands.
- Wet Mode (Adiabatic Cooling):
- During warmer conditions (e.g., 25°C to 35°C), water is introduced to the secondary airflow to enhance cooling capacity via evaporation.
- This mode is activated only when dry cooling is insufficient.
- Hybrid Mode (with Mechanical Cooling):
- In extreme heat (e.g., above 35°C) or high humidity, supplementary mechanical cooling (e.g., DX or chilled water coils) provides additional capacity to maintain temperature setpoints.
Application in Data Centers
Indirect adiabatic cooling systems are widely used in modern data centers due to their balance of efficiency, sustainability, and reliability. Specific applications include:
- Hyperscale Data Centers:
- Large facilities (e.g., those operated by Google, Microsoft, or Amazon) use these systems to manage massive heat loads while minimizing energy and water usage.
- Example: A 500 kW system can cool a data hall with a PUE (Power Usage Effectiveness) as low as 1.05-1.2.
- Colocation Facilities:
- Multi-tenant data centers benefit from the scalability and redundancy of indirect adiabatic systems, ensuring consistent cooling across diverse IT loads.
- Edge Data Centers:
- Smaller, distributed facilities in varying climates use these systems for their adaptability to local weather conditions and lower operational costs.
- Sustainability Goals:
- Data centers aiming to reduce carbon footprints and water usage (e.g., in water-scarce regions) adopt these systems to align with environmental regulations and corporate ESG (Environmental, Social, Governance) targets.
Advantages
- Energy Savings: Can achieve up to 70%-90% energy savings compared to traditional mechanical cooling, especially when combined with free cooling.
- Water Efficiency: Uses significantly less water than cooling towers (up to 95% less in some designs), as water is only employed during peak heat conditions.
- Air Quality: Maintains clean, dry air inside the data center, avoiding contamination from outdoor pollutants or humidity.
- Flexibility: Operates effectively across a wide range of climates, from dry desert regions to temperate zones.
Challenges
- Initial Cost: Higher upfront investment for heat exchangers, fans, and water distribution systems compared to basic air conditioning.
- Maintenance: Requires periodic cleaning of wetted media or heat exchanger surfaces to prevent scaling, corrosion, or bacterial growth (e.g., Legionella).
- Climate Dependency: Less effective in high-humidity environments where the wet-bulb temperature limits evaporative cooling potential.
Real-World Example
- Microsoft Data Centers: Microsoft has implemented indirect adiabatic cooling in several facilities, reporting water savings of millions of liters annually. In a 2022 report, they noted a 6.4 million m³ water usage reduction partly due to such systems.
- Telehouse North Two (London): This facility uses a multi-story indirect adiabatic system, achieving a PUE of 1.16, one of the lowest in the industry.
Conclusion
Indirect adiabatic cooling systems for data centers use evaporative cooling indirectly through a heat exchanger to pre-cool outdoor air, efficiently transferring heat from the data center environment while preserving air quality and reducing resource consumption. They are a cornerstone of modern, sustainable data center design, balancing energy efficiency, water conservation, and operational reliability. For facilities with specific heat loads or climate conditions, these systems can be customized to maximize performance, making them a versatile solution for the growing demands of digital infrastructure.
Counter current heat exchange core for food drying
The counter current heat exchange core used for food drying utilizes the principle of heat conduction to allow high-temperature drying exhaust gas and low-temperature fresh air to flow in a counter current manner inside the core. Heat exchange is carried out through a heat-conducting plate, allowing fresh air to heat up and exhaust gas to cool down, achieving energy recovery and improving the energy utilization efficiency of the drying system. By recovering heat through the heat exchange core, the drying temperature and humidity can be more accurately controlled.
The core frame is generally made of materials such as aluminum zinc coated plate, galvanized plate, or stainless steel plate to meet different environmental requirements and ensure long-term stable operation.
The counterflow design maintains a relatively large temperature difference between the cold and hot air flows throughout the entire heat exchange process, promoting heat transfer, improving heat exchange efficiency, and achieving energy recovery efficiency of over 50%. Widely used in various food drying fields, such as the processing of dried fruits, dried vegetables, dried meat products, dried seafood, and dried grains.
Heat exchangers for ship ventilation
The air handling units on board ships must be equipped with high-quality heat exchangers to provide uninterrupted fresh air. Our air to air heat exchangers are the perfect choice for ship or coastal applications.
The use of air-to-air heat exchangers in ship ventilation systems can not only introduce fresh air, but also recover the energy of the discharged air, preheat or pre cool fresh air, and reduce overall energy consumption. At the same time, it effectively reduces the risk of equipment failure due to high temperatures.
We accurately calculate the heat transfer area, air volume, and other parameters of the required heat exchanger based on the spatial size, ventilation requirements, and heat load of different areas of the ship. A plate fin heat exchanger with a large heat exchange area and high air volume can be selected to ensure efficient heat recovery and air exchange. Consider the operating environment of the ship and choose materials with strong corrosion resistance. We use hydrophilic aluminum foil heat exchange material, which not only has good thermal conductivity, but also effectively resists corrosion from seawater and humid air, extending the service life of the equipment.
Heat exchanger for cooling solar inverters
Solar inverters generate a large amount of heat during operation. If this heat is not dissipated in a timely manner, the internal temperature of the inverter will continue to rise, leading to a decrease in device performance, shortened lifespan, and even causing malfunctions. Therefore, based on solar inverters with different heat exchangers, we provide you with suitable cooling solutions.
Air cooled heat exchangers use air as a cooling medium and force air to flow over the surface of the heat exchanger through a fan to achieve heat exchange.
Design selection: We determine the size, heat dissipation area, and fan air volume and pressure of the air-cooled heat exchanger based on the power size, heating power, and operating environment of the inverter. Generally speaking, compact plate fin air-cooled heat exchangers can be used for small solar inverters, which have the characteristics of small size and high heat dissipation efficiency; Large inverters can use tube and strip air-cooled heat exchangers, which have a large heat dissipation area and can meet high-power heat dissipation requirements.
Liquid cooled heat exchangers use liquid as the cooling medium, which circulates inside the heat exchanger, absorbs the heat generated by the inverter, and then dissipates the heat to the external environment through the radiator.
If you have any needs, please contact us immediately.