The sensible plate heat exchanger is constructed with multi-layer aluminum foil plates stacked in a compact cross-flow structure, enabling efficient sensible heat transfer between two separate air streams. Through indirect air-to-air heat exchange, it recovers thermal energy while keeping exhaust air and fresh air completely isolated.
In high-temperature exhaust applications, the aluminum foil air-to-air heat exchanger recovers sensible heat from the hot exhaust air and uses it to preheat incoming fresh or make-up air, significantly reducing the demand for gas, electric, or steam heating. In warm or summer conditions, cooler exhaust air can also be utilized to pre-cool the incoming air, achieving effective air temperature reduction.
By lowering the temperature of hot and humid exhaust air, water vapor can be condensed, enabling dehumidification and visible white plume reduction. With no air mixing, low operating energy consumption, and stable performance, the sensible aluminum foil plate heat exchanger provides a reliable solution for industrial energy recovery, temperature control, and exhaust air treatment applications.
Exhaust Gas Heat Recovery System
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
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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
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Feed pellet drying and cooling systems
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Industrial drying and deodorization equipment
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Textile stenters and finishing machines
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Nonwoven and leather processing lines
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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.
Total Heat Recovery vs. Sensible Heat Recovery
Choose the Right Fresh Air System for Your Climate
When selecting a fresh air ventilation system, climate makes a critical difference.
Sensible heat recovery systems transfer temperature only, helping reduce heating and cooling loads. They are cost-effective and suitable for mild climates where humidity control is not a priority.
Total heat recovery systems go further by recovering both heat and moisture. In hot and humid regions, they pre-cool and pre-dehumidify incoming air. In cold and dry climates, they retain indoor humidity and improve comfort.
The more extreme the climate, the greater the advantage of total heat recovery—delivering better comfort with lower long-term energy consumption.
Sensible heat recovery exchanger
A Sensible Heat Recovery Exchanger is an energy-efficient device designed for air-to-air heat exchange, recovering only sensible heat based on temperature difference, without any moisture or humidity transfer. It is widely used in ventilation systems, industrial exhaust air treatment, drying processes, and fresh air applications, providing effective energy recovery while maintaining complete air separation.
Sensible heat recovery exchanger
Working Principle
The exchanger utilizes a metallic or composite heat exchange core that allows high-temperature exhaust air and low-temperature fresh air to flow through separate channels. Heat is transferred through the heat exchange surfaces without air mixing, preheating or precooling the incoming air and significantly reducing heating or cooling loads.
Key Features
Sensible heat recovery only, no moisture transfer
Complete separation of air streams, no cross-contamination
High heat transfer efficiency and stable performance
Compact structure, easy system integration
Suitable for high-temperature, high-humidity, and corrosive air conditions
Materials and Structure
The heat exchange core can be manufactured from aluminum foil, stainless steel foil, or other corrosion-resistant materials. Structural configurations include cross-flow, counter-flow, or multi-pass designs, tailored to specific application requirements.
Typical Applications
Industrial fresh air and exhaust ventilation systems
Waste heat recovery from drying equipment exhaust
Spray coating, textile, and chemical process exhaust air
Energy storage cabinets and equipment cooling systems
Agricultural, livestock, and mushroom growing ventilation systems
Benefits
Reduced energy consumption
Lower operating costs
Improved system thermal efficiency
Enhanced indoor air quality
Support for energy-saving and sustainable operations
2026 Spring Festival (Chinese New Year) Holiday Schedule
According to the official notice issued by the General Office of the State Council on November 4, 2025, the Spring Festival holiday arrangement for 2026 is as follows:
- Holiday Period: February 15 (Sunday, Lunar December 28) to February 23 (Monday, Lunar January 7), total of 9 consecutive days off.
- This is described as the "longest Spring Festival holiday in history," including time for preparations starting from Lunar December 28 and covering Chinese New Year's Eve through the first week of the new lunar year.
- Make-up Work Days: February 14 (Saturday) and February 28 (Saturday) will be regular working days.
Key Dates:
- Chinese New Year's Eve: February 16, 2026 (Monday)
- Chinese New Year (Lunar January 1): February 17, 2026 (Tuesday)
Waste Heat Recovery from Livestock Manure Fermentation Exhaust
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
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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. -
Reduced Exhaust Humidity and White Plume
After heat extraction, the exhaust temperature drops, reducing visible white vapor during outdoor discharge and improving environmental perception. -
Lower Corrosion Risks
Exhaust and fresh air remain completely separated. Tail gas channels can be coated for extended service life when handling corrosive components. -
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
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
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Energy Recovery: Recovers up to 60% of waste heat from exhausts.
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Cost Efficiency: Reduces heating costs in cold climates.
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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
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
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Equipment Longevity: Prevents overheating, extending component life.
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Efficiency: Maintains peak performance of turbines.
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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
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
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Energy Savings: Reduces cooling energy use by up to 50% compared to traditional systems.
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Environmental Friendliness: Uses no harmful refrigerants.
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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
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
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Air Quality Improvement: Eliminates visible smoke, reducing particulate matter.
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Regulatory Compliance: Meets stringent emission standards.
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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.